Introduction

Hoists are mechanical lifting devices designed to raise, lower and position loads safely and efficiently. Commonly found in factories, construction sites, shipyards, maintenance workshops and warehouses, hoists reduce manual handling risk and improve operational productivity when used and maintained correctly.

This document explains the operating principle of hoists and highlights safety and compliance practices consistent with the National Institute for Occupational Safety and Health (NIOSH) principles and the Department of Occupational Safety and Health Malaysia (DOSH) regulations, including references to OSHA 1994 and the Factories & Machinery Act where applicable.

Key Components

• Lifting medium — load chain (chain hoist) or wire rope (wire rope hoist).
• Drum or sprocket — around which the medium winds or rides.
• Motor / drive mechanism — manual hand-chain, electric motor with gearbox, hydraulic or pneumatic drive.
• Gearbox & transmission — reduces speed and multiplies torque for controlled lifting.
• Brake system — mechanical or electromagnetic brakes to hold load when motion stops.
• Limit switches — prevent over-travel at upper and lower travel limits.
• Load hook & safety latch — connection point to the load; must be inspected regularly.

Operating Principle

The operating principle of a hoist is straightforward: convert input energy (manual, electrical, hydraulic or pneumatic) into controlled mechanical torque that moves the lifting medium to raise or lower a load.

Energy conversion & transmission

Input energy rotates the motor or drive. A gearbox reduces rotational speed while increasing torque. The torque turns a drum or sprocket which winds (lift) or unwinds (lower) the chain or rope.

Controlled motion & holding

Brakes engage automatically when lifting stops to prevent unintended descent. Limit switches cut power or stop motion at safe travel extremes. Together, these systems provide controlled movement and load holding consistent with safe lifting principles.

Safety & Compliance Principles (NIOSH & DOSH)

Load capacity and marking

All hoists and lifting accessories must be clearly marked with their Safe Working Load (SWL) or rated capacity. Never exceed the marked capacity.

Inspection & maintenance

DOSH requires routine inspections by a competent person. Typical checks include:

Operating controls & ergonomics

Controls should be intuitive, labelled, and positioned to avoid operator strain. NIOSH emphasizes minimizing manual handling — use hoists to reduce repetitive lifting and awkward postures.

Safe operating practices

• Center loads beneath the hoist; avoid side pulls.
• Lift slowly to test load stability before full movement.
• Never allow personnel to ride on loads or stand beneath suspended loads.
• Use tag-lines for load guidance when necessary.

Overload & emergency protection

Hoists should include overload protection (mechanical or electronic), emergency stop functions, and clearly documented procedures for emergency lowering. DOSH and FMA regulations require documented maintenance records and periodic certification where applicable.

Typical Applications

Industries that commonly use hoists include manufacturing, construction, automotive repair, warehousing & logistics, shipbuilding and offshore operations. Selection of hoist type depends on capacity, height, duty cycle and environmental conditions.

Malaysia — Regulatory & Company Compliance

Relevant Malaysian regulations and guidance include:

• Occupational Safety and Health Act 1994 (OSHA 1994) — general employer duties to provide a safe workplace.
• Factories & Machinery Act 1967 (FMA) — specific requirements for lifting machinery and competent inspections.
• DOSH Guidance — technical circulars, guidelines and enforcement on lifting equipment safety.
• NIOSH Malaysia — training materials and ergonomic guidance relevant to manual handling and mechanical lifting.

Note: This article provides guidance; always consult the latest DOSH technical circulars and statutory instrumentation for legal compliance and refer to a qualified engineer or DOSH inspector for site-specific interpretation.

Suggested Outline for a DOSH‑Aligned Hoist SOP

1. Purpose and scope
2. Definitions (SWL, competent person, etc.)
3. Equipment identification and marking
4. Pre-use inspection checklist
5. Operational procedures (lifting, lowering, signaling)
6. Maintenance and inspection schedule
7. Record keeping and certification
8. Emergency procedures
9. Training requirements

Conclusion

Understanding the operating principle of hoists—and aligning practice with NIOSH/NIOSH‑based ergonomics and DOSH regulations—reduces injury risk, improves operational reliability and supports legal compliance in Malaysia. Implementing clear SOPs, regular inspections by competent persons and adequate operator training are essential steps.