Worker Safety Series - Warehousing.pdf

7/25/2019 Worker Safety Series - Warehousing.pdf

1/15

OSHA 3220-10N 2004


2/15

WORKERSAFETYSERIES WAREHOUSING 11

H azards & Solutions

Warehouse operat ions can present aw ide variety of potential hazards forthe worker.

For warehousing establishments, the10 OSHA standards most frequentlyincluded in the agencys citationswere:1 . Forklifts2 . Hazard communication3 . Electrical, wiring methods4 . Electrical, system design

5 . Guarding floor & wall openingsand holes

6 . Exits7 . Mechanical power transmission8 . Respiratory protection9 . Lockout/tagout

10. Portable fire extinguishers

Occupational Safety andHealth Administration

Think Safety More than 145,000 people work in over 7,000

warehouses. The fatal injury rate for the warehousing

industry is higher than the national averagefor all industries.

Potential hazards for workers in warehousing:

Unsafe use of forklifts;

Improper stacking of products;

Failure to use proper personal protectiveequipment;

Failure to follow proper lockout/tagoutprocedures;

Inadequate fire safety provisions; or Repetitive motion injuries.

Occupational Safety andHealth AdministrationU.S. Department of Labor

www.osha.gov


3/15



D ocksHazard: Injuries happen here when forklifts

run off the dock, products fall on employeesor equipment strikes a person.

Solutions:

Drive forklifts slowly on docks and dockplates;

Secure dock plates and check to see if theplate can safely support the load;

Keep clear of dock edges and never backup forklifts to the docks edge;

Provide visual warnings near dock edges;

Prohibit dock jumping by employees;

Make sure that dock ladders and stairs meetOSHA specifications.

ForkliftsHazard: About 100 employees are killed and95,000 injured every year while operatingforklifts in all industries. Forklift turnoversaccount for a significant percentage of thesefatalities.

Solutions:

Train, evaluate and certify all operators toensure that they can operate forklifts safely;

Do not allow anyone under 18 years old tooperate a forklift;

Properly maintain haulage equipment,including tires;

Before using a forklift, examine it for haz-ardous conditions which would make itunsafe to operate;

Follow safe procedures for picking up,putting down and stacking loads;

Drive safely, never exceeding 5 mph andslow down in congested areas or those withslippery surfaces;

2 WORKERSAFETYSERIES WAREHOUSING 3


4/15



Ensure that the operator wears a seatbeltinstalled by the manufacturer;

Never drive up to a person standing in frontof a fixed object such as a wall or stackedmaterials;

Prohibit stunt driving and horseplay;

Do not handle loads that are heavier thanthe weight capacity of the forklift;

Remove unsafe or defective trucks fromservice until the defect is properly repaired;

Maintain sufficiently safe clearances foraisles and at loading docks or passageswhere forklifts are used;

Ensure adequate ventilation either byopened doors/windows or using a ventila-tion system to provide enough fresh air tokeep concentrations of noxious gases fromengine exhaust below acceptable limits;

Provide covers and/or guardrails to protectworkers from the hazards of open pits,tanks, vats and ditches;

Train employees on the hazards associatedwith the combustion byproducts of forklift

operation, such as carbon monoxide.

C onveyorsHazard:Workers can be injured when they

are caught in pinch points or in the in-goingnip points, are hit by falling products ordevelop musculoskeletal disorders associatedwith awkward postures or repetitive motions.

Solutions:

Inspect conveyors regularly;

Ensure that pinch points are adequatelyguarded;

Develop ways of locking out conveyors andtrain employees in these procedures;

Provide proper lighting and working sur-faces in the area surrounding the conveyor.

M aterials StorageHazard: Improperly stored materials may falland injure workers.

Solutions:

Stack loads evenly and straight;

Place heavier loads on lower or middleshelves;

Remove one object at a time from shelves; Keep aisles and passageways clear and in

good repair.



5/15



M anual Lifting/H andlingHazard: Back injuries may occur from

improper lifting or overexertion.Solutions:

Provide general ergonomics training andtask-specific training;

Minimize the need for lifting by using gooddesign and engineering techniques;

Lift properly and get a coworker to help ifa product is too heavy.

