Model Curriculum

10. Forklift Operator/ Driver Forklift Operator/ Driver ASC/ Q9707, Version 1.0

SECTOR : LOGISTICS

SUB-SECTOR : WAREHOUSE STORAGE & PACKAGING

OCCUPATION : STORAGE- MATERIAL HANDLING

REF.ID : ASC/ Q9707, VERSION 1.0

NSQF LEVEL : 4

Certificate

Curriculum Compliance to qualification pack - National occupational standards

is hereby issued by the

Logistic Sector Skill Council of India

for the

Model Curriculum

Complying to National Occupational Standards of Job Role/ Qualification Pack: ‘Forklift Operator/ Driver’ QP No. ‘ASC/ Q9707 NSQF Level 4’

Date of Issuance: Valid up to:

May 1st, 2016 April 30th, 2017

Authorised Signatory

(Logistic Sector Skill Council of India) *Valid up to the next review date of the Qualification Pack

Forklift Operator/ Driver ASC/ Q9707, Version 1.0

TABLE OF CONTENTS

1. Curriculum 01

2. Trainer Prerequisites 05

3. Annexure: Assessment Criteria 06 Forklift Operator/ Driver ASC/ Q9707, Version 1.0

Forklift Operator/Driver

Curriculum / Syllabus This program is aimed at training candidates for the job of a “Forklift Operator/Driver”, in the “Automotive” Sector/Industry and aims at building the following key competencies amongst the learner

Program Name Forklift Operator/ Driver Qualification Pack Name & Reference ID. ID LSC/ Q9707, version 1.0 Version No. 1.0 Version Update Date 16-12-2014 Pre-requisites to Training Minimum qualification - Class XII

No experience is required. Training Outcomes After completing this Programme, participants will

be able to: • Obtain Knowledge on Warehousing activities: General introduction to warehouse layout and other warehousing activities such as Data Entry Operation, Receiving, Loading, Unloading, Packing, Dispatch and Quality parameters

• Demonstrate the Safe Operation Procedures for operating a forklift: Pre-operational conditions, Maneuvering & correct use of controls, Handling loads, Loading & off-loading, Specialized operations, Towing of lift truck, Emergency procedure.

• Know the cognitive and skills pertaining to various operating tasks: Pre-Operational checks, Operational checks, Parking/ stow procedure, Refueling, Loading, off-loading, securing & transportation of machines, Maneuvering of the machine, Lifting, moving & placing of loads, Stacking of loads & stacking rules, Loading / off- loading loads, Working in confined spaces / elevated positions, Communication , Know how to prevent and respond in emergency circumstances

• Conversant with all the related safety rules and procedures: Build on effective communication with inter departments, sub-ordinates and super- ordinates for smooth forklift operations and safety procedures.

• Acquaint with Environmental / Occupational Health & Safety: Get well versed with health and safety measures practised in warehouse, Individual Safety, PPE usage, security procedures, Quick Emergency Responses, First Aid, Fire Safety and general maintenance on Warehousing equipment.

Forklift Operator/ Driver ASC/ Q9707, Version 1.0 1

This course encompasses 3 out of 3 National Occupational Standards (NOS) of “Forklift Operator/ Driver” Qualification Pack issued by “ASDC: Automotive Skills Development Council”. Sr.

Module

Key Learning Outcomes

Equipment Required

No.

1 Introduction At the end of this module the learner will be able to: Teaching board • Discuss Supply Chain and Logistic Management Computer Theory Duration • Explain the different types of Inventory and its Projector (hh:mm) Importance Video player or TV, PPE’s • Discuss Warehousing industry and job

42:00 opportunities in it • Define your job roles and responsibilities as a Practical Duration forklift operator • Understand the various operations in warehouse 16:00 and their importance in the effective logistics • Understand the Expectations from a Forklift Corresponding operator in his/her job role NOS Code • Apprehend the various functions / operations of the warehouse

Bridge Module • Define the inbound and outbound activities

• Understand the major activities that are performed inside a warehouse • To get a clarity on the main roles of a Forklift Operator 2 Ensure that the At the end of this module the learner will be able to: Teaching board forklift is fit for • Understand the importance of pre-drive inspection Computer use for the forklift Projector • Explain the types of different operational checks Storage Bins Theory Duration • Understanding of company’s safety policies and Forklifts, Dummy Load Procedures (hh:mm) • Know various components in a forklift truck and its Test drive track with 08:00 Controls various simulation • Execute basic operational check needed for a forklift Dummy Pallet and Shelf Practical Duration • Understand the necessary visual checks need to Shop floor training facility (hh:mm) performed before starting a Forklift Warehouse training • Demonstrate how to check Fuel and Battery 72:00 charges before starting Forklift operations facility Corresponding • Examine the condition of Forklift mechanics and tyres for smooth operations NOS Code • Understand the importance of checking the

