Forklift Operator Evaluation Checklist for Warehouse Managers

Evaluating forklift operator competence is a Cal/OSHA requirement — but many warehouse managers aren't sure exactly what to look for during an evaluation. A thorough evaluation ensures that operators can work safely, identifies training gaps before they lead to accidents, and provides the documentation needed for OSHA compliance.

This checklist provides a comprehensive framework for evaluating forklift operators. Use it during initial certification, 3-year recertification, and any time you need to assess an operator's competence.

What Cal/OSHA Requires for Operator Evaluation

Before diving into the checklist, it's important to understand what Cal/OSHA actually requires. Title 8 CCR 3668(d)(3) states that "an evaluation of each powered industrial truck operator's performance shall be conducted" after initial training and at least every three years thereafter.

The evaluation must be conducted by a person who has the knowledge, training, and experience to train operators and evaluate their competence. This means the evaluator must be familiar with:

• The type of forklift being operated
• The workplace environment where the operator works
• Safe operating procedures and Cal/OSHA requirements

The evaluation must include observation of the operator performing normal operating tasks in the workplace. It cannot be conducted in a classroom or through a written test alone.

Pre-Evaluation Preparation

Before conducting an evaluation, prepare the following:

• The evaluation form — a checklist (like the one below) to document observations
• The operator's training records — to verify that the operator has completed required training
• The forklift — the specific truck the operator will be evaluated on, in safe operating condition
• The evaluation area — a route through the workplace that includes typical operating conditions (aisles, intersections, loading docks, ramps, etc.)
• Time — plan for 15-30 minutes per operator, depending on the complexity of the tasks

Inform the operator that they are being evaluated, but try to make the evaluation as natural as possible by having them perform their normal work tasks.

Forklift Operator Evaluation Checklist

Use this checklist during the practical evaluation. For each item, mark whether the operator performed the action correctly (PASS), needs improvement (NEEDS WORK), or failed to perform the action (FAIL).

Section 1: Pre-Shift Inspection (5 minutes)

Before operating the forklift, the operator should perform a pre-shift inspection and document it:

• [ ] Operator checks the forklift for visible defects — walks around the truck, inspects tires, forks, mast, hoses, and body for damage
• [ ] Operator checks fluid levels — engine oil, hydraulic fluid, coolant, brake fluid (for internal combustion trucks); battery water level and charge (for electric trucks)
• [ ] Operator checks safety devices — horn, lights, backup alarm, seat belt, overhead guard, load backrest
• [ ] Operator checks operational functions — lift, lower, tilt, steer, brake (performed in a safe area before entering the work zone)
• [ ] Operator documents the inspection — fills out the daily inspection log
• [ ] Operator reports any defects — if defects are found, the operator reports them and does not operate the forklift until repairs are made

Section 2: Starting and Stopping (5 minutes)

• [ ] Operator mounts the forklift correctly — uses three points of contact, faces the forklift
• [ ] Operator fastens the seat belt — before starting the engine or engaging the controls
• [ ] Operator starts the forklift correctly — follows the proper starting procedure for the truck type (key, neutral, parking brake off, etc.)
• [ ] Operator tests the controls — verifies that all controls function properly before moving
• [ ] Operator uses the horn appropriately — at intersections, blind corners, pedestrian areas, and when backing up
• [ ] Operator stops smoothly — uses brakes appropriately, does not slam to a stop
• [ ] Operator parks correctly — forks lowered, controls neutralized, parking brake set, key removed (when unattended)

Section 3: Driving and Maneuvering (10 minutes)

• [ ] Operator drives at a safe speed — not exceeding posted speed limits, reducing speed for conditions
• [ ] Operator maintains proper visibility — looks in the direction of travel, adjusts for load obstruction
• [ ] Operator yields to pedestrians — stops or slows for pedestrians, maintains safe clearance
• [ ] Operator maintains safe following distance — does not tailgate other forklifts or vehicles
• [ ] Operator proceeds through intersections cautiously — slows, looks both ways, sounds horn
• [ ] Operator backs up safely — looks behind before backing, uses horn, watches for pedestrians
• [ ] Operator turns corners safely — reduces speed, watches for rear-end swing, maintains control
• [ ] Operator drives on ramps correctly — drives with load uphill (when loaded), drives in reverse with load downhill (if required), maintains control
• [ ] Operator operates in narrow aisles safely — maintains clearance, watches for obstructions, uses horn at blind corners
• [ ] Operator maintains control at all times — no abrupt maneuvers, no speeding, no reckless operation

Section 4: Load Handling (10 minutes)