H azard Com m unicationHazard: Chemical burns are possible if spills

of hazardous materials occur.Solutions:

Maintain a Material Safety Data Sheet(MSDS) for each chemical to which workersare exposed in the facility;

Follow instructions on the MSDS for han-dling chemical products;

Train employees on the risks of eachchemical being stored;

Provide spill cleanup kits in any area where

chemicals are stored; Have a written spill control plan;

Train employees to clean up spills, protectthemselves and properly dispose of usedmaterials;

Provide proper personal protectiveequipment and enforce its use;

Store all chemicals safely and securely;

Store chemicals away from forklift trafficareas.



6/15



C harging StationsHazard: Fires and explosion risks are possible

unless proper guidelines are followed.Solutions:

Prohibit smoking and open flames in andaround charging stations;

Provide adequate ventilation to dispersefumes from gassing batteries;

Ensure that fire extinguishers are availableand fully charged;

Provide proper personal protectiveequipment such as rubber gloves and eye

and face protection; Properly position forklifts and apply brakes

before attempting to change or chargebatteries; follow required procedures whenrefueling gas or propane fueled forklifts;

Provide conveyors, overhead hoists orequivalent materials handling equipmentfor servicing batteries;

Provide an eyewashing and safety showerfacility for employees exposed to batteryacids.

Poor Ergonom icsHazard: Improper lifting, repetitive motion or

poor design of operations can lead to muscu-loskeletal disorders in workers.

Solutions:

If possible, use powered equipment insteadof requiring a manual lift for heavy materials;

Reduce lifts from shoulder height and fromfloor height by repositioning the shelf or bin;

Ensure overhead lighting is adequate forthe task at hand;

Provide employees with task-oriented

ergonomic training; Use your legs and keep your back in a natu-

ral position while lifting;

Test the load to be lifted to estimate itsweight, size and bulk, and to determine theproper lifting method;

Get help if the load exceeds the maximumweight a person can lift safely withoutassistance;

Dont twist while carrying a load, but shift

your feet and take small steps in the direc-tion you want to turn;

Keep floors clean and free of slip and triphazards.



7/15



O ther H azardsInadequate fire safety provisions, improper

use of lockout procedures and failure to wearpersonal protective equipment also createhazards in the warehouse workplace.

Employers should have an emergency planthat describes what is expected of employeesin the event of an emergency, including:

Provisions for emergency exit locations andevacuation procedures;

Procedures for accounting for all employeesand visitors;

Location and use of fire extinguishers andother emergency equipment.

Warehouse operations need a lockout/tagoutprogram to prevent equipment from beingaccidentally energized and injuring employees.Employees required to perform these opera-tions should be trained and all employeesshould have a working knowledge of theprogram.

Finally, management at warehouse operationsneeds to conduct a site hazard assessment to

determine what personal protective equipment(PPE) must be worn based on the hazardspresent and train warehouse employees onproper PPE selection, use and maintenance.

Think Safety Checklists

The following checklists may helpyou take steps to avoid hazards thatcause injuries, illnesses and fatalities.As always, be cautious and seek helpif you are concerned about a poten-tial hazard.

G eneral Safety

Exposed or open loading dock doors andother areas that employees could fall 4feet or more or walk off should be chained

off, roped off or otherwise blocked.

Floors and aisles are clear of clutter,electrical cords, hoses, spills and otherhazards that could cause employees toslip, trip or fall.

Proper work practices are factored intodetermining the time requirements for anemployee to perform a task.

Employees performing physical workhave adequate periodic rest breaks

to avoid fatigue levels that could result ingreater risk of accidents and reducedquality of work.

Newly-hired employees receive generalergonomics training and task-specifictraining.

The warehouse is well ventilated.

Employees are instructed on how to avoidheat stress in hot, humid environments.

Employees are instructed on how to work

in cold environments.

The facility has lockout/tagout procedures.



