Free Forklift Operator Course (4Months)

Forklift Operator (Driver):

Brief Job Description

Individuals at this job need to operate a forklift for loading and unloading heavy raw materials, parts, assemblies and finished goods within the shop floor and in stores/warehouse for various Manufacturing and R&D processes of an organization.

Personal Attributes

This job requires the individual to drive continuously for long hours in physically demanding conditions on the shop floor. Individual must be physically fit and have a good  sense  of  balance,  ability  to  judge distances and good eye-hand-foot coordination. The individual should also be able to demonstrate skills for information ordering, oral expression and comprehension.

Ensure that the forklift is fit for use:

Elements and Performance Criteria

Pre-drive inspection

To be competent, the user/individual on the job must be able to:

PC1.. visually check the forklift before starting for: Engine oil level, fuel level, radiator water level (LPG, gas and diesel forklifts). Battery is fully charged; check cables for exposed wires; battery plug connections not loose, worn or dirty; vent caps not clogged;(battery operated FLTs) electrolyte levels in cells; hold-downs or brackets to keep battery securely in place Bolts, nuts, guards, chains, or hydraulic hose reels are not damaged, missing or loose Wheels and tyres for wear, damage and air pressure, if pneumatic tyres Forks are not bent; no cracks present; positioning latches are in good working condition; carriage teeth not broken, chipped or worn Chain anchor pins are not worn, loose or bent Fluid Leaks – no damp spots or drips Hoses are held securely; not loose, crimped, worn or rubbing Horn is working and loud enough to be heard in working environment; other warning devices operational Lights – head lights and warning lights operational

Basic operational check before the start of work

To be competent, the user/individual on the job must be able to:

PC2.. check the following components of forklift for operational ease: Foot Brake that pedal holds and unit stops smoothly Parking Brake that brake holds against slight acceleration Seat Brake that brake holds when operator rises from seat Clutch and Gearshift shifts smoothly with no jumping or jerking Dash Control Panel that all lights and gauges are operational Steering moves smoothly Lift Mechanism operates smoothly (check by raising forks to maximum height then lowering forks completely) Tilt Mechanism moves smoothly and holds (check by tilting mast all the way forward and backward) Cylinders and Hoses not leaking after above checks Listen for any unusual sounds or noises

PC3.. start the forklift and check for the following once again: check that all warning devices operate (horn, indicator lights, rear and brake lights and the reverse alarm) check that the mast tilts forward and back correctly and that the mast extends ensure following preventive maintenance schedules as per laid down guidelines.

Escalation of technical problem

To be competent, the user/individual on the job must be able to:

PC4.. report actual or possible defects to the supervisorin enough detail so they can diagnose the problem

PC5.. in consultation with superiors conclude about the fitness of forklift and if found unfit to decide to use another forklift.

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. companys policies on: safety policies and procedures; warehouse safety standards; basic compliance to technical requirements and standards; safety and hazards

KU2. organization structure

KU3. escalation procedure

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1. read and understand technical standards of forklift operation in terms of safety precautions to be taken for driving with unladen/ laden condition , in narrow isles, congested environment & for loading unloading material using hoist/ forks

GS2. follow supervisors instructions while using the forklift

GS3.  when not to use the forklift due to technical and/or compliance related issues

GS4.  how to learn from past mistakes and identify potential problems

Pre-drive inspection

PC1.. visually check the forklift before starting for: Engine oil level, fuel level, radiator water level (LPG, gas and diesel forklifts). Battery is fully charged; check cables for exposed wires; battery plug connections not loose, worn or dirty; vent caps not clogged;(battery operated FLTs) electrolyte levels in cells; hold-downs or brackets to keep battery securely in place Bolts, nuts, guards, chains, or hydraulic hose reels are not damaged, missing or loose Wheels and tyres for wear, damage and air pressure, if pneumatic tyres Forks are not bent; no cracks present; positioning latches are in good working condition; carriage teeth not broken, chipped or worn Chain anchor pins are not worn, loose or bent Fluid Leaks – no damp spots or drips Hoses are held securely; not loose, crimped, worn or rubbing Horn is working and loud enough to be heard in working environment; other warning devices operational Lights – head lights and warning lights operational

Basic operational check before the start of work

PC2.. check the following components of forklift for operational ease: Foot Brake that pedal holds and unit stops smoothly Parking Brake that brake holds against slight acceleration Seat Brake that brake holds when operator rises from seat Clutch and Gearshift shifts smoothly with no jumping or jerking Dash Control Panel that all lights and gauges are operational Steering moves smoothly Lift Mechanism operates smoothly (check by raising forks to maximum height then lowering forks completely) Tilt Mechanism moves smoothly and holds (check by tilting mast all the way forward and backward) Cylinders and Hoses not leaking after above checks Listen for any unusual sounds or noises

PC3.. start the forklift and check for the following once again: check that all warning devices operate (horn, indicator lights, rear and brake lights and the reverse alarm) check that the mast tilts forward and back correctly and that the mast extends ensure following preventive maintenance schedules as per laid down guidelines.

