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Order Picker Inspection
Need your Order Picker inspected in line with LOLER98 regulations? Get a quote today to ensure you remain compliant.
Order Picker Thorough Examination
Order Pickers Within Industry
Order picker forklift trucks are specialised material-handling vehicles designed to allow operators to pick individual items or cases directly from storage racking. Unlike standard forklifts, the operator platform on an order picker rises with the forks, enabling safe and efficient access to goods stored at height. This makes them ideal for environments where goods are picked piece by piece rather than moved as full pallets.
Order pickers are commonly used in high-density warehouses with tall racking systems. They allow accurate order fulfilment, particularly in operations that handle a wide variety of products. Many order picker trucks are equipped with safety features such as guard rails, harness attachment points, and controlled lift speeds to protect operators working at height. Some models are designed for narrow aisles, helping maximise storage space and improve warehouse efficiency.
Order picker forklift trucks are widely used in industries such as logistics and distribution, retail warehousing, e-commerce, and wholesale operations. They are especially important in sectors where fast and accurate picking is essential, including food and drink distribution, pharmaceuticals, and consumer goods. By improving picking speed and reducing manual handling, order pickers play a key role in meeting high-volume and time-critical order demands.
Overall, order picker forklifts help businesses increase productivity while maintaining safety in warehouse environments. Their ability to combine lifting, access, and order picking into a single operation makes them an essential tool in modern supply chain and distribution industries.
What’s covered during your SEIS Order Picker Thorough Examination.
A LOLER thorough examination of an order picker focuses on the lifting elements of the machine, however, during the examination the entire vehicle will be checked, the non-lifting items will be examined under PUWER (Provision and Use of Work Equipment Regulations) and the findings will be documented on the report of thorough examination. LOLER examinations must be carried out by a competent person at legally defined intervals (usually every 12 months, or 6 months if the forklift is used to lift people).
Here’s a breakdown of what would typically be done during a LOLER thorough examination of an order picker:
 Visual Inspection of Lifting Components
The competent person will first carry out a detailed visual check of all lifting components to identify any signs of damage, corrosion, deformation, or excessive wear. This includes:
Manufacturers data plate (make, model, serial number, safe working load (SWL) etc.
Wheels and tyres (ensure tyres are suitable, no excessive damage or wear present.
Fork arms (checking for cracks, distortion, or wear to the heel and blade)
Mast assembly (checking the mast for straightness, damage, and smooth operation)
Chains and sheaves (looking for elongation, corrosion, or damaged links and sheave damage)
Hydraulic cylinders and hoses (checking for leaks, damage, or deterioration)
Tilt mechanisms (ensuring full and smooth range of movement without play)
Lifting carriage and load guard (examining for cracks, distortion, and security)
 Functional Checks
The competent person will test the lifting mechanism in operation to ensure all components perform safely and as intended. This includes:
- Raising and lowering forks
- Tilting the mast forward and back
- Checking the responsiveness and smoothness of hydraulic operations
- Ensuring there is no excessive play or unusual noises during movement
- Braking Function(s)
- Seat belt
- Working lights and reverse lights
- Audible reversing alarm
- Horn
- Emergency lowering function/ Rescue function
 Measurement and Wear Testing
Some components, particularly fork arms and load chains, are measured against manufacturer specifications to check for wear:
- Fork wear is typically assessed at the heel; if wear exceeds 10% of the original thickness, replacement is usually required.
- Chain wear is measured by elongation — typically, if elongation exceeds 2–3%, chains should be replaced.
 Safety Device Inspection
Any lifting-related safety systems are checked, including:
- Overload protection devices (if fitted)
- Limit switches (e.g., lift height limiters)
- Fork locking pins or mechanisms
- Operator visibility aids, if they affect lifting (e.g., cameras or mirrors near the mast)
- Operators seat inhibitor switch
- Emergency lowering
- Gate inhibitor switches
 Structural Integrity Checks
The competent person will assess the overall structural integrity of the lifting frame, mast carriage, and attachment points. Any evidence of welding repairs, cracks, or modifications will be critically examined for safety compliance.
 Attachments
If the forklift uses any lifting attachments (e.g., jib arms, drum handlers, clamps), these are also inspected under LOLER98. They must have their own markings, be suitable for the machine, and be in sound condition.
 Documentation and Reporting
After the inspection, the competent person will issue a LOLER Thorough Examination Report. This must include:
- Date of the examination
- Details of the equipment inspected
- Findings, including any defects
- Recommendations or required actions
- Â Date of next examination due
- Statement on whether the equipment is safe to continue using
If any serious defects are found that pose immediate danger, they must be reported to the duty holder and the enforcing authority (e.g., HSE) immediately.
 Summary
An order picker LOLER inspection ensures that the lifting elements of the machine are safe, compliant, and fit for use. It helps prevent accidents caused by worn forks, damaged chains, or malfunctioning lifting mechanisms. While it does not replace regular maintenance, PUWER and LOLER inspections are a crucial legal requirement for keeping lifting operations safe and avoiding costly breakdowns or incidents.
