About this guide
Warehouses across the United States face new and unusual security challenges - but warehouse security plans have not kept pace, as the rise in injury and death statistics shows.
Worse, companies trying to keep up with e-commerce giants tend to make radical changes and expect security processes to catch up. But if a company does not have a safe warehouse, they are in danger of losing high-quality workers, facing huge lawsuits and fines, and losing their customer base.
In this guide, we will study practical ways to prioritize and improve warehouse security plans.
Today's warehouse security challenges
There are many reasons for the decline in warehouse safety, but low unemployment and the lack of trained workers are two examples. Other challenges include changes in workflow and workload, employee engagement, and casualties, whether due to unsafe working conditions, human error, or other reasons.
Warehouse casualties
Warehouse injuries and mortality are rising every year, which is a disturbing trend. According to the Bureau of labor statistics, more than 683000 employees work in some type of warehouse environment. These roles range from truck and tractor operators to material porters to ordering fillers. 11 workers were killed in 2015; In 2016, 16 warehouse workers died due to work injuries.
In 2019, the injury rate of employees in the transportation and storage industry in the United States was 4.4 per 100 full-time employees. The sector has the second highest recordable case rate among private enterprises, after agriculture, forestry, fisheries and hunting. In 2019, the death toll in transportation and storage industry was 914, of which truck transportation accounted for 617. The death toll in the industry in 2015 was 765, showing a worrying trend.
Talent shortage
Although casualties may still occur among properly trained and high-quality workers, the number of casualties is often small. Like many other services and trade industries, warehouse jobs are many, but there is little labor to fill them. The shortage of experienced workers throughout the supply chain leads to a higher incidence of accidents, injuries and deaths.
Talent shortage is the product of many factors. First, the retirement rate of baby boomers is high, and companies don't need to change their managers. In addition, fewer and fewer high school graduates and workers with college degrees choose warehousing and transportation as a long-term career, which means entry-level applicants but lack of middle managers.
Cost cutting measures have also worked. The actual demand for warehousing, coupled with the relatively low wages and job security of some companies, led to higher annual turnover. Due to the seasonal variation of workload, storage employs more temporary workers, contract workers and aging chemical workers than manufacturing and other industries. In addition, the company reduced the number of employees and training programs during the economic downturn, which further reduced their talent pool.
E-commerce boom
The shortage of talents is a key problem aggravating year by year. In the United States, the growth of e-commerce requires an increase of 452000 warehouse workers in 2018-19. The covid-19 pandemic and the shift in online shopping trends are likely to mean a larger number in 2021-22.
With the continuous outbreak of e-commerce, the business slowdown and layoffs of physical retailers have affected the safety of workers. As more and more people turn to the Internet to meet their shopping needs, physical stores are difficult to keep up. These companies usually have to lay off staff in all shifts, which can be a particularly dangerous proposal for backstage, inventory and warehouse workers.
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OSHA issues more warehouse safety conditions to enterprises
Without sufficient inventory and warehouse workers, the back room and warehouse will be filled with boxes of goods, creating dangerous working conditions that are prone to injury.
In a 2019 article, business insider discussed the massive overnight inventory and back office shift cuts in target stores across the United States. Target employees expressed concern that these layoffs would cause more injuries to workers at work.
In Idaho, OSHA cited storage and walkway violations at four dollar tree stores, resulting in fines of more than $800000. Physical stores are not the only stores that face possible fines and allegedly put employees in dangerous conditions.
Changing workflows and workloads
Even under safe conditions, working in the warehouse is still a hard work. Workers constantly stand, walk, bend, lift weights and work; Make it a demanding job. Workload requirements in the warehouse are also dynamic, changing every day or even every hour.
Environmental factors such as high or low temperature, noise level and insufficient light will also affect the health and safety of workers in the warehouse. These changing situations, if not managed properly, may have a negative impact on safety.
2020 OSHA warehouse violations list
Over the past few years, there has been an increase in OSHA violations, especially those leading to six figure fines. In 2020, general storage and storage facilities received 300 federal OSHA warnings:
● powered industrial forklift - fine $296349
● material handling – general – fine $120300
● maintenance, safeguard and operational functions of exit routes - US $32149 fine
● general – fine $44170
● hazard communication - fine $26319
● hazardous energy control (Loto) – US $91658 fine
● general purpose wiring methods, components and equipment - US $22254 fine
● OSHA general liability - fine $104848
● respiratory protection - fine $23707
The referenced company failed to maintain OSHA compliance in one or more of the above areas. The resulting unsafe conditions cause injury or unnecessary risk to employees.
