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The most dangerous time in the warehouse for employees and goods is when things are moving. Loading and unloading pallets involves a lot of movement, so there’s a lot of risks, particularly in a warehouse where multiple deliveries and pick-ups are happening at the same time.
Lorries reversing, forklifts unloading, warehouse staff checking goods in and out. Each step of a pallet’s journey involves risk, which is why it’s so important to have safe loading and unloading procedures in place.
Importance of Storage Safety: Protection of Employees and Inventory
Loading and unloading involves all sorts of risks for employees and goods, from accidents and collisions to musculoskeletal injury from lifting heavy loads. Managing these risks through safe storage procedures protects both employees and inventory. Implementing proper safety measures significantly reduces the likelihood of accidents and injuries to your workforce.
Adequate training programs on manual handling techniques, safe use of equipment, and proper lifting procedures are essential for employees involved in loading and unloading activities. Clear communication and well-defined processes ensure that everyone understands their roles and responsibilities reducing the risk of accidents.
Proper organisation and storage techniques also contribute to worker safety. Maintaining clear pathways, uncluttered aisles, and designated loading and unloading zones minimises the risk of slips, trips, and falls. Adequate signage, including warning signs, directional indicators, and load capacity labels, helps employees navigate the warehouse safely and be aware of potential hazards.
Using appropriate personal protective equipment (PPE), such as safety shoes, hard hats, gloves, and high-visibility vests, provides an additional layer of protection for employees. Ensuring PPE is readily available and enforcing its use promotes a culture of safety within the warehouse.
Investing in storage safety measures and promoting a safety-conscious culture within the warehouse environment is vital for the well-being of employees and the safeguarding of valuable inventory.
Understanding Load Capacities: Guidelines for Safe Storage and Handling.
Understanding load capacities is crucial for safe storage and goods handling in warehouses. Whether it’s racking systems or pallets, adhering to weight limits and ensuring proper weight distribution and load stability is essential to prevent accidents and maintain the integrity of the storage infrastructure.
Pallets
The weight capacity of a standard 1200 x 1000mm UK wooden pallet is 1,000 to 1,500 Kg. Weight-bearing capability will also vary according to the specific type and condition of the pallet. When storing items on pallets, both the pallet’s load capacity and the weight distribution of the load must be considered. Pallets have weight limits indicated by the manufacturer, and it’s crucial not to exceed these limits. Additionally, the load should be evenly distributed on the pallet to maintain stability. Concentrating weight in a specific area of the pallet can cause imbalance and increase the risk of the load tipping or the pallet breaking. A fulfilment expert will be able to ensure the number and type of pallets will match your specific storage needs.
Racking
Racking systems have specific load capacity limits that must be strictly followed. Each type of racking system will have its own load capacity specifications. It’s essential to consult the manufacturer’s guidelines and ensure that the weight of the stored items does not exceed the system’s capacity. Overloading racks can lead to structural failures, collapse, and serious accidents. Most commercial warehouses will subcontract racking installation to a specialist installer, who will design and fit racking that is regulation-compliant and fit for purpose.
Pallets and racking and safe storage
To achieve proper weight distribution and load stability, stack heavier items at the bottom of pallets or storage racks, with lighter items on top. This ensures a lower centre of gravity and reduces the risk of instability. Wooden blocks or support beams can help distribute weight more evenly and provide additional stability, when necessary. Staff training can help ensure the team uses proper stacking techniques and understands the importance of adhering to weight limits and distribution guidelines. Employees should be aware of the potential hazards associated with overloading or unevenly distributing loads and should be encouraged to report any issues they encounter.
Regular inspections of storage systems and pallets should be conducted to identify any signs of damage, wear, or deterioration that may compromise their load capacity. Damaged racking components or weak pallets should be promptly repaired or replaced to maintain safety standards. By understanding and adhering to load capacity limits, ensuring proper weight distribution, and maintaining load stability. warehouses can minimise the risk of accidents, equipment damage, and structural failures.
