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Topic of the Month: Warehouse Safety

(Photo: HVBG/Senn)

Warehouse as an industrial facility that receives and stocks many types of product, then transports or ships it to various locations evokes the image of a simple operation moving materials around with forklifts, powered hand jacks, conveyors or by hand. Thanks to this image, warehouse employees often develop a false sense of safety. With no dangerous machines or high-risk operations to consider, many fail to see the need for a sound safety program. By nature, however, a warehouse is a busy place, and such fast-paced productivity often leads to injuries. Therefore, where safety is concerned, warehouse management must do more to protect employees.

What can be done to achieve a safer work environment and enhance worker safety? What programs should be implemented not only to comply with OSH regulations but also to provide for sound safety practices?

Focus Areas
Statistics indicate that certain areas or operations within a warehouse present greater hazards than others. The following operations have historically contributed to significant numbers of injuries and are considered to be the most hazardous:

docks,
powered industrial trucks,
conveyors,
materials storage,
manual lifting/handling and
charging stations.

Other serious problems include

inadequate fire safety provisions,
chemical exposure,
improper use of lockout procedures,
lack of ergonomics and
failure to wear personal protective equipment.

To improve warehouse safety, employers should focus on these areas and take steps to improve employee training, enforce safe practices and implement appropriate corrective action.

Loading Docks
Employees and visitors can easily fall off a dock. Due to operator error, a piece of powered equipment (such as a lift truck) may drive off a dock. If a tractor prematurely pulls out with a trailer, the lift truck and operator may crash to the dock floor, which could result in serious injury or death. A lift truck could also skid off the dock as a result of contact with a slippery surface.

Product stored or being moved can easily fall (on someone) if not stacked properly. Product can be damaged by a lift truck's forks or rear-end swing. In addition, sprinkler heads may be struck by loads being lifted; the resulting water flow may damage product.

Clearly, the hazards are many. Losses may arise due to injury, downtime, product damage and missed shipments. To enhance dock safety, management can take several steps.

Paint the dock edge yellow to provide a better visual perception of the hazard.
Require wheel chocking at every bay door. When a trailer creeps or pulls out prematurely, the lift truck may fall between the trailer and the dock floor, leading to serious injury or death.
Verify that ladders from dock surface to dock well meet OSHA specifications. In addition, management must prohibit dock jumping, which can lead to serious ankle, knee and back injuries.
Provide proper illumination for exit doors. Such doors should also feature an exit sign and be equipped with emergency lighting.
Allow only trained, authorized employees to operate powered hand trucks or hand jacks (also called walkies). Although these devices appear easy to operate, they actually pose hazards similar to those of forklifts. These units turn in a small radius, which can trap the operator's hand between the operating handle and a fixed object (such as storage racks).
Inspect the dock area daily to ensure that fire extinguishers are not blocked (by some obstacle) or damaged.
Make sure dock plates are designed for the loads and lift trucks that will use them. Attempts to manually place portable dock plates can lead to back injury. Some portable models have built-in handles and can be mechanically lifted using lift truck forks.
nstall dock plates with non-skid surfaces. Use yellow edging on fixed plates to help operators gain perspective on distance while driving on them. Color highlighting also helps prevent operators from driving off the side.
When dock plates need repair, rope off the surrounding area and post appropriate signage.
Clean out dock areas periodically in order to remove accumulated debris. Paper, wood and other combustible materials may fall into the holes along the open sides of dock plates, which poses a fire hazard. Dock well drainage must also be maintained to prevent standing water.
Identify overhead pipes and highlight them with color. Install barriers to protect pipes or other building structures that can be struck by a lift truck or load. Where possible, paint these barriers yellow.
Inspect the integrity of trailer floors before a lift truck is driven onto them. Support the trailer's nose if the base is poor, landing wheels are defective or the trailer is leaning. Also, inspect trailer wheels to make sure they are properly located and locked-in-place to prevent the trailer from tipping.

Powered Industrial Trucks
Powered industrial trucks are a key component of the material handling process in a warehouse. These vehicles are also dangerous. A lift truck has a high center of gravity, turns more sharply than an auto (because its rear wheels do the steering) and may weigh three to four times more than an auto. All of these factors contribute to forklift tipover. Management can implement additional safeguards as well.

