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U.S. manufacturers are moving away from using forklifts in their warehouses to improve safety and productivity. According to the Wall Street Journal, forklifts cause nearly 7,500 injuries and almost 100 fatalities annually in the U.S. In 2023, retail orders for forklifts fell 28%, marking the most significant decline in over a decade and likely attributed to factors such as the push for safer alternatives and the shift toward automation.
Forklift Accident Causes
- Forklift Turnovers
Nearly one-third of forklift accidents are due to rollovers or tip-overs, while these types of accidents account for almost half of the annual forklift injuries, signifying forklift tip-overs are extremely dangerous for employees.
Turnovers can be caused by turning a corner too quickly. When a forklift turns, the forklift shifts the center of gravity, which increases the risk of a rollover, especially at higher speeds.
Workers exceeding the forklift’s maximum load capacity can also increase the risk of a tip-over incident. Workers who create an uneven load balance will increase the risk of forklift turnover incidents. Operating the forklift with an elevated load can also cause a dangerous imbalance. Similarly, operating forklifts on uneven surfaces can cause sudden shifts in the center of gravity, resulting in tip-overs. - Collisions with Employees and Objects
Approximately 20% of forklift accidents involve collisions with other employees or stationary objects. Around 36% of forklift-related fatalities involve pedestrians, highlighting a significant risk factor.
The likelihood of accidents increases without designated pedestrian areas marked by physical or symbolic barriers. Additionally, the absence of warning lights and alarms can lead to accidents, as pedestrians may be unaware of a forklift's movements.
Distracted driving also contributes to pedestrian accidents. - Falling Loads
Falling inventory from forklifts or trucks poses a significant risk to forklift operators. Insecure loads and poor forklift maintenance can heighten the chances of accidents caused by falling inventory. - Untrained Personnel
Untrained individuals who use forklifts for convenience or efficiency increase the risk of accidents and injuries. - Emissions Poisoning
Operating forklifts in small, enclosed spaces can result in toxic fumes, causing employees to become ill.
New Technologies
Considering reported forklift accidents, alternatives such as overhead cranes, electric pallet jacks, and robotic tuggers have been implemented in companies like Whirlpool. These technologies have improved workplace safety, reduced injuries, and enhanced efficiency.
Challenges In Going Forklift-Free
Despite efforts to go forklift-free, many companies still rely on forklifts in specific situations, particularly in older facilities or for transporting extremely heavy or bulky items.
The Future of Forklifts
Forklift makers such as Toyota and Raymond have invented new safety features such as high-visibility seat belts and collision sensors and are offering more extensive training programs.
Experts predict a gradual reduction in forklift use over the next decade. Forklifts will not become obsolete as they remain necessary for some operations and production procedures.
CED Technologies boasts a team of highly skilled engineers with extensive experience in a wide range of industrial machinery accidents. Our OSHA-certified engineers have a proven track record of testing, evaluating, and consulting on various machinery cases, including those involving forklift loading equipment. Contact CED Technologies today for expert engineering support in industrial machinery cases.
