【Safety Management and Standardization of Special Equipment】What are the 9 most common issues encountered during on-site inspections of forklifts? (Including complete rectification requirements)

Question 2: Forklift operators working without proper licenses or with expired licenses that have not been renewed. Risk factor: Forklift operators are engaged in operations without the necessary N1 qualification certificate for operating special equipment； The certificate of the qualified person has expired or has not been renewed on time ； Unlicensed persons operate forklifts by taking over positions or working in place of authorized operators. Legal basis: Article 14 of the Special Equipment Safety Law ； Article 2.6 of TSG 08-2026 \"Rules for the Use and Management of Special Equipment\" ； TSG 81-2022 \"Safety Technical Regulations for Special Motor Vehicles Used in Sites (Factories)\", 5.1.1(8). Hazard classification: It is a general safety management violation and does not constitute a major accident hazard. Rectification requirements: 1. Immediately stop all unlicensed personnel from operating forklifts and remove them from their work positions ； 2. Forklift operators on duty must hold a valid N1 special equipment operation certificate, ensuring that the person and the certificate correspond and that they work with the appropriate certification ； 3. Establish a ledger for managing the certificates of operational personnel, record the expiration dates and renewal times of these certificates, and issue early warnings to ensure timely renewal ； 4. Conduct regular training on the safe operation procedures for forklifts as well as risk prevention and control.

Question 3: Forklifts are used continuedly despite not undergoing regular inspections or failing such inspections. Potential risks: Failure to have inspections conducted on time after the expiration of the regular inspection period, as well as prolonged neglect of inspection requirements； The results of the regular inspections were unsatisfactory; no corrective actions were taken, no re-inspections were conducted, and the equipment was still put into use on site. Legal basis: Article 40 of the Special Equipment Safety Law ； TSG 81-2022 “Safety Technical Regulations for Special Purpose Motor Vehicles within Premises (Factories)”, Clause 4.2 ； GB 45067-2024 \"Criteria for Identifying Major Hidden Dangers in Special Equipment\", 4.10. Nature of the hazard: Merely exceeding the inspection deadline; no operation while faulty: Minor violation ； Continued use despite failing inspections: directly deemed a major hazard potential. Rectification requirements: 1. Forklifts that have not undergone inspections on time must be suspended from use immediately, and a qualified inspection agency should be contacted promptly to schedule an inspection ； 2. Forklifts that fail the inspection must be immediately taken out of service and sealed up; defects and potential hazards must be addressed one by one, after which an application for re-inspection should be submitted ； 3. If the re-inspection still fails to meet the requirements of the safety technical specifications, the item shall be scrapped and deregistered in accordance with the law. It is strictly prohibited to continue using it after unauthorized repairs ； 4. Establish a ledger for forklift inspection schedules, plan inspections 1 month in advance to prevent overdue or missed inspections.

Question 4: Missing or damaged braking systems, steering systems, reverse warning devices, mirrors, roof racks, etc. Potential risks: failure of the forklift’s braking system, braking deviation； The steering is stuck and not responsive ； The reverse alarm and horn do not function and make no sound ； The absence or damage of mirrors affects visibility ； The roof protection frame is deformed, cracked, or has been removed without authorization, yet it is still used for normal operations. Regulatory basis: Relevant provisions of TSG81-2022 \"Safety Technical Regulations for Special Motor Vehicles Used in Sites (Factories)\\" ； GB 45067-2024 \"Criteria for Identifying Major Hidden Dangers in Special Equipment\", 4.10. Hazard classification: The use of braking systems that are missing, damaged, or malfunctioning is considered a major hazard, while other cases are classified as minor hazards. Rectification requirements: 1. Immediately stop using the forklift with safety defects, and conduct a thorough inspection of key safety devices such as the braking system, steering system, sound and light warning systems, mirrors, and roof guards ； 2. Damaged or missing components shall be repaired or replaced with compliant parts to restore the original factory-level safety features ； 3. After the maintenance is completed, it can be put back into use only after passing no-load and heavy-load test runs ； 4. Include the integrity check of safety devices as a mandatory item in the daily pre-shift inspection; stop the machine immediately in case of any abnormalities and report for repair.

