Last week, we spoke about the importance of racking inspection and its role in preventing racking collapse. However a collapse is one of many potential dangers in a distribution facility. Few businesses are slow to invest in preventive measures; as long as it hasn’t happened, it just isn’t a top priority. They often cite financial reasons for delaying inspection and repair, but is the alternative worth the sleepless nights?

October is synonymous with Halloween, ghost, ghouls, scaring the neighbours; but there are other situations that terrify our clients. Paying compensation, injury (and death) of staff, the bad publicity, are the stuff of nightmares for many warehouse managers. Yet, the safety figures till date show that accidents still occur as frequently as ever.

HSE reports that in 2015 alone, there have been over 170,000 reported injuries in the workplace, with much higher numbers reported in industrial settings. Is saving a few bob worth being part of that number?

A new mezzanine can create more space; a new pellet racking system can keep your employees and SKUs safe, but safety isn’t limited to the use of expensive equipment. Something as ‘simple’ as improving the lighting in the facility can create a more visible hence safer environment for workers.

There is a wealth of general information available on how to keep your employees safe, but here are a few tips to do so on a tiny budget.

1.Eliminate Collapse with Shrink Wrap

For warehouses that use use pallet floor storage, the fear of a collapse is constant; especially when the pallets are made up of different-sized products. But by following a few simple rules, the risk can be mitigated:

• When stacking, heavier loads must always be placed on lower or middle shelves.
• The right stacking for the situation must be used; block stacking is best used when the SKUs are of uniform size and bulk. The stack uses the SKUs to build a cube shape about 4 ft. tall, and the entire pallet is then bound together using shrink wrap. With the brick method, every other item is rotated by 90O as the stack is built up. This allows irregularly shaped items to be added without the risk of collapse.
• Even a well stacked and bound pallet can be destroyed if employees continue to remove objects from the middle of the stack, so this practice should be discouraged among pickers.

In creating the perfect stack of stacks, don’t forget to leave around 6ft. of space between the top of the tack and the warehouse sprinklers.

2. Prevent object Drops with Safety Netting

Protect your racking system by developing a custom Impact Protection Strategy i.e. what you do in the event of a racking accident.

• Ensure your columns are made from structural steel, as this can still maintain load capacity even when damaged.
• Add wire netting around racking in sections with high foot traffic or around your order picking areas.

 

3. Keep Pests Out with a Regular Clean

With the cold weather of the coming months, small animals like rodents will seek shelter in warmer spaces. A distribution facility offers a myriad of hiding places and food supplies; don’t let your business be that distribution centre.

Starting now, develop an integrated pest management policy that includes regular checks and cleaning of any disused areas. A plan should be made to dispose of abandoned equipment and to clean around anything that remains stationary.

If necessary, a redesign and modification of the building should be made to prevent re-entry.

 

4. Can You See Me?

Displaying simple signage in the right place is crucial to maintaining warehouse safety. Low cost methods include the use of floor marking tape or paint, to indicate forklift and pedestrian lanes.

To avoid overloading, simple documentation stating the beam capacity of each rack can be printed and affixed to the rack. Tape can also be used to mark the maximum height to which a shelf can be safely stacked.

 

5. Improve Worker Safety with Regular Meetings

An scheduled sit-down meeting with employees is often the only way that management learns about what goes on in the facility. These meetings (cuppa optional) can also be used to relay new safety guidelines and to generate feedback from employees.

Simple things like demonstrating the best way to lift; evaluate access point, gauge weight, lift, maintain visibility, educate staff and can help reduce the incidence of injury.  In 2015, there have been 169,000 new cases of musculoskeletal disorders so far.

Provision of spill cleanup kits and the right-size of PPE, along with adequate training also greatly lowers the possibility of accidents occurring. All these safety strategies can be done using equipment that cost only a few quid, yet offer large savings in the long run.

Don’t let ‘a lack of finances’ jinx your facility this Halloween. Contact Monarch for access to a massive range of safety add-ons for your warehouse.