Key Responsibilities and Required Skills for Reach Truck Forklift Operator

🎯 Role Definition

A Reach Truck Forklift Operator is a skilled warehouse professional responsible for safely operating reach trucks in narrow-aisle and high-rack environments to move, stack, and retrieve palletized goods. This role focuses on accurate order fulfillment, inventory management, safe load handling, and maintaining equipment readiness, while collaborating with shipping/receiving, inventory control, and production teams to meet throughput and quality targets.

📈 Career Progression

Typical Career Path

Entry Point From:

Warehouse Associate / Material Handler
Picker/Packer or Shipping & Receiving Clerk
General Forklift Operator (counterbalance)

Advancement To:

Lead Reach Truck Operator / Shift Lead
Warehouse Supervisor or Operations Team Lead
Inventory Control Supervisor or Logistics Coordinator

Lateral Moves:

Order Fulfillment Specialist
Yard Jockey / Yard Driver
Quality Control or Cycle Count Specialist

Core Responsibilities

Primary Functions

Operate a reach truck to accurately pick and place palletized products into high-bay racking, maintaining safe clearances and load stability while working at elevation.
Execute order picks from warehouse management system (WMS) pick lists, confirm SKUs and quantities with handheld RF scanners, and stage completed orders for shipping.
Load and unload trailers and containers using a reach truck, coordinating with dock staff to maintain fast, safe throughput and reduce turnaround times.
Perform daily pre-shift inspections of reach truck equipment, including brakes, hydraulic systems, forks, mast, seat belt, and safety lights, reporting defects immediately and tagging out unsafe equipment.
Conduct cycle counts and assist with physical inventory reconciliation, identifying and reporting discrepancies, and adjusting inventory in WMS as authorized.
Follow FIFO/LIFO and product rotation policies to ensure shelf life-sensitive stock is rotated properly and to minimize obsolescence or spoilage.
Securely stack and unstack mixed loads, ensuring pallet integrity, evenly distributed weight, and adherence to load height and aisle clearance policies.
Adhere to all safety, PPE, and lockout/tagout procedures while operating equipment in the warehouse, including compliance with OSHA and company-specific safety standards.
Communicate with shipping, receiving, and production planners to prioritize urgent orders, staging locations, and special handling requirements for fragile or hazardous materials.
Perform routine battery charging and basic battery maintenance (where applicable), including safe change-out procedures and electrolyte checks following site guidelines.
Complete accurate paperwork and digital records for outgoing and incoming shipments, including BOLs, packing lists, damage reports, and inventory adjustments.
Participate in on-site training and recertification programs for powered industrial truck operation and new equipment introductions.
Execute damage prevention protocols by inspecting incoming pallets and packaging, documenting damage, and coordinating quarantine/remediation with quality control.
Assist with inbound receiving functions by verifying purchase orders, offloading product, staging put-away, and updating receiving records in the WMS.
Maintain clear, unobstructed aisles and staging areas; remove debris and loose materials from staging zones and pallet racking to support safe operations and housekeeping standards.
Support cross-docking operations by transferring product directly from receiving to shipping areas using the reach truck to minimize handling and storage time.
Operate in narrow-aisle and high-density racking environments, using precision driving techniques and spatial awareness to maximize storage capacity without compromising safety.
Provide hands-on support during high-volume periods or inventory counts by increasing picking throughput while maintaining accuracy and compliance with picking procedures.
Conduct minor troubleshooting and basic preventative maintenance tasks on reach trucks (fluid checks, tire condition, fork inspection) and coordinate repairs with maintenance teams.
Enforce proper load securing and strapping methods for outbound pallets to minimize in-transit damage and claims while following carrier-specific loading requirements.
Assist supervisors with onboarding and mentoring new operators, demonstrating safe operation techniques, standard work procedures, and proper use of warehouse systems.
Report near-misses, incidents, or unsafe conditions using formal incident reporting channels and participate in follow-up corrective actions and safety meetings.

Secondary Functions

Support ad-hoc material moves and special projects such as staging promotional displays, returns processing, or kitting operations as directed by supervisors.
Collaborate with inventory control to implement continuous improvement suggestions for storage, labeling, and slotting to improve picking efficiency.
Help maintain accurate bin labeling and signage to support fast put-away and pick operations and reduce picking errors.
Assist in maintaining and updating standard operating procedures (SOPs) related to reach truck operation and warehouse safety practices.
Participate in cross-functional problem solving during service disruptions or system outages to maintain operational continuity.

Required Skills & Competencies

Hard Skills (Technical)

Certified reach truck / narrow aisle forklift operation (site-specific certification and OSHA-compliant training).
Proficient with Warehouse Management Systems (WMS) such as SAP EWM, Manhattan, HighJump, or similar for receiving, picking, and put-away transactions.
Hands-on experience with RF handheld scanners, barcode scanning, and mobile data terminals for order fulfillment and cycle counting.
Strong pallet handling and load securement skills, including use of stretch wrap, banding/strapping, and load stabilization techniques.
Knowledge of proper battery charging, swap-out procedures, and basic forklift electrical/hydraulic awareness.
Skilled in high-bay racking operations and narrow-aisle navigation, including load height management and rack damage prevention.
Familiarity with common shipping documentation (BOL, packing lists, manifests) and basic data entry for shipping/receiving logs.
Ability to perform accurate cycle counts, inventory adjustments in WMS, and reconcile discrepancies with physical counts.
Basic mechanical troubleshooting and coordination with maintenance for repairs and preventive maintenance scheduling.
Competent in material handling safety standards, PPE usage, lockout/tagout, and hazardous material segregation when required.

Soft Skills

Strong attention to detail and commitment to picking accuracy and inventory integrity.
Excellent spatial awareness and precision driving in confined or elevated workspaces.
Reliable time management and the ability to meet tight deadlines in high-throughput warehouse environments.
Clear verbal communication skills for coordinating with dock, shipping, receiving, and supervisory staff.
Team-oriented mindset with willingness to assist across functions during peak volume periods.
Problem-solving orientation to identify root causes of inventory variances or handling inefficiencies.
Positive safety mindset and the ability to influence peers to follow procedures and safe work practices.
Adaptability to changing priorities, schedules, and operational challenges.
Physical stamina and the ability to stand, climb, and perform manual tasks throughout the shift.
Professional work ethic with strong attendance and dependability.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED (preferred), or equivalent practical warehouse experience.

Preferred Education:

Vocational certificate in material handling, logistics, or industrial equipment operation.
Completion of certified reach truck training program and documented recertification.

Relevant Fields of Study:

Logistics and Supply Chain Management
Industrial Technology / Applied Mechanics
Occupational Safety and Health

Experience Requirements

Typical Experience Range:

1–5 years of warehouse experience, with at least 6–12 months operating reach trucks in a production or distribution environment.

Preferred:

2+ years of dedicated reach truck or narrow-aisle forklift operation in a high-bay distribution center.
Proven experience with WMS-driven picking, RF scanning, cycle counts, and high-volume shipping/receiving operations.
Prior experience in safety leadership or mentoring of new equipment operators.