Common Material Handling Mishaps: How to Increase Warehouse Safety

According to the Bureau of Labor Statistics, as of January 2017 there were 956,800 jobs in the warehousing industry in the United States. OSHA reports that every day more than 12 workers die on the job (more than 4,500 a year), and every year, more than 4.1 million workers suffer a serious injury or illness in the workplace.

The good news is that with proper training and awareness, most workplace accidents can be avoided altogether. Keep reading to learn more about some of the most frequent mishaps that occur in warehouses and distribution centers, and find out what you can do to boost warehouse safety.

Common problems in the material handling industry:

Ergonomics

This may not be an issue your think of right away when it comes to the material handling industry, but ergonomic safety is a big deal. OSHA says that lifting materials improperly, repeating the same motions over and over, and poor design of operations in your facility can cause musculoskeletal disorders in employees (find out more HERE). Make it a priority to promote ergonomic safety within your company. Recognize and reward workers who follow ergonomic safety protocols, such as using machines to help lift heavy items. Buy backrests, anti-vibrations seat cushions and other ergonomic devices for your lift trucks.

Falls

Falls in the workplace are a major safety concern. The Bureau of Labor Statistics reports that 81 percent of all fatal falls in 2015 were falls to a lower level, and more than 2/5 of fatal falls occurred from just 15 feet or lower. Falls can occur if an employee climbs a rack to retrieve a product rather than using a forklift, doesn’t use proper fall protection, or is lifted elevator-style by a forklift, among other scenarios. Safety training is IMPERATIVE in order to prevent falls. Train your employees to use forklifts or other equipment to access out-of-reach objects. Provide employees with the proper fall protection (which may include a safety harness, lightweight lanyard, or a combination of the two) when they need to be more than four feet off the ground.

Heavy Equipment Accidents

OSHA reports that nearly 100,000 workers are injured each year in forklift-related accidents, largely as a result of improper training or just plain carelessness. We cannot emphasize enough the important of training in order to enhance warehouse safety. Make sure all of your employees, even those who don’t operate heavy machinery, understand the dangers of material handling equipment. Post clear safety expectations near each machine as constant, visual reminders to stay safe and prevent accidents.

Loading Dock Injuries

The loading dock area of a warehouse poses some safety risks. Workers can become pinned between a forklift and the loading dock because of risky or complacent behaviors and attitudes. Ongoing training for all warehouse workers is necessary to remind them of risks and keep warehouse safety top-of-mind.

Pedestrian Injuries

Injuries to pedestrians in warehouse or distribution center environments can include anything from slips and falls to run-ins with forklifts.

According to the National Institute for Occupational Safety and Health (NIOSH), nearly 20 percent of forklift accidents involve pedestrians, with an estimated 19,000 people injured each year. Bad decisions by forklift operators (speeding, not using proper safety procedures) can cause accidents. The best way to prevent pedestrian accidents is with visual barricades, including quick-mount barricades, signs warning pedestrians that they’re entering hazardous areas, blue lights, and red zone warning lights to designate areas where heavy equipment is operating or approaching. Additionally, backup alarms can help notify pedestrians of an approaching forklift, or simply shouting “Coming through!” is an effective way to alert other workers that a forklift is on its way. Ongoing training for forklift drivers is necessary to keep safety at the top of your priority list, and don’t be afraid to discipline anyone who exhibits risky and unsafe behavior. Go HERE to learn more about preventing pedestrian accidents.

In 2015, the Bureau of Labor Statistics reports that falls, slips and trips accounted for 27 percent of all occupational injuries and illnesses. To prevent accidents, caution signs should be hung and clearly visible around problem areas. Fill in cracks or pits in the floor that could cause trips or damage equipment. Anti-slip tape, guard railings, and safety mats should be placed in spots where slips-and-falls have the potential to occur, and non-skid floor coating should be used in areas that are frequently wet. Additionally, add slip and trip hazards (including loose cords, spills, stray packing materials, etc.) to your safety checklists.

Storage and Racking Accidents

Having a facility that is thoughtfully laid out is imperative in order to minimize storage and racking accidents. Forklift collisions can cause racking to fail and damage inventory. Products can also be damaged if not properly stored. Forklift drivers need to be well-trained and certified in order to easily maneuver between aisles, and all employees should be trained the correct way to place inventory on pallet rack and know about the dangers of overloading them.

We can help you lay out your facility and make it as efficient as possible, while also increasing warehouse safety and minimizing risks. Check out our blog posts HERE and HERE to learn more about our services.

Traffic Accidents

Going back to the importance of having a well-planned out facility, poorly routed traffic in your warehouse or distribution center can lead to accidents and injuries. Some areas in your facility may be more likely to have incidents because of blind corners or other visual limitations. Additionally, forklifts that are old or not properly maintained can cause traffic issues. Put warning signs for troublesome areas where they are clearly visible, and make sure the layout of your facility is well thought out and efficient. Make sure your forklifts are always in good working condition and regularly maintained.

Besides keeping your employees safe and sound, a safe warehouse will also operate more efficiently–ultimately helping your company to be more successful. Take the time and effort to increase warehouse safety. It’s definitely worth it.