Question 5: The driver fails to wear the seat belt properly during operations, or the originally installed seat belt is damaged and no longer functional. Risk scenario: The forklift is equipped with a seat belt from the factory, but the driver habitually fails to wear it while operating the vehicle； The original safety belts come with issues such as damaged straps, malfunctioning buckles, and damaged components that prevent them from functioning properly ； Removing the original vehicle’s seat belt system without permission. Regulatory basis: Article 5.1.4 of TSG 81-2022 \"Safety Technical Regulations for Special Motor Vehicles Used in Sites (Factories)\\": Wear a safety belt (if available) while driving and operating. Risk classification: Applicable only to vehicles equipped with seat belts originally by the manufacturer; failures such as failure to wear them, damage to them, or unauthorized removal constitute violations resulting from habitual on-site practices, and are considered general safety management violations ； Forklifts designed by the manufacturer without seat belts do not constitute a safety hazard in the absence of such belts or when they are not worn; they therefore do not represent a serious risk of accident. Rectification requirements: 1. For forklifts equipped with original safety belts, immediately replace any damaged, defective, or worn-out belt components to restore them to a functional state ； It is strictly prohibited to remove the original vehicle’s seat belt system without permission ； 2. It is explicitly stipulated that for forklifts equipped with safety belts originally by the manufacturer, these belts must be worn properly throughout the entire process of starting the machine, operating it, and carrying out loading and unloading tasks ； 3. Safety warning signs shall be posted in the forklift cab equipped with seat belts to standardize operating practices.

Question 6: Illegal operations: overloading the load, using forks to carry people, having goods obstructing the view, driving at excessive speeds within the factory premises. Potential risk: lifting goods beyond the forklift’s rated load capacity； Using forks to position people and carry them for high-altitude work ； The goods are stacked too high, blocking the driver’s view; no reversing is done, and no dedicated person is assigned to give instructions ； Speeding, making sharp turns, and reckless driving within the factory premises. Regulatory basis: TSG81-2022 \"Safety Technical Regulations for Special Motor Vehicles Used in Sites (Facilities)\", 5.1.4. Hazard classification: A typical violation of safety procedures in on-site operations, which can very easily lead to overturning, collisions, falling of goods, and injuries to personnel. Rectification requirements: 1. Operate strictly in accordance with the rated load indication on the vehicle body; overloading is strictly prohibited, as is using the forks to carry people ； 2. When the cargo blocks the view, it is necessary to reverse at a low speed, or assign a dedicated person to direct traffic on site ； 3. Designate dedicated driving routes for forklifts and set speed limits within the factory area; speeding, sudden turns, and rough handling are strictly prohibited ； 4. Strengthen on-site inspections to correct violations, and include proper forklift operation in the team’s safety assessment.

Question 7: No safety technical records available, no pre-shift inspection and maintenance logs, and absence of safety management systems. Risk factor: No safety technical records specific to each forklift are kept； There are no records of daily pre-shift inspections, regular maintenance activities, or documentation of actions taken to address identified risks ； No safety management system for special equipment, forklift operation procedures, or plans for identifying potential hazards and responding to emergencies have been established. Legal basis: Article 35 of the Special Equipment Safety Law ； Article 3.3 of TSG 08-2026 \"Rules for the Use and Management of Special Equipment\" ； Nature of the risk: The primary responsibilities regarding special equipment have not been properly fulfilled, which constitutes a general violation related to archive management. Rectification requirements: 1. Ensure that each forklift has a dedicated set of documents: factory delivery records, usage registration information, inspection reports over the years, maintenance records, and records of any hazards that were addressed – all of these should be archived together ； 2. Strictly implement daily pre-shift self-inspections and periodic maintenance; ensure that records are accurate and complete, with proper signatures, to enable traceability and a closed-loop system ； 3. Compile and post on the wall the safety management regulations for special equipment, safety operating procedures for forklifts, systems for identifying and addressing potential hazards, and emergency response plans ； 4. Standardize ledger management, eliminate retroactive filling in and blank records, to ensure readiness for inspections at any time.

