THE
SAFETY ZONE
INSIDE THIS ISSUE Safety Zone..................... pg 4 A Comprehensive Guide to Warehouse Safety
Feature Story................ pg 16 How Warehouse Managers Can Prevent Cancer Among Their Employees
Business News............. pg 20 Seven Supply Chain Sustainability Practices
Feature People News.... pg 20 Three safety experts honored as ASSP Fellows
Supplement insert for Material Handling Network
Safety Storage Efficiency • • • • •
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Material Handling Network June 2021 3 20/05/2021 10:02:11
Safety Zone
A Comprehensive Guide to Warehouse Safety
The U.S. Bureau of Labor Statistics estimates that, in 2018, over 4.2 million workers held jobs as “Hand Laborers and Material Movers.” The conveniences of online shopping have increased the demand for warehouse space and workers to occupy those spaces. With the COVID-19 pandemic, remote shopping may sustain the need for warehouse labor. Warehouses have forklifts, numerous employees, merchandise in many places and people carrying items and using equipment. The activities and presence of people present potential threats of serious injury or death. In 2018, an average of about 4 out of every 100 warehouse workers was injured in some way on the job. For some companies, that number is significantly higher. For instance, Amazon reported an average of 9.6 injuries per 100 full-time workers in the same year, which more than doubled the national average. Warehouse injuries come with an average direct price tag of $38,000, with indirect costs registering approximately $150,000. These and other costs encompass lost productivity, responding to fines from the Occupational Safety and Health Administration (OSHA) that reach $70,000 and increases in workers’ compensation insurance premiums. This warehouse safety guide offers suggestions for workplace protection gear, conditions in the warehouse and the education and promotion of safe practices.
Protective Gear and Clothing Body Coverage Overall, your employees should avoid loose and baggy clothing. Tight-fitting clothes lessens the risk that dust, liquids, chemicals or small objects will touch your employees’ skin or get caught in belts, chains or hooks. Overalls, long-sleeve shirts and long pants reduce or 4 June 2021 Material Handling Network Safety
eliminate skin exposure in the warehouse. With overalls and belts, your workers get the practical benefit of storage places for tools, pens or devices that track inventory in the warehouse. Visibility plays a critical role in protecting your warehouse employees. Prevailing workplace safety gear standards classify vests in warehouses as “Class 1” or “Type O” protective gear. This means, as a general rule: • 155 square inches of reflective tape • Dimensions of reflective tape either 6.46 linear feet (if two-inch tape) or 9.39 linear feet (if 1 ⅜-inch tape) As with most vests, the colors should be high visibility, illuminating in either yellow or orange. Eye Protection Gear Roughly 60 percent (three out of five) eye injuries have as their culprit a worker not having proper protective gear for the eyes. Warehouses present hazards to eyes in the form of splashing liquids or chemicals, projectiles, dust and impacts with equipment or other objects. Sufficient protection of your employees’ eyes requires more than regular prescription or consumer eyeglasses. Safety glasses for your employees should bear the American National Standards Institute Z87 mark on the frame or lens. Beyond the minimum, the work duties and environment in the warehouse guide the types of protective eyewear you need. Goggles have high resistance to impacts from objects and protect against dust, chemicals and dust. The frames cover the entire eye and what otherwise are gaps on the sides of the eyes. Safety glasses should also come with side shields. Replace glasses with scratches or cracks on the lenses or other parts. Cracks and dirt can obscure vision. If you have workers who use laser scanners, equip the safety glasses with special filters or glare protectant. Gloves What your employees handle in the warehouse should guide the type of gloves needed. For handling non-chemical substances and soft items, a light-duty glove should suffice. These gloves primarily reduce the dirtiness of your hands. You’ll need cutresistant gloves for your employees who handle glass, knives, blades and other sharp objects in the warehouse.
