Powered Industrial Vehicles Safety Policy
Policy Summary & Core Standards
This policy mandates training, certification, daily pre-shift inspections, safe operation, and battery/refueling protocols for all Powered Industrial Vehicles (PIVs) operated at Yaskawa America, Inc. facilities in accordance with OSHA 29 CFR 1910.178 and ANSI/ITSDF standards.
Overview
Yaskawa America, Inc. recognizes the need for an evaluation and training program for Operators of Powered Industrial Trucks (e.g., counter-balanced forklifts, order pickers, reach trucks, powered pallet jacks, and material transfer carts) to ensure the safety of our associates, contractors, and visitors.
This program incorporates the requirements of the Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck Standard (29 CFR 1910.178), serving as the mandatory site program. Training and authorization are vehicle- and attachment-specific and must remain uniform in practical application.
Types of Powered Industrial Vehicles
Counter-Balanced Forklift
Used across warehouse floors to transport inventory, load/unload trailers, and place palletized loads.
Order Picker
Elevates the operator to inventory level for order picking. Operators must wear a full body harness with fall arrest SRL.
Reach Truck
Outfitted with extended pantograph reach mechanism for high-density, narrow-aisle pallet racking.
Turret Truck
Operator cab elevates with the fork carriage, delivering precise visibility in ultra-narrow aisles.
Powered Pallet Jack
Ground-level powered transport. Walkie and rider models each require independent qualification.
Material Transfer Carts
Motorized industrial carts. Operators must be trained and authorized prior to use.
Automated Guided Vehicles (AGV)
Driverless mobile transport robots. Follow ANSI/ITSDF B56.5 standards and safety zones.
Walk-Behind Stacker
Pedestrian-controlled stackers used for staging and lifting where full-sized forklifts are unnecessary.
Scissor Lifts / MEWPs
Classified as Mobile Elevating Work Platforms. Refer to Yaskawa Scaffolds & Fall Protection policies.
Definitions
- Authorized Evaluator
- An associate appointed by management who holds documented training, practical experience, and a Train-the-Trainer credential to train and evaluate PIV operators.
- Free Rigging
-
The practice of attaching rigging equipment (slings, shackles, hooks) directly to fork tines without an approved, certified attachment. Prohibited without prior written manufacturer approval.
- High-Tiering
- Placement or retrieval of materials into or from elevated rack tiers requiring maximum tilt control and overhead surveillance.
- Operator
- An employee who has successfully completed formal classroom instruction, hands-on practical training, and an operational evaluation specific to the equipment class.
- Operator Trainee
- An associate in training operating under the direct line-of-sight supervision of an Authorized Evaluator in non-hazardous operating areas.
Training Program Requirements
The powered industrial vehicle program consists of four distinct components:
Evaluations (Annual)
While OSHA 29 CFR 1910.178(l)(4)(iii) mandates an evaluation of each operator's performance at least once every three years, Yaskawa America requires that practical evaluations be conducted annually in conjunction with the associate's annual performance review, as well as following any transfer to a new department or equipment type.
Refresher Training Triggers
Refresher training is not time-based; it is event-driven. In accordance with 29 CFR 1910.178(l)(4)(i), refresher training in relevant topics shall be provided to the operator when:
- The operator has been observed to operate the vehicle in an unsafe manner.
- The operator has been involved in an accident or near-miss incident.
- The operator has received an evaluation that reveals the operator is not operating the truck safely.
- The operator is assigned to drive a different type of truck or use an unfamiliar attachment.
- A condition in the workplace changes in a manner that could affect safe operation of the truck.
Department Responsibilities
Department Managers and Supervisors shall:
- Ensure all operators possess a valid motor vehicle driver's license upon hire/assignment.
- Verify no associate operates any PIV without prior qualification and active authorization.
- Appoint certified Authorized Evaluator(s) for the operational area.
- Verify that operators are trained on the specific makes, models, and attachments used in their work areas.
- Enforce immediate removal from duty and refresher retraining following any unsafe operation or incident.
- Maintain all inspection checklists, maintenance logs, and evaluation records.
Safety Equipment and Facilities
Facilities must maintain designated battery charging and fueling stations equipped with:
- Operational emergency eyewash and safety shower stations located within 25 feet / 10 seconds of battery charging stations.
- Neutralizing agents and absorbent spill kits for battery electrolyte.
- Class ABC dry-chemical fire extinguishers mounted adjacent to charging and refueling stations.
- Adequate ventilation systems designed to prevent hydrogen gas accumulation during battery charging.
- Bollards and physical crash barriers protecting chargers and electrical infrastructure from vehicle impact.
Truck Attachments & Modifications
- Data plates must be updated to show the revised capacity, truck/attachment combined weight, and maximum elevated capacity.
- Removable attachments must display an official manufacturer plate listing model, serial number, hydraulic pressure rating, weight, and capacity.
- Department supervisors must complete a written Hazard Analysis before deploying any attachment.
Pre-Start Inspection Requirements
Operators must execute and document a documented pre-shift safety inspection (electronic via iWarehouse or physical checklist) before initial operation each shift:
- Key-Off Checks: Inspect hydraulic hoses, mast chains, tire condition, overhead guard integrity, data plate, fork condition/pins, fluid levels, and leaks.