Question 8: Failure to conduct safety assessments when operating beyond the original vehicle’s design parameters, beyond its designated scope of use, or beyond its designed service life. Risk scenario: Operating beyond the original vehicle’s design parameters and beyond its designated scope of use； Forklifts that have reached the design service life specified by the manufacturer continue to be put into use without undergoing a safety assessment in accordance with relevant standards. Regulatory basis: Relevant provisions of TSG 81-2022 \"Safety Technical Regulations for Special Motor Vehicles Used in Sites (Facilities)\\" ； GB 45067-2024 \"Criteria for Identifying Major Hidden Dangers in Special Equipment\" ； GB/T 44679-2024 \"Technical Specifications for Banning and Scrapping Forklifts\" is a recommended standard intended solely for reference; it shall not be used as a basis for legal determination or for identifying major safety hazards. Hazard classification: Continued use beyond the designed parameters or intended scope of use; in accordance with the relevant provisions of GB 45067-2024, it is classified as a major accident hazard ； It continues to be used after reaching its designed service life without undergoing a safety assessment; the current GB 45067-2024 does not contain explicit provisions for classifying this as a major hazard, and it is instead regarded as a minor violation of safety management regulations. Rectification requirements: 1. If it is used beyond the design parameters or specified scope, use must be stopped immediately; it can be reused only after rectification and passing inspection ； 2. For forklifts that have reached their designed service life, strictly control the loading capacity immediately and commission a qualified inspection agency to conduct a safety assessment ； For those that pass the evaluation, enhance regular inspections and maintenance, and shorten the inspection intervals ； For those that do not meet the conditions for safe use, they shall be shut down and scrapped in accordance with the law, along with the cancellation of their usage registration ； 3. Establish a ledger for forklift equipment, recording the date of manufacture and the designed service life; issue early warnings to prevent use beyond the designed lifespan without evaluation. Question 9: A working mechanism of \"daily monitoring, weekly inspections, and monthly scheduling\" as well as the corresponding record-keeping systems have not been established

Question 9: A working mechanism for daily monitoring, weekly inspections, and monthly coordination has not been established, nor are there any relevant records. Risk situation: No director for special equipment safety or safety officers have been appointed； A risk management checklist for forklifts has not been established ； The safety officer fails to conduct inspections on a daily basis in accordance with the risk management checklist, or inspections are carried out but there is no \"Daily Safety Inspection Record\" ； The Safety Director fails to organize risk and hazard inspections at least once a week, or although inspections are carried out, there is no \"Weekly Safety Inspection and Management Report\" ； The main person in charge of the enterprise fails to listen to the safety director’s work reports at least once a month and make corresponding arrangements, or although arrangements are made, there is no \"Minutes of Monthly Safety Coordination Meetings\" ； Relevant performance records are missing or merely formalities ； There is no closed-loop management for potential issues. Regulatory basis: Provisions on the Supervision and Management of Special Equipment Users’ Fulfillment of Their Primary Responsibilities for Safety in Use (Order No. 74 issued by the State Administration for Market Regulation). Classification of the hazard: It falls under the category of inadequate implementation of the responsibilities related to special equipment; a mechanism for daily monitoring, weekly inspections, and monthly reviews has not been properly established. The violations detected during on-site inspections are considered minor breaches of regulations. However, in recent years such issues have gradually become part of the key areas of focus in specialized inspections of forklifts across various regions. Any deficiencies must be corrected, and in severe cases, sanctions including public announcements or administrative penalties may be imposed. Requirements for rectification: 1. The main person in charge of the enterprise must appoint, in writing, a safety director and safety officers for special equipment, define their job responsibilities, and ensure that the main person in charge bears primary responsibility. It is necessary to \"manage these three types of personnel (the person in charge, the safety director, and the safety officers) properly and carry out three tasks (appointing personnel, defining responsibilities, and improving systems)\”. The safety director must hold a qualification certificate for special equipment safety management personnel ； 2. Based on the actual conditions of the unit’s forklift types, purposes, and operating environment, develop a \"Forklift Safety Risk Control List\" that identifies potential safety hazards in various aspects such as the equipment itself, operational procedures, and the surrounding environment ； 3. Establish and implement a daily management control system: The safety officer conducts inspections item by item based on the risk control checklist every day, and the results of these inspections are recorded in the «Daily Safety Inspection Record». Upon identifying a problem, preventive measures should be taken immediately. Issues that can be resolved on the spot should be fixed right away, while those that cannot be addressed immediately require a specified deadline for correction; follow-up inspections should then be conducted to verify that the corrections have been implemented ； 4. Establish and implement a weekly inspection system: The safety director shall organize at least one risk assessment per week to thoroughly examine any potential hazards that may arise at various stages of forklift use. The results of the inspections are compiled into a \"Weekly Safety Inspection and Management Report\", which is submitted to the Safety Director in a timely manner to urge the implementation of appropriate control measures and ensure that risks remain under control ； 5. Establish and implement a monthly scheduling system: The main person in charge of the enterprise should listen to at least one briefing per month from the safety director on forklift safety management, summarize and assess the issues identified through daily monitoring and weekly inspections during that month as well as the actions taken to address them, and make arrangements for the key tasks for the following month. The outcomes of the meeting are documented in the «Monthly Safety Coordination Meeting Minutes» ；

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