WAREHOUSE W SAFETY It I s t N o M ys yt ser t y er

Transcription

1 WAREHOUSE SAFETY

2 WAREHOUSE SAFETY This employee handbook is one of a series of fully-illustrated employee handbooks, informative posters, broadcast-quality video and DVD training programs, interactive CD-ROM and Web-based courses produced by Coastal Training Technologies Corporation. Each product is the result of painstaking analysis, design, development and production by the instructional designers and technical specialists on our staff. Our catalog is constantly being revised and expanded, so we would appreciate any comments on current titles or suggestions for future ones. For further information on any Coastal product, or to receive a free catalog, call Coastal Training Technologies Corp. (Virginia Beach, VA) at or send a FAX to Visit us on the Web at This handbook is for educational purposes only, and is designed to be used in conjunction with a qualified trainer. Nothing herein is to be regarded as indicating approval or disapproval of any specific practice or product. Copyright 1998, 1996 Coastal Training Technologies Corp. All rights reserved. No part of this handbook may be copied by any means or for any reason without the written permission of Coastal Training Technologies Corporation. Printed in U.S.A. Introduction ~~~~~~~~~~~~~~~~~~~~~2 Good Housekeeping ~~~~~~~~~~~~~~~3 Ladder Safety~~~~~~~~~~~~~~~~~~~~~4 Hazard Communication~~~~~~~~~~~~~~5 Labels MSDS Personal Protective Equipment~~~~~~~~~7 Ergonomics ~~~~~~~~~~~~~~~~~~~~~~8 Materials Handling ~~~~~~~~~~~~~~~~~9 Back Safety ~~~~~~~~~~~~~~~~~~~~~11 Forklift Safety ~~~~~~~~~~~~~~~~~~~~12 Safe Forklift Driving Working Around Forklifts CONTENTS Loading Dock Safety ~~~~~~~~~~~~~~~13 Summary ~~~~~~~~~~~~~~~~~~~~~~~14 Quiz ~~~~~~~~~~~~~~~~~~~~~~~~~~15

3 INTRODUCTION Mysteries aren t always found in the pages of detective paperbacks. In fact, most mysteries originate from a lack of knowledge. Hazards, like mysteries, are created by a lack of knowledge. Making a warehouse safe is no mystery if you have the knowledge you need. While many hazards exist in a warehouse, you can avoid a serious accident if you follow safe work practices. This handbook will introduce you to warehouse hazards and safety precautions such as: Good housekeeping Safe material handling Ladder safety Back safety Hazard communication Forklift safety Personal protective equipment (PPE) Loading dock safety. Ergonomics GOOD HOUSEKEEPING An uncluttered work area has fewer distractions which allows you to focus on your work. Less clutter can also reduce the risk of accident injury. Clean up trash and other objects on the floor that may cause slips, trips and falls. Always keep aisles clean and clear so forklifts and pedestrians can move freely. Dispose of scraps, broken glass and trash immediately. Always keep items stored in the appropriate places. Important: Always clean up spills and leaks. Report any slick or uneven surfaces to your supervisor immediately. 2 3

4 LADDER SAFETY When using a ladder, be sure you: Choose a ladder capable of supporting the total weight of you and the item you are carrying. Place the ladder on firm, dry and level ground. Make sure the ladder is fully open and the spreaders are locked. Always use both hands to climb the ladder. Ask co-workers to hand work items up to you after you ve climbed up and are ready to work. Never overreach. Come down and move the ladder if you can t reach something. Do not climb, straddle, sit or stand on the ladder s top rungs. HAZARD COMMUNICATION You have a right to know the hazards of materials you work with and how to properly protect yourself. Your employer should provide hazard communication (HazCom) training to teach you how to read labels and Material Safety Data Sheets (MSDSs). LABELS Every label in the warehouse must include the following information: Material name Material hazard warnings, such as its flammable or explosive properties Manufacturer name and address. If your employer transports or receives hazardous materials, you must be able to recognize Department of Transportation (DOT) labels and placards. Never remove a label unless it is damaged or unreadable. You should replace it immediately with an accurate label. 4 5

