Free job hazard analysis · 29 CFR 1910.178
Forklift JHA Template: From Inspection to Parking
A forklift JHA maps the hazards of moving loads from the first truck inspection through shutdown. The template covers pedestrian contact, unstable loads, tip-over risks, rack placement, and parking. Warehouse supervisors and operators use it to agree on traffic routes and handling controls for their trucks, loads, and storage layout.
The full forklift JHA template
Forklift Operation. Blanks in [brackets] are for your own details.
The printable copy downloads as a web page file: open it in your browser, then print it or save it as a PDF.
Job hazard analysis for powered industrial truck operation including loading, unloading, and travel.
- Step 1
Pre-operation inspection
Medium riskHazards
Operating defective equipment
Controls
Complete daily checklist: brakes, steering, horn, lights, forks, tires, fluids, seatbelt, overhead guard.
- Step 2
Start and travel to pick location
Medium riskHazards
Pedestrian strikes, collision with structures
Controls
Sound horn at intersections. Travel with forks 4-6 inches off ground, tilted back. 5 mph max in warehouse.
- Step 3
Approach and pick up load
High riskHazards
Tip-over, load instability, crushing
Controls
Check load weight vs. capacity plate. Center forks under load. Tilt mast back before lifting. No riders.
- Step 4
Travel with loaded forklift
High riskHazards
Tip-over on turns, obstructed view, pedestrian strikes
Controls
Travel in reverse if load blocks view. Slow down on turns. No sudden stops. Seatbelt worn at all times.
- Step 5
Place load at destination
Medium riskHazards
Falling load, rack collapse, pinch points
Controls
Ensure rack capacity not exceeded. Level forks before placing. Back away slowly after disengaging forks.
- Step 6
Park and shut down
Low riskHazards
Unattended forklift rollaway, unauthorized use
Controls
Lower forks flat to ground, set parking brake, turn off ignition, remove key. Chock wheels on inclines.
The printable copy lays the steps out as a table with Prepared by, Reviewed by and Date lines.
A starting point, not legal advice. Have a qualified person check it against your site, your state's rules and the standard before you rely on it.
Forklift JHA: when it’s needed
Use this analysis when introducing a truck, changing warehouse routes, handling unfamiliar loads, or reviewing a near miss. Federal rules do not generally demand a written forklift JHA, but the operating duties still apply. Operator training and evaluation are addressed in 29 CFR 1910.178(l). Section 1910.178(q)(7) requires examination before service, at least daily, with examination after each shift for continuous use. An unsafe truck must stay out of service; writing down its defect is not enough.
How to use this forklift JHA template
- Identify the truck model, attachments, load types, and operating areas before reviewing the six handling steps with operators.
- Set pedestrian separation and intersection controls using an actual walk through the warehouse during normal activity.
- Check load weight, load center, rack limits, and attachment effects against the truck’s capacity information before approving handling methods.
- Replace generic travel speeds and fork heights with operating rules suited to visibility, surfaces, and manufacturer instructions.
Before you use this forklift JHA template: what to fill in and check
- Truck identification, capacity plate details, attachments, and authorized operator names.
- Blind corners, dock edges, slopes, pedestrian crossings, and restricted travel lanes.
- Inspection responsibility, defect reporting contact, and the process for removing unsafe trucks.
- Rack load ratings and floor conditions along each planned transport route.
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- Printable table with Prepared by and Reviewed by lines
- Blanks marked for your company details
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Forklift JHA questions
Does a forklift JHA replace operator certification?
No. The analysis explains task hazards and controls; it does not establish that an operator can safely drive a particular truck. Under 29 CFR 1910.178(l), training includes formal instruction, practical training, and workplace evaluation. The employer certifies training and evaluation. Use the JHA to support discussions about the specific routes and loads an authorized operator will encounter.
Is five miles per hour the OSHA forklift speed limit?
The template uses five miles per hour as a warehouse example, not a universal federal limit. Section 1910.178(n)(8) requires a speed that permits safe stopping under all travel conditions. Set your limit after considering pedestrians, stopping distance, floor traction, corners, and visibility. A posted limit does not excuse traveling too fast for conditions.
What changes when a forklift attachment is added?
Attachments can change capacity, load center, visibility, and handling. Review the truck and attachment information before changing the JHA’s load pickup and placement controls. Modifications or additions affecting capacity and safe operation require the manufacturer’s prior written approval under 29 CFR 1910.178(a)(4), with the relevant markings changed accordingly. Do not estimate a new safe capacity from experience alone.