At Toyota, safety is always our top priority. We understand the serious impact that forklift and workplace accidents can have on both people and businesses, which is why we are committed to helping you maintain a safer working environment.
We continuously monitor safety challenges and develop countermeasures to help reduce risk in material handling operations. According to the latest data, the most common fatal accidents at work were falls from height, being struck by moving vehicles, and being hit by moving objects - together accounting for around 70% of all fatal injuries to workers.
So, what are the most common forklift accidents and how can you prevent them?
Some of the most frequent forklift-related incidents happen due to:
- Forklift rollovers
- Pedestrian collisions
- Lack of operator training
- Falling loads
- Blocked visibility
- Poor maintenance
- Improper loading
- Excessive speed
- Ignoring safety rules
Ways you can prevent forklift accidents:
1. Pre-operational checks
Before each shift, operators should carry out thorough checks to ensure their forklift is in safe working condition. Identifying faults early helps prevent breakdowns and serious incidents. Operators should also inspect the surrounding area for potential hazards before starting work.
2. Physical protection measures
Use barriers, guardrails, and clearly marked pedestrian walkways to separate people from vehicles. In high-traffic zones, this kind of physical protection significantly reduces the risk of collisions. Designated safety zones around racking, corners, and doorways also help prevent accidents. Personal protective equipment (PPE) such as high-visibility clothing and steel toe cap shoes adds an extra layer of safety, especially in busy operational areas.
3. Regular forklift servicing and maintenance
Keeping your trucks regularly serviced is essential for safe and efficient operation. Routine maintenance prevents costly breakdowns and contributes to accident prevention. A regular Thorough Examination (LOLER) is legally required to ensure the truck meets safety standards.
4. Clear and understandable site signage
Proper signage helps everyone stay aware of their surroundings. Display speed limits, pedestrian-only areas, blind spot warnings, and load capacity signs at key points around your site. Clear signage supports a culture of safety and helps reduce incidents.
5. Forklifts equipped with safety features
Safety technology plays a vital role in preventing accidents. Advanced safety systems such as the Toyota System of Active Stability (SAS) are important because they help prevent accidents before they occur. They not only protect operators and pedestrians but also reduce downtime, minimise damage, and improve overall productivity.Other safety systems worth exploring include SEnS+, an assistance system designed to detect potential hazards and prevent incidents before they occur. There are also a full range of safety lights, sensors and camera options that can be fitted to forklifts for extra protection.
Fleet management systems, such as I_Site, also support safety by offering features like driver access control, pre-operational checks, speed and collision monitoring, and remote visibility of truck activity.
6. Preventing accidents through forklift operator training
Training is the foundation of maintaining a safe working environment. In the UK, it is a legal requirement that all forklift operators receive training on all equipment they are operating. Refresher training should be carried out regularly, and all team members, not just operators, should understand the risks and responsibilities involved.
7. Enforcing safe operating practices and a culture of safety
Establishing clear safety protocols and encouraging safe behaviour are essential to reducing risks across your operation. Setting and enforcing speed limits, prohibiting unauthorized riders, and ensuring only trained operators are able to use equipment also reduces the risk of incidents. Tools such as I_Site can help manage driver access and monitor performance.Conducting regular safety meetings, encouraging incident reporting, and open communication also help keep safety front of mind. Recognising and rewarding safe behaviours can further reinforce a culture where safety is valued and consistently prioritised - something we encourage at Toyota Material Handling through our Pride in Performance approach - watch the video below.
Accidents often happen when risks go unnoticed or safety procedures are overlooked. That’s where our Safety Resources come in. From checklists and posters to easy-to-follow guides, these tools are designed to keep safety front of mind in your daily operations.