5 MSDS For more information on a material, read the Material Safety Data Sheet (MSDS) provided by your employer. MSDSs include: Material name and other common names Manufacturer name, address and emergency phone numbers Any hazardous ingredients Safe exposure limits Information to help identify the material, such as its appearance and physical properties Fire and explosion information Health hazards Symptoms of overexposure First-aid information Medical conditions that can be aggravated by exposure Spill and clean-up information Personal protective equipment needed. RIGHT-TO-KNOW INFORMATION PERSONAL PROTECTIVE EQUIPMENT Personal protective equipment (PPE) offers you head-to-toe protection from workplace hazards. PPE includes: Safety glasses, goggles or face shields to prevent potential harm from flying objects, chemical splashes or harmful light. Hard hats to protect against head injury from falling objects Earplugs or earmuffs in areas of excessive noise Gloves to protect against cuts, punctures or chemical burns Protective footwear to guard against heavy or sharp objects. Important: Always wear PPE suited to the hazards in your workplace. Even wellpackaged hazardous materials can break and spill, so it is important that you wear proper PPE at all times. Make sure you keep your PPE clean and store it properly. Never wear damaged PPE. Instead, dispose of it immediately. Remember: Know the hazards of the materials you re handling, then you can help prevent accidents or injuries. Read your employer s Emergency Action Plan for emergency contact information and how to evacuate safely. 6 7

6 ERGONOMICS Your comfort and safety on and off the job depends on keeping your body in neutral positions. To put your body in a neutral position: Stand up straight with arms relaxed at your side. Maintain three curves in your back: In at the neck Out at the chest In at the lower back. Do not allow your shoulders to slump or your back to arch. Practice keeping your body in a neutral position so that you can avoid unnecessary stress and strain. A comfortable working area includes: Keeping your workstation at the proper height Keeping tools within easy reach to eliminate excess stretching Taking rest breaks Using power tools when available to prevent joint and muscle strain Using step ladders to reach objects that are too high. MATERIALS HANDLING Moving product pallets may require using a hand truck or pallet mover. When using a hand truck, make sure it s on firm, dry and level ground. Be sure the handles are sturdy and straps are not torn or frayed. Also, check that there are no holes in the tires. Always know the weight limit of the truck and shelving as provided by the manufacturer. Keep the load to a height that can be managed and does not block your vision. To move a loaded hand truck: Stand behind the hand truck with one foot on the axle. Put one hand on the handle and one on the load. Pull both arms toward you and push the bottom out with your foot. Always push the hand truck, unless you need to pull it over a curb, through a doorway or up a ramp. When unloading a hand truck: Chock the wheels with your foot and lower the load. Chock the wheels with blocks to keep the hand truck from rolling or sliding. Remember: Never ride on a hand truck. Always watch your feet and co-worker s feet around moving hand truck wheels. 8 9

7 A pallet mover, or pallet jack, has forks that may be hand- or power-operated. Never ride on a pallet mover unless it is designed for that purpose. Watch your feet so you don t trip over the forks. Always inspect pallets for broken deck boards, loose nails or splintered wood. Never use a damaged wood pallet. Damaged wood pallets can be a fire hazard, so store them away from buildings. be sure to stretch-wrap or bind together irregular objects on a pallet. Here are a few general safety tips for storing and retrieving materials: Store heavier objects below lighter objects. Keep objects stacked neatly. Make sure the shelves are labeled to identify their contents. Keep stacked objects from poking out into the aisle. BACK SAFETY Back injuries make up about 40 percent of all warehouse injuries. You can prevent back injury by following these lifting techniques: Exercise at the start of your shift to loosen up the muscles you use most often on the job. Stagger your feet and bend your knees when lifting. Lean over your forward leg and rise upright using your legs. Never twist your back while carrying a load. Use your feet to pivot and turn your body instead. Although back belts give support to your back, don t count on them completely to save your back from injury, Make sure you know how to wear a back belt before you use it. Always ask for help when lifting an object that is too heavy for one person to lift alone. Remember: Be cautious when working around conveyors. Your clothes and fingers can easily get caught or pinched in a moving conveyor. Always walk around conveyors instead of hopping over or crawling under them

