A forklift evaluation is the formal observation of an operator's performance that OSHA requires to confirm they can safely operate a powered industrial truck in the workplace. Evaluations must be conducted at least once every three years, not as a refresher training session but as a documented assessment of actual driving competence.
OSHA does not prescribe a specific duration for an evaluation. Instead, the evaluator must watch the operator performing their routine job functions and verify that all safety rules are followed. The evaluation must be conducted by someone "with the knowledge, training, and experience to train operators and evaluate their competence" — not just any supervisor.
What the Evaluation Must Cover
Oregon OSHA lists specific elements that must be included in the competency evaluation, though this is a benchmark for all states:
Loading and unloading
Stacking and tiering
Traveling and maneuvering
Lifting and lowering
Ramps and inclines
Pedestrian awareness
Driving in reverse
Using attachments
Docks and narrow aisles
Fueling or charging
Inspecting the forklift
Parking and shutting down
Horn usage and visibility
Getting in and out safely
A standardized evaluation form (such as those provided by the Kansas State University Environmental Health and Safety department) breaks down the assessment into specific observable behaviors:
Pre-Use Inspection: Following the daily checklist, documenting damage, and verifying findings.
Picking Up a Load: Squaring up to the center of the load, leveling forks, clearing personnel, lifting smoothly, tilting back, and looking over both shoulders before moving.
Traveling: Not raising or lowering forks while moving, maintaining safe speed, keeping arms/legs inside the truck, slowing for corners, using the horn, and traveling with the load facing uphill on inclines.
Putting Down a Load: Checking clearance, squaring up, raising to correct height, lowering into position, and backing out straight.
Parking: Lowering forks, neutralizing controls, setting the brake, turning off power, and blocking wheels on inclines.
Special Tasks (if applicable): Removing loads from high stacks safely.
Common Mistakes Evaluators Watch For
The following errors are frequently cited as reasons for failing a practical evaluation or requiring immediate refresher training:
Not wearing a seatbelt – This is an automatic safety violation.
Improper load handling – Forks too high or too low, causing imbalance, or moving while loading.
Incorrect mast tilt – Failing to tilt the load back toward the carriage while traveling, or tilting too far forward.
Failure to use the horn – Approaching corners, doorways, or blind spots silently.
Inadequate observation – Failing to look in the direction of travel or not checking over both shoulders before reversing.
Speeding – Loss of control and tip-over risk.
Lack of secure parking – Not applying the parking brake or leaving the forklift running unattended.
What Happens If an Operator Fails
If the evaluation reveals unsafe operating habits, OSHA requires the employer to provide refresher training. This training does not necessarily need to repeat the entire initial course; it may be limited to the specific topics where the deficiency occurred. However, after the refresher training is complete, the operator must be reevaluated to confirm the training was effective.
Additionally, if the operator understood the rules but deliberately violated them (e.g., speeding due to pressure to work faster), training alone may not be the solution. The employer must address the root cause or motivation.
When Additional Evaluations Are Required (Beyond 3 Years)
Refresher training and a follow-up evaluation are mandatory when:
The operator is observed operating unsafely.
The operator is involved in an accident or a near-miss incident.
The operator receives an evaluation that indicates unsafe operation.
The operator is assigned to a different type of forklift.
A condition in the workplace changes (e.g., new racking layout, new ramp, changed floor surface).
Certification Documentation
After a successful evaluation, the employer must update the operator's certification file. OSHA requires the certification to include:
Operator's name
Date of training
Date of evaluation
Name(s) of the person(s) performing the training or evaluation
Summary
The forklift operator evaluation is an objective, skills-based assessment conducted every three years to verify that an operator can safely handle the specific equipment and navigate the specific hazards of their workplace. It is distinct from initial training and focuses entirely on demonstrated competence in real-world tasks.
Failing the evaluation triggers targeted refresher training rather than automatic decertification. Successful completion results in updated employer certification, which serves as proof of compliance with 29 CFR 1910.178(l).