Warehouse safety standards
Establishing general warehouse safety standards that can be fully applied is a way to improve working conditions. At present, the general industry standards are pieced together to manage the safety in the warehouse environment, but not all hazards, such as fever and ergonomic hazards, are included in the current standards executable in the warehouse industry.
The role of OSHA in warehouse safety
To help promote the safety of warehouse workers, the occupational safety and health administration has provided a manual on safety, worker safety series: warehousing. This publication covers the most common hazards in the warehouse environment. It covers specific areas of the warehouse, from the dock to the conveyor belt, and provides tips to reduce the hazards in these areas. The manual also contains thinksafety checklists, including:
● general safety: dock areas, floors and other areas, ventilation systems and staff procedures
● material handling: any loose and unpackaged materials, storage areas, appropriate lifting techniques
● hazard communication: hazardous materials training, procedures and documents
● forklift: training and maintenance
Other useful security related resources provided by OSHA include:
● OSHA standard training requirements
● recommended practices for safety and health plans
OSHA warehouse standard
In assessing the safety of properties and companies, OSHA recognizes 10 warehouse standards. These safety standards include:
● forklift
● hazard communication
● electrical and wiring methods
● electrical and system design
● protect floor and wall openings and holes
● exit
● mechanical power transmission
● respiratory protection
● lock out / tag out / loto
● portable fire extinguishers
PPE (personal protective equipment) required for warehouse
OSHA requires employers to provide appropriate PPE to all employees in the warehouse. Employers looking for comprehensive PPE guidelines can use OSHA's personal protective equipment manual. OSHA requires employers to conduct ongoing hazard assessments to determine what types of PPE are required. Each employer is also responsible for:
● provide employees with required PPE
● train employees to use and maintain PPE correctly
● maintain personal protective equipment and replace as needed
The employer is not solely responsible for the correct use of PPE. Employees must wear PPE correctly, attend training courses, take care of, clean and properly store PPE, and notify the supervisor when PPE needs to be replaced or repaired. Common types of PPE used in warehouses include:
● safety helmet
● high visibility jacket
● safety glasses or goggles
● safety boots with steel wrap
● work clothes
● safety gloves
Mandatory safety signs
Mandatory safety signs must also be posted in each warehouse. All OSHA signage guidelines can be found in 29 CFR 1910.145. The signage guide tells employers what type of signage they need, where it should be placed and what it should look like.
The safety signs in the warehouse are divided into several different categories: Notice, general safety, access, fire safety and non hazard. In these categories, the sign shall have one of three classification levels.
Danger signs warn of the most serious danger. Warning signs indicate areas where there may be a hazard but where caution is not required as in hazardous areas. Finally, warning signs highlight areas that may cause minor injury or damage but should still be taken seriously.
Here are some useful resources to help you identify the signage you need in your warehouse:
● graphic 名媛直播: five methods to meet the requirements of OSHA safety signs
● ID Tags: guidelines for warehouse marking
Training required for warehouse workers
Other OSHA requirements include mandatory training for employees. Training requirements for general industrial, maritime, construction, agricultural, and federal employee programs are listed in OSHA's OSHA standard training requirements manual. The company should consult the manual to understand which requirements apply to its warehouse and overall business. For additional training, employers can use OTI Education Center. These non-profit organizations are authorized by OSHA to provide occupational safety and health training for workers, supervisors and employers. OSHA also provides educational materials to supplement training, including:
● brochures and brochures
● situation statement
● online safety and health theme page
● posters
● online communication
Warehouse safety management
Warehouse safety begins with a reliable management plan, including training, regular meetings with employees and safety strategies.
How to conduct warehouse safety training for employees?
As mentioned earlier, trained and qualified workers are safer workers. Although employers cannot control the type of training employees bring to their jobs, they can determine that any continuous training is applicable, useful and comprehensive. For today's multi-ethnic workforce, it is particularly important to provide training in the main language spoken by workers.
When evaluating and considering what training programs to provide employees, look for programs that apply to all workers and those that contribute to more specific warehouse roles. Everyone should learn the correct procedures for dangerous material leakage, and only some workers who operate forklifts need detailed forklift operation training.
OSHA's hazard identification training tool helps companies identify hazards in their warehouses. Using this information, employers can develop and find the most needed training programs.
Test employees with quizzes to see what information they have and what needs more review.