8 Safe Forklift Driving A properly-loaded forklift always has the pallet sitting squarely on the forks and against the heel of the forks. Stretch-wrap or bind together unstable loads before you move the lift. Never travel with a load on raised forks or down an incline. Never overload a forklift. Be aware of your surroundings. Watch for pedestrians, especially around blind corners. Watch for low beams that could catch the lift mast. In an emergency, bring your forklift to a stop and exit safely. Working Around Forklifts Always play it safe around forklifts, even though you as a pedestrian, have the right-of-way. Never assume you know where the lift is going. Never change directions after indicating to the driver where you are going. Remember: Always give drivers plenty of space. Forklift turns are sharp. Never ride on a forklift. Always stand clear of the forks. FORKLIFT SAFETY LOADING DOCK SAFETY Since most of the activity at a warehouse is at the loading dock, the probability of having an accident there is much greater. Some loading dock accidents can be caused by: Congested dock areas Inattentive forklift drivers Unexpected truck departments Trailer creep. When a truck comes in, stand clear of the doors. Improperly packaged products may shift and spill from the truck when the doors are opened. Make sure the trailer wheels are choked before you enter the trailer with a forklift. An unchocked trailer could creep away from the loading dock and cause a forklift to fall. Unexpected truck departures are the result of miscommunication between workers at the dock and the truck driver. Be sure to follow a pre-established set of hand signals, signs and lights to communicate with the truck driver. Important: Keep the dock area clear of all unnecessary debris. make sure all trash and damaged materials are disposed of properly. Be sure forklifts have adequate turning space on the dock

9 SUMMARY By now you have the knowledge you need to make the warehouse a safe workplace for you and co-workers. In this handbook you ve learned: Good housekeeping Ladder safety Hazard communication Personal protective equipment (PPE) Ergonomics Safe material handling Back safety Forklift safety Loading dock safety. If you follow these safety precautions, warehouse safety will be no mystery. QUIZ 1. True False Any slick or uneven floor should be immediately reported to a supervisor. 2. True False Always push trash and debris blocking an aisle to one side to clear a path for forklifts. 3. True False When climbing a ladder, it s safe to carry a load up using one hand. 4. True False Back injuries make up about 40 percent of all warehouse injuries. 5. True False You have the right to know the hazards of all the materials with which you work. 6. True False A label includes the most detailed description about a material. 7. True False Always dispose of and replace worn or damaged PPE before returning to work. 8. True False When working around sealed, packaged hazardous materials, it is okay to remove uncomfortable PPE. 9. True False Shifting your body into a neutral position is a good way to prevent stress and muscle strains. 10 True False Sitting on a ladder s top step is okay only if you straddle your legs. 11. True False If you are moving a hand truck over a curb, through a doorway or up a ramp, it s safer to pull it instead of pushing it. 12. True False Damaged wood pallets should be stored away from buildings. 13. True False Most objects can be safely stored anywhere, regardless of their weight