Forklift breaking systems and different types of ASC/N9712 Forklift Breaks • Demonstrate how to carry out various operational control checks • Exhibit the proper way of Forklift lifting and tilting Mechanism • Understand various roles and responsibilities of different colleagues on the shop floor • Describe the importance of safety policies and security procedures for operating a forklift in the Warehouse • Know the escalation procedures for technical Problems

Forklift Operator/ Driver ASC/ Q9707, Version 1.0 2

Sr. Module

Key Learning Outcomes

Equipment Required

No.

3 Load and unload At the end of this module the learner will be able to: Teaching board the materials • Understand the startup procedure for a forklift Computer safely • Know safety methods for loading and unloading Projector Materials Caution Boards Theory Duration • Explain why wearing a seat belt is important for a Do’s and Don’ts charts (hh:mm) Forklift operator Forklifts, Dummy Load 08:00 • Define the stability and driving rules of a forklift Test drive track with • Understand the necessary safety requirements various simulation Practical Duration while operating a Forklift Dummy Pallet and Shelf (hh:mm) • Explain what necessary mandatory checks are Shop floor training facility 98:00 before operating a Forklift Warehouse training • Demonstrate how to operate a Forklift inside the facility Corresponding warehouse area and aisle systems NOS Code • Explain the dos and donts in operating the Forklift ASC/N9713 • Brief about the necessary safety measures while operating the Forklift • Explain the basic Forklift parking procedures and the importance of parking Forklift in the proper allocated area • Understand the necessary precautionary care to be taken before parking the Forklift • Explore the basic safety signage’s needs to be know while operating a Forklift • Understand the details of each and every safety signage’s related to Forklift operations

4 Ensure safe and At the end of this module the learner will be able to: Teaching board healthy driving • Understand the basic safety requirements to be Computer practices followed inside the warehouse operation Projector • Identify potential work hazards and safety issues Personal Protection Theory Duration • Explain the possible common hazards that will take Equipment: Gloves, Safety (hh:mm) place inside the warehouse Shoes, goggles, ear plugs, 32:00 • Demonstrate the necessary precautionary steps to boiler suit be taken to prevent work hazards Workshop Safety: Fire Practical Duration • Explain the Forklift load capacity and the maximum extinguishers (hh:mm) weight allowed to handle First Aid kits 24:00 • Understand the safe loading position in operating Safety signs the Forklift and mitigate the risk in Forklift operation SOP Charts on safety Corresponding • Describe the basic Forklift technical details related norms and drills. NOS Code to safety Charts of dos and Don’ts ASC/N9714 in work area

Forklift Operator/ Driver ASC/ Q9707, Version 1.0 3

Sr. Module Key Learning Outcomes

Equipment Required

No.

• Understand the safety details given by the manufacture for Forklift operations • Understand the importance of the usage of Personal protective equipment • Know the different types of PPEs and get Clarity on the purpose of PPEs • Get knowledge on the Forklift blind spots and how to prevent and reduce accidents • Recognize the procedures to be followed for safety • Understand the importance of First aid mock drills Total Duration Unique Equipment Required: • Corrugated cardboard boxes • Storage Bins • Sample Picklist • Labels & Signages • PPE – Hard hat helmet, Hand Gloves, Eye Theory Duration Goggles, Dust masks, High Visibility Jackets, Safety shoes etc • Material Handling (hh:mm) Equipment like HOPT, BOPT, Stacker, ladder, Forklift etc • Pallets • Storage racks • 90:00 Sample reports & documents like Requisition forms, Incident reports etc • Do’s and Don’ts charts • Forklifts, Dummy Load • Test drive track with various simulation • Practical Duration Dummy Pallet and Shelf • Shop floor training facility • Warehouse training facility (hh:mm) 210:00 Grand Total Course Duration: 300: 00 Hours (This syllabus/ curriculum has been approved by ASDC: Automotive Skills Development Council) Forklift Operator/ Driver ASC/ Q9707, Version 1.0 4

Trainer Prerequisites for Job role: “Forklift Operator/ Driver” mapped to Qualification Pack: “ASC/Q9707”

Sr. No. Area Details 1 Description To deliver accredited training service, mapping to the curriculum

detailed above, in accordance with the Qualification Pack “ASC/ Q9707”.

2 Personal Attributes Aptitude for conducting training, and pre/ post work to ensure competent, employable candidates at the end of the training. Strong communication skills, interpersonal skills, ability to work as part of a team; a passion for quality and for developing others; well-organised and focused, eager to learn and keep oneself updated with the latest in the warehousing vertical.

