The warehousing and distribution industry, like many other industries, is prone to inefficiency. But in the warehousing industry, simple errors can lead to costly safety issues that reduce production, cause lengthy delays to the supply chain and can cause major safety problem as well.
While many of these errors can be spotted and quickly addressed, a large number go unnoticed. Spotting them can be done by employing an independent reviewer/efficiency expert or using a specialised WMS. But nothing beats the expert knowledge of the folks on the ground. A recent poll of industry experts turned up over 30 mistakes that they have experienced in the warehouses they manage.
Running a warehouse requires a high level of precision, yet there are certain common mistakes that prevail in warehouses everywhere. Here are 3 of the most common errors we see in warehouses we work with.
1. Using the wrong equipment
It may seem simple, but proper management of your storage, inventory and order profiles can increase overall efficiency levels. It’s very common for warehouses to attempt to save costs by buying in one type of equipment, and then trying to use it for multiple uses.
An example is the use of manual pallet jacks to move loaded cages. Apart from being totally inefficient, such activities put staff at risk of severe musculoskeletal injuries.
Another example is the use of the right lift truck. If your facility has maximised space and installed a VNA, using a standard lift trucks among the aisles is a recipe for disaster. Reach trucks, counterbalanced trucks, and turret trucks are better suited for reaching into the tight corners of your warehouse.
2. Lapse in forklift training programmes
Forklifts accidents kill. There is no getting around the fact that forklifts are involved in the riskiest activities in your warehouse. According to figures released by the Fork Lift Truck Association, 43 people are badly injured by forklifts in the average week. This includes 11 serious injuries such as amputations and 20 injuries caused by a moving forklift truck.
On average somebody is killed every 6 weeks in the UK by a forklift truck. In 2013 133 people in the UK died as a result of a forklift accident in a warehouse or distribution.
Who’s to blame? Sadly, forklift drivers are responsible for almost every incident of rack collapse in the history of warehousing. Any bump into beams causes them to weaken over time, which means that any incident of poor driving can result in a potential fatal accident.
While it is mandatory to have a licence before you get behind the wheel of any vehicle, there is an issue in many warehouses over how often are forklift drivers re-trained.
Staying up to date with lifting regulations, how drivers handle traffic, their physical fitness etc., are all elements that managers have a responsibility to keep on top of.
3. Using the wrong racking
Depending on the industry and the seasons, your business can experience carrying a wide range of products.
At other times, the volume and velocity of SKUs can also fluctuate wildly. This can quickly degenerate into insufficient and incompatible racking space for the new units.
Buying rows of cantilever racking in anticipation of storing long, bulky materials, becomes counter-intuitive when most of your SKUs become small enough to be moved with mobile pallet racking systems.
Are you committing any of these errors in your warehouse?
It is vital for all managers of distribution centres to maintain their safety records. By examining your processes and correcting them, you can limit the possibility of fatal accidents and improve efficiency as well.
At Monarch Shelving Ltd, we help warehouses to maintain their safety record by providing high quality refurbished and new pallet racking, and by advising warehouse managers on the best processes and equipment to use. We also supply high quality shelving, bins and work benches and a range of safety products. Contact us today for excellent deals on the best and safest warehouse equipment.
