Free template
Warehouse and forklift skills matrix template.
In a warehouse, some levels expire by law. A forklift driver whose evaluation lapsed is not a level 3 any more, however well they drive, and the shift that counted on them is one driver short without knowing it.
This template tracks the usual warehouse skills next to the evaluations that keep them valid. The example opens with one gap in equipment and one in paperwork.
Warehouse and forklift skills matrix, Excel
The matrix below, a qualification log with expiry dates and a cross-training plan. Free, no email needed. Opens in Excel, or in Google Sheets through File, Import.
The example it opens on
Warehouse, 6 people. Levels 0 to 4, where only 3 and 4 count as coverage. Training status is the number at level 3 or higher minus the number the station needs.
| Skill | Op A | Op B | Op C | Op D | Op E | Op F | Needed | Status |
|---|---|---|---|---|---|---|---|---|
| Counterbalance forklift | 3 | 3 | 3 | - | 3 | 1 | 2 | +2 |
| Reach truck | 4 | 1 | - | - | 2 | - | 2 | −1 |
| Order picking (RF scanner) | 3 | 3 | 3 | 3 | 3 | 2 | 2 | +3 |
| Receiving and put-away | 3 | 2 | 3 | 1 | 2 | - | 2 | ✓ |
| Shipping and loading | 3 | 3 | 2 | 2 | 1 | 1 | 2 | ✓ |
| Cycle counting not critical | 3 | 2 | - | - | - | 1 | 1 | ✓ |
| Hazmat handling and shipping | 3 | - | - | - | - | - | 2 | −1 |
Two rows read −1. Reach truck: only Op A can work the high racks alone, so high-bay put-away stops when A is out. Hazmat: only Op A holds current hazmat training, so hazmat shipments wait for A as well. The rest of the shift is well covered, which is exactly why the risk on A is easy to miss.
What is different in warehouse and forklift
A lapsed evaluation drops the level
Treat the forklift evaluation as a condition of level 3. When it expires, the person stops counting as coverage until it is renewed, and the log shows it 30 days ahead.
Count each truck type separately
Counterbalance, reach truck and order picker take different skills and separate evaluations. One forklift row hides the reach truck gap.
Paper skills are skills
Hazmat shipping is mostly paperwork, but a shipment cannot leave without it. Give it a row and a coverage rule like any piece of equipment.
Qualifications and expiry
| Qualification | Interval | Source |
|---|---|---|
| Powered industrial truck operator evaluation | At least every 3 years, and refresher training after an accident, near miss or unsafe operation | OSHA 29 CFR 1910.178(l)(4) |
| Hazmat employee training | At least every 3 years | 49 CFR 172.704(c)(2) |
| First aid and CPR, if your site names responders | Typically 2 years | Training provider (e.g. American Red Cross) |
Rules differ by country and state. Check the ones that apply to your site; the intervals above are the US federal baselines.
The template's Qualification log calculates each expiry date and flags anything due within 30 days or overdue.
The cross-training plan
Every gap becomes a dated entry with a trainee and a trainer. In the example:
| Skill | Trainee | Level | Trainer | Practice | Assessed by |
|---|---|---|---|---|---|
| Reach truck | Op E | 2 → 3 | Op A | Two high-bay put-away blocks a week | 2026-12-04 |
| Hazmat handling and shipping | Op B | 0 → 3 | External trainer | Hazmat employee training course | 2026-11-20 |
The method behind it
The levels, the evidence for each one and the coverage rules are explained in the skills matrix guide, with a worked example from an assembly cell. When the matrix has to cover several teams, shifts or sites, see how skills matrix software in TeamGuru counts the gaps the same way for all of them and shows, per skill, who is expired or expiring soon. Comparing tools? Start with the buyer's guide.
Templates for other areas:
Frequently asked questions
How often do forklift operators need to be evaluated?
In the US, OSHA requires an evaluation of each operator's performance at least once every three years, and refresher training after an accident, a near miss, unsafe operation or a change in truck type or workplace (29 CFR 1910.178(l)(4)). Other countries set their own intervals.
Should each truck type be a separate skill?
Yes. Counterbalance trucks, reach trucks and order pickers need different skills and are evaluated separately, so one forklift row would hide the gaps that matter.
What happens to a level when the evaluation expires?
Treat it as no longer valid for coverage until it is renewed. The template's Qualification log flags evaluations due within 30 days so you can book them in time.