Install back-up alarms on trucks, which can prevent many struck-by or caught-between injuries. Typically, alarm volume may be adjusted so it poses no nuisance to those nearby. Evaluate the working area to make sure the alarm acts as a warning device and does not confuse employees. Flashing lights can also aid safety. Like back-up alarms, lights should act only to warn (not annoy) others.
Equip trucks with rear-view mirrors that are convex or panoramic in design to give operators the best view possible.
The goal of these safeguards is to aid operators and alert others to the movement of powered equipment.

Conveyors
Conveyors are common in the warehouse and distribution industry. Management can enhance conveyor safety via the following safeguards.

Inspect conveyors on a regular basis. The manufacturer or an outside engineering firm can inspect the devices using a comprehensive checklist. In addition, supervisors and safety committee members should conduct planned inspections on a regular basis.
Color code off/on buttons and ensure easy accessibility. These buttons should be available at various intervals along conveyors. These emergency controls are in addition to controls at the front and back ends of the system. Another alternative is to install a flag switch and emergency pull cords along the sides of conveyors.
Develop a means of locking out the conveyor and train employees in these procedures.
Install netting or other protective guarding (to prevent product from falling) on the sides or under conveyors in areas where pedestrians may walk. If employees must cross over a conveyor, provide stairs and railing or enable one section of the conveyor to fold up in order to accommodate access. Climbing onto or over conveyors must be prohibited.
nstall a shutoff device (in the form of electronic sensors or sensitivity wires) to prevent over-stacking and falling product at the ends of conveyors. Over-stacking exposes employees to manual material handling, which can cause productivity problems and product damage.
Focus on pinch points unguarded drive sprockets and drive belts during conveyor inspections. Color code guards with yellow paint to increase awareness.
Post signage, and install alarms and warning lights to alert employees when the system starts or stops. Make sure light-beam switches and emergency controls are fully functional.
Provide proper lighting and working surfaces in the area surrounding the conveyor. Special floor mats can enhance employee comfort. Verify that conveyor height is adjustable at both the feeding and removal end to accommodate employee height. Adjustable pallet stackers further reduce the need for bending and lifting.
Use portable conveyors that are designed to roll into place. If a conveyor must be manually lifted, train employees to seek assistance (e.g., a lift truck) in order to avoid injury to the back, foot or hand.

Materials Storage
A warehouse provides a building where product and materials are brought in, stored and later retrieved for shipment to another location. Product movement and storage pose risk to all present. To improve safety and productivity, employers should take the following steps.

Visually inspect pallets as they arrive and remove those in poor condition. Loads can fall from racking or storage if a pallet breaks. Also, lifting a bad pallet that is loaded can cause product to unexpectedly fall on employees.
Stack loads straight and evenly. Place loads directly on racking. Correct loads that look out of balance.
Where possible, shrinkwrap loads or place plastic or metal banding around them. A secure load helps protect lift truck operators.
Place yellow protective posts or barriers at the ends of racking to prevent damage caused by lift truck movement.
Space racks so that pallets being handled cannot damage other loads. Spotting a load on one side of a rack could easily push the adjacent load into the next aisle perhaps onto unsuspecting employees.
Provide sufficient space so lift trucks can turn properly and safely, without damaging storage racks.
Make sure floor surfaces and aisles are smooth and free of ruts, debris and slippery surfaces (e.g., oil, chemicals, fluids, water), which may hinder operators' ability to stop powered equipment. In addition, the jarring motion of a forklift operating on a poorly maintained floor can seriously injure operators' legs and back.
Store product on shelving, not in aisles or on the floor.
Store low-sales (infrequently handled) product out of the way. Place product that is regularly handled (manually) on shelves that are knee high and not above shoulder height.

Manual Materials Handling
Manual materials handling can easily produce back and hand injuries. In fact, back injuries result in the most-expensive claims within industry.

Develop employee awareness regarding pinch points. Hand traps can occur while setting down heavy boxes; working near pulleys in conveyor belts; adjusting lift truck forks; operating walkies; shutting trailer doors; and manually handling product. Proper-fitting gloves provide additional protection.
Identify fixed pinch points (e.g., the two horizontal doors that come together on a freight elevator) with yellow paint or black-and-yellow-striped tape. Post appropriate signage as well.
Place guards on any moving gears or hazardous rollers to protect hands and other body parts.
To ease manual lifting, add handles to containers. Train employees in proper lifting techniques bend at the knees, keep close to the load, and use the arms and legs to lift. They should also know how to shift feet not twist at the waist when turning with a load.