10 14. True False You do not have to ask for help lifting a heavy object by yourself if you re not moving it very far True False Always wear PPE suited to the specific hazards in your workplace. 16. True False Never drive a overloaded forklift or a forklift that has a load stacked higher than eye level. 17. True False A properly-loaded forklift always has the pallet sitting squarely on the forks and against the heel of the forks. 18. True False Forklift drivers can always see pedestrians, so it s safe to assume that they will see you. 19. True False In the loading dock, stand in front of a truck s trailer doors so you can start unloading immediately. 20. True False A truck driver always chocks is wheels when he stops at a loading dock, so you don t need to check them. ACKNOWLEDGEMENT OF TRAINING I have read and understand the training handbook, Warehouse Safety: It s No Mystery. I have also completed and passed the comprehensive quiz at the conclusion of this handbook. Employee s Signature Trainer s Name Date Date NOTE: This record may be included in the employee s personnel or training file. Asbestos Awareness Back Safety Bloodborne Pathogens Confined Space Entry Defensive Driving Electrical Power Generation Electrical Safety Employment Terminations Environmental Awareness Ergonomics Fall Protection Fire Safety First Aid Accident Investigation Anhydrous Ammonia Asbestos Series Back Safety Series Behavior-Based Safety Series Bloodborne Pathogens Series Chemical Handling Series Chlorine Safety Series Commercial Driver Series Confined Space Series Contractor Safety Construction Safety Series Crane Safety Series Disaster Planning Series DOT Drug & Alcohol Testing Driving Safety Series Electrical Safety Series Electrical Power Generation Series Emergency Planning Series Employment Terminations Environmental Series Ergonomics Series Fall Protection Series Fire Safety Series First Aid First Aid for Schools Foot Protection Forklift Safety Series Asbestos Series Back Safety Bloodborne Pathogens for Schools Bloodborne Pathogens Series Chemical Handling Series Chlorine Safety Confined Space Series Contractor Safety Driving Safety Series DOT Drug & Alcohol Testing Electrical Safety Series Environmental Series Ergonomics Series Eye Protection Fall Protection Series Fire Safety First Aid for Schools First Aid on the Job Foot Protection Forklift Safety Series CD-ROM AND WEB COURSES FROM COASTAL Forklift Safety Hazard Communication Hearing Protection HAZMAT Preparation HAZMAT Transportation HAZWOPER Awareness Hydraulics Indoor Cranes Industrial Electricity Interviewing Lab Safety Lockout/Tagout Office Ergonomics VIDEO-BASED PROGRAMS FROM COASTAL Groundskeeping Safety Hand Safety Hand Tool Safety Series Handwashing Hard Hat Safety Hazard Communication for Schools Hazard Communication Series HazWaste Transportation Series HAZMAT Transportation Series HAZWOPER Training Series Hearing Protection Heat Stress Highway Work Zone Series Hotel Safety Orientation Hydrogen Sulfide Indoor Cranes Interviewing ISO 9000 Series Lab Safety Series Laser Safety Lead Safety Line Breaking Lockout/Tagout Series Low-Lift Trucks Machine Guarding Mechanical Power Press Safety Media Relations Motor Vehicle Awareness ILLUSTRATED HANDBOOKS FROM COASTAL Hand Safety Hazard Communication Series HAZMAT Transportation Series HAZWOPER Training Series Hearing Protection Heat Stress Holiday Safety Series Hotel Safety Hydrogen Sulfide Indoor Cranes Interviewing Lab Safety Lead Safety Lockout/Tagout Series Low-Lift Trucks Machine Guarding Mechanical Power Press Safety Office Safety Performance Appraisals Personal Protective Equipment Office Safety Performance Appraisals Personal Protective Equipment Pneumatics Respiratory Protection Safety Orientation Sexual Harassment Stairways and Ladders Teamwork Time Management Trenching and Shoring Walking and Working Surfaces Vibration Analysis Off-the-Job Safety Series Office Safety OSHA Inspection Series Performance Appraisals Phosphoric Acid Pollution Prevention Series PPE Series Pro-Active Safety Series Process Safety Series RCRA Respiratory Protection Series Rope Rescue Series Safety Orientation Sexual Harassment Slips, Trips & Falls Stairways and Ladders Static Electricity Substance Abuse Prevention Series Teamwork Time Management Train the Trainer Series Trenching & Shoring Series Tuberculosis Awareness Walking & Working Surfaces Welding Safety Series Winter Safety Series Workplace Violence Pollution Prevention Series Pro-Active Safety Series Process Safety Respiratory Protection Safety Orientation Scaffold Safety Series Sexual Harassment Slips, Trips & Falls Stairways and Ladders Static Electricity Teamwork Time Management Trenching & Shoring Series Tuberculosis Awareness Vacation/Summer Safety Video Display Terminals Walking & Working Surfaces Warehouse Safety Winter Safety Series Workplace Violence

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