HSE Approved Code of Practice for forklift training explained

Since the first publication of the HSE's Rider-Operated Lift Trucks: Operator Training – Approved Code of Practice and Guidance L117, UK forklift usage has almost doubled. Meanwhile, accidents have fallen dramatically.

Back in 1988, when Mentor Training was founded and the ACoP was introduced, there were around 350,000 fork lift truck operators in the UK. Lift trucks accounted for a sizeable share of around 100 workplace transport deaths per year. 

Today, that number of operators has risen to nearer 625,000 – with a further 1.5 million workers in logistics-related roles nearby. However, last year there were just seven fatal lift truck accidents.

What has made that lifesaving difference? Better training has played a part.

Certain technical refinements to forklift truck design – such as better driving positions and overhead guard design, clear view masts and the widespread adoption of seat belts – have played their part in reducing the accident toll. Equally, some other changes may yet prove to be gimmicks.

What is clear is that, although some speciality machines, like articulated trucks, have become mainstream in the past 25 years, the fundamental design of a forklift truck, and the essential principles of safe use, are broadly the same today as they were in 1988.

Virtually all lift truck accidents involve a strong element of human error, just as operators have always been the greatest influence on running costs.

Training those operators well remains the most powerful lever available to lower a company's accident risk, reduce stock damage and improve efficiency overall.

The industry has changed. In the past there were more dedicated forklift drivers, now more people do it as part of their jobs. Even if you only use a forklift once a week, you still need to be competent.

Training now also needs to be more comprehensive. It needs to tie up loose ends. For example, a company may take action against an employee for using a mobile phone on a forklift and the employee may defend themselves by saying that the trainer said it was permitted. The trainer needs to be able to prove it taught him correctly. It all has to be written down.

The new code of practice has a new section detailing how supervisors should prove they can recognise good and bad practice. In response, we have designed a course to help managers and supervisors on what they should look out for. 

Since Mentor started training operators, we've noticed a shift in attitudes as managers have come to understand the ACoP as a benchmark for what a good training programme should include. That has doubtless made a significant contribution to reducing the misery and cost of lift truck accidents.

The current system works well, and most companies understand the importance of training to safety, compliance and the law. The challenge now is to explain how it improves productivity too: not just a cost of compliance, but an investment that gives real bottom-line returns.