Escalation of technical problem

PC4.. report actual or possible defects to the supervisorin enough detail so they can diagnose the problem

PC5.. in consultation with superiors conclude about the fitness of forklift and if found unfit to decide to use another forklift.

Load / unload the materials safely:

Scope

The unit/ task covers the following: start up procedure for forklift

movement of the materials and placing it at its designated shop floor location parking the forklift

escalation of problems to supervisor/reporting

Elements and Performance Criteria

Start up procedure for forklift

To be competent, the user/individual on the job must be able to:

PC1..    follow the procedure for starting the forklift : fasten the seatbelt check that the park brake is engaged check that transmission control lever is in neutral position and safety locks are on(if fitted) and all attachment controls are in the neutral position check that the throttle control or accelerator pedal is pushed past any constriction that may be fitted and is in the low idle position turn the ignition switch to start the engine. If it fails to start within approximately 10 seconds, allow the starter to cool down and try again; in cold conditions pre-heating may be required check all gauges for correct operation allow the engine and components to warm up to operating temperature for approximately 5 minutes before operating. During this period operate all attachment controls checking for correct operation, unusual noises and any vibrations re-check all gauges, horn and warning lights for correct operation ensure that the area is clear of all personnel and equipment before moving drive the forklift to the desired location

Movement of materials

To be competent, the user/individual on the job must be able to:

PC2..     drive the forklift near to the storage location where the material is kept; be it at the shop floor or the stores/warehouse

PC3..     lower the forkswhile keeping the mast in upright condition

PC4..    level the fork before inserting it into the pallet

PC5..    insert the fork all the way under the material

PC6..     adjust the fork as wideas possible to fit the load and to provide a more even distribution of weight

PC7..     ensure that the material on pallets isstable, neat, cross-tied if possible and evenly distributed

PC8..     tilt loads backwards

PC9..    travel with forks as low as possible from the floor and tilted back

PC10..  match speed to driving, load and workplace conditions

PC11.. reach the designated location steering clear of any obstacles, material etc and being on the designated isles

PC12.. lower the forks as slowly as possible until the pallet touches the ground

PC13.. rest the pallet on ground and slowly start removing forks out of the pallet ensuring that the material is not being damaged

PC14.. afterwards , again lift the forks slightly above the ground and drive it back to the next destination. Take care not to meet with any obstacles as in the unladen condition the FLT balance is rear heavy

PC15.. repeat Pc1. to Pc14. till all the materials have been moved and stored at the respective locations

Parking of the forklift

To be competent, the user/individual on the job must be able to:

PC16.. once the job is over , reach the parking area and park the forklift with the forks and attachments (if any)touching the ground

PC17.. place all attachment control levers in the neutral or hold position

PC18.. do not allow lift chains to go slack, as they may jump clear of the top carrier rollers

PC19.. place the transmission and forward reverse levers into the neutral position and apply any safety locks

PC20.. apply park brake

PC21.. if it is an LPG powered forklift, turn off the fuel isolating valve as this prevents a build up of explosive gases prior to starting up again

PC22.. switch off the ignition

Escalation of problems

To be competent, the user/individual on the job must be able to:

PC23.. inform about anything that affects the normal operation of the forklift and tell the supervisor immediately

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. companys policies on: safety policies and procedures; warehouse safety standards; basic compliance to technical requirements and standards; safety and hazards

KU2.  storage locations , loading unloading points (shop, despatche etc.)

