IRIA

• By Michelle Coleman
• Aug 01, 2011

Safety is the top priority when designing a warehouse and choosing storage. Well-utilized storage equipment is conducive to creating a safer work environment and reducing workplace injuries for the 145,000 warehouse workers in America. The fatal injury rate in the warehousing industry is higher than the national average for all industries, and taking necessary considerations for storage equipment and warehouse design will help to minimize workplace hazards while also creating an efficient warehouse.

Accidents and injuries in warehouses are preventable and come with many serious consequences. Preventable costs of a rack collapse include worker’s compensation and insurance rate increases, fines and safety violations, legal expenses, and replacing storage and damaged material. To avoid the pitfalls and detrimental effects of an accident, use the utmost caution when planning warehouse storage and design. Proper design, installation, and maintenance of storage racks will make the warehouse environment a safe and healthy workplace for all employees.

Choosing a Provider The first step to warehouse storage safety is choosing an experienced, reputable provider. When you choose a company to assist you with warehouse design and installation, you are placing your trust and employee safety in that company’s hands. Conduct research about potential suppliers’ safety history, brands used, and look for red flags, such as lawsuits and negative reviews. Researching prospective storage companies will prepare you to choose a reputable supplier.

Designing for Inventory When choosing storage for a warehouse, the size, shape, and weight of the items to be stored needs to factor into the style of racking that is selected. Ensuring the pallet racking will accommodate the proper object size and weight capacity can reduce falling items and injuries related to overloading. Loads on the racks need to be stacked even and straight to ensure weight capacity is distributed properly. Spacing between items on the racks can affect the stability of storage.

Consider how the items held on racks will be retrieved, and plan accordingly. Heavier and larger loads should be stored on lower or middle shelves to minimize lifting and forklift injuries. Making sure stacked materials are accessible for handling will help to reduce injuries and strain from challenging lifting situations. Ensuring all hazardous chemicals are properly labeled and stored, and an MSDS sheet is kept in an accessible location, is an important step in having an emergency response plan.

Assembly and Maintenance of Storage Safety begins with an effective warehouse design and installation of storage, performed by personnel experienced in the assembly of racks, according to manufacturer instructions. They will help you assess what will be stored and analyze the size, weight, and quantity to recommend the most suitable products and configuration.

Be sure that adequate aisle spacing is provided to allow forklifts to safely pass and transport loads. Check to make sure racks are not exposed to excessive dampness or other elements that would compromise the structural integrity. Appropriate lighting needs to be available to provide adequate visibility in work areas. It is highly recommended that capacity signs are installed on storage for reference.

A sprinkler system should be installed that corresponds with rack structure. Employees should be informed about the location of fire extinguishers, emergency response equipment, hazardous materials logs, and storage capacity information. Emergency preparedness is equally important to prevention in maintaining a safe workplace.

When installing new pallet racking, verify with the architect that the floor can safely handle proposed weight loads. The floor where storage will be installed needs to be even to support rack structure. Precautions also should be taken if there are risks for seismic or natural disasters in the region that could potentially damage the facility. Ensure columns are properly anchored to concrete slab flooring. Obtain the load capacity of the floor from the building’s architect prior to planning warehouse storage and layout. Check local building codes and stay informed about OSHA regulations to prevent violations.

Regularly checking storage is essential to maintaining the safest possible working conditions. Pallet racking should be regularly assessed to ensure it is in proper condition, with no threats to structural integrity. Checking weight capacity is in line with storage guidelines, and installing capacity plates will help to prevent overloading. Check for cracks, dents, bends, and twists that may compromise the functionality of the storage.

Nuts and bolts should be checked to verify they are tightened and that safety locks are functioning. Inspections of pallet racking should involve checking the hardware to ensure it is tightened, looking for missing pieces in hardware, and a visible assessment to check whether racks are level, square, and plumb.

If racks need to be reconfigured or adjusted, always contact your provider to ensure proper set-up and compatibility. Different brands and style of racks are incompatible with each other and could pose a risk to employees if improperly assembled.

Buying Used Rack Buying used pallet racking can offer savings in equipment cost, an option to recycle products, and can offer a similar quality to new product. However, extra precautions should be taken when assessing the quality of used storage.

If buying used rack, look for signs it has been repaired, such as areas that look painted or evidence of welding. There is no way of knowing whether the individual who repaired the rack is qualified or that it is in acceptable condition to use. Buy used rack only if it is in prime condition and shows no sign of rust, welding, dents, or bends.

