What Are the Most Common Forklift Safety Violations and How Can You Avoid Them?

May 22, 2025

Forklifts are essential in warehouse and material handling operations, but they also pose serious safety risks if not used properly.

In honor of National Safety Month, we’re breaking down the most frequent OSHA forklift violations, how businesses can improve operator training and compliance and the latest safety technologies that help prevent accidents.

Top OSHA Forklift Violations

OSHA (Occupational Safety and Health Administration) has rules and requirements for safe operation, maintenance and training when operating powered industrial trucks. Don’t fall victim to the most common violations:

1. Lack of Proper Operator Training & Certification

OSHA requires forklift operators to undergo formal training, hands-on instruction and certification testing. It’s essential to implement an OSHA-compliant forklift training program and keep detailed certification records.

2. Failure to Conduct Pre-Shift Inspections

Forklifts must be inspected before each shift to ensure they’re safe to operate. Require daily safety checklists and immediate removal of unsafe equipment.

3. Unsafe Load Handling

Overloading forklifts or improperly balancing loads can cause tip-overs and accidents. Train operators on load distribution, stability and correct lifting techniques.

Safety Technologies That Help Prevent Forklift Accidents

Investing in modern safety technologies can significantly reduce forklift-related injuries and OSHA violations. Check out some of the most effective solutions:

1. Telematics & Real-Time Monitoring

  • Tracks operator speed, braking habits, and impact events.
  • Sends alerts for unsafe driving behaviors.
  • Allows managers to enforce safety policies based on data-driven insights.

2. Proximity Sensors & Collision Avoidance Systems

  • Detects pedestrians and obstacles in real time.
  • Alerts operators with visual and audio warnings.
  • Prevents accidents in high-traffic areas.

3. Speed Control & Geofencing

  • Automatically reduces forklift speed in designated safety zones.
  • Restricts unauthorized areas, preventing forklifts from entering dangerous locations.

Prioritize Forklift Safety to Avoid Costly Violations

Preventing forklift accidents isn’t just about compliance – it’s about protecting workers, reducing downtime and improving overall efficiency. By addressing common OSHA violations, enhancing training programs and investing in safety technology, businesses can create a safer work environment while avoiding costly fines.

Need expert forklift safety solutions?

MHS Lift provides OSHA-certified operator training, advanced fleet management tools, and safety technology integrations to help businesses stay compliant. Contact us today to improve forklift safety in your warehouse!