3 Minimum Educational Class 8th or equivalent

Qualifications

4a Domain Certification Certified for Job Role: “Forklift Operator/Driver” mapped to QP: “ASC/Q9707”. Minimum accepted score of 70%.

4b Platform Certification Recommended that the Trainer is certified for the Job Role: “Trainer”, mapped to the Qualification Pack: “ASC/Q9707”. Minimum accepted score of 85%

5 Experience Minimum 1 year Experience with certification of Forklift Operator/ Driver Forklift Operator/ Driver ASC/ Q9707, Version 1.0 5

Annexure: Assessment Criteria

Assessment Criteria for Forklift Operator/ Driver Job Role Forklift Operator/ Driver Qualification Pack ASC/Q9707 Sector Skill Council Automotive Skill Council

Sr . NO Guidelines for Assessment

Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each

1 Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC.

2 The assessment for the theory part will be based on knowledge bank of questions created by the SSC Individual assessment agencies will create unique question papers for theory part for each candidate 3 at each examination/training center (as per assessment criteria below) 4 Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criteria

5 To pass the Qualification Pack , every trainee should score a minimum of 40% in every NOS overall 50% pass percentage 6 In case of successfully passing only certain number of NOS’s, the trainee is eligible to take subsequent assessment on the balance NOS’s to pass the Qualification Pack. Forklift Operator/ Driver ASC/ Q9707, Version 1.0 6

NOS Performance Criteria

Marks Allocation Total Marks Viva Practical

ASC/N9712 PC1. Visually check the forklift before starting for: (Pre-drive • Engine oil level, fuel level, radiator water level (LPG, gas inspection and diesel forklifts).

• Battery is fully charged; check cables for exposed wires; battery plug connections not loose, worn or dirty; vent caps not clogged; (battery operated FLT’s) • Electrolyte levels in cells; hold-downs or brackets to keep battery securely in place • Bolts, nuts, guards, chains, or hydraulic hose reels are not damaged, missing or loose • Wheels and tyres for wear, damage and air pressure, if pneumatic tyres 15 40 • Forks are not bent; no cracks present; positioning latches are in good working condition; carriage teeth not broken, chipped or worn • Chain anchor pins are not worn, loose or bent • Fluid Leaks - no damp spots or drips • Hoses are held securely; not loose, crimped, worn or rubbing • Horn is working and loud enough to be heard in working environment; other warning devices operational • Lights - head lights and warning lights operational 100 PC2. Check the following components of forklift for operational ease: • Foot Brake - that pedal holds and unit stops smoothly • Parking Brake - that brake holds against slight acceleration • Seat Brake - that brake holds when operator rises from seat • Clutch and Gearshift - shifts smoothly with no jumping or jerking • Dash Control Panel - that all lights and gauges are 15 50 operational

• Steering - moves smoothly • Lift Mechanism - operates smoothly (check by raising forks to maximum height then lowering forks completely) • Tilt Mechanism - moves smoothly and holds (check by tilting mast all the way forward and backward) • Cylinders and Hoses - not leaking after above checks • Listen for any unusual sounds or noises Forklift Operator/ Driver ASC/ Q9707, Version 1.0 7

NOS Performance Criteria

Marks Allocation

Total Marks

Viva

Practical

PC3. Start the forklift and check for the following once again: • Check that all warning devices operate (horn, indicator lights, rear and brake lights and the reverse alarm) 10 10 • Check that the mast tilts forward and back correctly and that the mast extends PC4. Ensure following preventive maintenance schedules 10 as per laid down guidelines.

Escalation of To be competent , the user/individual must be able to: technical PC4. Report actual or possible defects to the supervisor problem in enough detail so they can diagnose the problem 10 PC5. In consultation with superiors conclude about the

fitness of forklift and if found unfit to decide to use another forklift. Total 60 100 ASC/N9713 PC1. follow the procedure for starting the forklift : (Startup • Fasten the seatbelt procedure for • Check that the park brake is engaged forklift) • Check that transmission control lever is in neutral position and safety locks are on(if fitted) and all attachment controls are in the neutral position • Check that the throttle control or accelerator pedal is pushed past any constriction that may be fitted and is in the low idle position • Turn the ignition switch to start the engine. If it fails to start within approximately 10 seconds, allow the starter to cool down and try again; in cold conditions pre-heating may be required 100 10 50 • Check all gauges for correct operation • Allow the engine and components to warm up to operating temperature for approximately 5 minutes before operating. During this period operate all attachment controls checking for correct operation, unusual noises and any vibrations • Re-check all gauges, horn and warning lights for correct operation • Ensure that the area is clear of all personnel and equipment before moving • Drive the forklift to the desired location Forklift Operator/ Driver ASC/ Q9707, Version 1.0 8