8/15



M aterials H andling Safety

There are appropriately marked andsufficiently safe clearances for aisles andat loading docks or passageways wheremechanical handling equipment is used.

Loose/unboxed materials which might fallfrom a pile are properly stacked by block-ing, interlocking or limiting the height ofthe pile to prevent falling hazards.

Bags, containers, bundles, etc. are storedin tiers that are stacked, blocked, inter-locked and limited in height so that theyare stable and secure to prevent sliding

or collapse.

Storage areas are kept free from accumu-lation of materials that could lead to trip-ping, fire, explosion or pest infestations.

Excessive vegetation is removed frombuilding entrances, work or traffic areasto prevent possible trip or fall hazardsdue to visual obstructions.

Derail and/or bumper blocks are providedon spur railroad tracks where a rolling car

could contact other cars being worked onand at entrances to buildings, work ortraffic areas.

Covers and/or guardrails are provided toprotect personnel from the hazards ofstair openings in floors, meter or equip-ment pits and similar hazards.

Personnel use proper lifting techniques.

Elevators and hoists for lifting materials/containers are properly used with ade-quate safe clearances, no obstructions,

appropriate signals and directional warn-ing signs.

H azard Com m unication Safety

All hazardous materials containersare properly labeled, indicating thechemicals identity, the manufacturersname and address, and appropriatehazard warnings.

There is an updated list of hazardouschemicals.

The facility has a written program thatcovers hazard determination, includingMaterial Safety Data Sheets (MSDSs),labeling and training.

There is a system to check that eachincoming chemical is accompanied bya MSDS.

All employees are trained in the require-ments of the hazard communicationstandard, the chemical hazards to whichthey are exposed, how to read andunderstand a MSDS and chemical labels,and on what precautions to take toprevent exposure.

All employee training is documented.

All outside contractors are given a com-plete list of chemical products, hazardsand precautions.

Procedures have been established tomaintain and evaluate the effectivenessof the current program.

Employees use proper personal protectiveequipment when handling chemicals.

All chemicals are stored according to themanufacturers recommendations and

local or national fire codes.



9/15



Forklift Safety

Powered industrial trucks (forklifts) meetthe design and construction requirementsestablished in American NationalStandard for Powered Industrial Trucks,Part II ANSI B56.1-1969.

Written approval from the truckmanufacturer has been obtained for anymodifications or additions that affectthe capacity and safe operation of thevehicle.

Capacity, operation and maintenanceinstruction plates, tags or decals are

changed to specify any modifications oradditions to the vehicle.

Nameplates and markings are in placeand maintained in a legible condition.

Forklifts that are used in hazardous loca-tions are appropriately marked/approvedfor such use.

Battery charging is conducted only indesignated areas.

Appropriate facilities are providedfor flushing and neutralizing spilledelectrolytes, for fire extinguishing, forprotecting charging apparatus fromdamage by trucks and for adequateventilation to disperse fumes fromgassing batteries.

Conveyors, overhead hoists or equivalentmaterials handling equipment are providedfor handling batteries.

Reinstalled batteries are properlypositioned and secured.

Carboy tilters or siphons are used forhandling electrolytes.

Forklifts are properly positioned andbrakes applied before workers start to

change or charge batteries.

Vent caps are properly functioning.

Precautions are taken to prevent smoking,open flames, sparks or electric arcs inbattery charging areas and during stor-age/changing of propane fuel tanks.

Tools and other metallic objects are keptaway from the top of uncovered batteries.

Concentrations of noxious gases andfumes are kept below acceptable levels.

Forklift operators are competent to oper-ate a vehicle safely as demonstrated bysuccessful completion of training andevaluation conducted and certified bypersons with the knowledge, training andexperience to train operators and evalu-ate their performance.

The training program content includesall truck-related topics, workplace-relatedtopics and the requirements of 29 CFR1910.178 for safe truck operation.

Refresher training and evaluation isconducted whenever an operator hasbeen observed operating the vehicle inan unsafe manner or has been involvedin an accident or a near-miss incident.

