According to OSHA there are 145,000 employees who work in over 7,000 warehouses in the United States. The fatality rate for this industry is higher than the national average for all industries. Employees are exposed to many hazards in this environment. They may include:
Unsafe use of forklifts
Improper stacking of products
Failure and improper use of PPE (Personal Protective Equipment)
Failure to follow proper lockout/tagout procedures
Inadequate fire safety controls
Repetitive motion injuries
Warehousing affects how materials are received, stored, and dispersed within your facility and shipped to customers. With a great amount of inventory to control, deadlines to meet, and employees to oversee, warehouses may create more hazards than other areas. When working in a warehouse, it is important to keep safety in mind at all times and to remain focused on the task at hand. The following controls for each warehouse area can minimize chances of a work-related injury or a potential OSHA citation and fine.
Docks
Injuries can occur at the docks when an employee falls, products fall on or strike an employee, or when a forklift runs off the dock.
Drive forklifts slowly and cautiously.
Keep the forklift clear of dock edges.
Provide visual warnings near dock edges.
Rope off areas where employees could fall 4 feet or more, such as exposed or open bay doors.
Prohibit employees from jumping from docks.
Secure dock plates and ensure they have the ability to safely support the load.
Ensure ladders and stairs used at the docks meet OSHA guidelines.
Forklifts
Operating a forklift can be very dangerous. Forklift turnovers account for the majority of forklift-related fatalities. Depending upon the size and purpose of your warehouse, you may have a significant amount of forklift traffic.
Ensure that all operators are properly trained, evaluated and certified to safely operate a forklift.
Do not allow anyone under 18 years of age to operate a forklift.
Implement a preventative maintenance and inspection program to ensure that the forklifts are in safe working order.
Inspect forklifts prior to each use.
Report, tag and remove defective forklifts from service until repaired.
Ensure operators wear a seatbelt at all times.
Follow safe operating procedures for picking up, putting down and stacking loads.
Never handle loads that are heavier than the forklift’s capacity.
Always drive safely, while never exceeding 5 m.p.h.
Slow down in congested areas or areas with slick or slippery surfaces.
Prohibit horseplay and stunt driving.
Ensure operators never drive up to employees or others standing in front of a fixed object, such as a wall or shelving.
Maintain safe clearances for aisles, loading docks and passages.
Maintain engine exhaust gases below acceptable limits through adequate ventilation.
Train employees regarding the hazards associated with combustion byproducts of forklift operations, i.e., carbon monoxides.
Protect open pits, tanks, vats and ditches by use of covers or guardrails.
Ensure all manufacturers’ labels with load capacities are attached to the forklift.
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Warehouse Safety