NOS Performance Criteria

Marks Allocation

Total Marks

Viva

Practical

Movement of PC2. Drive the forklift near to the storage location where materials the material is kept; be it at the shop floor or the stores/warehouse PC3. Lower the forks while keeping the mast in upright condition PC4. Level the fork before inserting it into the pallet. 20 50 PC5. Insert the fork all the way under the material. PC6. Adjust the fork as wide as possible to fit the load and to provide a more even distribution of weight. PC7. Ensure that the material on pallets is stable, neat, cross- tied if possible and evenly distributed PC8. Tilt loads backwards PC9. Travel with forks as low as possible from the floor and tilted back PC10. Match speed to driving, load and workplace conditions PC11. Reach the designated location steering clear of any obstacles, material etc. and being on the designated isles. PC12. Lower the forks as slowly as possible until the pallet touches the ground PC13. Rest the pallet on ground and slowly start removing forks out of the pallet ensuring that the material is not being damaged PC14. Afterwards again lift the forks slightly above the 20 60 ground and drive it back to the next destination. Take care not to meet with any obstacles as in the unladen condition the FLT balance is rear heavy PC15. Repeat Pc1. to Pc14. till all the materials have been moved and stored at the respective locations Parking of the PC16. Once the job is over , reach the parking area and forklift park the forklift with the forks and attachments (if any)touching the ground PC17. Place all attachment control levers in the neutral or hold position. PC18. Do not allow lift chains to go slack, as they may jump clear of the top carrier rollers.

10

40

PC19. Place the transmission and forward reverse levers

into the neutral position and apply safety locks. PC20. Apply park brake. PC21. If it is an LPG powered forklift, turn off the fuel isolating valve as this prevents a buildup of explosive gases prior to starting up again PC22. Switch off the ignition

Forklift Operator/ Driver ASC/ Q9707, Version 1.0 9

NOS Performance Criteria Marks Allocation

Total Marks

Viva

Practical

Escalation of PC23. Inform about anything that affects the normal problems operation of the forklift and tell the supervisor

immediately Total 70 200 ASC/N9714 PC1. In case of a fuel leak occurrence or suspicion, (Potential immediately stop the machine, tag the area around safety issues) the leak and inform the supervisor PC2. Inform the shop floor personnel in case of more than maximum load put on the forks of the forklift/

10 20 imbalance in load kept on the forks.

PC3. In case of accident, rush the person to the in-house medical center immediately ; inform the supervisor PC4. Vacate the premises in case of fire and immediately inform the supervisor Standard PC5. Know the recommended load limit of the forklift safety and never exceed it.

standards PC6. Know how to assess the weight of the load to be lifted. PC7. Do a visual and operational check of the forklift at the start of the shift. PC8. Check for adequate overhead clearance before raising the load. PC9. Operate the equipment smoothly when stopping, starting, lifting and tilting. PC10. Know the blind spots of the lift truck with and without a load. PC11. Keep pedestrians away from a forklift in operation. 100 50 70 PC12. Stop when anyone crosses the route being

travelled. Lower the load to the floor, and wait until clear. PC13. Operate only as fast as conditions safely permit. PC14. Wear leather gloves when moving or shifting loads PC15. Wear fully laced safety boots to give impact protection when moving loads or skids and to provide ankle support PC16. Remain alert and prepare for the unexpected PC17. Ensure that the shop floor area where forklift is operating is free from oil spots, wet spots, loose objects, holes, rough surfaces, people and other vehicles Forklift Operator/ Driver ASC/ Q9707, Version 1.0 10

NOS Performance Criteria

Marks Allocation

Total Marks

Viva

Practical

PC18. Keep hands, arms, head, feet and legs inside the confines of a moving forklift. PC19. Stay in the truck in case of overturn Limit damage PC20. Stop when anyone crosses the route being 10 10 to people and travelled. Lower the load to the floor, and wait Public until clear PC21. Sound horn before moving on shop floor PC22. Take care not to let the FLT / or load touch obstacles while driving PC23. Eliminate usage of damaged bins Total 70 100 Grand

200

400

Total

Forklift Operator/ Driver ASC/ Q9707, Version 1.0 11

Forklift Operator/ Driver ASC/ Q9707, Version 1.0 12

Logistic Sector Skill Council of India Unit E, 10th Floor, IIT Madras Research Park, Kanagam Road, Taramani, Chennai, Tamil Nadu - 600 113