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June 2021 5
Safety Zone continued Pallets and other wood objects might have splits or splinters that can cut or puncture hands in the absence of gloves that resist punctures. Heavy-duty gloves come in handy for those who handle the steering wheels for forklifts or lift boxes. Your selection of hand protective equipment should account for whether your employees handle hot or cold items and the potential exposure to chemicals. Shoes Warehouse workers spend much of their workdays on their feet. An estimated 300,000 workers average five miles of walking throughout their shifts. Blisters, cramps and aches on feet are inevitable without proper footwear. Your employees face risks to toes and the tops of feet from falling objects or impacts with items left on the floor or running into the edges of doors, shelves, racks or other fixtures. The right kinds of shoes reduce discomfort and the chances of sudden foot injuries. Your employees’ safety shoes need to meet standards, especially the ASTM International F2413-18. Such footwear has steel toe caps especially designed to reduce the chances of toe injuries from falling objects. The standard requires the shoes to be resistant to punctures, water, compression of the feet, electric shock or currents, and impacts. Ensure that the shoes are resistant to slips and falls. Helmets OSHA-compliant hard hats constitute part of your Warehouse Safety program. The agency’s regulations require hard hats where objects might fall upon workers or where beams or other fixtures may cause side head impacts.
and operating the forklift on uneven floors or on inclines. To prevent overturning and other forklift accidents, make sure that you have only trained forklift operators. Your employees should have training from an OSHAcertified program, such as one conducted by the National Safety Council. Clean and Clear Floors Slips and falls account for nearly one in four injury claims and 15 percent of fatalities to warehouse workers. These accidents arise chiefly from unclean floors or objects left on them. Among the hazards left on warehouse floor aisles or walkways are: • Extension or drop cords • Hoses • Boxes • Tools • Paper, including forms or labels • Pallets • Oil • Water • Cleaners and other chemicals • Dust and other particles Promptly removing these objects and liquids are imperative to preventing slips, trips and falls. If your employees use tools and equipment, instruct them to not leave them unattended. Warehouse staff should place signage indicating wet or slippery floors, whether during routine cleaning or upon noticing leaks. The Exits Inadequate or poorly designed means of escape translate Make and Keep the Warehouse Safe to potentially fatal and tragic results. Employees and Forklift Safety other occupants must have the ability to promptly, Forklift accidents represent significant culprits of orderly and safely leave the warehouse in case of a fire or injuries in warehouses. On average, 90 fatalities per other danger. year arise from forklift incidents. According to the U.S. A proper exit strategy for workers starts with clearly Bureau of Statistics, 614 people died at the hands of marked signage for exits and routes. The word “Exit” forklifts between 2011 and 2017. must have at least six inches of height and ¾ inch of Nearly one in four width. You must provide exit routes at least 28 inches forklift accidents wide. Clearly indicate which doors or areas are “Not an involve overturning. Exit” or have another function, such as closet, storage or Employees can janitorial. Otherwise, your employees may have a difficult reduce the chance of time finding a safe exit. overturning forklifts Keep exits free of clutter and unlocked. They should by operating at slow or otherwise appropriate empty people into an open area outside the warehouse and facility, such as a parking lot, sidewalk, alley or street. speeds for the conditions and not attempting to move Exit doors need to swing to the outside. heavy loads or excessive numbers of pallets or materials. Other causes of overturning include turning too sharply 6 June 2021 Material Handling Network Safety
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June 2021 7
Safety Zone continued Fire Prevention Equip your warehouse with a mix of automatic sprinkler systems and manual fire suppression equipment. OSHA rules mandate that you have fire extinguishers placed generally within 75 feet of all stations or places where you have employees. Use an in-rack sprinkler in conjunction with ceiling sprinklers to stunt the spread of fires, especially if your warehouse has high ceilings. Your fire prevention protocols should include properly operating alarms and smoke detectors. Organization
