Lockout/Tagout Procedures
Various machines, devices and operations in a warehouse present the need for a zero-energy state and, thus, the need for a lockout/tagout (LOTO) program. Employees required to perform LOTO should be thoroughly trained, and all employees should have (at least) working knowledge of the program.
Following are examples of situations that may require LOTO.
A malfunctioning conveyor requires maintenance. Pull down the disconnect that powers the conveyor, and lock and tag it. Mark the disconnect box to identify what it controls and its voltage. The conveyor could also be locked out via the circuit breaker box. Here, label each disconnect switch properly. Close the box door and key lock it after moving the switch to “off,” or place an LOTO attachment on the switch (in the off position).
A forklift needs brake repair. Safely park the unit in an approved area, remove the key and add a tag that identifies who locked it out, when and why. For additional safeguarding, turn off the propane tank valve or disconnect the battery (depending on the model).
Several employees have received electrical shocks from a large floor fan. Pull the plug, place a cover over it, and add a lock and tag. This prevents the defective fan from being plugged in.
A battery charger begins to emit smoke. Pull the proper disconnect switch and add a lock and tag. This is why each disconnect box should be marked to match the appropriate battery charger. Alert the maintenance department to schedule corrective action. To ensure that LOTO procedures are properly executed, management should take the following steps.
dentify circuit breaker boxes (on the outside) by number or letter code; this makes it easier to locate. Inside each box, test individual switches to verify what they control, then label them accordingly. Also, ensure that the panel contains no openings which expose employees to live current, and install barriers (rails or guards) to protect power panels and boxes against impact by powered equipment.
Practice specific lockout procedures. An LOTO photo book is an excellent training tool. In addition, listing all LOTO procedures increases effectiveness. Review the program annually.
Ergonomics
Ergonomic improvements are designed to make jobs less stressful. Often, minor changes can have great impact.
Store heavy materials that must be manually lifted on shelving that allows lifting to take place between the knees and chest. If possible, use powered equipment instead of requiring a manual lift.
Position picking bins waistor chesthigh and tilt them for maximum access. Eliminate or tape sharp edges on containers in order to prevent cuts. Where parts must be lifted in individual containers, do not store containers on the floor or overhead. Add handles to ease lifting.
Ensure that overhead lighting is appropriate for the task at hand. Replace burned out bulbs and clean globes or reflectors. Increase illumination in areas that require a greater degree of accuracy in parts or product selection.
To employees working on a mezzanine, gates (that must be manually moved to an open position in order to accept product) pose a serious fall hazard. To prevent this, install a mechanical sliding gate equipped with a drive motor (like that on a garage door). To use such a device, the forklift operator pushes a button mounted in the lift truck, and the door slides open so the load can be deposited properly. S/he then pushes the button again, and the gate closes. A flashing red light increases hazard awareness when the gate is open.
Ventilation is critical. Carbon monoxide and other gases, fumes, vapors, mists and dusts must not exceed permissible exposure limits. General ventilation should provide the proper amount of air exchange and create a draft (in warm weather when doors are open). Local ventilation may be needed in areas above battery-charging or similar exposures.
Personal Protective Equipment
Management must conduct a site hazard assessment to determine what PPE must be worn, based on hazards present. In addition, employees must be trained regarding proper PPE selection, use and maintenance. General guidelines follow.
Provide hard hats to all personnel. Product can easily fall off a rack or shelf and strike an employee’s head. When moving product under racking, an employee could easily strike his/her head.
Require foot protection where appropriate. Steel-toe shoes protect feet against falling product or when caught between two objects. Such shoes also protect the feet while operating powered pallet jacks, stock chasers and similar equipment.
Require eye and face protection for employees who sweep, cut metal or plastic banding, handle wire strands or perform maintenance.
Provide appropriate gloves to protect against sharp, hot, heavy and chemically unstable products. Depending on the hazard, gloves may be leather, rubber, cotton or other material. Thus, glove selection should be based on the exposure.
Where necessary, provide hearing protection (e.g., ear plugs or ear muffs). Since worker acceptance of this equipment depends on the comfort it provides, workers should be involved in its selection.
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Warehouse Safety