KU3. maintenance responsibility ( Preventive with driver)

KU4. escalation procedures

KU5.  material storage location layout of the plant

KU6.  safety measures to be taken while driving the forklift

KU7. proper direction for tilting the load for safe driving on shop floor

KU8. the emergency exits and the doorways location in shop floor

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.  the signboards mentioning about the safety precautions displayed on the shop floor

GS2.  information written on the packaging labels of materials

GS3. shop floor personnel for guiding himproperly to lift the materials

GS4. supervisor in case of any issue observed while material loading/unloading

Start up procedure for forklift

PC1.. follow the procedure for starting the forklift : fasten the seatbelt check that the park brake is engaged check that transmission control lever is in neutral position and safety locks are on(if fitted) and all attachment controls are in the neutral position check that the throttle control or accelerator pedal is pushed past any constriction that may be fitted and is in the low idle position turn the ignition switch to start the engine. If it fails to start within approximately 10 seconds, allow the starter to cool down and try again; in cold conditions pre-heating may be required check all gauges for correct operation allow the engine and components to warm up to operating temperature for approximately 5 minutes before operating. During this period operate all attachment controls checking for correct operation, unusual noises and any vibrations re-check all gauges, horn and warning lights for correct operation ensure that the area is clear of all personnel and equipment before moving drive the forklift to the desired location

Movement of materials

PC2.. drive the forklift near to the storage location where the material is kept; be it at the shop floor or the stores/warehouse

PC3.. lower the forkswhile keeping the mast in upright condition

PC4.. level the fork before inserting it into the pallet

PC5.. insert the fork all the way under the material

PC6.. adjust the fork as wideas possible to fit the load and to provide a more even distribution of weight

PC7.. ensure that the material on pallets isstable, neat, cross-tied if possible and evenly distributed

PC8.. tilt loads backwards

Ensure safe and healthy working practices:

Scope

This unit/ task covers the following:

identification of potential sources of safety issues in driving follow standard safety standards

communicate to reporting supervisor aboutsafety issues

handling of emergency situations such as accident, fire, passenger, client related issues

Elements and Performance Criteria

Potential safety issues

To be competent, the user/individual on the job must be able to:

PC1..    in case of a fuel leak occurrence or suspicion, immediately stop the machine, tag the area around the leak and inform the supervisor

PC2..     inform the shop floor personnel in case of more than maximum loadput on the forks of the forklift/ imbalance in load kept on the forks

PC3..     in case of accident, rush the person to the in-house medical centre immediately inform the supervisor

PC4..    vacate the premises in case of fire and immediately inform the supervisor

Standard safety standards

To be competent, the user/individual on the job must be able to:

PC5..     know the recommended load limit of the forklift and never exceed it

PC6..     know how to assess the weight of the load to be lifted

PC7..    do a visual and operational check of the forklift at the start of the shift

PC8..     check for adequate overhead clearance before raising the load

PC9..    operate the equipment smoothly when stopping, starting, lifting and tilting

PC10.. know the blind spots of the lift truck with and without a load

PC11.. keep pedestrians away from a forklift in operation

PC12.. stop when anyone crosses the route being travelled. Lower the load to the floor, and wait until clear

PC13..  operate only as fast as conditions safely permit

PC14..  wear leather gloves when moving or shifting loads

PC15.. wear fully laced safety boots to give impact protection when moving loads or skids and to provide ankle support

PC16.. remain alert and prepare for the unexpected

PC17.. ensure that the shop floor area where forklift is operating is free from oil spots, wet spots, loose objects, holes, rough surfaces, people and other vehicles

PC18.. keep hands, arms, head, feet and legs inside the confines of a moving forklift

PC19.. stay in the truck in case of overturn

Limit damage to people and public

To be competent, the user/individual on the job must be able to:

PC20.. stop when anyone crosses the route being travelled. Lower the load to the floor, and wait until clear

PC21.. sound horn before moving on shop floor

PC22.. take care not to let the FLT / or load touch obstacles while driving

PC23.. eliminate usage of damaged bins

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. organization’s instructions or guidelines relating to dealing with and reporting safety and emergency issues

KU2.  what action you can take, and are authorized to take, to limit danger

KU3. methods of effective and appropriate communication to let others know about the safety, cleanliness and emergency situations

KU4. where and how to get help in dealing with safety and emergency situations

KU5.  how to use appropriate equipment and alarm systems to limit danger

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1. effectively communicate the safety, cleanliness and emergency issues

GS2. keep the work environment clean

GS3.  report potential sources of danger

GS4. follow prescribed procedure to address safety and emergency issues

GS5. learn from past mistakes regarding use of safety and emergency issues

GS6. spot safety and cleanliness issues

Assessment Guidelines

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Element/ Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each Element/ PC.

• The assessment for the theory part will be based on knowledge bank of questions created by the SSC.

• Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.

• Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below).

• Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/ training center based on these criteria.

• To pass the Qualification Pack assessment, every trainee should score the Recommended Pass % aggregate for the QP.

• In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.