Don’t neglect safety in rush for efficiency

Some suppliers face a challenge: the need to manage increasing numbers of product lines within the same space. This has partly come from greater demand for particular items – more and more, business buyers are seeking providers that offer a wide-ranging, consolidated set of products. This is also forcing warehouse managers to think more laterally about how inventory is stored and picked, alongside considerations around the safety of staff.

Meeting the challenge head on

A number of suppliers have met this challenge by increasing the proportion of automated systems to deliver products. This is particularly helpful where items are ‘fast-moving’ or ordered regularly. From a safety perspective, warehouse managers should ensure walkways and thoroughfares are clearly marked so that employees are not at risk of colliding with automatic pickers or vehicles, known collectively as Mechanical Handling Equipment (MHE). It is also vital that staff wear hi-visibility workwear at all times. Furthermore, there should be strict protocol in place where pedestrians and vehicles are in close proximity. For example, stipulating a three metre clearance between any moving vehicle and pedestrians.

Floor markings should also follow specific ‘lines of desire’ or the logical route that people take around a warehouse facility. The risk of straying into the path of an oncoming vehicle is significantly reduced if there are clear, coloured markings to follow. These markings also help address risks surrounding ‘vanishing points’ and ‘blind corners’ where it is difficult to see a warehouse vehicle, picker or person until the moment of impact.

Many warehouse facilities tailor aisle widths depending on the popularity of certain products. For example, wider aisles are best suited to inventory that is ordered on a regular basis. This means that items can be easily accessed by operatives or automatic pickers. Less popular items are often stored in narrower aisles where automated systems are not required and products can be selected manually.

A risk assessment should be carried out to determine the correct footwear required, for example where heavy items or wooden pallets are used that could cause injury, foot protection may be required. Wherever possible, pedestrian and vehicle routes should be kept separate to minimise the risk of collision.

Managing machinery operation

Many warehouses incorporate numerous pieces of machinery under one roof that aid the overall efficiency of the space. These include box and lid makers, waste compactors, strapping machines and automatic shrink wrappers. However, employees that operate these machines must be thoroughly trained to do so safely. To reinforce the importance of this, strict control measures must be put in place by warehouse managers denoting that only trained staff can operate these machines, with absolutely no exceptions. Furthermore, employees operating and using automatic conveyor systems must ensure that long hair is tied up and that suitable clothing is worn to minimise the risk of becoming entangled.

Marrying the right approach with regular checks

It is also important to carry out daily due diligence checks of floor areas to make sure they are clear of any spilled liquids, surface water and other clutter that could cause employees to slip or trip over. This is of particular importance where items are being carried manually. Power cords must also be protected by heavy duty covers to prevent trips and also to stop the cables from getting damaged. Cables running at floor level should only be considered as temporary.

The role of technology

Modern technology can play a significant part in aiding the efficient organisation of a warehouse facility. For example, computerised CAD design and 3D modelling allows warehouse managers to overlay possible solutions to the way a space is planned. The most efficient and effective layouts can then be closely analysed before committing to physically reorganising a warehouse. This also allows for a ‘bird’s eye view’ assessment of the potential safety hazards that exist. This should by no means replace daily manual safety checks but instead be just one element of a wider and comprehensive approach to warehouse safety.

Communication is key

The importance of following key safety procedures and performing daily checks must be  practised through regular and thorough communication with warehouse operatives. This is particularly important where temporary staff are used. Managers should ensure that they are briefed thoroughly about warehouse safety as part of the employee induction process. Managers should also make sure that their teams are following set safety measures and daily checks and also during regular team meetings. These help aid the performance of individual warehouse employees by reinforcing the valued contribution they make to the overall performance of a team or facility. However, it is also the ideal opportunity to reiterate and test employee awareness of safety measures.

Saying what’s been said

Warehouse facilities are increasingly viewed by suppliers as a way to improve efficiencies and customer service levels. This has meant that there has been an increasing focus on storing and picking inventory on the basis of popularity. Despite this, the importance of maintaining excellent levels of safety within a more unpredictable space like the warehouse cannot slip down the list of priorities. Any revisions to the way the warehouse is managed must be accompanied by a review of safety measures designed to aid efficient operational management instead of stifling it.