Be sure used rack has been stored indoors in a climate-controlled area. Rust can be hidden by paint and other surface coverings, so an experienced eye is needed to determine quality. Make sure you recognize and trust the original manufacturer of the material. Confirm that racking is structurally sound and properly handled during installation and tear down. Rigorous inspection standards will help you avoid purchasing a product that will deteriorate and potentially put employees at risk for injuries.

Forklift Safety A large portion of all warehouse injuries involve improper use of forklifts or insufficiently trained operators. First and foremost, hiring licensed and experienced forklift operators is essential to minimizing workplace injuries. Selecting storage racks that accommodate forklift traffic can help to facilitate a better working environment for forklift operators.

All aisles in the warehouse should be clear to allow safe forklift traffic and permit sufficient clearance. When forklifts will be used for item retrieval, consider purchasing drive in or drive through pallet rack. This type of rack will allow a forklift to pass under or through the shelves to provide easier access to the items being stored and can maximize floor space.

Drive in and drive through rack optimizes space and creates aisles but is more susceptible to damage from repeated forklift impact. Utilizing aisle protectors, upright protectors, and guardrails will help to reduce destruction and prolong the life of storage equipment. Corner protectors and other safety products are worth purchasing to protect the investment of storage materials and to help preserve the structural integrity of the rack.

When installing new rack or hiring new employees, ensure operators can have supervised practice loading and unloading materials. This will ensure they can confidently maneuver the storage and handle materials without damaging the product.

Ensure that the drivers center their loads when moving items to prevent forklifts from tipping and loads from falling. Make sure drivers are aware of weight limits of the forklifts and never overload them. Drivers should ensure the loads are secured during transport and loaded as close to the mast as possible to maintain balance and security. Establish an ongoing training program for forklift operators within your warehouse. Purchase safety equipment that will protect drivers from falling materials.

Conclusion By taking the necessary precautions when planning warehouse storage and design, a safe warehouse environment will be created. Creating an ongoing education program within your company will help employees stay informed and keep safety in mind at all times for every situation. Addressing risks and effects associated with specific equipment will help employees avoid common mistakes and improve your rates of injury and lost-time incidents.

This article originally appeared in the August 2011 issue of Occupational Health & Safety.

http://ohsonline.com/articles/2011/08/01/safety-and-warehouse-storage.aspx?sc_lang=en 8/4/13

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NEW SOUTH WALES, Australia March, 2013 – Have you noticed an emotional change in someone you work with or perhaps yourself? Things like erratic behaviour, being withdrawn from colleagues, inability to concentrate or loss of confidence could all be early warning signs that someone is not coping at work.

Learning to identify the early warning signs and how to respond appropriately to these signs could help avoid a workplace injury. In most cases, workplace injuries can be avoided if that person is supported through an early intervention program. Early intervention practices have proven to be more effective in fostering a happy and healthy workplace as it promotes a workplace that is supportive and committed to the health and wellbeing of workers. Healthy workers in general are more productive and have better overall morale.

Employers that ignore the early warning signs and do not have an early intervention program in place are more susceptible to a workplace injury occurring which could lead to additional costs associated with that injury. According to Safe Work Australia, the total economic cost of work-related injuries and illnesses for the 2008-09 financial year is estimated to be $60.6 billion dollars.

Robert Keft, Managing Director for Safety Australia said “the direct and indirect costs associated with an injury will ultimately cost an organisation more in the long term than what it would to set up a health & wellbeing program”. Workplace injuries can lead to absence from the workplace and in cases where chronic illness has developed it can be long term absences. “This will have an impact on your workers compensation premium and productivity. The key here is to be proactive with safety in the workplace and for employers and employees to work collaboratively around health & wellbeing issues”. For the worker it will avoid the financial, health and emotional impacts on them and their family.

This month WorkSafe Victoria have launched a major new campaign to help injured workers get back on their feet and back to work. Assistant Treasurer Gordon Rich-Phillips said the move follows the release of new statistics which shows the longer injured workers are off work, the more likely they are to require psychiatric and psychological help. “This campaign aims to highlight that returning to work as soon as it is safe to do so can be an important part in the injured worker’s recovery,” Mr Rich-Phillips said. “Being off work for an extended period of time can be extremely detrimental to a worker’s health”. “New data shows injured workers who remain off work one year after their injury are six times more likely to access mental health treatment than injured workers who went back to work after a month”.

