PREVENTING COMMON WAREHOUSE HAZARDS

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1 DEXTERS GUIDE TO PREVENTING COMMON WAREHOUSE HAZARDS

2 NEW ZEALAND IN REVIEW ACCIDENT STATISTICS 233,000 claims in ,700 for serious claims in 2016 Someone in New Zealand is injured every 20 seconds COMMON ACCIDENTS & HAZARDS IN THE WORKPLACE SLIPPING FALLING TRIPPING LOADING DOCKS MOVING MACHINE PARTS BODILY STRAIN HEAVY EQUIPMENT HAZARDOUS SUBSTANCES ERGONOMICS STORAGE LOADING DOCKS LACK OF SAFETY EDUCATION FIRE FALLING OBJECTS

3 RECEIVING AREA 1 Trailer Creep Product Congestion Docks Trailers unexpectedly move away from the dock area which creates a gap. When this happens forklifts and dock workers can fall leading to injuries and equipment damage. Within the receiving area of a warehouse, pallets, boxes, scrap materials, forklifts, pallet jacks, and people are all vying for the same space, meaning things can get out of hand very quickly, leading to crashes. The presence of physical hazards in your loading dock can lead to serious worker injury, and sometimes result in a fatality. It is important to be proactive in identifying potential hazards in the loading dock are Wheel chocks A simple solution that is often forgotten, wheel chocks are small and most-commonly rubber devices that wedge under trailer wheels to prevent movement. Vehicle restraints and stabilizing jacks There are various types of restraints that can be utilized. Most are activated by pushing a button located inside the docking area. This link shows a variety of trailer stabilizing jacks Floor marking tape Although something as simple as floor tape might not seem like a critical piece of safety equipment, marking product staging areas is the first step in keeping areas organized. Barrier rail Along the same lines of marking tape, barrier rail helps define areas for pedestrians, equipment and storage. Addressing Uneven Surfaces This can cause pedestrian slips and falls including forklift turnovers which can result to injuries. Forklifts Drive forklifts slowly on docks and dock plates. Secure dock plates and check to see if the plate can safely support the load. Keep clear of dock edges and never back up forklifts to the dock s edge. And provide visual warnings near dock edges.

4 PALLET STORAGE AREA 2 Damaged Pallets Damaged Racking Unsafe stacking In most warehouses, a large amount of space is dedicated to pallet storage, making it important that pallets are stored properly and racking is well-maintained. Dents, scratches, and other damage on racking can be extremely dangerous if not repaired. Any kind of damage weakens the racking system and could cause sections to collapse. Improperly stored materials may fall and injure workers. Stacks should not be built within 450 mm of a wall. Most building walls are not retaining walls and may not withstand the pressure set up by stacks laid against them Quality pallets A pallet being used for product storage should have all support legs intact and level, no serious deformities, and no major cracks or holes. Racking guards There are a variety of guards that can be put into place to protect the rack such as bollard posts, upright column guards, and aisle protection beams. Each of which can be found in a range of metal and flexible solutions. Training Training your staff so they know how to safely stack products on a pallet and also how to store empty pallets will help your staff stay safe.

5 PICKING AREA 3 Repetitive Motion Injuries Within the warehouse environment, employees are often tasked with performing constant, repetitive motions that can occasionally lead to injury. Improper lifting, repetitive motion or poor design of operations can lead to musculoskeletal disorders in workers. Forklifts About 100 employees are killed and 95,000 injured every year while operating forklifts in all industries. Forklift turnovers account for a significant percentage of these fatalities. Manual Handling Injuries and suffering can be linked to any work involving handling of loads. There are risks in handling even light loads if a repetitive task is being carried out in poor conditions. Ergonomic floor mats Another way to provide extra comfort and support for employees is the use of ergonomic floor mats. By placing these mats in areas where a lot of standing or walking occur, leg and back injuries can be reduced. Pallet handling devices Pallet jacks, positioners, turn-tables, and lift tables, can all greatly reduce strain on employees tasked with moving large amounts of product. These devices help reduce and even eliminate lifting, bending, and stretching that can lead to injury. Forklift training Proper forklift training can go a long way in preventing accidents in busy receiving areas. Surrounded by pallets, boxes, and people, an untrained forklift operator can easily cause a major accident. Properly maintain haulage equipment, including tires. Before using a forklift, examine it for hazardous conditions which would make it unsafe to operate; Employee education A good education program can teach employees about proper lifting techniques, correct posture, load characteristics, and safe use of equipment. If employees understand the actions needed to protect themselves, they can not only reduce injury, but also be more comfortable while working.

6 SORTATION & SHIPPING AREA 4 Powered Conveyor Sortation areas often use a large amount of powered conveyor to move products to the correct shipping area. When properly guarded, powered sortation conveyor is a relatively safe piece of material handling equipment; however, if necessary safety precautions are not taken, serious injury can occur. Charging Stations Fires and explosion risks are possible unless proper guidelines are followed. Human Interaction Demand for faster shipping times combined with the need for more ergonomic working conditions has led to an increased use of robotic palletisers. As more of these systems are introduced, it becomes increasingly important for employers to educate workers on how to safely interact with and service these machines. Conveyor guards To keep operators safe, all conveyors should have guards around moving parts, including gears, sprockets, belts, pulleys, and motors. There should also be some type of rail or netting to prevent product from falling over the edge. Training All operators and maintenance personnel should be properly trained on conveyor safety, including how to operate, maintain, and shut down the system as needed. Prohibit smoking and open flames in and around charging stations Provide adequate ventilation to disperse fumes from gassing batteries Ensure that fire extinguishers are available and fully charged Provide proper personal protective equipment such as rubber gloves and eye and face protection Barriers Both interlocked and fixed barriers effectively block off a robotic cell, thus preventing warehouse employees from entering while the robot is in motion.

7 NOTES

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