Refresher training and evaluation isconducted whenever an operator isassigned to drive a different type of truckor whenever a condition in the workplacechanges in a manner that could affectsafe operation of the truck.

Evaluations of each operators perfor-mance are conducted at least once everythree years.



10/15



Load engaging means are fully lowered,with controls neutralized, power shut

off and brakes set when a forklift is leftunattended.

Operators maintain a safe distance fromthe edge of ramps or platforms whileusing forklifts on any elevated dock,platform or freight car.

There is sufficient headroom for the fork-lift and operator under overhead installa-tions, lights, pipes, sprinkler systems, etc.

Overhead guards are provided in goodcondition to protect forklift operators

from falling objects.

Operators observe all traffic regulations,including authorized plant speed limits.

Drivers are required to look in the direc-tion of and keep a clear view of the pathof travel.

Operators run their trucks at a speed thatwill permit the vehicle to stop in a safemanner.

Dock boards (bridge plates) are properlysecured when loading or unloading fromdock to truck.

Stunt driving and horseplay are prohibited.

All loads are stable, safely arranged andfit within the rated capacity of the truck.

Operators fill fuel tanks only when theengine is not running.

Replacement parts of trucks are equivalentin terms of safety with those used in theoriginal design.

Trucks are examined for safety beforebeing placed into service and unsafeor defective trucks are removed fromservice.

W arehouse Safety &H ealth Resources

Most resource materials can be foundon the OSHA website: www.osha.gov

M aterials H andlingMaterials Handling and Storage

OSHA Publication 2236 (Revised 2002).

559KB PDF, 40 pages.

A comprehensive guide to hazards and safe

work practices in handling materials.

http://www.osha.gov/Publications/osha2236.pdf

Electrical H azardsControl of Hazardous Energy (Lockout/Tagout)


174 KB PDF, 45 pages.

This booklet presents OSHAs general require-

ments for controlling hazardous energy during

service or maintenance of machines or equipment.


Controlling Electrical Hazards


349KB PDF, 71 pages.

This publication provides an overview of basic

electrical safety on the job.


Safety and Health Topics:Lockout/Tagout

OSHA website index to information about

lockout/tagout, including hazard recognition,

compliance, standards and directives, Review

Commission and Administrative Law J udge

Decisions, standard interpretations and

Compliance Letters, compliance assistance

and training.

http://www.osha.gov/SLTC/controlhazardousenergy/index.html



11/15



Evacuation Plans and Procedures

An eTool designed to help small, low-hazard

service or retail businesses implement an emer-

gency action plan and comply with OSHA'semergency standards.

http://www.osha.gov/SLTC/etools/evacuation/

index.html

Fire SafetySafety and Health Topics:Fire Safety

OSHA website index to information on fire safety.

http://www.osha.gov/SLTC/firesafety/index.html

Fire Safety Advisor

OSHA's Fire Safety Advisor is an interactive

expert software. It will help explain and applyOSHA's Fire Safety-related standards. It can

be used online or is available for download.

http://www.osha.gov/dts/osta/oshasoft/

softfirex.html

Forklift SafetySafety and Health Topics:Powered

Industrial Trucks

OSHA website index links to specific require-

ments and other Federal agency requirements.

http://www.osha.gov/SLTC/poweredindustrial-

trucks/index.html

Sample Daily Checklists for Powered Industrial Trucks http://www.osha.gov/dcsp/ote/trng-materials/pit/daily_pit_checklist.html

Preventing Injuries and Deaths of Workers

Who Work Near Forklifts

NIOSH Alert Pub. No. 2001-109 (J une 2001).

This alert instructs workers in the steps they can

take to protect themselves near forklifts. It is also

available as a downloadable PDF document.

http://www.cdc.gov/niosh/2001-109.html

Protecting Young Workers:Prohibition

Against Young Workers Operating Forklifts

OSHA Safety and Health Bulletin (2003), 4

pages. Available as a PDF document, 109 KB.

http://www.osha.gov/dts/shib/shib093003.html

H azard Com m unicationOSHAs website index for resources on hazard

communication.

http://www.osha.gov/SLTC/hazardcommunica-

tions/index.html

M ore H azard Com m unicationFrequently Asked Questions for Hazard

Communication. OSHA, 6 pages.

http://www.osha.gov/html/faq-hazcom.html

Hazard Communication Standard.

