How to minimise accidents or collisions during unloading in a warehouse?

1. Use only qualified forklift operators and handlers.

2. Use safety work wears like safety coverall, safety caps and gloves, safety shoes etc.

3. Check the forklift and other handling tools to be in safe and functional form before their use.

4. Observe all safety signs and follow only the marked safe movement track.

5. Do not overload than the prescribed load on pallet, tools, forklift and vehicle.

6. During goods movement no any unauthorized person should be around .

7. Do not leave the forklift unattended while loaded with goods.

8. There must always be adequate space for the smooth movement and for loading and off-loading of the goods from a forklift.

9. First Aid box should always be filled with the required material in case of emergency.

. Do not overexert onto the "load-handling workers" to work over time or overnight more than the fixed duty hours.

. Maintain periodic check log of all tools, goods' shelves, racks and vehicles.

. Off-load the material with extra care and do not exceed the prescribed limited height. 

. Strictly follow all warehouse management rules.

You have to find the best practice to avoid damaging goods and the responsibil superviser most find the solution.

Thanks for the Invitation !

 

Inside most warehouses or distribution centers there are six main areas:

1.      Receiving

2.      Putaway

3.      Pallet Storage

4.      Picking

5.      Sortation

6.      Shipping

 

Receiving - Common  hazard: trailer creep

Prevention:

1.      1. Wheel chocks – These wedge-shaped devices are placed in front of the rear wheels on a trailer to prevent it from moving while powered vehicles enter and exit during the  unloading process.  Wheel chocks can be effective when used  consistently and correctly.  However, since they require  workers to manual position them, they are often forgotten or simply not used at all.  Additionally, sloped docking areas with poor water drainage can flood during bad weather, further discouraging workers from going outside to place the chocks.

2.      Vehicle restraints – There are various types of vehicle restraints that can be utilized in place of traditional wheel chocks.  Most are activated by pushing a button located inside the docking area, while others are automatically activated once a trailer contacts a sensor on the restraint.  Typically, these restraints consist of a hook or handle that attaches to the rear impact guard on a trailer.  Once the restraint is activated, a trailer cannot move until the device is released. In addition to the actual restraining device, dock stations can now be equipped with warning lights.  These lights will flash green to let workers know when it is safe to enter the trailer and red to let them know if a trailer is not properly secured to the dock.

Putaway - Hazard: Product Congestion

Prevention:

1.      Floor Marking Tape – Although something as simple as floor tape might not seem like a critical piece of safety equipment, properly marked product staging  areas are the first step in keeping areas organized.  If employees know—and can  visually see—where to place pallets and boxes, aisles and walkways will stay clear of  miscellaneous items that can get in the way of moving vehicles and pedestrians.

2.      Forklift Training – Proper forklift training can go a long way in preventing accidents in busy putaway areas.  Surrounded by pallets, boxes, and people, an untrained forklift operator can easily cause a major accident.  It is important that drivers understand the necessary safety precautions when traveling in tight areas.  Forklift safety is an extensive topic, but the following are a few key tips to remember:

·        Always sound the horn when approaching corners, blind spots, or dark areas to notify pedestrians of your presence.

·        Keep the forks at least 6 inches off the floor while the vehicle is in motion so the forks do not catch on bumps or other low lying objects.

·        Ensure product load does not exceed the rated capacity of the vehicle or the load could fall, resulting in damaged product or injured bystanders.

·        Make sure any products being transported are well secured and stable to prevent the load from falling.

3.      Trash Receptacles – Without a doubt, all warehouses will have trash receptacles on hand; however, the key is to have plenty of them available and to have them well distributed throughout the facility.  Along those same lines, it is also important that the bins be emptied on a regular basis.  It is hard to keep the putaway area, or any area, clean and organized without a proper place to dispose of used packaged materials and other trash that can quickly pile up.

 

Pallet Storage

 

Common  hazard: damaged  pallets & racking

Prevention:

1.      Quality Pallets – The use of quality pallets might seem like common sense, but more often than not, damaged pallets are being used despite the safety hazards they present. A pallet being used for product storage should have all support legs intact and level, no serious deformities, and no major cracks or holes.

2.      Racking Guards – There are a variety of guards that can be put into place to protect the rack from damage that might occur when forklifts or other powered vehicles strike a column or shelf.  Bollard posts, upright column guards, and aisle protection beams can all be used to limit such damage.  With the extra protection and support, the racking structure is less likely to fall if something strikes it.

3.      Spacious Aisles – Possibly the first and easiest step in preventing damage to racking structures is to design a warehouse that has spacious aisles.  With plenty of room to turn around or simply perform necessary tasks, forklifts and other powered vehicles are less likely to strike the storage rack or the products it contains.

 

Picking

Common  hazard:repetitive  motion  during  manual  labor

 

Prevention: 

1.      Ergonomic workstations – The design and setup of an ergonomic workstation will help reduce employee strain and fatigue while facilitating task performance.  Creating an ergonomic workstation often includes modular  workbenches that can be customized to the job function as well as the size, strength, and range of motion of the worker.  Another way to provide extra comfort and support for employees is the use of ergonomic floor mats.  By placing these mats in areas where a lot of standing or walking occur, leg and back injuries can be reduced.

2.      Pallet handling devices - Pallet jacks, positioners, turn-tables, and lift tables, can all greatly reduce strain on  employees tasked with moving large amounts of product.  These devices help reduce and even eliminate lifting, bending, and stretching that can lead to injury.

3.      Employee education – A good education program can teach employees about proper lifting techniques, correct posture, load characteristics, and safe use of equipment.  By doing this, employers can take the first step in reducing repetitive motion and strain injuries.  If employees understand the actions needed to protect themselves, they can not only reduce injury, but also be more comfortable while working.

