Hello. 

We are having key issues with our forklifts. We run 24/7 and have a lot of turn over and it seems we cannot cut enough keys to keep people happy. We have tried glueing them in the key slot (which works until someone breaks it off), cable tieing them to the dash board etc. We are going to switch over to just a "start button" on our forklifts. This will be a conversion purchased from the manufacturer/ authorized dealer servicer and will either be installed by the servicer or by our in house guy.

But one of our maint guys recalls a past issue at a previous job that OSHA did not like the lack of keys. My guess is that the concern would be that it is too easy for an unauthorized driver to use a forklift if there is no key to help control that issue? We would have to step up our policing of drivers and send home early anyone cought driving one without a license.

 I dont see anything that specifically says boton start forklifts are illeagel. Has anyone been through this situation?

 Thanks

Akula,

It sounds like you have two different issues. The first would be the modification of the forklift. Since it is taking place with the permission of the manufacturer it is legal. The second issue is who can drive the truck. Since it is a violation to operate a forklift without training and certification, you need to identify the trained drivers in some way. The cheapest and easiest is a decal for the operator's hard hat or badge. If you wanted to get fancy, you could tie the starter into an onboard badge reader.

 MikeCJ

Right. For identification they have licenses issued (photo forklift operator IDs) it should be easy enough for the dept floor supervisors and leads to know the usual drivers per shift.  Only about 25 production people per shift so we will just have to tighten up on the enforcement to counter the easy access to driving. Spot checks for the Licenses to weed out the joy riders. Just wanted to follow up on if the coworkers previous knowledge was legit or not. Thanks.

As a side note, has anyone actually gotten a letter from a manufacturer to authorize a forklift modification? All I want to do is remove the tail lights that are continuously broken rather than continue the expense to repair/replace. These are only indoor forklifts. And yes the real issue is they should not be running into so much stuff but other than firing them nothing seems to work.

Akula,

1910.178(a) addresses modifications and it basically addreses changes that affect the capacity or performance of the forklift. So I would not expect anything from the manufacturer on the push button ignition issue.

With respect to the removal of the tail lights, I think OSHA would have big issue with it since the tailights are "safety equipment" on the forklift. OSHA's intent is for you to keep the forklift the way manufacturer intentded it unless a change is absolutely necessary.

MikeCJ

There is a company out there that makes "impact sensors" for forklifts. If someone hits something, hard enough to knock a light off for example, the impact sensor shuts down the forklift and sounds an audible alarm. Maintenance holds the only key to turn the alarm off. That way maintenance can survey the area for damage and get it repaired. We had a problem with high bay racking supports getting hit and bent, but not reported. The sensors worked great. It was with my last employer so I do not have the name handy but I could find out if you cannot find anything online.

I would suggest documented training with each employee signing that the battery disconnect will be turned off after each operators' use. In addition that you can show that only authorized operators and anyone that operates that is not authorized has been disciplined will give you a defense. Also, signs on the forklift that only authorized operators may use the vehicle.