Be sure to emphasize the importance of organization in work spaces in order to promote efficiency and safety. Dedicate the shelves and areas closest to the receiving and shipping areas for your best sellers. Using inventory tracking and sales data software helps you rank those items that fetch more orders. Group alike items together by: • Size, quantity or volume • Color • Material used or texture Generally, you can determine similarity and sorting by the model number of products. Employee Safety Instruction and Training The right type and quantity of safety equipment, uniforms and plans will not avail your business without a culture committed to warehouse safety. This involves safety training for new hires and current warehouse workers. Your training program should cover topics such as: • Wearing safety uniforms and equipment such as vests, helmets, goggles and other eye protective gear • Handling materials, including sharp objects and chemicals 8 June 2021 Material Handling Network Safety
• Proper lifting of boxes (squatting rather than bending) • Operation of forklifts and other equipment • Stacking and shelving of merchandise • Using fire extinguishers In your safety training, provide simple and direct instructions. Demonstrate for employees how to wear and use workplace protection gear and lift items. Take your new employees on a tour through the warehouse, showing them the fire or escape routes, exits and fire extinguishers or fire alarms. You and the management team should remain informed on changes to regulations and standards from OSHA, the National Fire Prevention Association and your state occupational safety agencies, local fire department or other public safety agencies. Fire Drills Periodically, you should conduct fire drills. If your warehouse has flammables, consider every three months for fire drills. With unannounced drills, management might better assess the readiness of the employees and supervisors to handle an emergency. Drills themselves can become teachable moments for your employees. In addition to training, fire drills allow you to assess the adequacy of your overall fire prevention program. Take note of the following: Whether fire alarms or smoke detectors were audible or malfunctioning, whether aisles, stairways and escape routes remained free of obstructions How many employees did not participate in the fire drill? Effectiveness of voice commands or notices over loudspeakers Ways to Encourage Employee Safety Safety programs can offer incentives for employees to follow OSHA rules and work safely. Rewards for avoiding injuries, incidents and actions that violate OSHA and other standards include bonus pay, increase in hourly rates and eligibility for drawings to win money or other prizes. Companies can also post the number of consecutive days since an accident or injury. By following some of these safety protocols, you can increase your warehouses’s safety measurements and ensure better safety for yourself and others. If you feel that your workplace does not follow many of these steps, speak with a manager about how you can bring some better practices into the workplace Emily Newton is the Editor-in-Chief of Revolutionized Magazine. She has over 3 years covering stories about warehousing, logistics and distribution.
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Warehouse Mirrors
Indoor Convex Detection Mirrors
Indoor Convex Detection Mirrors are designed to prevent intersection accidents in an industrial application. Convex mirrors can be positioned to reflect a hidden area to a forklift operator. These mirrors can also be directed to allow equipment operators to view co-workers approaching from behind to reduce accidents. Convex mirrors should be mounted at the end of alternating aisles to reflect the view of the traffic moving from the neighboring aisles. Small convexes can be used in offices to view hallways or reception areas for visitors or moving an traffic. pedestrian
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Fork Lift Mirrors
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Provide your employees with Fork Lift safety mirrors. Reduce blind spots in tight loading dock areas. Convex or Dome models available.
is the most versatile mirrored product for intersections in warehouse and industrial applications. Se-Kure Domes and Mirrors produces domes from 18” to 60” that are suspended by a 3 point chain set, which is included with each unit. The customers will have varying distances from the ceiling, so we do not include additional lengths of chain beyond the top of the chain’s tri-pod point.
Dome
Four way intersections are the most common application for the domes. The ratio of viewing distance is estimated at one foot of viewing distance for each inch of dome diameter. In a warehouse setting, a wider viewing distance would help provide a safer view due to increased vehicle speed. The dome should be suspended as low as possible, yet taking into consideration elevated material activity. Available with Hardboard Back. MFG# DESCRIPTION ONV-360-18 Acrylic Dome Mirror, 18" ONV-360-26 Acrylic Dome Mirror, 26" ONV-360-32 Acrylic Dome Mirror, 32" ONV-360-36 Acrylic Dome Mirror, 36" ONV-360-48 Acrylic Dome Mirror, 48" ONV-360-60 Acrylic Dome Mirror, 60” HB - Add Suffix for Hardboard (18” thru 48”) PB - Add for Plastic Back (18” thru 36”) PC - Add for Polycarbonate Mirror (18” thru 36”)
DM-CFM-8 The view distance ratio is about 1 foot of viewing distance to each inch of the diameter of the dome. Made in U.S.A.