- Key-On / Operational Checks: Test horn, steering, service & parking brakes, headlights, warning beacons, backup alarm, lift/tilt hydraulics, and seatbelt.
- Defect Protocol: If any safety defect or leak is detected, immediately remove the key, apply a Lockout/Tagout tag, and notify the supervisor. Never operate a damaged truck.
Operational Requirements
- Forward View Obstruction: If a load obstructs the operator's forward view, the operator MUST drive in reverse with the operator facing the direction of travel.
- Pedestrian & Operator Interaction (No Assumed Right-of-Way):
No one has the automatic or absolute right-of-way. Safe operation depends upon mutual awareness and deliberate contact:
- Pedestrians must stop and establish positive communication (direct eye contact and hand signaling) with the vehicle operator before entering an aisle or crossing travel paths.
- Operators must stop and acknowledge the pedestrian through clear communication and hand signaling before proceeding.
- Intersections and Blind Areas: Operators must come to a complete stop and sound the horn before entering all blind spots, doorway crossings, rack intersections, and pedestrian pathways. Never rely on speed or mirrors alone.
- Traveling Height: Keep forks carried low (4 to 6 inches off the floor), with tines tilted back just enough to stabilize the load.
- Seatbelts & Restraints: Operators must wear seatbelts at all times on sit-down lift trucks. Full body harnesses with SRL lanyards are required on order pickers.
- Ramps & Inclines: On inclines greater than 10%, point the load uphill (drive forward ascending; drive in reverse descending).
- Following Distance: Maintain at least three (3) truck lengths behind preceding vehicles; adjust for slippery or uneven floor conditions.
- Dock Safety: Engage dock locks or wheel chocks before entering trailers. Inspect trailer flooring and ensure dock plates are securely positioned.
- NEVER raise or lower forks/loads while the vehicle is traveling.
- NEVER assume another person sees you or that you have the right-of-way without positive visual and physical acknowledgement.
- NEVER permit passengers or riders on any lift truck unless an approved manufacturer passenger seat with seatbelt is installed.
- NEVER allow anyone to stand, walk, or pass underneath elevated forks or attachments.
- NEVER engage in stunt driving, speeding, or reckless maneuvers.
- NEVER attempt to push, pull, or open facility freight doors using the forklift or its tines.
- NEVER practice Free Rigging without certified attachment engineering documentation.
Loading and Unloading Procedures
- Never exceed the truck's rated load center and lifting capacity indicated on the nameplate.
- Center the load squarely across the forks; ensure the load is resting firmly against the mast carriage.
- Inspect pallets for structural defects, broken boards, or protruding fasteners before lifting.
- When tiering into racks, elevate directly in front of the rack opening, level the forks before entering, and observe all overhead clearances (sprinklers, light fixtures, HVAC conduits).
Refueling, Charging, and Maintenance
- PPE Requirements: Wear acid-resistant face shield, chemical splash goggles, rubber apron, and neoprene gauntlet gloves when servicing batteries or checking electrolyte.
- No Smoking / Hot Work: Smoking, open flames, sparks, and hot work are strictly prohibited within 25 feet of charging and fuel staging areas.
- Battery Handling: Use approved hoisting beams/spreader bars when changing industrial batteries; apply parking brakes and chock wheels.
- Acid Dilution: Always pour acid into water—never pour water directly into concentrated sulfuric acid.
- Authorized Technicians: Only certified service technicians are permitted to execute mechanical, electrical, or hydraulic repairs.
Contractor Use of Yaskawa Equipment
Outside contractors are strictly prohibited from operating Yaskawa-owned or leased Powered Industrial Vehicles without prior written authorization from one of the following officials:
Authorized contractors must supply proof of current OSHA certification, sign equipment waiver documents, and abide by all site safety operating standards.
Document & Records Retention
| Record Type | Custodian / Location | Retention Period |
|---|---|---|
| Pre-Operation Shift Checklists (Paper/Electronic) | Department Supervisor / Facility Telematics System | 1 Year (Minimum) |
| Operator Training & Practical Evaluations | Yaskawa LMS / Associate HR File | Tenure + 5 Years |
| Equipment Maintenance, Service, & Alteration Records | Cost Center / Facilities Manager | Life of Equipment |
| Train-the-Trainer Evaluator Credentials | Corporate EHS | Active Designation + 5 Years |
Revision History & Annual Program Review
| Rev # | Description of Change | Release Date | Approved By |
|---|---|---|---|
| 0 | Conversion of old safety documents, rewrite, and issue | 5/19/2016 | Thurwanger |
| 1 | Modernized HTML/PDF responsive styling; incorporated reverse travel for obstructed view; established mutual-communication requirement (no assumed right-of-way) and mandatory stop-and-honk protocol for intersections and blind spots. | 9/16/2026 | Thurwanger |
Program Review Log
| Review Date | Reviewed By | Changes Required | Rev # |
|---|---|---|---|
| 1/21/2025 | Thurwanger | No | 0 |
| 2/11/2026 | Thurwanger | No | 0 |
| 9/16/2026 | Thurwanger | Yes (Updated format, view obstruction rule, mutual right-of-way protocol, and blind spot stop/honk mandate) | 1 |