Maximising Safety with Forklifts and Material Handling Tools
Well-maintained equipment is an important part of storage safety. Regular inspections of forklifts and material handling tools can identify potential issues that may compromise safety. A pre-operation checklist covering brakes, steering, lights, horn tyres and fluid levels should be completed before each shift and any identified problems reported and addressed by qualified maintenance personnel. Additionally, scheduled maintenance should be conducted to ensure the ongoing performance and safety of the equipment.
Proper training is crucial for employees who will be operating forklifts and other material-handling tools. Training programs should cover not only the technical skills required for operation but also safety procedures and guidelines. This includes teaching employees how to properly load and unload materials, how to safely manoeuvre the equipment, and how to handle potential hazards such as ramps, inclines and narrow aisles.
Employees should also be educated on the weight capacities and limitations of the equipment they are using to prevent accidents caused by overloading. Furthermore, regular refresher training sessions can help reinforce safe operating practices and update employees on any changes in equipment or regulations.
It is important to emphasise the importance of wearing appropriate personal protective equipment (PPE) while operating machinery, such as high-visibility vests, hard hats, and safety shoes.
Clear signage should be displayed throughout the warehouse, indicating speed limits, designated traffic areas, and pedestrian only zones. This pedestrian are should be designed so that people are separated from the forklift traffic as much as possible. Installing mirrors, barriers, and warning systems can provide additional safety by improving visibility and alerting workers to the presence of moving machinery.
Maximising safety with forklifts and material handling tools requires a comprehensive approach. Regular inspections, proper maintenance, thorough employee training, and clear signage are all important for workshop safety. Fostering a safe and efficient working environment through these measures will minimise accidents, injuries, and equipment damage, protecting workers and goods.
Warehouse Layout and Organisation: Optimising Safety and Efficiency
Warehouse layout and organisation play a crucial role in making storage areas safe and efficient. A well-planned warehouse will help prevent accidents and injuries.
This begins with ensuring there are clear pathways throughout the warehouse, allowing for smooth and unobstructed movement of personnel and equipment. By designating specific loading zones and pedestrian areas, the risk of collisions between workers and moving machinery is minimised.
Proper signage should be prominently displayed, clearly indicating potential hazards, safety procedures and emergency exits. These measures are designed to prioritise the safety of employees but will also contribute to the overall efficiency of the warehouse.
Pallet Safety: Best Practices for Loading, Stacking and Storage
Pallet safety starts with the pallets themselves. They must be inspected before use to make sure that they are in good condition and capable of supporting the intended weight.
Pallet protectors can be used to reinforce the corners and edges of the pallets. Strapping can also provide another layer of load security. Tightly fastening straps around the stacked pallets improves stability and makes them less prone to shifting.
Lastly, secure wrapping, such as stretch film, can be used to tightly bind the items together. This wrapping adds an additional layer of support and helps maintain the integrity of the pallet stack during transportation or storage.
Following pallet safety guidelines is crucial to preventing collapses or shifting loads both in the warehouse and on the lorry. Securing goods correctly with pallet protectors, strapping and secure wrapping, significantly reduces the risk of collapses or shifting loads, which is a key step to ensuring the safe and efficient handling of goods.
Techniques to Prevent Shifting and Falling Objects
When it comes to transporting and storing goods, one of the key concerns is preventing shifting and falling objects. Securing loads effectively not only ensures the safety of the items being transported but also minimises the risk of accidents and damage.
Recent government guidelines state that a load must be secured to the pallet to form a single unit before loading onto a vehicle. When prepared in this way pallet goods are safer to store and load. The best way to secure goods onto a pallet will depend on the size, weight and type of load. Three of the most effective methods are, shrink wrapping, strapping and banding.
Shrink wrap or pallet wrap is made from stretchable polythene. It is typically applied using a motorised shrink-wrap machine, and is ideal for securing pallets safely and efficiently. Because it is applied under tension it keeps goods securely together even when pallets are moved. Shrink wrap also offers some protection from dust and water.
Strapping can be applied manually using tensioners, or via a strapping machine, for increased speed and efficiency. Strapping can be made of paper, polypropylene, and HDPE plastic and is available in a range of widths.
Banding is a practical alternative to strapping because the tensioning process is more accurate and less likely to damage the goods. Fully automated ultrasonic banding technology aligns the product on the pallet and automatically adjusts to ensure bundles are correctly fastened.
