Forklift & Tugger Pre-Operation Checklist

This comprehensive forklift & tugger pre-operation checklist helps teams maintain regulatory compliance and operational control against OSHA 29 CFR 1910, NFPA 70E, and related requirements. Designed for Plant Supervisor / EHS / Quality Lead, complete all sections, capture evidence, and log corrective actions to reduce risk and improve readiness.

  • Industry: Automotive
  • Frequency: Daily
  • Estimated Time: 20-35 minutes
  • Role: Plant Supervisor / EHS / Quality Lead
  • Total Items: 35
  • Compliance: OSHA 29 CFR 1910, NFPA 70E, IATF 16949, ISO 45001

Pre-Start & Documentation

Verify the shift starts with required permits, procedures, and records in place.

  • SOPs and work instructions available at point of use?
  • Latest risk assessment/JSA reviewed with team?
  • Required permits validated (hot work, LOTO, confined space) if applicable?
  • Previous shift issues reviewed and assigned?
  • Notes / exceptions

Machine Guarding & Safe Operation

Confirm safeguarding and safe operating controls per machinery safety standards.

  • Machine guards installed, intact, and not bypassed?
  • Emergency stops tested and accessible?
  • Interlocks/light curtains functional where present?
  • Lockout points labeled and accessible?
  • Photo evidence of guarding

Process Quality & Traceability

Verify critical quality checks, process parameters, and traceability controls.

  • Critical-to-quality checks completed at required frequency?
  • Gauges/fixtures within calibration date?
  • Traceability labels present and correct (lot/serial/date)?
  • Nonconforming material identified and segregated?
  • Record key readings (torque/press force/paint thickness)

Chemical Handling & WHMIS

Check hazardous products management, labeling, and SDS access.

  • All chemical containers labeled and in good condition?
  • SDS accessible for all chemicals in use?
  • Secondary containment used where required?
  • Spill kit stocked and available in area?
  • Notes on chemical issues

Preventive Maintenance & LOTO

Confirm maintenance readiness, planned work, and isolation controls.

  • PM schedule up to date for critical assets?
  • LOTO procedure available and followed for servicing?
  • Tools and parts stored safely (no trip hazards)?
  • Compressed air/hydraulic lines inspected for leaks?
  • Corrective actions assigned for any defects?

Ergonomics & Manual Handling

Reduce MSD risk by checking lifts, reaches, and workstation setup.

  • Lifts within limits or mechanical assist used?
  • Workstation height and reach zones acceptable?
  • Job rotation/breaks applied per plan?
  • PPE available and used (gloves, eye/ear)?
  • Photo of workstation setup

Emergency Preparedness & Reporting

Ensure emergency equipment is ready and incidents are reported correctly.

  • Fire exits/routes clear and illuminated?
  • First aid kit and AED accessible (if applicable)?
  • Incident/near-miss reporting process posted and understood?
  • Emergency contacts and muster points posted?
  • Corrective action summary

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Why Use This Forklift & Tugger Pre-Operation Checklist?

This forklift & tugger pre-operation checklist helps automotive teams maintain compliance and operational excellence. Designed for plant supervisor / ehs / quality lead professionals, this checklist covers 35 critical inspection points across 7 sections. Recommended frequency: daily.

Ensures compliance with OSHA 29 CFR 1910, NFPA 70E, IATF 16949, ISO 45001. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Forklift & Tugger Pre-Operation Checklist cover?

This checklist covers 35 inspection items across 7 sections: Pre-Start & Documentation, Machine Guarding & Safe Operation, Process Quality & Traceability, Chemical Handling & WHMIS, Preventive Maintenance & LOTO, Ergonomics & Manual Handling, Emergency Preparedness & Reporting. It is designed for automotive operations and compliance.

How often should this checklist be completed?

This checklist should be completed daily. Each completion takes approximately 20-35 minutes.

Who should use this Forklift & Tugger Pre-Operation Checklist?

This checklist is designed for Plant Supervisor / EHS / Quality Lead professionals in the automotive industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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