Safety Across the Global Supply Chain

By Pete Saldana

Whether working with pallets in a manufacturing facility, fulfillment center, or retail setting, workers can minimize the potential for injury by heeding several safety tips.

When we think of the supply chain — which moves materials and finished goods around the world, and eventually into the hands of customers — we often think of warehouses, with forklifts shuttling around between tall racks of crates and pallets. But the true scope of the worldwide supply chain is unimaginably vast, stretching all the way from the factories that manufacture the raw materials, to the stores where shoppers load their carts. Along the way, the opportunities for accidents are immeasurable. The rapid growth of the industry — Amazon has increased its headcount by about two-thirds since late 2019 — will potentially increase injury risks, as less experienced supply chain workers enter the labor market.

But supply chain operators who demonstrate a commitment to safety training and preparedness, proper materials usage, and a dash of common sense, can reduce the risk not only of people getting hurt, but also of products and equipment getting damaged.

Safety Starts at the Top

While the workers “in the field” are typically the ones most at risk for injury, a commitment to supply chain safety begins at the management level. Leaders should consider these important best practices:

• No one is exempt from following safety procedures. Those in leadership positions who demonstrate that safety is important will serve as role models for others. A CEO who tours a factory floor but declines to wear the required hardhat, for example, is sending the wrong message.
• Communication is essential. Effective safety programs are built in a culture of teamwork and collaboration. Leadership should ensure that there is a proper and consistent forum for employees to share their safety concerns.
• Sometimes it’s OK to be flexible. If nobody wants to wear the safety vests because they’re ugly and uncomfortable, perhaps the path of least resistance is finding nicer and more comfortable vests. Instead of expecting employees to follow the unpopular policy, think outside the box to find solutions that work — while still ensuring that safety is not compromised.

Pallet Safety 101

No column on supply chain safety is complete without a focus on pallets, and although pallets are generally safe when used properly, any large object can be dangerous. Whether working with pallets in a manufacturing facility, fulfillment center, or retail setting, workers can minimize the potential for injury by heeding several safety tips:

• Inspect pallets carefully. Wood pallets are built from multiple boards which can pull free of the stringers or blocks they are attached to. Nails can work free of a pallet’s boards as the pallet flexes during handling or as the wood shrinks and swells due to moisture; this can pose the risk of snagging clothing or puncturing skin.
• Wear gloves when handling wood pallets, to minimize the risk of injuries from splinters and loose nails.
• Don’t stack empty pallets too high. Pallets should be stored on a smooth, level surface and should not be stacked higher than the limit for which they are designed, which may vary. A toppling stack of pallets can cause serious injuries.
• Have two people lift pallets weighing more than 50 lbs. Empty reusable wood pallets should be lifted and carried by two people. If only one employee is available, they should exercise caution, lifting with their legs and bracing the edge of the pallet against the stack so at least part of the weight is supported for them before attempting to lift the whole pallet.

Remember, pallet safety does not pertain only to warehouse and loading dock workers. Pallets are no longer an invisible, behind-the-scenes piece of equipment. They have become an increasingly common sight in retail environments, such as club stores. It is quite typical, these days, to see pallets of bottled water and paper goods in the middle of grocery store aisles, acting as a sort of temporary shelving. Retail workers who fail to handle and stack pallets with care can risk injury not only to themselves and each other, but also to unsuspecting customers.

Other Safety Considerations

Newcomers in any supply chain setting, such as a factory, fulfillment center, or cargo ship, may often assume that automated equipment and hazardous materials pose the greatest hazards. But what about the dangers of a simple slip and fall? Not only are such accidents common, but they are the leading cause of worker compensation claims. According to the Bureau of Labor Statistics, falls account for more than 10% of job-related fatalities for male workers, and about 5% for women. Employees should make sure that they and their colleagues have appropriate footwear in any workplace setting, and if they see a spill or debris on the floor, they should never assume it’s someone else’s responsibility. It is also important to remember that humor belongs in the break room. We all enjoy having a laugh with a coworker, but pranks and stunts have no place in a supply chain setting.

As noted earlier, what materials you use can also make a big difference across the span of the supply chain. Just ask Costco, which announced that they saved 9 million eggs per year from breaking and entering the waste stream simply by using recyclable plastic packaging. Plastic pallets and shipping containers tend to be lighter and more durable than wooden ones, which results not only in safer worker handling and improved ergonomics, but also a longer lifespan. They are also free of nails and splinters, and easier to clean and sanitize due to their non-porous surfaces.

As we continue to navigate our way through the complexities of the ongoing pandemic, which has added its own disruptions to the global supply chain, the importance of worker health and safety will remain at the forefront. By communicating and taking accountability, we can ensure that as many hardworking supply chain professionals as possible make it to the end of 2021 in one piece.

Pete Saldana serves as Engineering and Safety Manager for at iGPS Logistics, which provides pallet pooling (rental) solutions to over 100 leading manufacturers who ship to more than 2,000 locations at major distributors, wholesalers and retailers. For information about a sustainable shipping solution that eliminates the need to purchase and maintain pallets visit www.igps.com.