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Theme of warehouse safety meeting
The extension of training and regular meetings are indispensable for putting safety in the eyes of employees.
Warehouse safety topics cover:
● personal protective equipment
● forklift
● corridor
● loading dock
● trolleys
● lifting platform
● hazardous substances
● conveyor
● material storage
● equipment charging station
● fire safety and evacuation plan
● medical emergencies
● Ergonomics
● heatstroke prevention
The above safety meetings can be obtained as a free template in safesite. To access them, create a free account or download the safesite app on Android or IOS. Then, search the meeting template library to find what you want. Next, edit it to suit the needs of your organization. Finally, use your mobile device to hold meetings, attend meetings, and record your meetings.
Warehouse safety list
Maintaining all safety requirements is a daunting task. Use the checklist to make sure nothing is missing. Here are some examples from our article on the basic warehouse list:
● worker safety series: Warehousing includes a safety checklist covering general safety, material handling, hazard communication and forklift safety.
● drill: means monthly inspection. This list covers general warehouse area, internal and external wharf, equipment, sanitation and general safety.
● forklifts: since forklifts are part of the daily work of warehouse workers, it is important that they are well maintained and workers receive appropriate training. Parts of this list can be used every day.
● ergonomics: protect employees' bodies by ensuring that they use appropriate ergonomics in their daily work.
Each of these templates can be used as safesite. To access them, create a free account or download the safesite app on Android or IOS. Then, search the template library to find the list you want. Next, edit it according to your organization's needs, or use the list as is and check it immediately with your mobile device.
Standard operating procedures
Each warehouse security plan shall also include standard operating procedures. These SOPs provide a detailed overview of how to perform various warehouse tasks and responsibilities so that everyone who needs to perform these operations can follow the same protocol. SOP should include all contents covered in safety checklist, training and emergency procedures.
Safety observation, inspection and audit
OSHA has more than 7 million workplaces under its jurisdiction and does not have the ability to inspect all workplaces unless unsafe conditions or reports of illness / injury occur.
Avoid OSHA inspections by maintaining compliance. Warehouse owners and managers should conduct their own audits and inspections. Basic high-level inspections should be conducted daily or weekly, while detailed audits should be conducted at least once a year.
Warehouse safety rules and tips
The following are warehouse safety tips covering different fields, which can help you start making your own safety management plan.
General / OSHA
● lock or block any open dock with ropes and chains where employees may fall 4 feet or more.
● all floors and aisles should be free of anything that employees may stumble or trip over.
● give employees sufficient rest time and assign them achievable and realistic goals.
● new employees should receive ergonomic training.
● the warehouse shall be well ventilated.
● employees should be trained to work in extremely hot or cold conditions.
● all facilities shall have lock out / tag out procedures.
● keep the emergency button or the pull rope of the conveyor belt at each employee workstation.
● guidance and training on how to deal with fires, natural disasters and other dangerous emergencies.
● conduct safety terminology and Terminology Training for all employees.
Stacking / loading / unloading
● stack the load directly and keep the items as uniform as possible.
● place heavier loads on lower shelves.
● eliminate tripping hazards in storage areas.
● store hazardous materials that may cause fire, explosion or pests in designated storage areas.
● maintain safe clearance for access using mechanical handling equipment.
● the central load shall be as close to the mast of the forklift as possible and centered on the fork.
● cross layer load during stacking for higher stability.
● separate incompatible items to maintain stable storage.
● paint walls or columns to show maximum stack height.
● observe height restrictions when stacking materials.
Forklift
● operators must be trained and licensed by the company.
● check the forklift before each use.
● be sure to check all directions before moving the forklift.
● always fasten your seat belt.
● only operate the forklift in a well lit area without any danger.
● during operation, no one other than the operator shall stand on any part of the forklift.
● workers who do not operate the forklift should always know the operating position of the forklift.
● do not overload the forklift or lift the load to an unsafe height.
● create a designated path for safe travel of forklifts.
● sound forklift horn at intersections, crosswalks and other busy areas.
Cold storage
● provide employees with appropriate cold environment work clothes.
● remove ice deposits regularly and keep all areas clean.
● install safety functions, such as doors that can be unlocked from the inside and alarms in case of locking.
● regularly check the health and physical fitness of employees to ensure that they can cope with the harsh cold storage.
● provide regular training on what to do in lock out or other types of emergencies.
Signs and tape
● create an organizational system that best suits your warehouse and label it accordingly.
● identify potential hazardous areas, such as docks, entrances and exits, and clearly mark emergency exits.