 

Sortation

Common  hazard:  powered conveyor

 

1.      Prevention: Conveyor Guards – To keep operators safe, all conveyors should have guards around moving parts, including gears, sprockets, belts, pulleys, and motors. There should also be some type of rail or netting to prevent product from falling over the edge of a conveyor, which would damage the product and possibly injure nearby workers.

2.      Training – All operators and maintenance personnel should be properly trained on

conveyor safety, including how to  operate, maintain, and  shut down the system  as needed. Important safety precautions   include:

·        Never operate a conveyor unless all necessary guarding and covers are in place.

·        Never wear loose clothing or jewelry that could get caught in moving parts, such as gears or rollers.  If performing maintenance, completely shut down electricity to the system and follow proper Lock Out/Tag Out procedures.

·        If performing maintenance, completely shut down electricity to the system and follow proper Lock Out/Tag Out procedures.

 

Shipping :

Common  hazard: human/robotic interaction :

 

PREVENTION:

1.      Barriers – There are a few different types of barriers that can be used to effectively block off a robotic cell, thus  preventing warehouse employees from entering while the robot is in motion.  Types of barriers include:

·        Interlocked Barriers are a form of cage equipped with gates containing interlocks. The

interlocks are designed so that all robotic operations are stopped if a gate is opened.  This ensures that no operators or other warehouse employees can go near the robotic work cell while it is in  motion.  Operations will not resume until the gate has been closed and the interlock reactivated.

·        Fixed Barriers are also a form of cage that does not allow entry into the robotic cell from any  direction without first unlocking a section of the fencing.  However, fixed barriers require tools in order to be opened and operations are not automatically stopped when this occurs. Awareness Barriers are comprised of railing or suspended chain and do not fully block the area surrounding a robot.  The purpose of these barriers is to define a safety perimeter in which workers should be aware of and remain outside of unless maintenance is being done.

 

2.      Presence-sensing Devices – The two most common presence detectors used for robotics safety are pressure mats and light curtains. Each of these devices are capable of detecting a person if he or she steps within a dangerous area near a robotic work cell.

 

Impact or collision

I'd like to add to my colleagues that Color coding for the areas, team members, walls, pallets, forklifts and floor Clear pass ways Verified trainings Continuous monitoring and improvement

The question has been answered by other esteemed members here , excellent informative answers ,

i would like to add Gemba Walks , spaghetti diagrams, kaizen , and warehousing movement mapping as tools to initiate the various  suggestions given below. Use of flow charts/movement charts and safety images for better and continous reminder.

After a kaizen event on the warehouse about accidents , a benchmark / KPI chart should be created and continous improvement be developed as a culture of the warehouse.

I am completely agree with Mr. Arif Mahmood. There are some standard rules and regulations for handling materials during both loading and unloading. Besides that usage of Forklift also helps in managing the inventory properly. Implementation of Factory EHS regulations helps in reducing accidents or collisions during unloading of materials at Warehouse.

In order to minimize accidents during loading & unloading is to apply safety procedures and have separate entrances for loading and unloading. make sure that the ramps of the loading & unloading are about the same hight of the cargo surface of the vehicle/truck/trailor for easy loading and unloading and to allow forklift easy access in and out of the container. And of coarse have as minimum laborers as needed in loading / offloading area with the warehouse keeper monitoring the movements of laborers as well as the equipments. 

Safety first. Correct wearing - forklifts in good condition - weight no over 75% of capacity. Good safety sings. Operator Training and Involvement. Continuous Improvement of Process. Correct Material Handling Equipment. Reducing Manual Touch Points. Making the Decision to Move Forward.

1.  Loading areas should always have good lighting. They should also be away from both vehicles and pedestrians.2.  Loading areas should be firm, flat and free from potholes and other obstructions that may cause slips or trips. 3.  Inspect the vehicle and make sure that horns, reflectors, lights and other safety features are in good condition. 4.  Provide guards for dangerous parts of the vehicle such as chain drives, power take-off and exposed exhaust pipes. 5.  Before loading transport, ensure that the vehicle is braked and stabilized. 6.  Clean off first any junk or loose materials (crates, cables, wires, chains, and bins) in the vehicle before loading tools or equipment. 7.  A rule of thumb when securing cargo in the vehicle: one tie-down must be used for every ten feet of cargo. Make sure, though, to use at least two tie-downs for any cargo regardless of its length. 8.  Use a red flag to mark loads that extend more than three feet beyond the body of the vehicle. When transporting cargo at night, use a red light instead. 9.  Use at least 4 binders for loads like pipes and logs that are 27 feet long. Ensure that the spacing between binders is equal. 10.  Never load unsecured items on the backseat or rear window deck of the vehicle. This can cause the load to hit passengers or the driver when the vehicle comes to a sudden stop. 11.  As much as possible, use a compartment or tool box to keep small items secure in a vehicle. If this is not feasible, use a tarp to cover the small items, making sure that it is securely tied down with ropes or straps. 12.  When on the road, stop frequently to check your cargo. This is all the more necessary when traveling long distances.

To minimize accidents in the warehouse, one has to sensitize the warehouse teams of the importance of safe handling procedures. Ensure that you have a warehouse safety policy in place. Also, make sure that you plan every job before actually executing it. If it involves heavy lifting, plan for the lift and make all the machines involved ready by checking them with a pm checklist. Ensure that you notify or cordon off offloading areas to keep unauthorized/uncontrolled movement at the offloading areas. Also, ensure that all visitors undergo an induction training on the safety procedures and that they are made aware of the safety signs at the warehouse. Last but not least, hold frequent/periodic safety toolbox talks with warehouse staff and the offloading teams.