How Material Handling Elements Can Produce Safer Warehouse Operations Part 1.

Implementing material handling concepts in warehousing and distribution, is one way businesses try to achieve operational excellence.

Material handling involves the correct handling, sorting, moving, organising of tools, equipment and goods. Getting any one of these wrong can lead to lost goods, injured workers and even fatalities.

Figures from the HSE show that 133 people died in warehouse related incidents in 2013.

Another 78,000 also reported injuries at work in the same time period. While some of these were genuine accidents, a few were as a result of wrong material handling. When the correct equipment is used, in the way it was designed for, meeting efficiency KPIs is guaranteed. Note that we are not talking about using forklifts to lift forklifts simply because there is a high platform to be reached. Or using scaffolding in place of pallet racking.

While company targets must be met, attaining and maintaining long accident-free periods, are just as important. By organising and optimising warehouse equipment and practices, we can make our processes safer. When loads are handled safely and tasks are properly segmented and organised, workers suffer less injuries, are less easily fatigued and operations are generally safer. Examining typical warehouse practices, we identified the sections where safety measures are required and give our recommendations:

1. pallet racking – Use safety netting to prevent accidents from loads falling on your warehouse pickers and pallet truck movers. Not securing the loads, also risks damaging the stock. Depending on the size of the load, you can use heavy rigid wire or a light but sturdy nylon mesh to cover the back of your pallet racks.

2. Walkways – Forklifts, trailers, pedestrians; a recipe for disaster if combined. To avoid a horrible accident, create clearly marked designated lanes for foot traffic. Ensure forklift drivers know there are areas where they cannot drive into. With these rules, people can still miss the markings. Therefore, invest in steel rails to separate pedestrian areas from the rest of the warehouse floor.

3. Machinery – Prolonged exposure to noise, from heavy machinery, at work can lead to noise-induced hearing loss. Diminished hearing capacity can affect the individual in many adverse ways, both at work and in their life. Carry out routine tests to determine the noise levels your workers are exposed to. To counter above normal noise (85dB), companies can ensure they obtain noise data from manufacturers before buying machinery. They can also insist on panels to be lined with noise absorbing material. If workers MUST work in the vicinity of the machine, earplugs or earmuffs must be worn at all times.

4. Pallet Rack Frames – Ensure regular inspection and maintenance, by a qualified manufacturing engineer, of your upright beams. Forklifts and motorised pallet trucks are the chief culprits in damaging the structural integrity of pallet rack frames. While there are methods to protect upright frames, a regular inspection should be carried out to detect any dents, gouges or twisted sections, before it leads to a major collapse.

5. Conveyor/Carousel – Conveyors are used to quickly and safely move packages for sorting or from one storage area to another. In some situations, employees remove the guards bolted on, in an effort to work faster. This removal exposes internal machinery that can be dangerous if left unguarded. Horizontal carousel controls are also subject to this abuse. The on/off switch and the Emergency stop button are abused by staff who may be overwhelmed by the amount of goods coming down the carousel.

Join us next week for a rundown of how more material handling elements can help you achieve and maintain efficiency & safety.

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