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MFG#
DESCRIPTION
DM-CFM-8 DM-DFM-8
8" Convex Fork Lift Truck Mirror 8" Dome Fork Lift Truck Mirror
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Material Handling Network Safety June 2021 9
EnginEErEd
rack rEpair
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Full Service Engineered
Rack REpaiR
Your One-Stop Shop for Engineered Rack Repair & Protection Products & Services We produce over 30 column designs which allows Mac Rak to offer repairs for all types of racks on all types of rack systems. We also provide the nation’s best Turn-key solutions:
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Mac Rak is an associate member of the Rack Manufacturers Institute. (RMI) We are North America’s largest, most respected turn-key supplier of engineered approved pallet rack repair and protection solutions. Headquartered in the Midwest since 2001, our family owned and operated business achieves constant growth from focusing exclusively on one thing: the engineered pallet rack repair and protection business. Our performance commitment is backed by the “best in class” lifetime impact warranty.
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country’s top structural pallet rack Professional Engineers and Seizmic Inc. is our engineer of record. All Mac Rak repair kits exceed ANSI/RMI 16.1 engineering requirements, and are guaranteed to result in a repaired frame as strong or stronger than the original. This strong engineering background has provided a baseline for continued innovative product and service offerings. Offerings range from rack engineering services, to damaged rack assessments, to turn key repair projects, to DIY training programs, to planning and documentation services.
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NON-MARKING MATERIAL HANLDING TIRES
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A PATENTED NON-MARKING ANTI-STATIC (NMAS) TECHNOLOGY Camso offers the industry’s first complete line-up of solid tires to overcome the challenges of high intensity applications where static build-up can cause major safety hazards. The Solideal RES Xtreme NMAS and Solideal PON 775 NMAS have been designed to dissipate accumulated electricity on every rotation, thanks to an anti-static plug easily noticeable when looking at the tire: there is a black dot on the face of the tread.
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14 June 2021 Material Handling Network
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Feature Story
How Warehouse Managers Can Prevent Cancer Among Their Employees
While it is an incredibly important component of our economy, warehouse work is not for everyone. It can be repetitive, challenging, and physically exhausting, but the hard-working men and women of this workforce get the job done. Many people take warehouse positions because they know it is important, but most would not sign up knowing that there is a chance of getting cancer from their work. There have been amazing strides made and a lot of money raised over the years in the name of worker protection, but there is work yet to be done. Dangerous chemicals still exist, and they can be lifethreatening without the safety precautions put in place by management. Let’s look at some threats that still challenge us to this day and how managers can help our warehouse workers come home safe each night. Chemical Dangers Chemicals are found in just about everything a warehouse worker comes in contact with, from the cleaners made to sanitize the equipment to the packaging used to box up the products. As management, the key is to stay up to date on the chemicals that are most hazardous to the health of your staff. For instance, if your warehouse manufactures wood products, the resins used could contain formaldehyde, which can cause irritation to the face and lead to cancer if the worker is exposed to excessive levels. While many may be aware of the common carcinogens that could infiltrate your warehouse, sometimes, a deadly substance can arrive unexpectedly and cause health concerns. Just last year, an employee took legal action when it was found that the medical equipment that was left near the truck loading bay of a warehouse had been sterilized with a toxic gas called ethylene oxide, which is 16 June 2021 Material Handling Network Safety
a dangerous carcinogen. Due to the length of time this went unnoticed, the ethylene oxide made its way into the warehouse, affecting more than 50 people. The point is that managers need to be vigilant when it comes to the products made and delivered to their warehouses. Shipments should be inspected and notice should be taken if a delivery has warning labels or documentation that states that it is dangerous. Any questionable items that are received should be reported immediately so no worker is even unintentionally put in danger. Dangers of the Warehouse Itself Sometimes it is not only the products that come through your warehouse that cause danger but the actual warehouse itself. For instance, many older factories and warehouses that were built before the 1990s may have been made out of building materials that contain asbestos. While this chemical was commonly used back in the day, asbestos chemicals have since been found to be a carcinogen that can lead to