Lift Truck Tips: Take training to the next level

Ideally, lift truck operator training practices in the average facility are better than they were five years ago. Technologies like simple impact sensors have improved accountability, and simulators can help educate operators about complex narrow aisle equipment. But optimal training is not just about delivering the same old information in more frequent and user-friendly ways. Technologies on and around lift trucks are broadening the scope of what operators should know about the equipment and their role in wider business processes.

“Safety is always the central focus, but the training component of safety is changing,” says John Rosenberger, manager of iWarehouse Gateway and global telematics for The Raymond Corp. “That is because lift truck safety technology is becoming more sophisticated.”

For instance, impacts above a certain threshold might automatically slow a piece of equipment to 1 mph to allow the operator to drop the load and move to a safe place. Or, proximity sensors could trigger a handle vibration, create an audible warning or decelerate a truck to prevent an impact.

“You have to incorporate the lift truck’s response into operator training so there are no surprises,” Rosenberger says. “If you’re in the middle of a tight corner and you see lights, feel the handle shake, hear beeps or what have you, what is the proper response?”
In addition to integrated sensors, Rosenberger predicts increased use of wearable cameras, fork-mounted cameras and rear-mounted cameras to give operators and managers more visibility.

“These will be great for safety, records and accountability, but it’s also good for everyday usage and productivity,” he says. “If an operator can see from the fork’s perspective on the way up, he will line them up quicker. And, if he can more readily see around a corner or behind the lift truck, that’s good for safety and efficiency.”

Of course, each camera also requires a training element and not just for the operator. Supervisors will need to consistently support the proper use of the technology and emphasize the benefits to the operator and the operation.

“If after a while I find that nobody is actually watching the cameras, I might go right back to old behaviors,” Rosenberger says. “It’s the same for telematics systems. Operators are supposed to log on and off, enter task codes, and it seems like busy work. What’s in it for them?”

The first part of the answer is a safer environment, but perhaps more compelling is that the more margin a company can make in a warehouse, the more it can help employees. “An operator might skip the task codes and leave some steps outside that process since he has experience and thinks that’s fine,” Rosenberger says. “But the data is what’s helping confirm the company is more efficient—and then pay, benefits and incentive programs will reflect it.”

Telematics systems can also help identify the root cause of problems so operators don’t take the blame for something out of their control. One customer recently increased lift truck speed by 1 mph, which had an unexpectedly large impact.

“Operators started finishing a hour early, and it looked like they were slacking, but the problem was with the task queue,” he says. “Everyone has gut feelings, but now you can use data to support them.”