• [ ] Operator approaches the load correctly — perpendicular to the load, forks level and adjusted to the correct width
• [ ] Operator inserts forks fully — forks go all the way under the pallet, not just partially
• [ ] Operator tilts the mast back — tilts the mast back slightly before lifting to stabilize the load
• [ ] Operator lifts the load smoothly — no jerk or sudden movements, lifts to the required height
• [ ] Operator checks load stability — verifies the load is stable and secure before traveling
• [ ] Operator travels with the load low — forks 4-6 inches off the ground, not elevated
• [ ] Operator tilts the mast back when traveling — maintains the load in a tilted-back position for stability
• [ ] Operator places the load correctly — lowers the load smoothly, tilts the mast forward to deposit, withdraws forks smoothly
• [ ] Operator stacks loads correctly — aligns with the existing stack, lowers gently, does not damage the lower load
• [ ] Operator does not exceed load capacity — checks the load weight against the forklift's rated capacity, does not lift overweight loads
• [ ] Operator handles awkward loads safely — uses attachments if needed, secures unstable loads, asks for assistance if needed

Section 5: Loading Dock Operations (if applicable)

• [ ] Operator approaches the dock cautiously — checks that the dock plate is secure and properly positioned
• [ ] Operator verifies trailer stability — checks that the trailer is chocked or restrained before entering
• [ ] Operator enters the trailer straight — aligns the forklift with the trailer, enters smoothly
• [ ] Operator operates inside the trailer safely — watches for overhead clearance, floor condition, and trailer capacity
• [ ] Operator exits the trailer safely — backs out slowly, checks behind for pedestrians and vehicles

Section 6: Pedestrian and Workplace Awareness

• [ ] Operator is aware of pedestrians at all times — scans for pedestrians, yields right-of-way
• [ ] Operator uses designated travel lanes — stays in marked forklift lanes, does not operate in pedestrian areas
• [ ] Operator follows workplace signage — obeys speed limits, stop signs, one-way indicators
• [ ] Operator reports hazards — identifies and reports spills, obstacles, damaged racking, or unsafe conditions
• [ ] Operator communicates with coworkers — uses horn, eye contact, or verbal communication at intersections and when sharing space

Section 7: End-of-Shift Procedures

• [ ] Operator parks the forklift in the designated area — not blocking aisles, exits, or emergency equipment
• [ ] Operator lowers the forks — forks fully lowered and tilted forward
• [ ] Operator neutralizes the controls — transmission in neutral, parking brake set
• [ ] Operator turns off the forklift — key removed and stored properly
• [ ] Operator reports any issues — reports defects, damage, or unsafe conditions to the supervisor
• [ ] Operator completes the end-of-shift documentation — logs hours, fuel/battery level, and any issues

Documentation of the Evaluation

After completing the evaluation, document the results on the evaluation form:

• Operator name
• Date of evaluation
• Evaluator name
• Equipment type evaluated (e.g., sit-down counterbalance forklift, propane)
• Evaluation results — PASS, NEEDS WORK, or FAIL for each section
• Notes — specific observations, areas of concern, and any corrective actions needed
• Overall result — PASS (operator is competent) or FAIL (operator needs additional training)
• Operator signature — acknowledging the evaluation was conducted
• Evaluator signature — certifying the evaluation results

If the operator does not pass any section, document the specific areas that need improvement and schedule refresher training to address those areas before the operator returns to forklift operations.

What to Do If an Operator Fails the Evaluation

If an operator fails the evaluation (either a specific section or the overall evaluation):

1. Do not allow the operator to operate the forklift until the deficiencies are corrected
2. Provide refresher training on the specific areas where the operator did not demonstrate competence
3. Re-evaluate the operator after refresher training to verify that the deficiencies have been corrected
4. Document the refresher training and re-evaluation — including the date, trainer, topics covered, and results
5. If the operator continues to fail after refresher training and re-evaluation, consider removing the operator from forklift duties

How Often to Conduct Evaluations

Cal/OSHA requires evaluations at the following times:

• After initial training — before the operator begins working independently
• Every 3 years — at least once every three years, regardless of whether issues have been observed
• After an accident or near-miss — refresher training and re-evaluation after any incident
• After unsafe operation is observed — refresher training and re-evaluation when unsafe behavior is witnessed
• When switching truck types — evaluation on the new truck type before the operator begins using it

Need help evaluating your forklift operators? Call (840) 259-0943 or schedule operator evaluation — our certified trainers provide on-site operator evaluations, refresher training, and 3-year recertification throughout Los Angeles, Orange County, and the Inland Empire.