Putting Safety First

Exploiting and overcoming warehouse safety concerns.

By: Shawn Mantel, Contributor

In a world where “Safety First” is the mantra above all, one area that seems to lack focus is warehouse safety. While these facilities do not have metal cutting, grinding, or forming equipment, warehouses come with their own set of extreme hazards requiring immediate action. The Occupational Safety and Health Administration (OSHA) does not have a regulation code specific to warehouse safety, but it does fall under the general industry codes based on the type of equipment and related job tasks. Pedestrian traffic, process equipment, and ergonomic safety should all be considered in making a warehouse safe. Lean manufacturing techniques can also be factored in when exploring process improvements for improving the safety and health of the given workspace.

Pedestrian traffic hazards

Pedestrian traffic, process equipment, ergonomic challenges and mezzanines can all be sources of warehouse hazards. © Petinovs – stock.adobe.com

Pedestrian traffic can be extremely dangerous as it generally factors in powered industrial trucks (PIT). This requires strategic planning of flow patterns for both process and foot traffic. Four essential areas to concentrate on are guardrails, handrailing, dock safety, and PIT/pedestrian notification: each bringing their own set of design standards and regulations.

Guardrails are used to create traffic patterns and create a lifesaving barrier between the PIT and pedestrian. Guard railing should be installed by entrances, exits, stairways, restrooms, and walkways and ensure the proper impact resistance has been factored in.

Handrailing is to be used in areas where trips and falls could exist, such as ramps, staircases, and elevated work surfaces. This solution requires specific heights and mid-bars along with toe kicks on mezzanines.

Dock safety has multiple factors to consider: dock door constraints, padding, truck wheel chocks, floor markings for walking and material staging, and indicator lights when loading trucks. Some areas could also include a cardboard compactor requiring proper safety doors.

Due to the inherent dangers PIT presents to pedestrians, identifiers such as mirrors, proximity light sensors, working horns, and speed regulators are highly recommended, and in most cases, are required per OSHA. Proper maintenance of the PIT as well as authorized and certified personnel is required.

Process equipment hazards

Process equipment such as conveyors, palletizing systems, wrapping and taping machines present a wide range of hazards. These hazards under 1910.212 regulation consist of box formers, pinch, sheer, cut, and crush points that can lead to serious injuries or death. These types of accidents can happen quickly due to lack of experience or training, distractions, overconfidence or unexpected machine malfunctions.

Proper machine guarding and safety devices are a critical factor in reducing or eliminating risks on these machines. Lockout-Tagout (LOTO) training and procedures are vital to this area as well to prevent accidents caused by all kinds of stored energy, not just electrical.

Ergonomic safety

Ergonomic safety can often be an overlooked concern because it does not present an apparent or obvious hazard. However, injuries such as neck and back pain, carpal tunnel, muscle strain, and overall body fatigue can occur if the environment is not set up properly.

Work areas require evaluations of the process as it relates to the operations “green zone” defined as minimal stress for tasks as it relates to reaching, bending and lifting. Once ergonomic studies have been concluded, measures can be taken with functionality and probability of workstations, adjust height lift tables, low friction cars, ergonomic mats, user-friendly tools, and lift assists.

Storage racks and mezzanine workspaces bring safety concerns that could prove to be catastrophic. Hazards that can occur are products being pushed off the back of racks, products being dropped from overhead or people falling off mezzanines, and racks tipping over or collapsing due to PIT impacts or overloading. All is preventable with proper measures of adding rack backs, fastening racks to the floor while adding bumpers and corner protection, gated railing with toe boards along with a potential need for fall protection.

Warehouse safety expectations

With more clarity on the expectation of warehouse safety, we all now can do our required parts to help lower the statistics of workplace injuries and deaths. To ensure measures are being taken to review and mitigate these areas of safety, it is recommended to regularly hold meetings with a formal safety committee, perform internal audits, create action items and execute said items with urgency. In addition, good housekeeping, organized and proper PPE all positively impact a safe environment.

This can feel overwhelming due to time constraints, lack of experience, or not knowing where to start. The cost of waiting can change a person’s life in an instant. It is also a good practice to reach out to a safety company that focuses on total turnkey solutions. Safety experts can explain how to achieve total employee safety and implement solutions. WMHS

Shawn Mantel is the CEO and sales engineer at PowerSafe Automation, a leading provider of turnkey machine safety guarding and industrial automation solutions. PowerSafe Automation specializes in custom design, fabrication, assembly, and nationwide installation services including electronic integration — unique services that help customers reduce hazards, improve workplace safety and minimize downtime. To learn more about PowerSafe Automation’s innovative solutions and commitment to meeting compliance and OSHA regulations, visit www.powersafeautomation.com.