Promoting a Safety-Conscious Environment
Warehouse safety is everyone’s responsibility. Establishing robust safety practices and procedures is key, but they are not static and they should be monitored and adapted to match changing risks.
Professional organisations such as the UK Warehousing Association (UKWA) offer independent quality and safety assessments as a condition of accreditation. Membership to UKWA shows that a business follows best practices in a range of areas including; health and safety, quality standards, regulatory compliance and employee and data security.
The Fleet Operator Recognition Scheme (FORS) requires a full safety audit of vehicles, drivers and operations. The certification covers a wide range of measures designed to promote a safety-conscious environment including, inspection and maintenance records, staff induction and development and evidence of safe operational practices.
BRC Global Standards is recognised as the highest certification for safety and accountability. It was set up in 1996 and is recognised as a world leader in safety and quality assurance. It is only awarded after a rigorous inspection process, that involves an independent policy audit and extensive site check. InvoFulfilment has been awarded the highest AA rating, demonstrating that we operate our warehouses under the strictest levels of safety and security.
InvoFulfilment is BRCGS AA certified, a UKWA member and FORS registered, and we pride ourselves in offering the highest standards of quality in everything we do every day. We are part of Involvement and are founded on the principle that everyone makes a difference. It means that we don’t sit still and are always looking for ways to improve, to be better, and to offer the best service possible to our customers.
Personal Protective Equipment (PPE): Ensuring Employee Safety
Personal protective equipment (PPE) does not make a warehouse safe. It is simply the last line of defence and must be part of a wider culture of warehouse safety.
The Health and Safety Executive (HSE) advises using a hierarchy of controls to help ensure employee safety. This is a sliding scale, where elimination is the most effective and PPE is the least effective at providing a safe workplace.
- Elimination – physically remove the hazard
- Substitution – replace the hazard
- Engineering controls – isolate people from the hazard
- Administrative controls – change the way people work
- PPE – protect the worker with equipment
Employers have a legal duty to protect their workers from health and safety risks. If a risk assessment shows that PPE is required it must be provided to employees free of charge. In a warehouse environment, PPE would include safety helmets, gloves, hearing protection, high-visibility clothing, safety footwear and harnesses.
The Personal Protective Equipment at Work Regulations 1992 places a duty of care on employers to ensure that PPE is; fit for purpose, maintained and properly stored, provided with instructions for safe use and used correctly by workers.
Emergency Preparedness: Handling Potential Accidents or Hazards
Prevention is always better than cure, and this is especially the case when it comes to workplace safety. However it is important to have emergency procedures in place, just in case the worst does happen. A proactive employee training programme can help make sure your team is prepared in the event of an emergency.
The Health and Safety Executive (HSE) has set out the minimum requirements for first-aid provision at work. This includes; having designated, trained first-aiders and suitably stocked first-aid boxes, in signed, accessible locations. The specific number of first-aiders needed and their level of qualification will vary depending on the number of employees and type of workplace. Acting swiftly and appropriately can save lives in the event of an accident, so it is important that qualifications are up-to-date and that everyone knows who the first-aiders are.
The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) are designed to protect employees from fire and explosion risks. This risk can be high in warehouses that could contain large quantities of flammable materials, such as paints, coatings, and chemicals. The guidelines should be followed to ensure risks are mitigated as much as possible. This will include steps such as classifying hazardous zones, protecting goods from ignition sources and following EPS and COSHH guidelines. Fire can spread quickly, particularly in a warehouse, so it is essential to have regular fire drills and include fire safety guidance in each employee’s induction process.
Prioritising Safety in Loading and Unloading for an Efficient Warehouse
Safety and efficiency go hand-in-hand. Many of the measures necessary to provide a safe workplace will also ensure an efficient one. Effective warehouse organisation, clear procedures, properly maintained vehicles, a trained workforce and a purpose-built warehouse ensure the safety of staff and goods
When your stock IS your business it makes sense to partner with a trusted fulfilment provider. We started as a packaging distributor in the early 1970s and have been storing and shipping goods ever since! It means that we know how to operate our warehouses safely and efficiently, you are welcome to see for yourself, please get in touch to arrange a visit or to find out more.
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