lung diseases, including mesothelioma. Another chemical that can be found in building materials is radon, which also can cause lung cancer. The paint on your walls can be hazardous as well as some paints contain traces of benzene and arsenic, both of which can lead to cancer if absorbed in excess. To ensure that your workers are not exposed to these deadly chemicals, your warehouse needs to be inspected for all potential hazards, and your staff should cease operations until the building is determined to be clean and safe. On the subject of cleaning, management also needs to ensure that safe products are used for sanitation to avoid those that contain dangerous components. For instance, avoid commercial sink cleaners that contain ammonia and drain cleaners that contain sodium hydroxide. Both are dangerous components that can cause burns and irritation or worse. Before any cleaning agents are used, management should inspect the labels and advise proper use. Also, doors and windows should be opened when using all cleaning products to avoid overexposure. Dangers of Sun Exposure It can be easy to forget about the dangers of the sun, but skin cancer and other sun-related threats are still very real. If your staff works outside, management needs to www.mhnetwork.com
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CLARK® and S-SERIES® and the “Hot Yellow Green” also known as “CLARK Green” are trademarks registered in the U.S Patent and Trademark Office. ©2021 CLARK Material Handling Company
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Feature Story continued be extra vigilant about protection and taking this threat seriously. For starters, ensure that workers wear eyeglasses or contact lenses with UV protection whenever they are outside. The UV light that they deflect can otherwise cause permanent damage. To protect against skin cancer, ensure that your team members are wearing pants and long-sleeved shirts while using a sunscreen of SPF 15 or higher. Whenever possible, make it so your team can work in the shade, especially during the hours of 10 AM to 4 PM when the sun is at its most extreme. Also, a provision should be made in your health insurance policy that provides a professional skin exam by a dermatologist at least once per year. As a final point, it is important for management to keep in mind that, while it can often be a roll of the dice, certain variables can make a worker more likely to be at risk of cancer. For instance, those who are obese,
older, or have a poor diet are more likely to get sick. This is why it is important for management to work with human resources to create a benefits package that includes extensive health insurance so workers can get their yearly checkups and see a doctor if they are feeling ill. On top of that, consider a wellness program with benefits, like a lower insurance premium for those who meet certain health thresholds. While protecting your employees is always a top priority, avoiding potential cancer risks is of utmost importance. Warehouse managers who take the time to investigate potential dangers will have a happier and healthier team for years to come. “Noah Rue is always wondering where his next trip will take him. When he’s not traveling the world, he writes about technology, workplace management, career development, and other interests. Noah also enjoys a good meme from time to time. For more of Noah’s work follow him on Twitter.”
Feature People News Three safety experts honored as ASSP Fellows The American Society of Safety Professionals (ASSP), the world’s oldest professional safety organization, is bestowing the honor of Fellow on three longtime members who have made significant contributions to the occupational safety and health profession. Timothy R. Fisher, Michael W. Hayslip and Carl W. Heinlein are the 2021 recipients of the Society’s highest honor. “ASSP Fellows are leaders in safety and have played key roles in improving workplace environments as well as the profession itself,” said ASSP President Deborah Roy, M.P.H., RN, COHN-S, CSP, CIT, FASSP, FAAOHN. “The career accomplishments of Tim, Mike and Carl in helping to prevent injuries, illnesses and fatalities are a true inspiration.” • Timothy R. Fisher, CSP, CHMM, CPEA, CAE, ARM, STS, FASSP, is director of Standards Development and Technical Services at ASSP. He has made significant contributions to the Society as a staff member and volunteer during a professional career that spans more than 30 years.
• Michael W. Hayslip, J.D., P.E., CSP, FASSP, is in-house legal counsel for Cleveland Construction Inc. and president and CEO of National Excavation and Safety Training Institute (NESTI), an international construction safety training and litigation support firm. His valuable contributions to ASSP and the occupational safety and health profession include serving on ASSP’s Board of Directors, Government Affairs Committee, ANSI/ ASSP A10 Standards Committee and National Advisory Committee for Construction Safety and Health. • Carl W. Heinlein, ARM, CIT, CPEA, CRIS, CSHM, CSP, OHST, STSC, FAIHA, FASSP, is senior safety consultant at American Contractors Insurance Group. He is a well-regarded advocate for the occupational safety and health profession, contributing to workplace safety in the federal government, academia and the private sector.