Charging Stations for Equipment
To allow powered equipment to function, a refuelling or recharging area is needed. Units may be powered by gasoline, diesel, liquid petroleum gas (LPG), compressed natural gas (CNG) or battery. Thus, in areas where vehicles are refuelled or recharged, management must exercise special care to reduce the risk of fire and explosion. Some guidelines follow.

Ensure that refuelling systems are professionally designed for the specific risk. The manufacturer should provide guidelines regarding system design or safety features.
Prohibit smoking and open flames in and around charging stations and post signage reinforcing these restrictions. Ensure that fire extinguishers are readily available and fully charged. Dry chemical or CO2 are the most effective extinguisher types. In addition, automatic fire suppressant discharging systems (such as CO2) can facilitate effective response during an emergency.
Consult with the local authorities to determine the required distance (based on fire codes) between the filling station and a building structure.
Verify that safety devices for vapor recovery, flash arrestors, automatic shut-offs, etc., are in place and in good operating condition.
Equip battery-charging areas with an eyewash unit that will provide at least 15 continuous minutes of running water. Depending on the potential exposure, a full drench shower may also be required.
Post information about extinguisher placement and job hazard analysis near the chargers, along with an informational placard from the battery company.
Provide equipment to protect against battery acid (e.g., rubber gloves, rubber apron, goggles, face shield and rubber boots). If LPG trucks are used, provide appropriate gear for changing tanks.
Mount circuit breaker boxes or wall disconnects near chargers (should they need to be shut off in the event of emergency or maintenance). Properly identify boxes or controls and indicate voltage. Enforce lockout/tagout procedures.
If cranes or hoists are used to handle batteries, inspect cranes and hoisting slings. Ensure that hook latches and appropriate PPE are available. In addition, a competent person (preferably from a crane firm) must inspect the cranes each year.

Fire Safety
Many warehouses are protected by automatic sprinkler systems. As noted, management must be sure that the product stored can be extinguished by this system should a fire occur. Management should take the following steps to make sure a warehouse is protected against fire.

nspect sprinkler systems and conduct flow and alarm testing each month. Document inspections. Having professionals periodically evaluate the fire prevention system and complete a facility emergency plan will pay dividends.
Store all flammables and plastics according to code. Plastics fires are much hotter and may render a standard sprinkler system ineffective.
nspect fire hoses and extinguishers regularly. Remove any obstructions and make sure these items are readily available. Only employees trained in appropriate firefighting techniques should handle this equipment.
Perform annual fire drills and practice emergency drills. Post large emergency evacuation maps throughout the facility.
Develop an emergency plan that assigns specific tasks to certain employees.
Train all employees in basic principles of firefighting including how to identify fire types and use extinguishers. Local fire departments or firms that provide extinguisher recharging services can provide on-the-job training.
Maintain fire alarms, smoke detectors and emergency lighting in proper operating condition.

Chemical Exposure
Chemical exposure is not unusual at a dock. For example, a lift truck fork could easily puncture a container holding solvent with a low flashpoint, which may result in fire or explosion. Containers may be damaged if dropped. Other exposures range from everyday use of chemicals to battery acid. To protect employees, management must take several key steps.

Provide information (at least MSDS) for each chemical in the facility. This is best achieved by filing MSDS in binders and storing the binders in key locations Chemical manufacturers must provide this information to the purchaser (warehouse). The purchaser must also provide MSDS to new purchasers of product from the warehouse.
Maintain a master chemical inventory and number each chemical. A matching number should accompany each MSDS (using tabbed reference sheets).
Provide spill clean-up kits in any area where chemicals are stored. For example, a battery acid spill is foreseeable in the battery-charging area. Therefore, a clean-up kit should be available.
Develop and implement a written spill control plan. Train employees to clean up spills, protect themselves and properly dispose of used materials.
To minimize risk of container damage, store chemicals safely and securely. Do not stack heavy loads atop small chemical-holding containers, because the weight could easily crush the smaller containers. Where possible, store chemicals away from lift truck traffic areas.
Provide PPE and enforce its use.
Monitor and control carbon monoxide (CO) exposure caused by use of propane-powered lift trucks. To prevent exposure, use battery-powered equipment. If this is not possible, tune-up propane trucks or add catalytic converters to reduce CO from combustion engines. In addition, install CO alarms and test air quality on a regular basis (with calibrated instruments).

Lockout/Tagout Procedures

Various machines, devices and operations in a warehouse present the need for a zero-energy state and, thus, the need for a lockout/tagout (LOTO) program. Employees required to perform LOTO should be thoroughly trained, and all employees should have (at least) working knowledge of the program.