OSHA Fact Sheet (1993), 3 pages.

http://www.osha.gov/pls/oshaweb/owadisp.shw

_document?p_table=FACT_SHEETS&p_id=151

Hazard Communication Guidelines for

Compliance.OSHA Publication 3111 (2000), 112

KB PDF, 33 pages.

This document aids employers in understanding

the Hazard Communication standard and in

implementing a hazard communication program.

http://www.osha.gov/Publications/osha3111.pdfChemical Hazard Communication. OSHA

Publication 3084 (1998), 248 KB PDF, 31 pages.

This booklet answers several basic questions

about chemical hazard communication.


NIOSH Pocket Guide to Chemical Hazards.

Handy source of general industrial hygiene

information on several hundred chemicals/

classes for workers, employers and occupa-

tional health professionals.

http://www.cdc.gov/niosh/npg/npg.html



12/15

Ergonom icsSafety and Health Topics:Ergonomics

OSHA website index to resources and publica-tions on ergonomics.

http://www.osha.gov/SLTC/ergonomics/index.html

Grocery Warehousing Ergonomics

An e-tool specific for warehousing operations in

the grocery industry.

http://www.osha.gov/SLTC/etools/grocery

warehousing/index.html

Personal Protective Equipm entSafety and Health Topics:

Personal Protective Equipment

OSHAs website index to hazard recognition,

control and training related to personal protec-

tive equipment.

http://www.osha.gov/SLTC/personalprotective

equipment/index.html

Personal Protective Equipment. OSHA

Publication 3151 (2004), 695KB PDF, 44 pages.

Discusses equipment most commonly used for

protection for the head, including eyes and face,

and the torso, arms, hands and feet. The use of

equipment to protect against life-threatening

hazards is also discussed.http://www.osha.gov/Publications/OSHA3151/

osha3151.html

W arehouse Industry

Cooperative Program s

Voluntary Protection Program sNumerous VPP worksites that OSHArecognizes for their excellent safety and health

management systems deal with the hazardsof warehousing and storage. These modelworksites are willing to share their expertiseand many are available to mentor otherbusinesses. For further information on howVPP participants can help you, contact the VPPManager in your OSHA Regional Office or theVoluntary Protection Programs ParticipantsAssociation, 7600-E Leesburg Pike, Suite 440,Falls Church, VA 22043, telephone (703) 761-1146.

Alliance ProgramAlliances enable organizations committed toworkplace safety and health to collaboratewith OSHA to prevent injuries and illnesses inthe workplace. A number of Alliances havean impact on the warehousing industry,

including the following:Retail Industry Leaders Association

The OSHA Alliance with the Retail IndustryLeaders Association (RILA) is focused on





13/15




sharing safety and health best practices andtechnical knowledge, including ergonomics inretail warehousing and distribution facilities.

Industrial Truck Association

The Industrial Truck Association (ITA) andOSHA also have an Alliance to promote thesafe operation of powered industrial trucksthrough training and outreach. The goal of theAlliance is to assist employers and employeesin reducing and preventing exposure topotential hazards associated with the use ofpowered industrial trucks in general, and inwarehouses in particular.

International Warehouse Logistics AssociationOSHA and the International WarehouseLogistics Association (IWLA) work togetherto protect employees safety and health,including hard-to-reach youth workers. TheAlliance addresses materials handling, forkliftsafety, hazard communication and otherissues unique to the public warehouse industry.

National Lumber and Building Material

Dealers Association

OSHA has an Alliance with the NationalLumber and Building Material DealersAssociation (NLBMDA) to increase overallsafety awareness in that industry whilespecifically addressing recordkeeping issues,preventing forklift accidents and avoidinglifting strains.

