Operator behaviour
The behaviours that drive damage down
- Approach the bay square-on, not at an angle.
- Tilt the mast back before and after every lift.
- Lower forks to travel height before reversing out.
- Sound the horn at every blind corner.
- Slow to walking pace within 3m of a person.
- Never cut across an aisle to reach the next bay.
Training
A training program that sticks
Forklift training that works in Australian warehouses is short, regular and tied to recent incidents. The once-a-year theatre session does not move behaviour. Five-minute toolbox talks every fortnight, tied to a specific damage finding from the last walk-around, do.
Tie training to data
Pull the last month's damage findings into your toolbox talk. Operators respond to specific photos from their own warehouse far more than to generic safety videos.
Layout
Aisle layout choices that change everything
| Aisle type | Width | Damage profile |
|---|---|---|
| Wide | 3.6–4.2 m | Lowest impact rate |
| Standard | 2.8–3.4 m | Moderate impact rate |
| Narrow (NA) | 1.8–2.4 m | High — guidance systems essential |
| Very narrow (VNA) | 1.5–1.8 m | Low impact (rail or wire-guided) |
Technology
Where technology earns its keep
- Impact-detection telematics — measurable reduction in incidents.
- Proximity sensors at blind corners and pedestrian crossings.
- Speed governors on units used in tight aisles.
- Blue-spot LED warning lights on forklifts.
- CCTV at the most damage-prone aisles.
- Pre-start digital checklists tied to operator login.