Tips for Reducing Forklift Operator Fatigue and Injury

In many factory, warehouse and industrial environments, operating a forklift is a crucial part of the job. While these machines are important for efficiency, forklift operators face a range of challenges. 

Over time, this can lead to forklift operator fatigue, a state of mental or physical exhaustion that reduces alertness and increases the risk of forklift injuries. Here at East Midlands Forklifts, we provide forklift training to clients in Loughborough, Leicester, Derby, Nottingham and the surrounding areas to promote warehouse safety and reduce the risk of accidents. 

In this article, we’ll provide you with our top tips for reducing forklift operator fatigue and injury. 

Common causes of forklift operator fatigue and injury

There are a wide range of causes that make forklift operator fatigue or injury more likely, including: 

• Long working hours and insufficient rest – Extended shifts or a lack of breaks can reduce alertness and slow reaction times as the operator is more likely to become tired or unfocused over time. According to the UK’s Working Time Regulations, employees are entitled to a 20-minute break every six hours and at least 11 hours’ rest between shifts. You may want to have longer or more frequent breaks for those behind the wheel of a forklift. 

• Poor sleep quality – Adults need between seven and nine hours of sleep a night, but this varies by individual. However, consistently getting less than seven hours of sleep can impact mental focus and decision-making. 

• Environmental factors – Extreme levels of noise, temperature and poor lighting can make it more difficult for forklift drivers.

• Mechanical issues – Problems with the forklift, like excessive vibration, stiff controls and uncomfortable seats, can make them more difficult to operate. 

• Lack of forklift training – Without proper training, employees are more likely to operate forklifts incorrectly. 

Best practices to reduce forklift operator fatigue 

Now we know what can cause operator fatigue or injury, let’s look at some best practices to try and avoid it:

• Get adequate rest and sleep – Operators should get at least seven hours of sleep a night and take regular breaks to stay alert.
• Stay hydrated – Drinking plenty of water will help prevent fatigue and boost focus.
• Use ergonomic equipment – More comfortable seating will reduce physical strain on the body.
• Encourage open communication – Encourage your staff to speak up if they’re feeling tired. 
• Vary tasks and responsibilities – Doing the same tasks over and over again can become monotonous and cause operators to lose focus. Rotating duties will help avoid repetitive strain and mental exhaustion. 

Tips to operate forklifts safely 

In addition to keeping operators alert and focused to avoid fatigue and injury, here are some tips to ensure forklifts are being used safely:

• • Choose the right forklift for the job – Make sure you match the truck to the job. At East Midlands Forklifts, we have a wide range of options for you to choose from.
  • Ensure only trained personnel operate forklifts – Proper forklift training ensures safe and competent handling.
  • Conduct regular maintenance and inspections – Before each shift, check the forklifts’ tyres, brakes and forks to ensure safety. We can assist with maintenance as well as thorough examinations – a legal requirement for every forklift. 
  • Keep forks low while moving – This is the safest way to operate a forklift, and it also enhances visibility and reduces the risk of tipping.
  • Avoid overloading and sharp turns – This helps maintain the truck’s stability and prevents forklift injuries.

Increase safety and reduce injuries with our forklift training courses 

The best way to reduce forklift operator fatigue and prevent injuries is with expert forklift training. At East Midlands Forklifts, we offer professional training courses across the East Midlands. All our instructors are AITT-accredited and qualified to train your staff in a wide range of forklift types. What’s more, we can come to your site to carry out the training courses. For more information, get in touch with our team today.