# Standard Operating Procedure: [WAREHOUSE TASK NAME, e.g. Forklift Pre-Shift Inspection and Safe Pallet Handling]

## Document Control

| Field | Entry |
|---|---|
| SOP ID | [SOP-WHS-001] |
| Version | [1.0] |
| Effective Date | [YYYY-MM-DD] |
| Owner | [WAREHOUSE MANAGER NAME] |
| Approver | [OPERATIONS DIRECTOR / EHS MANAGER NAME] |
| Next Review Date | [YYYY-MM-DD — annually and after any recordable incident] |
| Facility / Zone | [SITE, e.g. DC-East, Zones A–C] |

## 1. Purpose

Prevent powered-industrial-truck injuries and product damage by standardizing [TASK, e.g. forklift pre-shift inspection and pallet put-away] in accordance with OSHA 29 CFR 1910.178 and [SITE SAFETY POLICY].

## 2. Scope

- **Applies to:** all certified forklift operators and [ROLES] in [ZONES], all shifts, including temporary workers who hold current certification.
- **Does not apply to:** [e.g. "order pickers and reach trucks, covered by SOP-WHS-004; dock operations, covered by SOP-WHS-006"].
- Operating a truck without current certification is prohibited (29 CFR 1910.178(l)) and grounds for [DISCIPLINARY POLICY REFERENCE].

## 3. Definitions

| Term | Definition |
|---|---|
| PIT | Powered Industrial Truck (forklift, pallet jack, reach truck) |
| Load center | Distance from the fork face to the load's center of gravity; capacity plate assumes [24 IN / 600 MM] unless stated |
| Pedestrian zone | Marked walkways where PITs must yield; [GREEN-PAINTED] lanes at this site |
| Spotter | A second person guiding the operator when vision is blocked or when working near [DOCK EDGES / RACKING REPAIRS] |

## 4. Responsibilities

| Role | Responsibility |
|---|---|
| Forklift Operator | Completes the pre-shift inspection; refuses to operate a defective truck; follows this SOP |
| Shift Supervisor | Collects inspection checklists; removes defective trucks from service (tag + key control); enforces speed and pedestrian rules |
| EHS / Safety Lead | Audits inspections [WEEKLY]; maintains certification records (valid 3 years, refresher per 1910.178(l)(4)) |
| All warehouse staff | Make eye contact with operators before crossing PIT lanes; report near-misses via [SYSTEM] |

## 5. Required Materials and Equipment

- Assigned PIT [TRUCK ID] with legible capacity plate
- Pre-shift inspection checklist [FORM ID] (paper or [APP NAME])
- PPE: high-visibility vest, safety-toe footwear ([ASTM F2413]), [HARD HAT IN ZONES WITH OVERHEAD WORK]
- Seatbelt functional — wearing it is mandatory whenever the truck is in motion
- "OUT OF SERVICE" tags and key-control box at [LOCATION]

## 6. Procedure

### Part A — Pre-shift inspection (required before first use each shift, 29 CFR 1910.178(q)(7))

1. **Walk-around, power off:** check forks (no cracks, heels not worn past [10%]), mast chains, hydraulic hoses (no leaks), tires, overhead guard, capacity plate legible, battery/LP tank secured.
2. **Power-on checks:** test horn, lights, backup alarm, steering, service and parking brakes, lift/tilt controls, and gauge readings. Brakes must hold on the [DOCK RAMP / TEST GRADE].
3. **Record results** on [FORM ID] with time and initials. **Any failed item:** park the truck at [LOCATION], attach an OUT OF SERVICE tag, drop the key in the control box, and notify the supervisor. Never operate a tagged truck.

### Part B — Pallet pick-up and put-away (example task; adapt to yours)

4. **Check the load first.** Verify weight from [WMS / LABEL] is within truck capacity at the load center. Refuse leaning, broken, or shrink-wrap-torn pallets — restack per [SOP-WHS-00X].
5. **Approach square, forks level,** spread to at least [75%] of pallet width. Enter fully until the fork heels touch, then lift [4–6 IN / 10–15 CM] and tilt the mast back before traveling.
6. **Travel rules:** forks [4–6 IN] off the floor, mast tilted back; speed limit [5 MPH / 8 KM/H] and [3 MPH] in pedestrian areas; sound the horn at intersections and blind corners; travel in reverse if the load blocks forward view; keep [THREE TRUCK LENGTHS] behind other PITs.
7. **At the rack:** stop square to the bay, raise the load just above beam height, move forward, lower onto both beams, confirm the pallet is fully seated with no overhang past [ALLOWED OVERHANG], back out, lower forks, then travel.
8. **Parking:** forks flat on the floor, controls neutral, parking brake set, key removed [OR PER SITE KEY POLICY]. Never park blocking exits, electrical panels, or fire equipment (extinguisher clearance per [1910.157]).

## 7. Stop-Work Conditions

Stop and call the supervisor immediately if you observe: damaged racking (bent upright, missing safety clip), a pedestrian in the working aisle, an unstable stacked load, a hydraulic leak, or dock-plate movement. Damaged racking gets a [RACK DAMAGE TAG] and the bay is emptied per [SOP-WHS-00X].

## 8. Safety and Compliance Notes

- Regulatory basis: OSHA 29 CFR 1910.178 (powered industrial trucks), 1910.176 (materials handling), [STATE PLAN EQUIVALENTS].
- Battery charging only in the designated area with eyewash within [25 FT]; no smoking; PPE per [SOP-WHS-00X].
- Incidents and near-misses reported within [SHIFT END] via [SYSTEM]; recordables follow [OSHA 300] logging.
- Inspection checklists retained [PERIOD, e.g. 12 months] for audit.

## 9. Related Documents

- [SOP-WHS-004 — Reach Truck and Order Picker Operation]
- [SOP-WHS-006 — Dock and Trailer Loading]
- [FORM PIT-01 — Pre-Shift Inspection Checklist]

## 10. Revision History

| Version | Date | Author | Summary of Changes | Approved By |
|---|---|---|---|---|
| [1.0] | [YYYY-MM-DD] | [NAME] | Initial release | [NAME] |
| [ ] | [ ] | [ ] | [ ] | [ ] |

---
Template by Pellucida (pellucida.ai) — turn this SOP into a training video at pellucida.ai/solutions/sop-to-training-video