An organisation should have robust injury management policies and guidelines in place supported by training. “Training will help employers and supervisors to understand the injury management process and identify the early warning signs” says Mr Keft. A return to work coordinator is an employee nominated by an employer or a contractor engaged for the role who can assist in this process. “A proactive return to work co-ordinator will work closely with workers and their supervisors to create an environment that encourages safe work practices and early reporting of injuries”.

If an injury has occurred, employers must ensure that the injured worker is supported and that they are given assistance to either remain at or return to safe and sustainable work. As the studies show, returning to work quickly and safely benefits both the employer and worker. A return to work coordinator will develop a return to work plan and identify suitable duties. They will be your key liaison person between injured worker, treating practitioners and insurer to ensure the best possible outcome.

Employers have a legal obligation to appoint a return to work coordinator for premiums or wages over a certain threshold so if you are not sure, it is best to check with the regulator in your state or Territory. In June 2012, the NSW government introduced changes to their Workers Compensation Scheme and WorkCover inspectors are now authorised to issue legally binding improvement notices to employers not meeting their injury management and return to work obligations. Failure to comply with the improvement notice can attract maximum penalties of up to $11,000.

The Safety Australia Group has been helping organisations with experienced return to work coordinators to review current outstanding claims, develop return to work plans, return to work policies and procedures, early intervention and health and wellbeing programs.

To learn more about return to work and injury management, visit our website: www.safetyaustraliagroup.com.au .

http://www.webwire.com/ViewPressRel.asp?aId=172043 26/03/13

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In June, WorkSafe Victoria launched a year-long campaign targeting musculoskeletal injuries. Commenting at the launch of the campaign, Victoria’s Assistant Treasurer Gordon Rich-Phillips noted that “musculoskeletal injuries are the most common workplace injury, costing nearly $1 billion a year in medical costs, wages and other expenses.”

While this campaign is being conducted in Victoria, the risk of musculoskeletal injuries is the same at any workplace in the country, so here Ferret.com.au will look at some of the most common causes of these injuries, and discuss potential solutions to the problem as suggested by WorkSafe Victoria.

According to Mr Rich-Phillips, dangerous manual handling, particularly lifting, lowering and moving things account for about 68 per cent of all musculoskeletal injury claims, while about 20 per cent are the result of slips, trips and falls.

In the first parts of this series, we will focus on specific manual handling processes, and the procedures and safety devices that can be employed to minimise the risk of injury when these are undertaken. We have previously discussed safety solutions for preventing slips, trips and falls in the workplace, but will return to the subject later in the week to look at preventing falls from mezzanine floors.

The first manual handling process we will discuss is the stretchwrapping of pallets. When this is done manually, it requires poor postures and movements, and often high force. WorkSafe Victoria notes that this can cause musculoskeletal injuries particularly to the back, shoulders, knees, wrists, fingers and forearms.These injuries can occur suddenly or develop gradually over time.

To reduce the risk of injuries when stretchwrapping, WorkSafe Victoria suggests:

• installing an automatic pallet wrapper
• using a semi-automatic stretchwrapping machine; or
• using a vacuum-sealing or shrink-wrapping device.

Many companies on Ferret.com.au offer such machinery, such as Integrated Packaging , which supplies a range ofcustomised wrapping equipment and stretch film pallet wrappers designed with workplace safety in mind.

Multiple configurations of these machines are available, allowing for custom specifications. All machines in the range feature Pallet-Grip locking technology, which is designed to reduce the risk of operator injury by securely holding products in place

Optimum Handling Solutions also provides a range of stretch wrapping machines, including manual, semi-automatic and fully automatic models.

Where it is not practicable to utilise a wrapping machine or device, WorkSafe suggests minimising the risk of injury by using:

• a raised automated scissor lift and turntable to improve posture and movements; or
• an alternative packing product such as tape-wrapping.

Optimum Handling Solutions also stocks a range of scissor lifts, in electric, hydraulic, static spring and mobile models. These devices are specifically designed to increase productivity and operator safety, and are available in configurations to suit all manual handling requirements, with capacities ranging from 250kg up to 4,000kg.

Safetech is Australia’s largest manufacturer of industrial and commercial scissor lifts. The company is able to create scissor lifts and turntables to suit any individual application or requirement, with load capacities ranging from 100kg to 25 tonne.

As an alternative to stretch wrapping, Safetech also offers a stretch tape wrapping system. Designed and manufactured in Australia, the Stretch Tape Easy Wrapper has a galvanised base to withstand corrosion and a large diameter chequerplate turntable with a capacity of 2,000kg. The base incorporates fork tyne sockets and the mast folds down for easy relocation and transport.

