Warehouse Shelving Safety Basics

Jul 09, 2020

What comes to mind first when you think about the safety of your warehouse? Even well-trained employees and properly maintained equipment can’t mitigate the risk that’s presented when you ignore the safety of your warehouse shelving and racks. Accidents and costly OSHA violation fines could create a working environment that’s far from ideal, and could even cause disruption to your workflow and even closure of your facility.

With that in mind, there are a handful of best practices and OSHA guidelines that should be followed in order to maintain safety for everyone. 

 

Check the Height

OSHA states that the freestanding shelves can reach no higher than 15 feet, but that’s the only clear standard regarding safety. There is a clause, however, that states employers can be cited if an accident occurs, the warehouse can be cited for lack of due diligence. All shelves (of any height) should be bolted to each other and to the floor, and where possible, bolted to the wall as well. Additionally, pallet racks need to be loaded properly with weight concentrated on the lower racks and lighter objects up higher.

 

Get a Closer Look

The little things make a big difference in the safety of your warehouse shelving. Missing bolts, warped shelves, and regular wear and tear could lead to massive failure that causes an accident during loading and unloading. Even a forklift nicking the edges of the shelving unit can create a chain effect that could impact your shelving safety. Make it a habit to run through an inspection checklist regularly and especially should an accident occur.

 

 

Look for Leaning

Visually inspecting warehouse shelving can give you an idea of shelves that are not level, but leaning isn’t always visible to the naked eye. As part of your regular safety inspections, use a level tool to get an exact angle of the lean. OSHA has a specific guideline that lays out when a shelving unit needs to be straightened or replaced. Keep a thorough record of these measurements and repairs, and if you notice a pattern, it’s likely time to thoroughly replace shelving units.

 

Watch the Weight

Here’s a reminder: Too much weight on warehouse shelving is a recipe for disaster. It’s a fundamental fact of loading shelves, but it bears repeating. Even if heavy objects don’t cause any immediate damage, overexerting shelving units can cause them to collapse. This is an area of warehouse management where supervisors need to enforce safety standards — it’s not easy to gauge the weight of inventory on shelves just by looking at them.

 

Create Clearance

It can be tempting to pack in the shelving with the thought that you’re maximizing space in your warehouse, but that limits how your forklifts can operate efficiently and safely without hitting, denting, or damaging the shelving. OSHA recommendations dictate that aisles should be at least 4 feet wide. There are also guidelines that state aisles should be 3 feet wider than the largest piece of equipment used in your warehouse. For example, if your forklift is 4 feet wide, aisles need to have a width of 7 feet to allow workers to navigate safely. 

 

 

Prioritize Training

Forklift training is mandated by OSHA, and even if it wasn’t, it should still be an integral part of your onboarding and continuing education processes. Don’t limit this training to just forklift operators; all employees need to be aware of guidelines and best practices for loading and unloading in the shelving areas of your website. Make it a fun process so employees stay engaged in the process and the training will stick and help encourage the entire team to contribute to a culture of safety.

 

Think About Upgrading

Increasing safety means minimizing factors that lead to accidents, beyond eliminating human error. Upgrade your lighting to brighter, more efficient LED fixtures. Implement automated systems that reduce stress and fatigue on the “human” workforce. Invest in a new fleet of forklifts that have innovative safety features. Most importantly, understand when it’s time to replace your warehouse shelving that helps support OSHA-defined safety guidelines.

Whether you need to repair or maintain your existing racking systems or are ready to invest in new technology, Benco is here to help. We service all major warehouse racking manufacturers and keep a variety of spare and replacement parts in our inventory. If something breaks, we can fix it. If something needs to work better, we’ll figure it out. Call 636-486-1693 to learn more or get in touch with our team here.