ASSP’s three new Fellows will be honored at a virtual awards ceremony this summer. The honor of Fellow recognizes an ASSP member’s lifetime commitment to occupational safety and health. Nominees must have a history of major contributions to the profession for at least 15 years. To see the Society’s list of Fellows dating back more than 50 years, visit ASSP Fellow recipients. 18 June 2021 Material Handling Network Safety
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Material Handling Network Safety June 2021 19
Business News
Seven Supply Chain Sustainability Practices Before you can determine which parts of your supply chain need a sustainability boost, you’ll need to get a big-picture view of your entire supply chain ecosystem. Because today’s supply chains aren’t linear, you can start your map by creating a list of your sales channels, suppliers, warehouses, logistics providers, and store locations. Technologies like unified commerce software can give you visibility into how each of these channels and locations are operating and give you the benchmarks you need to start evaluating your overall sustainability. #1: Cut Down on Paperwork with Integrated EDI There are plenty of reasons to automate your order processing methods, like saving time, preventing errors and scaling your operations. But an added benefit of integrated EDI is that it eliminates the need for paper order documents. The average office worker uses 10,000 sheets of copy paper per year, but with EDI, every transaction and communication, from purchase orders to shipping manifests to invoices, can be sent, received, and saved electronically. #2: Choose the Right Packaging There are two ways to look at packaging. From the production side, many companies are looking at how they can save on plastic use or use recycled materials in their product packaging. From the supply chain side, packaging refers more to picking the right box for each order. Choosing a huge box that dwarfs the product is not only a waste of space, plastic, and cardboard—it can also drastically increase your shipping costs. Instead, take advantage of pack optimization software, which can help you choose the perfect box based on the contents of each order. #3: Consolidate Your Shipments The more trucks you need to use, the bigger your carbon footprint, so many companies have taken to consolidating orders and shipments, which allow them to save on transportation costs while being eco-friendly. On the individual consumer level, a great example of this is Amazon. During checkout, Amazon customers have two options. They can choose fast delivery, where items might be shipped separately, or choose to ship their items together in the “fewest possible packages.” #4: Choose Suppliers Who Care Supply chain sustainability goes beyond your internal operations. Your suppliers contribute significantly to your environmental impact. By requiring environmental 20 June 2021 Material Handling Network Safety
impact reports from your trading partners, you can find the most eco-friendly performers, encourage others to become more sustainable, and decide which suppliers don’t fit into your sustainability vision. Many top retailers like Walmart, CVS and Target use a non-profit called CDP, which measures suppliers by their impact on climate change, water security and deforestation. #5: Optimize Your Inventory Inventory technology solutions like vendor managed inventory (VMI) enable businesses to collaborate with their suppliers. The same processes that help increase sales while reducing inventory investments also help make your business more sustainable. For example, technology that gives a vendor visibility into location-specific demand can help them schedule replenishment deliveries. This helps the supplier or manufacturer understand how much product to produce (curbing overproduction that leads to waste), prevent overstocking (which often ends with the disposal or return of unsold goods) and optimize truckloads to reduce transportation costs (and fuel emissions). #6: Use Analytics to Your Advantage As you implement greener supply chain practices, it’s important to come back to the benchmarks and goals you set on a regular basis. You can use reporting and analytics from your various systems and integrations to see how you are progressing on each key performance indicator. You’ll also start beginning to see the outliers—which projects or processes are running efficiently, and which supply-chain touchpoints are creating waste. By using the data already at your fingertips, you can find new efficiency drivers, both for your sustainability efforts, and for other parts of your operations. #7: Create a Circular Supply Chain The circular supply chain model takes the idea of recycling to the next level, by encouraging manufacturers and sellers to reuse and repurpose everything from their own products to their packaging and transportation materials. Increasing Supply Chain Sustainability with TrueCommerce Going green is good for the Earth and for your company’s reputation, but it can also help improve your bottom line. By cutting down on waste from paper and single-use materials, your business can save hundreds of thousands of dollars per year. www.mhnetwork.com
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Material Handling Network
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22 June 2021 Material Handling Network
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IT TAKES MORE THAN THIS
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