Following are examples of situations that may require LOTO.

A malfunctioning conveyor requires maintenance. Pull down the disconnect that powers the conveyor, and lock and tag it. Mark the disconnect box to identify what it controls and its voltage. The conveyor could also be locked out via the circuit breaker box. Here, label each disconnect switch properly. Close the box door and key lock it after moving the switch to "off," or place an LOTO attachment on the switch (in the off position).
A forklift needs brake repair. Safely park the unit in an approved area, remove the key and add a tag that identifies who locked it out, when and why. For additional safeguarding, turn off the propane tank valve or disconnect the battery (depending on the model).
Several employees have received electrical shocks from a large floor fan. Pull the plug, place a cover over it, and add a lock and tag. This prevents the defective fan from being plugged in.
A battery charger begins to emit smoke. Pull the proper disconnect switch and add a lock and tag. This is why each disconnect box should be marked to match the appropriate battery charger. Alert the maintenance department to schedule corrective action. To ensure that LOTO procedures are properly executed, management should take the following steps.
dentify circuit breaker boxes (on the outside) by number or letter code; this makes it easier to locate. Inside each box, test individual switches to verify what they control, then label them accordingly. Also, ensure that the panel contains no openings which expose employees to live current, and install barriers (rails or guards) to protect power panels and boxes against impact by powered equipment.
Practice specific lockout procedures. An LOTO photo book is an excellent training tool. In addition, listing all LOTO procedures increases effectiveness. Review the program annually.

Ergonomics
Ergonomic improvements are designed to make jobs less stressful. Often, minor changes can have great impact.

Store heavy materials that must be manually lifted on shelving that allows lifting to take place between the knees and chest. If possible, use powered equipment instead of requiring a manual lift.
Position picking bins waistor chesthigh and tilt them for maximum access. Eliminate or tape sharp edges on containers in order to prevent cuts. Where parts must be lifted in individual containers, do not store containers on the floor or overhead. Add handles to ease lifting.
Ensure that overhead lighting is appropriate for the task at hand. Replace burned out bulbs and clean globes or reflectors. Increase illumination in areas that require a greater degree of accuracy in parts or product selection.
To employees working on a mezzanine, gates (that must be manually moved to an open position in order to accept product) pose a serious fall hazard. To prevent this, install a mechanical sliding gate equipped with a drive motor (like that on a garage door). To use such a device, the forklift operator pushes a button mounted in the lift truck, and the door slides open so the load can be deposited properly. S/he then pushes the button again, and the gate closes. A flashing red light increases hazard awareness when the gate is open.
Ventilation is critical. Carbon monoxide and other gases, fumes, vapors, mists and dusts must not exceed permissible exposure limits. General ventilation should provide the proper amount of air exchange and create a draft (in warm weather when doors are open). Local ventilation may be needed in areas above battery-charging or similar exposures.

Personal Protective Equipment
Management must conduct a site hazard assessment to determine what PPE must be worn, based on hazards present. In addition, employees must be trained regarding proper PPE selection, use and maintenance. General guidelines follow.

Provide hard hats to all personnel. Product can easily fall off a rack or shelf and strike an employee's head. When moving product under racking, an employee could easily strike his/her head.
Require foot protection where appropriate. Steel-toe shoes protect feet against falling product or when caught between two objects. Such shoes also protect the feet while operating powered pallet jacks, stock chasers and similar equipment.
Require eye and face protection for employees who sweep, cut metal or plastic banding, handle wire strands or perform maintenance.
Provide appropriate gloves to protect against sharp, hot, heavy and chemically unstable products. Depending on the hazard, gloves may be leather, rubber, cotton or other material. Thus, glove selection should be based on the exposure.
Where necessary, provide hearing protection (e.g., ear plugs or ear muffs). Since worker acceptance of this equipment depends on the comfort it provides, workers should be involved in its selection.

Further information

Warehouse Safety: A Comprehensive Review
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Warehouse Safety
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Promoting Health and Safety in Warehouses
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Warehousing Think Safety
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Manual Handling of Product
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Warehouse Safety Checklist
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Machine Guarding
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Forklift Safety/Power Industrial Trucks
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Personal Protective Equipment
Read more ...

Safe Handling Of Chemicals
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Docks Safety
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Hand Truck Operations
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Walkie Trucks/Pallet Jack Use
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