The hidden costs of non-compliant inspections

The risk of relying on incomplete inspections

It’s easy to assume that once your materials handling equipment has been inspected, you’re covered. Many businesses will hear the term “thorough examination” and naturally assume everything has been inspected.

Photograph: CFTS

But what if that inspection hasn’t checked everything? Many businesses are unknowingly leaving themselves exposed to serious risks by relying on incomplete Thorough Examinations – and the consequences can be costly.

Equipment owners often take the inspections that come as part of insurance cover for granted. In many cases, the problem comes down to misunderstanding. They’ll assume that an inspection which only covers the lifting mechanisms is enough to keep them compliant and safe.

But a full Thorough Examination should go beyond that, covering all crucial components and safety systems as well. If these areas are missed, you’re not only risking equipment failure – you could also be looking at expensive downtime, hefty fines, or even tragic accidents.

For businesses that depend on equipment like forklifts, MEWPs and telehandlers, ensuring safety is critical. That’s why it’s vital to understand exactly what should be covered in a truly thorough Thorough Examination, and why choosing the right inspector can make all the difference.

LOLER vs. PUWER: why both matter

When most people hear the term ‘Thorough Examination’, they immediately think of LOLER (Lifting Operations and Lifting Equipment Regulations 1998) – the regulations that cover the lifting mechanisms of equipment, such as forks, chains and masts. However, that’s only part of the picture. While LOLER ensures that the lifting components are safe and compliant, it doesn’t address other critical aspects of materials handling equipment that are equally important for safety.

This is where PUWER comes in. The Provision and Use of Work Equipment Regulations 1998 cover the driving mechanisms (including brakes, steering and tyres), and even safety systems like operator guards and seatbelts. If you’re only getting a LOLER check, you could be missing these vital areas, leaving them at risk of failure.

Unfortunately, many inspections focus solely on LOLER requirements, mistakenly believing that this is enough to meet legal obligations. This leaves significant safety gaps, particularly around the operation of the truck. For example, a forklift might pass a LOLER inspection because the forks are in good condition, but if the steering hasn’t been checked under PUWER, it could still pose a serious danger.

A proper Thorough Examination should address both LOLER and PUWER – ensuring that your equipment is not only lifting safely but also operating safely. It’s crucial to understand the distinction between the two and make sure your inspection covers everything needed to keep your staff and workplace protected.

The hidden costs: what you’re not seeing

At first glance, skipping parts of an inspection might seem like a time-saver. But the hidden costs of cutting corners can quickly add up.

When safety-critical components are missed, the consequences can range from equipment breakdowns to severe accidents – and the associated costs can be far greater than the price of a proper Thorough Examination.

Imagine a forklift that’s only been inspected under LOLER. The brakes haven’t been checked. One day, those brakes fail. The result is not only damage to goods and equipment but also costly downtime and potentially serious injury (or worse). Suddenly, the small savings from a rushed or incomplete inspection pale in comparison to the financial hit your business is taking.

According to HSE figures, around 50 per cent of deaths involving moving vehicles on British farms could have been prevented if those elements covered by PUWER, including brakes and steering, had been properly inspected and maintained.

Beyond the immediate costs, there’s also the risk of non-compliance. Fines for failing to meet safety standards can be steep, and prosecutions by the Health and Safety Executive (HSE) are on the rise. Even worse, the damage to your reputation could linger far longer than any financial penalty. A Thorough Examination might seem like an upfront cost, but it’s really an investment in avoiding these hidden and often unexpected expenses.

Geoff Martin is chairman of CFTS. Photograph: CFTS

Don’t be afraid to ask your provider to confirm that the inspection meets both LOLER and PUWER requirements. If a truck is only inspected under one regulation, in the event of an inspection by HSE you will be liable for not meeting the other.

The CFTS difference: going beyond the basics

What sets CFTS members apart is a commitment to going beyond the basics. A CFTS-accredited Thorough Examination doesn’t just cover the lifting components – it examines every aspect of the equipment, ensuring both LOLER and PUWER requirements are fully met. This comprehensive approach gives businesses the peace of mind that their equipment is safe, compliant and ready for action.

CFTS-accredited examiners are specially trained and equipped to provide a thorough and precise inspection. They must agree to a 60-page Quality Assurance Procedural Code that requires them to meet our stringent standards. Using specialist tools, they ensure that every safety-critical component is properly assessed. And it’s not just about the tools – they follow detailed, standardised checklists tailored to the specific equipment being examined, ensuring consistency and quality across every inspection.

It’s a level of scrutiny and thoroughness that goes beyond a simple tick-box exercise. You’re getting an inspection that’s backed by industry-leading standards and audited regularly to ensure compliance. With a CFTS-standard inspection, you can be confident that no shortcuts are taken, and nothing is left to chance.

Protect your business

Now is the time to take a closer look at your inspection practices. Are you confident that your equipment is receiving a complete Thorough Examination – or are you leaving safety to chance? Don’t let an incomplete inspection put your business, your staff, or your reputation at risk.

With over 800 CFTS-accredited depots across the UK, finding a qualified examiner has never been easier. Whether you operate a single site or manage multiple locations, you can trust CFTS members to provide a consistent, high-quality inspection that covers every aspect of your equipment’s safety.

Geoff Martin is chairman of CFTS.

For more information or to find your nearest CFTS-accredited examiner, visit:

thoroughexamination.org