N J W arehouseO peration -

A Success StoryOSHA recommendations result inimmediate, high payoff for an EastCoast warehouse operation.

Injury ReductionRecently, a New J ersey warehouse operationhad been averaging two back injuries amonth. After adopting several OSHA

recommendations for reducing ergonomicrisk factors specific to their operations, thecompany reported zero back injuries.

Boosting M orale & ProductivityAnd there was another benefit from adoptingOSHAs recommendations. According to theMarlton, NJ OSHA area office, companysources reported that both the morale andproductivity of the companys 50 warehouseemployees had subsequently increased.

O ngoing H elpAs part of OSHAs ongoing efforts to do abetter job in promoting workers safety andhealth, the agency has developed a programto help identify certain industries that haveexceptionally high injury rates. One of theseindustries is warehousing. By identifyingthese workplaces, OSHA is better able toassist businesses in reducing their high injuryrates. Through the Site Specific TargetingPlan, OSHA performs a comprehensive

evaluation of a workplace and, with the helpof its technical experts, helps the employerdevelop a plan for improving its employeessafety and health.


14/15




Feasible ControlsIn OSHAs detailed evaluation, each hazard

was carefully described, including photo-graphs illustrating the task to help clearlyshow the hazard. For each hazard, OSHAspecialists detailed several feasible controls.

These were straightforward, easy-to-imple-ment actions such as:

Adjusting the height of shelves;

Providing stools or ladders to employees;

Reducing the depth of shelving;

Raising loading heights;

Evaluating the flow and volume of ordersso faster-moving products are placed oneasier-to-reach shelves.

Also, OSHAs evaluation report detailed a listof available resources, including on-siteconsultation visits, that the company coulduse in developing improved ways to preventinjuries.

The company adopted 13 of the 19 feasiblecontrols that OSHA recommended. And the

result, thus far, speaks for itself: a perfect zerofor back injuries, improved productivity andhigher employee morale.

Specific Recom m endationsOSHAs recommendations were developed

specifically for this New J ersey warehouseoperation by OSHAs Salt Lake City TechnicalSupport Center following an inspection of the186,000 square foot facility under theagencys Site Specific Targeting Plan whichincluded a comprehensive walkaround of theworkplace and a review of its injury records.

Avoiding M SD sOSHA compliance officers worked withexperts at the Salt Lake City Center to tailorspecific recommendations to address the

potential ergonomic risk factors theyobserved. Specialists at Salt Lake Cityanalyzed the warehouses various operationsand recommended 19 steps, known asfeasible controls, that the employer couldtake to help employees to avoid muscu-losketal disorders (MSDs).

H azards IdentifiedSome of the hazards identified by OSHAincluded:

Employees had to reach elevated anddistant locations in storage shelves toaccess materials;

Workers had to repeatedly bend to reachlow-level locations at floor level to accessmaterials;

Employees were lifting and placing heavyboxes onto pallets placed on the floor;

Employees were performing forceful fingertasks with their wrists in bent postureswhile pricing products at poorly designed

workstations.


15/15

Occupational Safety and

Health AdministrationU.S. Department of Laborwww.osha.gov

OSHAs role is to assure the safety and health ofAmericas workers by setting and enforcing stan-dards; providing training, outreach and education;establishing partnerships; and encouraging con-tinual improvement in workplace safety andhealth.

This informational booklet provides a generaloverview of a particular topic related to OSHAstandards. It does not alter or determine compli-ance responsibilities in OSHA standards or theOccupational Safety and Health Act of 1970.Because interpretations and enforcement policymay change over time, you should consult currentOSHA administrative interpretations and decisionsby the Occupational Safety and Health ReviewCommission and the Courts for additional guid-ance on OSHA compliance requirements.

This publication is in the public domain and maybe reproduced, fully or partially, without permis-sion. Source credit is requested but not required.

This information is available to sensory impairedindividuals upon request. Voice phone: (202) 693-1999; teletypewriter (TTY) number: (877) 889-5627.

Worker Safety Series - Warehousing.pdf

Documents

Transcript of Worker Safety Series - Warehousing.pdf