Why Order Picker Thorough Examinations Matter For You & Your Business.Â
Why LOLER98 Thorough Examinations Matter
LOLER98 thorough examinations are a legal requirement in the UK for all lifting equipment used at work, and for good reason. These inspections ensure that lifting equipment, such as cranes, hoists, slings, and lifting accessories are safe to use, and fit for purpose. The nature of lifting operations means that equipment failure can lead to catastrophic consequences, including serious injury, fatalities, and significant damage to property. By carrying out regular, scheduled thorough examinations by a competent person, businesses can identify wear and tear, structural damage, or faulty mechanisms before they result in an incident.
Pros of Getting a Thorough Examination in line with LOLER98
Legal Compliance and Risk Reduction: The most obvious advantage is staying compliant with health and safety law. Compliance avoids potential legal action, fines, or even prosecution. More importantly, it drastically reduces the risk of workplace accidents caused by lifting equipment failure.
Improved Safety Culture: Regular inspections foster a proactive safety culture within the organisation. Employees are more likely to trust equipment and feel safe in their work environment when they know thorough checks are in place.
 Extended Equipment Lifespan: Regularly maintained and inspected equipment typically lasts longer. Examinations can identify early signs of damage or fatigue, allowing for preventative maintenance that avoids costly replacements or repairs.
 Insurance and Liability Protection: Insurers may require evidence of LOLER compliance in the event of an incident. Without valid inspection records, insurance claims could be denied or reduced, leaving the business liable for damages.
 Operational Efficiency: Detecting potential issues before they lead to equipment failure helps prevent unscheduled downtime. This keeps operations running smoothly and avoids the knock-on effects of delayed projects or interrupted workflows.
Cons of Failing to Carry Out LOLER Thorough Examinations
 Legal and Financial Consequences: Failing to comply with LOLER can result in enforcement action from the Health and Safety Executive (HSE), including improvement notices, prohibition notices, fines, or even prosecution. Legal battles and associated costs can be financially crippling.
 Increased Risk of Accidents: Equipment that hasn’t been thoroughly examined is far more likely to fail. Such failures can lead to injuries or fatalities, particularly in high-risk environments like construction or manufacturing. Beyond the human cost, the reputational damage to a business can be severe and long-lasting.
 Higher Repair and Replacement Costs: Neglecting inspections can allow minor issues to develop into major faults. These may require costly emergency repairs or complete equipment replacement, expenses that could have been avoided through routine examinations.
 Loss of Business and Clients: Clients often expect their contractors or suppliers to uphold strict safety standards. A failure to meet legal obligations like LOLER can result in lost contracts or blacklisting from future work, especially in regulated industries.
 Increased Insurance Premiums or Invalidated Coverage: As mentioned, insurers may increase premiums or deny coverage entirely if a business can't provide evidence of up-to-date LOLER compliance, placing a heavier financial burden on operations.
LOLER thorough examinations aren’t just a box-ticking exercise - they are an essential component of a responsible, safety-first approach to using lifting equipment. The benefits of compliance are wide-ranging, from protecting human life to reducing costs and maintaining operational integrity. Conversely, the risks of neglecting these inspections can be devastating on multiple levels.
Key Points;
Examinations must be carried out by a competent person -Â A competent person is someone with the right practical and theoretical knowledge and experience to conduct thorough examinations of lifting equipment.
Key Points;
Examinations must be carried out in the following situations;
 Before lifting equipment has been put into service, unless -Â
- The equipment has never been used before.
- An EC declaration of conformity has been drafted up and issued no longer than one year prior to the equipment being put into service.
Key Points;
An employer shall ensure that where the safety of lifting equipment depends of installation conditions, it is thoroughly examined;
- After installation and before being put into service.
- After assembly and being put into service at a new site, or a new location at it's current site.
Key Points;
Lifting periods;
- Every 6 months for lifting accessories and attachments, or for lifting equipment which is used for lifting persons.
- Every 12 months for other types of lifting equipment which does not fall into the above or below category.
- In line with an examination scheme, of which, the competent person deems the necessary intervals based on working environment and use etc.Â
Key Points;
 A report of thorough examination must contain the following;
- The date the examination was undertaken and where it was undertaken
- Means of identifying the equipment (make, model, serial number, SWL etc)
- Any findings, comments and defects made by the competent person
- Defects highlighting imminent danger must be forwarded to the relevant authority (HSE) within 28 days.Â
Great experience working with Oliver on the PSSR for our compressors! The team was very professional, knowledgeable, and easy to work with. They made the entire process smooth and stress-free. We would definitely use them again.
We’ve been using Statutory Equipment Inspection Solutions Ltd for our inspection needs, and their service is unmatched by any competitor we’ve worked with. They are extremely professional, always quick to respond to messages, and consistently provide prompt, detailed reports to help us stay compliant with regulations. Highly reliable and a pleasure to work with — we wouldn’t hesitate to recommend them.
SEIS have delivered LOLER and PSSR Thorough Examinations for us across Lincolnshire and Cambridgeshire with the utmost professionalism and the highest standards. With brilliant communication and a friendly, knowledgeable approach, we highly recommend their services.
Oliver at SEIS turned up on short notice to help us out after our current inspections provider let us down. He had our overhead cranes and fork trucks examined, and reports sent to us on the same day. Fantastic service.
The engineer surveyor SEIS sent was personable, and knowledgable. They was happy to work around our operational needs and examined our tailboard lifts with minimal disruption.
Thanks again!
Craig
Thanks again!
Craig