Key Tips for Warehouse Safety
The number of warehouses in the US has grown rapidly in recent years. This growth reflects the increased demand for warehousing due to e-commerce and logistics. As of the first quarter of 2024, there were over 22,000 warehouses in the United States. This includes businesses in the private, local, and state governments.
Warehouses present a high-risk environment, with injury rates significantly exceeding national averages. According to The Bureau of Labor Statistics (BLS) the “incident rate” for warehouse injuries is 4.0 for every 100 workers, making warehouses one of the most dangerous work environments. And with more and more warehouses being built every day, the statistics are only getting worse.
A 2023 report by the U.S. Department of Labor showed that incidents nearly
doubled from 42,500 in 2016 to 80,500 in 2021
In January 2021, the U.S. Bureau of Labor Statistics reported more than 1.4 million workers in the warehousing and storage industry. Further, in 2022, fulfillment and distribution centers employed an estimated 1.8 million workers, up 37% since January 2020. And the hiring trend is supposed to continue.
These alarming statistics emphasize the critical need for enhanced safety measures.
OSHA Identifies the Main Safety Hazards in a Warehouse
Warehousing hazards are addressed in specific standards for general industry (29 CFR 1910).
The hazards vary widely and affect all employees as well as a variety of warehouse environments. From falling objects, to forklift mishaps, to improper PPE, these are some of the many hazards that can pose significant risks to workers.
Identifying these risks early and implementing warehouse safety guidelines and risk mitigation measures is crucial.
The main hazards include:
- Unsafe use of forklifts
- Improper stacking/storage of products
- Loading dock accidents and injuries
- Hazard communication
- Ergonomic issues such as safe lifting, and repetitive motion injuries
- Failure to use or have proper personal protective equipment (PPE)
- Failure to follow proper lockout/tagout procedures
- Inadequate fire safety provisions
Here is more information on some of the main warehouse safety hazards, such as forklift safety, material storage safety, and loading dock safety.
Forklift Safety
Forklifts are necessary for warehouse operations but pose significant risks if not operated correctly. Forklift operators require specific training and certification, and mandatory refresher courses to maintain competency. Safe forklift operation is critical in preventing accidents and injuries.
Materials Stacking/Storage Safety
Proper material handling, stacking, and storage is crucial in preventing injuries and fatalities from falling objects. This includes maintaining adequate safe clearances, using material handling equipment appropriately, and ensuring storage areas are organized and free from potential hazards.
Loading Dock Safety
With nearly 25% of warehouse injuries occurring in loading dock areas, loading docks pose significant risks, contributing to many workplace accidents. Falls from loading docks are one of the main risks and protection must be provided for heights of more than 4 feet, as specified in OSHA standard 29 CFR 1910.28.
Hazard Communication
Hazardous materials pose great risks in a warehouse environment. Educating workers about hazardous substances and their proper use and storage methods is crucial.
Proper labeling and storage are fundamental and must include a signal word, pictogram, hazard statement, and precautionary statements for the respective chemical.
Handling hazardous chemicals in warehouses requires strict adherence to OSHA’s Hazard Communication Standard (29 CFR 1910.1200). Also, maintaining and updating Safety Data Sheets (SDSs) is the employer’s responsibility.
Ergonomics and Safe Lifting Practices
OSHA does not have specific ergonomics standards for general industry. However, employers are still required under the General Duty Clause (Section 5(a)(1) of the OSH Act) to provide a safe workplace free from recognized hazards that could cause serious injury.
Smart lifting techniques, such as lifting within the power zone (from mid-thigh to mid-chest height), can help prevent a range of injuries. Mechanical devices like overhead hoists and forklifts can significantly reduce muscle stress during lifting.
This recap does not cover all the potential hazards in a warehouse and additional resources are available from OSHA.
Here is a great site to get you started.
https://www.osha.gov/warehousing/hazards-solutions
Do I Need a Warehouse Safety Checklist?
A comprehensive warehouse safety checklist is fundamental for addressing potential warehouse hazards, it also helps in maintaining a safe work environment and staying OSHA compliant.
OSHA does not have an official, one-size-fits-all warehouse safety checklist, but employers can create their own based on OSHA standards and create one that addresses the needs of their specific warehouse situation.
Regular inspections are vital in identifying and mitigating risk factors in warehouse operations. The warehouse safety checklist assists employers in systematically evaluating safety practices and making necessary improvements. Employers who use a warehouse checklist can enhance safety protocols and ensure compliance with OSHA standards.
Invest in Employee Training for Warehouse Safety
Employee training across all the potential risk and hazard areas can significantly enhance safety in a warehouse environment.
Prioritizing warehouse health and safety training ensures that employees are well-prepared to handle various safety hazards in their work environment.
There are many areas to consider in terms of warehouse training and overall safety training programs. Compliance Consultants, Inc. offers a variety of flexible Safety Training Programs to meet your employees’ needs.
Get Started Today with Compliance Consultants, Inc.
Regular OSHA inspections, proper equipment and PPE, fall protection, implementation of a warehouse safety checklist, and continuous employee training are all crucial elements for maintaining a safe warehouse environment.
By implementing these practices and utilizing tools like a comprehensive warehouse safety checklist, you can create a safer workplace that not only complies with OSHA standards but also protects the safety of workers.
Compliance Consultants, Inc. has trained professionals who are knowledgeable in all areas of warehouse safety and can assist you in your safety efforts.
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