● follow the OSHA logo color guidelines: red indicates danger, yellow indicates warning, and orange indicates warning.
● all equipment (forklift, manual crane, etc.) shall be printed with operation instructions and danger warnings.
● the charging station shall be well labeled and contain instructions on the measures to be taken in case of fire in the area.
● when using motor machinery, use warning or danger tapes to temporarily isolate areas where pedestrians may be at risk.
Ergonomics / promotion skills
● use power equipment instead of manual lifting whenever possible.
● train workers when and how to use manual lifting equipment.
● ensure that all areas of the warehouse have appropriate ceiling lights.
● teach and enhance correct weightlifting techniques.
● always use your legs when lifting and keep your back in a natural position.
● test the load weight, size and volume before lifting to determine the best lifting method.
● if the load is too heavy or too large to lift manually, please ask for help.
● do not twist when loading; Move your foot in small steps to move the direction.
● ensure that workers have appropriate safety equipment, including gloves, safety glasses, safety helmets and steel toe boots.
● give injured employees sufficient time to rest and recover before resuming normal work activities.
Warehouse management solutions for security challenges
All of these tips and resources help solve general security problems in the warehouse. What will you do when you encounter special situations or particularly difficult problems?
Behavior based warehouse security plan
Behavior based security plan is a relatively new concept in the field of security and risk management. It first improves security by changing behavior. These schemes are the cooperation between employers and employees and require the cooperation of both parties.
Through BBS, you can observe the situation of employees under various working conditions. Employers then use this data to determine how they should train employees to react, behave or take different actions in a safe situation.
Work with HR department to develop safety related policies
Work with your human resources department to develop policies, expectations and accountability plans related to safe behavior. Incorporate safe behavior into your job description and leadership development plan.
Create a positive safety culture
Workplace safety should also be part of the corporate culture. From top management to employees, everyone needs to integrate into a safe atmosphere. The company can create a positive safety culture in the following ways:
Communication, communication, communication
Always maintain smooth communication channels between management and employees, colleagues and the company and the public. This transparent atmosphere ensures that everyone is on the same page in terms of security and can move towards a common goal. Open communication also ensures that problems can be solved quickly and effectively when they arise.
Talk about safety at every company meeting, mention it in employee newsletters and other publications, and provide a lot of training opportunities. When encouraged and expected to communicate, it can be more fully responsible.
Care about workers' welfare
Cultivating safe workers and a safe working environment begins with management and senior leaders caring for their workers and their well-being. This starts when the manager hires an employee and continues throughout the employee's stay in the company.
When employees feel that people in management positions really care about them, they usually perform better with better output. Employees who feel valued at work also tend to remain loyal to their employers.
Pay attention to dangerous behavior
Even if it is carried out in a joking or joking way, dangerous behavior is also a danger signal of other unsafe behaviors. If employers see workers involved in pranks, pranks, teasing and / or bullying, they should address the situation. These types of behaviors can lead to more serious unsafe behaviors and ignore your safety culture.
Reward safety
Another effective way to encourage positive workplace safety. Industry weekly offers several simple ways to reward safety, including:
● set reasonable and achievable long-term and short-term goals. Some examples include "reducing the minor injury rate by 10% next year" and "100% attending the next safety meeting".
● use recognition rewards and monetary and commodity rewards in combination with different types of programs.
● often publicly acknowledge workers' efforts. Seeing their colleagues work hard and receive rewards can motivate other employees. Recognize that positive behavior can also strengthen your safety culture.
● give frequent small rewards, not just big ones. This allows more people to be rewarded and makes workers more likely to want to be rewarded.
Invest in leadership development
The company can ensure the continuity of its safety culture by cultivating leaders who are proficient in these ideas and beliefs. Company leaders should invest in leadership development programs to train the company's next generation of leaders.
Even if these employees do not hold higher positions in the company, leadership development will give them a sense of ownership of the company and make them more likely to work hard and be loyal. When company leaders lead by example, it helps employees understand the importance of safety and why the company places it in such a high category.
conclusion
Creating a safe and efficient warehouse environment begins with a safety culture. Managers at all levels, especially executives and owners, should strengthen this culture.
Creating a safe work environment begins with a safety plan that covers all parts of the warehouse and applies to all employees. Owners and managers should expect to use time and money resources for security and be willing to include these costs in the overall budget.
Employers should always remember that safe employees are more efficient and more likely to remain loyal to the company. If employers take good care of their employees, their employees will take good care of their work.
