The role of a spotter in forklift operations

With great lifting power comes great responsibility—especially when visibility is limited. That’s where the spotter, also known as a points person or banksman, becomes indispensable.

Whether you’re operating a small warehouse forklift, a medium-sized machine moving unusual loads, or a large forklift designed to handle empty shipping containers (and empty container handler or ECH), the presence of a spotter can significantly enhance safety and efficiency. In this article, we’ll explore why having a spotter is critical when the forklift operator cannot see where they are going, focusing on different types of forklifts and the unique challenges they face.

Why visibility matters

Forklift operation is inherently risky, with the operator’s visibility often limited by the load being carried, the machine’s design (e.g. the masts), or the environment in which it’s operating (e.g. tight aisles). When a forklift operator’s line of sight is obstructed, the chances of accidents increase dramatically. These accidents can result in damage to goods, injury to personnel, or even fatalities.

The role of the spotter

Spotter training is important for any member of the team that will guide a manoeuvring vehicle. A spotter serves as the operator’s eyes and ears when visibility is compromised. This person is responsible for guiding the forklift, ensuring that the path is clear, and preventing accidents. The spotter’s job is to provide clear, concise communication and directional signals to the operator, allowing them to manoeuvre the forklift safely and efficiently.

The spotter’s role can include:

• Navigating tight spaces or congested areas
• Reversing with limited visibility
• Handling oversized or unusual loads
• Operating in environments with heavy foot traffic or other machinery

Spotters for small forklifts: Pallet handling and confined spaces

Small forklifts, often used in warehouses and retail settings, are typically designed to handle pallets and other relatively lightweight loads. However, even these forklifts can face significant visibility challenges. For example, when a forklift is carrying a tall stack of pallets, the operator’s forward view can be entirely obstructed. In some cases, it’s not possible or desirable to drive in reverse (e.g. when it would mean reversing up a ramp, which would increase the chance of the load falling forward off the backrest).

In confined spaces, such as narrow aisles or where there is plant, materials or other machinery cluttering the environment, the spotter can help the forklift safely. They ensure that the forklift does not collide with racks, walls, or other obstacles. Additionally, in environments where pedestrians and forklifts share the same space, a spotter can help prevent accidents by keeping an eye out for anyone who might unknowingly step into the forklift’s path.

Spotters for medium-sized forklifts: Handling unusual or oversized loads

Medium-sized forklifts are commonly used in industries like manufacturing, construction, and distribution. These machines often handle heavier and sometimes unusual loads, such as large equipment components or bundles of materials. Or they might suspend a load rather than lifting it from below. These loads can easily obstruct the operator’s view, making it difficult to see what lies ahead or behind.

Again, if reversing is not possible or desirable, the spotter plays a critical role in ensuring the load is safely manoeuvred. They can guide the operator around obstacles, help align the forklift for precise placements, and ensure that the load is balanced and secure. This is particularly important when dealing with unusual loads that may not sit evenly on the forks, creating an additional risk of tipping or dropping.

Spotters for large forklifts: Moving empty shipping containers and heavy-duty loads

Large forklifts, such as those used in ports or large-scale construction sites, often handle empty shipping containers or other heavy-duty loads. These forklifts are massive machines with significant blind spots due to the mast thickness and the size of the counterbalance, and the size of the loads they carry only exacerbates the visibility issues.

When operating these behemoths, the operator’s view can be limited to a small portion of the surrounding area, making it nearly impossible to see pedestrians, other vehicles, or even the edges of the load. The spotter’s role in this scenario is crucial, as they guide the operator safely through complex manoeuvres, such as stacking containers or navigating tight spaces.

In port environments, where multiple large machines operate in close proximity, the spotter can also help coordinate movements, ensuring that forklifts and other equipment do not interfere with each other’s operations.

Communication: The key to effective spotting

For a spotter to be effective, clear communication between the operator and the spotter is essential. This communication can be verbal, through the use of radios or headsets, or non-verbal, using standardised hand signals that you can learn in our spotter course. Whatever method is used, it’s vital that both the operator and the spotter are well-trained and understand each other’s signals and instructions.

Standard hand signals are often the preferred method, especially in noisy environments where verbal communication might be drowned out. These signals must be clear, unambiguous, and known by both parties to avoid confusion. The forklift operator is the one that decides the hand signals.

Training and teamwork

Both forklift operators and spotters need proper training to understand the importance of their roles and how to perform them effectively. This training should cover:

• Understanding and using hand signals
• Identifying potential hazards in the operating environment
• Learning the capabilities and limitations of the specific forklift being used
• Coordinating movements to ensure safe and efficient operations

Our spotter course covers how to guide multiple different vehicles. Search for it in the courses section above.

The presence of a spotter is not just a nice-to-have but a necessity when operating forklifts where visibility is compromised. Whether handling small pallets in a warehouse, unusual loads in a manufacturing plant, or massive shipping containers at a port, the spotter’s role is vital in preventing accidents and ensuring smooth operations.