How do you design a warehouse layout that minimizes safety hazards and risks?

Space is ALWAYS better than lack of space. Make things react to you. DO NOT react to things. Companies that have had their facilities built 40+ years ago often run into space issues. Fork trucks are bigger, product quantities are larger, there are more workers. Business development is a war, not a battle. Fight for the future, not just today!

Remember, the goal is to create an environment that balances efficiency, safety, and adaptability. A well-structured, planned layout can boost operational efficiency and productivity while mitigating potential safety hazards.

Most importantly, with any racking systems, ensure you have protected areas experiencing non linear or high traffic (e.g. transfer aisles) with protection on legs, or go the whole hog and install crash barriers at aisle ends. The most important training area is making sure, for instance, trucks designated for an area, stay in that area. I once heard a thud at a client I was working with. The supervisor had suggested to a new operator "and you take it to despatch". What he meant was, deposit the pallet in the "despatch" P&D station. The VNA mast was about 3 foot higher than the door way to the despatch area. Be very cautious of what you say, and how it might be interpreted.

The 5S (or 6S) methodology that is Sort, Set in Order, Shine, Standardize, Sustain and Safety can also be used as an effective optimization tool for warehouses.

Ensuring proper ventilation is also a vital safety aspect in warehouse designs as poor ventilation can affect the health of employees. With proper ventilation, you can dilute or remove impurities and odours as well as dissipate excess heat. Stale air can also affect the integrity and quality of some stored products.

One solution that I know is particularly effective is using LED lights with DALI control. LED lights are known for their energy efficiency and longevity, which makes them a cost-effective choice in the long run. They provide bright, uniform light that can significantly reduce the risk of accidents caused by poor visibility. The addition of DALI control takes this a step further. With DALI, you can control each light individually, allowing for greater flexibility and customization. You can adjust the brightness of each light based on the time of day, the amount of natural light available, or the specific task at hand. This can further enhance visibility and reduce the strain on the eyes of your workers.

In my experience, repetitive use and lifting related injuries are less common than trips, slips, and strikes from objects. While training employees on proper ergonomics, lifting techniques, and stretching is important, instilling a strong culture of 5S and the importance of a clean warehouse is far more impactful. Floors that are free of debris, items in specific locations, and clear indicators of where to walk and work not only improve productivity but also reduce the amount of work-related injuries and time lost.

Accidents at the dock are common and have the highest possibility of being highly serious, even lethal. Do your personnel have proper ramps to transition materials in and out of trucks? Does your equipment become wet during stormy weather? Are you personnel at risk in hot weather conditions loading and unloading trailers and containers? Is there adequate lighting that reaches the end of 53' trailers? Do your personnel risk strain placing dock plates and/or levelers? If you have pit levelers, do your light weight personnel struggle to walk down mechanical levelers? Do you secure trailers, or are your personnel at risk of drivers leaving the dock mid-service? It is far too easy today to provide safe process and equipment.

Is your facility safe? Does your warehouse need an upgrade? We suggest the use of frame guards and aisle guards to protect your employees and investments. When you need safety guards or need to retrofit your business to increase flow and conveyance, be sure to contact us for a quick turnaround. WWW.S3INSTALL.COM ■+1 4169081039 ■ Info@s3install.com