Checklist template

Forklift, racking and overhead storage safety for home improvement stores

A ready-to-use checklist with 117 items in 6 sections, covering Operator certification, Racking, Overhead stock, Aisle closures, Pedestrians, Inspections. Use it as-is in Bindy, or adapt it to your own standards in minutes.

  • 6 Sections
  • 117 Items
  • 100 Yes / No checks
  • 6 Scored ratings
  • 130 Points

Use this template How audits work

1. Operator certification 18 items

  1. Lift truck operators on today's schedule Number
  2. Operators on today's schedule without a current certification Number
  3. Each operator's certification names the truck type driven: forklift, reach truck, order picker or sideloader Yes / No 1 pt
  4. Certification records at the store show the date, the trainer and the practical evaluation Yes / No 1 pt
  5. Operators were re-evaluated within the interval required by local regulation Yes / No 1 pt
  6. Operators involved in an incident or near miss were retrained before driving again Yes / No 1 pt
  7. The list of certified operators is posted where the truck keys are kept Yes / No 1 pt
  8. Truck keys or access codes are issued only to certified operators Yes / No 1 pt
  9. No employee under the minimum age set by local regulation operates a lift truck Yes / No 1 pt
  10. Operators were trained to carry long loads such as lumber, pipe and molding Yes / No 1 pt
  11. Operators asked could read the capacity plate and state the capacity at full lift height Yes / No 1 pt
  12. Attachments in use (carpet pole, fork extensions, boom) are listed on the truck's capacity plate Yes / No 1 pt
  13. Order picker operators observed wore a harness attached to the anchor point Yes / No 1 pt
  14. Operators observed wore the seat belt Yes / No 1 pt
  15. Operators observed traveled with the forks low and the mast tilted back Yes / No 1 pt
  16. Spotters have a training record for aisle closures and signaling Yes / No 1 pt
  17. Operators have a training record for changing propane cylinders or connecting batteries Yes / No 1 pt
  18. Operator certification Rating
    • All operators certified for the trucks they drive 5 pts
    • Certified, records incomplete 3 pts
    • Uncertified operators driving 1 pt

2. Racking 22 items

  1. Load capacity signs are posted on each run of pallet racking Yes / No 1 pt
  2. Pallets of tile, concrete mix and pavers sit on levels rated for their weight Yes / No 1 pt
  3. Rack uprights are free of dents, twists and tears Yes / No 1 pt
  4. Number of damaged uprights found Number
  5. Column protectors are in place on uprights along lift truck aisles Yes / No 1 pt
  6. End-of-aisle guards protect the rack frames at the main aisles Yes / No 1 pt
  7. Each upright footplate is anchored to the floor with all of its bolts Yes / No 1 pt
  8. Beam locking clips or pins are present at both ends of the beams sampled Yes / No 1 pt
  9. No beam shows visible sagging under its load Yes / No 1 pt
  10. Wire decking or pallet supports are in place on every level above the sales floor Yes / No 1 pt
  11. Damaged racking has been unloaded and tagged out of use Yes / No 1 pt
  12. Rack repairs are made by a qualified installer using the manufacturer's parts Yes / No 1 pt
  13. Racking shows no store-made welding, drilling or added parts Yes / No 1 pt
  14. Load signs were updated after the last change of beam levels Yes / No 1 pt
  15. Cantilever arms holding lumber, pipe or molding have end stops fitted Yes / No 1 pt
  16. Cantilever arms are straight and at the same angle along the run Yes / No 1 pt
  17. Loads on cantilever racks do not overhang the arm ends beyond the limit set by company policy Yes / No 1 pt
  18. Sheet goods, doors, countertops and ladders stored upright are held by a fastened chain or bar Yes / No 1 pt
  19. The flue space between back-to-back rows is clear of stock Yes / No 1 pt
  20. Stock is kept at least 18 in (46 cm) below sprinkler heads, or the greater clearance set by the local fire code Yes / No 1 pt
  21. Row spacers connect back-to-back rack frames Yes / No 1 pt
  22. Condition of racking Rating
    • Undamaged, anchored and signed 5 pts
    • Minor damage reported and under repair 3 pts
    • Unreported damage or missing safety parts 1 pt

3. Overhead stock 20 items

  1. Pallets in overhead storage are stretch-wrapped or banded Yes / No 1 pt
  2. Number of unsecured overhead pallets found Number
  3. Partial pallets were re-wrapped after product was picked from them Yes / No 1 pt
  4. Loose cartons in overhead positions are held by safety cable, netting or a rack guard as the company standard requires Yes / No 1 pt
  5. Tile, toilets, vanities and bagged goods are stored no higher than the level set by company policy Yes / No 1 pt
  6. Overhead pallets sit square on both beams Yes / No 1 pt
  7. No pallet overhangs into the aisle beyond the limit set by company policy Yes / No 1 pt
  8. No broken or split pallet is used overhead Yes / No 1 pt
  9. No overhead stack leans Yes / No 1 pt
  10. Pipe, carpet rolls and rolls of fencing stored overhead are chocked or contained Yes / No 1 pt
  11. Long product stored overhead does not stick out beyond the rack face Yes / No 1 pt
  12. Bays that customers walk under have full decking and a back guard Yes / No 1 pt
  13. Boxed water heaters are stacked no higher than the limit printed on the carton Yes / No 1 pt
  14. Pails of paint and joint compound are stacked no higher than company policy allows Yes / No 1 pt
  15. Mirrors, glass and shower doors are stored upright in their designated racks Yes / No 1 pt
  16. Flammable liquids and aerosols overhead are limited to the locations the store's fire plan allows Yes / No 1 pt
  17. Top stock on gondola shelving stays below the height line and is one layer deep Yes / No 1 pt
  18. Rolling ladders used for top stock have working wheel locks Yes / No 1 pt
  19. Overhead stock was walked after last night's replenishment, shown by a signed check Yes / No 1 pt
  20. Security of overhead stock Rating
    • Wrapped, restrained and stable 5 pts
    • A few unsecured items 3 pts
    • Many unsecured or leaning loads 1 pt

