Stacker Course

Lesson 1 • Stacker Equipment Overview

Covers the main categories of stackers and their industrial applications. Establishes the vocabulary and context needed for all subsequent technical content.

Lesson 2 • Operator Roles and Responsibilities

Defines the duties, accountability, and professional conduct expected of a stacker operator. Connects individual behaviour to team safety and operational efficiency.

Lesson 3 • Anatomy of a Stacker

Identifies every major component and its function within the machine. Provides the structural knowledge required for safe operation and maintenance tasks.

Lesson 1 • Hazard Identification and Risk Assessment

Teaches systematic methods for spotting and evaluating workplace hazards before operation. Builds the analytical habit of assessing risk before every task.

Lesson 2 • Safety Signage and Floor Markings

Decodes the meaning of warehouse signs, floor colours, and warning labels. Enables operators to interpret visual safety cues accurately during daily operations.

Lesson 3 • Emergency Procedures and Incident Response

Outlines actions required during tip-overs, collisions, fires, and medical emergencies. Prepares operators to respond decisively and minimise harm in critical situations.

Lesson 4 • Personal Protective Equipment Standards

Specifies required PPE for stacker environments and correct usage procedures. Ensures operators select and maintain protective gear appropriate to each task.

Lesson 1 • Structural and Mechanical Inspection

Guides operators through checking the frame, mast, forks, and moving parts for damage. Builds competence in detecting wear, cracks, and misalignment before operation.

Lesson 2 • Fluid Levels and Lubrication Checks

Identifies hydraulic fluid, lubricant, and coolant inspection points on applicable models. Connects proper fluid levels to smooth lift performance and component longevity.

Lesson 3 • Electrical and Battery Inspection

Covers battery state, cable condition, and control system checks for powered stackers. Ensures electrical faults are caught before they cause operational failures or fires.

Lesson 4 • Purpose and Importance of Pre-Checks

Explains why pre-operation inspections are legally required and operationally critical. Motivates consistent inspection habits by linking them to safety outcomes.

Lesson 1 • Lifting and Lowering Loads

Introduces hydraulic lift controls, smooth operation technique, and load positioning. Develops the precision needed to lift and lower loads without damage or instability.

Lesson 2 • Starting and Shutting Down Safely

Covers the correct startup sequence, seat adjustment, and safe shutdown procedure. Establishes disciplined machine handling habits from the first moment of operation.

Lesson 3 • Parking and Securing the Stacker

Defines correct parking locations, fork lowering, and machine securing steps. Ensures the stacker is left in a safe state that does not create hazards for others.

Lesson 4 • Steering and Directional Control

Teaches steering input, turning radius management, and directional changes at low speed. Builds the fine motor control needed for precise navigation in confined spaces.

Lesson 1 • Pallet Types and Condition Assessment

Identifies standard pallet formats and teaches inspection for damage before engagement. Reduces load drops caused by using compromised or incompatible pallets.

Lesson 2 • Handling Irregular and Oversized Loads

Addresses techniques for managing non-standard loads that challenge balance and visibility. Prepares operators for real-world load variety beyond standard pallet configurations.

Lesson 3 • Understanding Load Capacity and Stability

Explains rated capacity, load centre concepts, and the stability triangle. Prevents overloading errors by connecting physics principles to real operational decisions.

Lesson 4 • Engaging and Disengaging Loads

Covers correct fork insertion depth, load centring, and clean disengagement technique. Builds the precision skills that prevent product damage and dropped loads.

Lesson 1 • Racking Load Limits and Signage

Explains how to read racking load notices and calculate bay and beam capacities. Prevents structural overloading that leads to catastrophic racking collapse.

Lesson 2 • Safe Placement and Retrieval Procedures

Details the step-by-step process for placing and retrieving loads from racking safely. Reinforces precision techniques from the load handling chapter in a racking context.

Lesson 3 • Inventory Placement and Location Systems

Introduces location coding, FIFO and LIFO principles, and slot assignment logic. Enables operators to place and retrieve stock accurately within warehouse management systems.

Lesson 4 • Racking Damage Identification and Reporting

Teaches operators to spot upright damage, beam deflection, and missing safety pins. Connects damage reporting to preventing rack collapse and protecting coworkers.

Lesson 1 • Narrow Aisle Operation Techniques

Covers reduced-clearance driving, side-shift use, and aisle entry and exit procedures. Builds the fine control skills required for very narrow aisle and turret stacker work.

Lesson 2 • Operating in Congested Environments

Teaches hazard anticipation, right-of-way rules, and communication in busy warehouses. Reduces collision risk by developing situational awareness in high-traffic zones.

Lesson 3 • Working Near Dock Levellers and Loading Bays

Covers safe approach, wheel chock verification, and trailer stability checks at docks. Prevents fall-into-dock and trailer-creep incidents during loading and unloading operations.

Lesson 4 • Multi-Level High-Reach Operations

Addresses stability management, mast extension limits, and load control at height. Prepares operators for the increased risk and precision demands of high-level stacking.

Lesson 1 • Operator-Level Maintenance Tasks

Defines the maintenance tasks within operator authority versus those requiring technicians. Prevents unauthorised repairs while ensuring operators fulfil their daily upkeep duties.

Lesson 2 • Scheduled Maintenance and Service Records

Explains planned maintenance intervals, service log entries, and technician coordination. Connects operator record-keeping to the broader preventive maintenance programme.

Lesson 3 • Fault Recognition and Diagnosis

Teaches operators to interpret warning lights, unusual sounds, and performance changes. Builds early fault detection skills that prevent minor issues from becoming major failures.

Lesson 4 • Shift Handover Best Practices

Defines the information, documentation, and verbal communication required at shift change. Ensures incoming operators receive accurate machine status and task continuity data.