When Does OSHA Require a Forklift Pre-Operation Inspection? Scenarios Explained
Forklifts are essential tools in warehouses, construction sites, and manufacturing facilities—but they're also heavy, powerful machines that can pose serious risks when not properly maintained. That’s why OSHA (Occupational Safety and Health Administration) mandates daily pre-operation inspections of powered industrial trucks (including forklifts) before they are put into service. But how often is “daily,” and how does this requirement apply in different real-world situations? Let’s break it down by scenario.
The OSHA Rule in a Nutshell
OSHA regulation 29 CFR 1910.178(q)(7) requires that forklifts be examined at least once per day before being placed into service. If they're used around the clock (multiple shifts), then they must be inspected at the beginning of each shift. The goal is to identify and correct any safety issues—like leaking hydraulics, worn tires, or malfunctioning brakes—before they become a hazard.
Scenario 1: One Person, Multiple Forklifts in the Same Shift
Let’s say a worker uses three different forklifts throughout their shift—perhaps each for different tasks or in different parts of a facility. Does each forklift need to be inspected?
Yes. OSHA’s requirement applies to the forklift, not the operator. Even if the same person is using multiple machines, each individual forklift must be inspected before it is used for the first time in that shift. The operator should complete a separate pre-use checklist for each vehicle.
Scenario 2: Multiple People Using the Same Forklift During a Single Shift
In this case, different employees use the same forklift back-to-back throughout the day. Is each operator required to do their own inspection?
Not necessarily. If a proper inspection was performed at the start of the shift, and the forklift has been in continuous use with no issues, OSHA does not require a new inspection for each operator. However, if the forklift is shut down for any extended period or suspected of being damaged, a new inspection is wise—and may be necessary depending on company policy. It’s also good practice for each operator to do a quick visual check before hopping on.
Scenario 3: One Forklift, One Operator, Day After Day
What about a situation where one operator uses the same forklift every day, and no one else touches it?
Even in this case, a daily inspection is required. Familiarity with a vehicle doesn’t replace the need for a formal safety check. Issues can develop slowly or suddenly—like a hydraulic leak, worn brakes, or a loose mast chain. A routine inspection keeps safety top-of-mind and helps catch problems early.
Bottom Line
No matter how a forklift is used, OSHA’s baseline requirement is clear: inspect each forklift before its first use of the shift. Whether it’s one operator or several, multiple machines or just one, the inspection is about ensuring the equipment is safe to use at the start of each work period. Skipping it isn’t just a violation—it’s a risk.
Want to stay compliant and keep your team safe? Build inspection checklists into your daily routine, train your operators thoroughly, and document every check. Safety starts before the engine does.
