Workplace safety remains a critical issue across Australia. According to Safe Work Australia, there were 3,414 work-related fatalities between 2013 and 2016. More recent data shows 200 fatalities in 2023 and 198 in 20024 and 167 in 2025. While this reflects improvement, every incident is one too many.

Creating a safer workplace requires consistent systems, training, and awareness. Below are ten practical steps that can significantly reduce the risk of accidents—particularly in environments where forklifts operate.

1. Ensure Operators Are Properly Trained

Forklifts are powerful machines that require skill and awareness to operate safely. In Australia, it is a legal requirement for operators to hold a valid high-risk work licence issued through a registered training organisation.

Properly trained operators should be able to :

• Understand safe operating procedures
• Navigate warehouse environments efficiently
• Reduce the likelihood of incidents

Training should also be updated whenever warehouse layouts or processes change.  Make sure its documented as well.

2. Understand the Stability Triangle

A forklift’s stability is based on a three-point suspension system—two front wheels and a pivot point at the rear axle.

For safe operation of the forklift make sure:

• The combined centre of gravity must remain within this triangle
• Heavy or elevated loads shift the centre of gravity forward
• Loads should always be carried low while traveling

If the centre of gravity moves outside the triangle, the risk of tip-over increases significantly.

3. Complete a Pre-Start Safety Checklist

A pre-start inspection should be completed at the beginning of every shift.

Typical checks include:

• Tyres
• Fluid levels
• Controls and brakes
• Warning devices
• Mast and hydraulics
• Fork tines and guarding

Any defects must be reported immediately and the machine taken out of service if required.

4. Maintain Equipment Regularly

Routine servicing and maintenance are essential for safe forklift operation.

Well-maintained equipment:

• Reduces unexpected breakdowns
• Improves efficiency
• Minimises safety risks

5. Keep Pedestrians Clear of Equipment

Separation between people and machinery is one of the most effective safety measures.

Best practices include:

• Mandatory high-visibility clothing
• Clearly defined pedestrian walkways
• Use of warning devices such as horns and reversing alarms
• Visitor sign-in procedures with supervision

6. Establish and Enforce Traffic Flow

Warehouses should operate with clearly defined traffic management systems.

This includes:

• Marked lanes and pedestrian crossings
• Speed limits and signage
• No-parking zones
• Directional flow indicators

All staff must be trained on traffic flow, especially after layout changes.

7. Operate Safely on Slopes and Ramps

Slopes and inclines present a higher risk of instability.

Operators should always:

• Approach ramps slowly
• Maintain a safe distance from edges
• Ensure loads are stable and suitable for the gradient

8. Never Overload the Forklift

Overloading is a leading cause of forklift accidents.  Operators must always refer to the forklift’s data plate, which outlines:

• Load capacity
• Lift height limits
• Mast specifications
• Tyre requirements
• Gross vehicle mass

9. Ensure Adequate Lighting

Poor visibility contributes significantly to workplace accidents.

Effective lighting should:

• Be positioned over aisles and work areas
• Eliminate shadows and dark spots
• Support safe operation of equipment

LED lighting is often the preferred solution due to its efficiency and clarity.

10. Maintain a Clean and Organised Workplace

A clean workspace is a safer workspace.

Clutter and debris can:

• Obstruct forklift movement
• Increase collision risk
• Create fire hazards

Regular cleaning and proper storage practices help maintain a safe and efficient environment.

Our Final Thoughts

Reducing workplace accidents requires a proactive approach built on training, systems, and accountability.  By implementing these ten steps, businesses can significantly reduce risks, protect their workforce, and create a safer, more productive workplace.