Common Hazards in Your Warehouse (And How to Avoid Them)

08 Apr, 2024
Warehouses are the backbone of many industries, storing and distributing goods to keep the economy moving. However, behind the scenes of this logistical hub lurk various hazards that can pose severe risks to employees and property. Let's investigate some of the most common warehouse hazards and explore proactive mitigation strategies. Slips/Trips/Falls Slips, trips, and falls are among the most prevalent hazards in warehouse spaces. Spills, cluttered aisles, and uneven surfaces can easily lead to accidents if not adequately addressed. To prevent such incidents, warehouses should prioritize proper housekeeping, including regular cleaning and maintenance of floors. Additionally, using signage to highlight potential hazards and ensuring adequate lighting throughout the facility can significantly reduce the risk of slips, trips, and falls. Fires Flammable materials and electrical equipment in warehouses make them susceptible to fires. Faulty wiring, improper storage of combustible materials, and lack of fire suppression systems can all contribute to the risk of fire outbreaks. Implementing preventive measures such as regular equipment maintenance, proper storage protocols for flammable materials, and employee training on fire safety procedures are crucial in mitigating this hazard. Harmful Substances Warehouses often house various chemicals and hazardous substances, which can pose risks to employees' health if not handled properly. Exposure to harmful substances can lead to respiratory issues, skin irritation, and other serious health problems. To mitigate this hazard, warehouses should properly store and label hazardous materials, provide employees with appropriate personal protective equipment (PPE), ensure adequate ventilation systems, and conduct regular training on safe handling procedures. Falling Objects With shelves stacked high with merchandise, falling objects present a significant hazard in warehouses. Poorly secured storage systems, improper stacking of items, and inadequate safety measures can all increase the risk of objects falling and causing injury. Warehouses can minimize this risk by adequately securing shelves and storage systems, using barriers or guardrails to prevent objects from falling, and conducting regular inspections of overhead storage areas. Overexertion The physical demands of warehouse work can lead to overexertion injuries if employees lack adequate training or don't perform tasks ergonomically. Lifting heavy objects, repetitive motions, and working in awkward positions can all contribute to overexertion injuries such as strains and sprains. To prevent such injuries, warehouses should provide comprehensive training on proper lifting techniques, encourage the use of mechanical aids such as forklifts and pallet jacks, and implement ergonomic workstations to reduce strain on employees' bodies.

Common Inventory Management Mistakes

08 Mar, 2024
Effective inventory management practices influence the success of each warehouse, the supply chain, and the business at large. Inventory management involves many moving parts and elements – everything from the product catalog to the warehouse space to tracked KPIs. Experienced warehouse managers know that no matter how fool-proof your inventory management systems are, there’s always room to improve and prepare for unexpected circumstances. Let’s discuss common inventory management mistakes (and what to do instead). Overstocking or Understocking One of the most prevalent inventory management mistakes is maintaining too much or too little inventory. Overstocking ties up valuable capital and warehouse space, leading to increased carrying costs and a higher risk of obsolescence. On the other hand, understocking can result in stockouts, backorders, and dissatisfied customers. Businesses should leverage historical sales data, market trends, and advanced forecasting techniques to accurately predict demand and optimize inventory levels. Inaccurate Demand Forecasting Businesses are prone to making costly inventory planning errors without precise demand forecasting. Relying on outdated data or flawed forecasting methods can lead to inefficiencies and missed opportunities. By utilizing advanced analytics and predictive modeling, businesses can better anticipate shifts in demand, seasonal fluctuations, and emerging trends, allowing for more informed inventory decisions and improved responsiveness to customer needs. Lack of Inventory Visibility Poor visibility into inventory levels across multiple locations or channels can result in operational inefficiencies and errors. Without real-time data on stock levels and movement, businesses may struggle to fulfill orders on time, leading to customer dissatisfaction and lost sales. Implementing integrated inventory management systems that provide comprehensive visibility into inventory across the supply chain can help businesses optimize inventory allocation, reduce stockouts, and improve overall operational performance.

A Beginner’s Guide to Electric Forklifts

By Denis Benden • 08 Feb, 2024
Efficient material handling is crucial for businesses of all sizes and industries. It directly impacts productivity, cost-effectiveness, and overall operational success. Effective material handling ensures that goods are moved, stored, and transported in a streamlined and organized manner, minimizing delays, damages, and errors. Electric forklifts play a significant role in effective material handling, transforming the […] The post A Beginner’s Guide to Electric Forklifts appeared first on Benco Industrial Equipment.
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