4. Aisle closures 18 items

  1. Gates or barriers close both ends of the aisle before a lift truck raises or lowers a load during opening hours Yes / No 1 pt
  2. The aisle on the other side of the rack is closed when pallets are moved in overhead positions Yes / No 1 pt
  3. Closures span the full aisle width, with no reliance on cones or tape alone Yes / No 1 pt
  4. The aisle is walked to confirm no customer is inside before it is closed Yes / No 1 pt
  5. Gates carry a sign that tells customers an employee will fetch the item for them Yes / No 1 pt
  6. A spotter stands at the closure while the truck works Yes / No 1 pt
  7. An employee fetches items for customers waiting at a closed aisle Yes / No 1 pt
  8. Number of aisle gate sets available in the store Number
  9. Aisle gates have working latches and no broken panels Yes / No 1 pt
  10. Overhead replenishment is scheduled outside opening hours where company policy requires it Yes / No 1 pt
  11. A closure observed during the visit followed each step of the procedure Yes / No 1 pt
  12. Closures stay in place until the load is set down and the forks are lowered Yes / No 1 pt
  13. The lumber aisle is closed while a sideloader or forklift pulls long stock from cantilever racks Yes / No 1 pt
  14. In the yard, customers wait in their vehicle or at a marked spot while a forklift loads Yes / No 1 pt
  15. No load is carried over or past a customer Yes / No 1 pt
  16. Pallets set down in an aisle are attended, or the aisle stays closed Yes / No 1 pt
  17. Employees asked could say when the adjacent aisle must be closed Yes / No 1 pt
  18. Aisle closure practice Rating
    • Closed at both ends with spotter every time 5 pts
    • Closed but steps skipped 3 pts
    • Lifts made with customers in the aisle 1 pt

5. Pedestrians 19 items

  1. A spotter walks ahead of any lift truck moving on the sales floor during opening hours Yes / No 1 pt
  2. Lift trucks on the sales floor move at walking pace Yes / No 1 pt
  3. Operators sound the horn at aisle ends and intersections Yes / No 1 pt
  4. Warning lights and the reverse alarm work on each truck in use Yes / No 1 pt
  5. Parked trucks have the forks flat on the floor Yes / No 1 pt
  6. Parked trucks have the key removed or the access code logged out Yes / No 1 pt
  7. No one rides on a lift truck, on the forks or on a pallet Yes / No 1 pt
  8. Pedestrian walkways in receiving and the yard are marked with visible paint Yes / No 1 pt
  9. Convex mirrors are in place at blind corners in receiving and the lumber building Yes / No 1 pt
  10. Employees working in the yard and receiving wear a high-visibility vest Yes / No 1 pt
  11. Signs keep customers out of the receiving area Yes / No 1 pt
  12. The drive-through lumber building has one-way arrows and a posted speed limit Yes / No 1 pt
  13. Pallet jacks are parked with forks down and out of walkways Yes / No 1 pt
  14. Customers pushing lumber carts with long loads are offered help through the store Yes / No 1 pt
  15. Operators stop when a pedestrian comes within the distance set by company policy Yes / No 1 pt
  16. A pedestrian door separate from the dock doors is used in receiving Yes / No 1 pt
  17. The truck parking and charging area is marked off from customer areas Yes / No 1 pt
  18. Near misses between lift trucks and pedestrians recorded in the last 90 days Number
  19. Separation of pedestrians and lift trucks Rating
    • Spotters, walkways and warnings all in use 5 pts
    • Some controls missing 3 pts
    • Trucks move among customers without controls 1 pt

6. Inspections 20 items

  1. Pre-use checklists are on file for each truck for the last 30 days without gaps Yes / No 1 pt
  2. Trucks with a reported defect are tagged out of service with the key removed Yes / No 1 pt
  3. Each lift truck was serviced by a qualified technician on the maintenance schedule Yes / No 1 pt
  4. Date of the last service of the oldest lift truck Date
  5. Forks and lift chains were examined as required by local regulation Yes / No 1 pt
  6. A racking inspection by a qualified person is on file for the period required by company policy Yes / No 1 pt
  7. Date of the last racking inspection Date
  8. Open findings from the last racking inspection Number
  9. Each open finding from the racking report has a repair date Yes / No 1 pt
  10. A manager walks the racking each month with a checklist Yes / No 1 pt
  11. The eyewash station at the battery charging area works when tested Yes / No 1 pt
  12. Order picker harnesses and lanyards have a recorded inspection within the interval set by company policy Yes / No 1 pt
  13. Employees asked know to report any truck impact on racking immediately Yes / No 1 pt
  14. Rack impacts are logged with the location and the inspection result Yes / No 1 pt
  15. Lift truck incidents and near misses have a written investigation with corrective actions Yes / No 1 pt
  16. Material handling was discussed at a safety committee meeting in the last quarter Yes / No 1 pt
  17. Findings from the last insurer or regulator visit on material handling are closed Yes / No 1 pt
  18. Name of the manager responsible for material handling safety Short text
  19. Overall material handling safety Rating
    • Excellent 5 pts
    • Good 4 pts
    • Fair 3 pts
    • Poor 1 pt
  20. Comments and corrective actions Comments

About this template

This checklist is part of the Bindy template library. Yes / No checks score 1 point when met; ratings score the points shown for each option. The overall score is the percentage of points earned, with N/A answers excluded. In Bindy you can add photos, assign corrective actions, require sign-off and compare results across sites.

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