All of Safetech’s materials handling equipment is compliant with Australian standards.

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Companies Must “Improve-the-Fit” between Work Tasks & Workers Capabilities

We are now in the busiest sales period of the year for order fulfillment centers. For many companies the end of the year peak can be 3x or more the average. Even in the most efficient and mechanized distribution centers, there are still lots of manual tasks to be performed and companies typically double or triple their workforce for the last 100 days or so of the year. That adds up to a lot of temporary “hands-on-deck” and an increased risk for work related injuries.

Various studies have shown that the main risk factors (or conditions) associated with the development of injuries in manual material handling tasks include the following:

• Awkward postures – bending, twisting

• Repetitive motions – frequent reaching, lifting, carrying

• Forceful exertions – carrying or lifting heavy loads

• Pressure points – grasping (or contact from) loads, leaning against parts or surfaces that are hard or have sharp edges

• Static postures – maintaining fixed positions for a long period of time
Repeated or continual exposure to one or more of the above factors initially may lead to fatigue and discomfort. However, over time injury to the back, shoulders, hands, wrists, or other parts of the body may occur. MSD (muscular skeletal disorder) injuries include damage to muscles, tendons, ligaments, nerves and blood vessels. In addition, poor environmental conditions such as extreme heat, cold, noise, and poor lighting, typical to many DCs, may increase workers’ chances of developing other types of problems.

The amount of training that companies can provide for temporary workers is limited. Yet, it is in the best interest of the both the company and the worker to pay close attention to DC environmental and ergonomic issues for safety reasons. While accidents will happen – nobody should go home from the job with chronic pain and/or injury.

Types of Ergonomic Improvements

In general, there are (2) types of ergonomic improvements that can be made to “improve the fit” between the demands of work tasks and the workers’ capabilities to perform them:

Operational Improvements – These include rearranging, modifying, redesigning, providing or replacing tools, equipment, workstations, packaging, parts, processes, or systems. The Materials Handling Industry of Americawww.mhia.org and the Material Handling Equipment Distributors Associationwww.mheda.org are comprised of many diverse and specialized manufacturers and engineering firms offering a large variety of solutions.

http://www.scdigest.com/experts/Holste_12-10-24.php?cid=6356 25/10/12

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An 18 year-old man who was caught in a printing machine at a carton manufacturing plant in Thomastown on Tuesday has died.

The man suffered severe injuries after he was dragged head first into a box-printing machine at a factory in the northern suburb of Thomastown shortly after 2pm (AEDT) on Tuesday, a WorkSafe Victoria spokesman said.

It took firefighters about 45 minutes to extract the man from the machine.

He was taken to the Royal Melbourne Hospital, where he later died.

His death brought to four the number of people killed in a Victorian workplace this year.

WorkSafe Victoria is investigating the death and said it is a warning to all employers and workers.

Worksafe executive director John Merritt said on Wednesday that every employer should be meeting with their staff about known or predictable safety issues, and then develop and act on a safety improvement plan.

“If you already have one – review it,” Mr Merritt said.

“If machines are unguarded, if people don’t have appropriate training, licensing or supervision and workers do not have the equipment needed to do their job safely – or if they’re not using it – those issues must be dealt with today.”

A WorkSafe spokesman has confirmed the man’s clothing caught in rotating parts of the machine, dragging him into it.

WorkSafe has issued notices ordering the company to install better guards on the machine.

It is not yet clear if charges will be laid over the incident.

AAP

http://www.brisbanetimes.com.au/articles/2009/02/18/1234632886722.html 18/2/12

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Recently safety alerts were issued in mining to warn people to be aware of the potential to walk into hazards whilst being distracted or awaiting for sensor response particularly to rapidly depleting oxygen…

Speed is important

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The right of workers to speak up about safety without fearing for their jobs has been upheld in the Melbourne Magistrates’ Court, in the first discrimination conviction under the Occupational Health and Safety Act 2004…

Right to speak up about safety upheld

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Safe Work Tasmania recently released statistics that show mental stress as being one of the main causes of workplace injuries in Tasmania. Safety is the number one OHS and risk issue facing Australian organisations as they head into 2011…

Mental stress a major cause of workplace injuries

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Forklifts are dangerous to operate and their potential to cause serious injuries is often underestimated. Automation technology provides a new avenue for forklift safety…

Forklift Safety Improved

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