Risky Business?
In materials handling, a good safety program will lighten your load
By Barbara A Somervill -- Industrial Distribution, 2/1/1998
Pinched toes. Tipped shelving. Dropped loads. Repetitive stress injuries. Fork lift collisions. If you are in the materials handling game, these are just a few of the accidents and injuries that can put your top players on the bench.Can't happen in your business? Guess again. Workers' comp claims account for 50% of all medical care costs. Over $20 billion in annual compensation claims deal with repetitive stress injuries. Ouch!
There is a way to reduce on-the-job injuries: a well-constructed, well-managed safety program that starts from the top and works its way through your organization.
Most major insurance companies are more than willing to assist in developing and implementing a safety program. It is an economic necessity for keeping premiums under control and pay-offs at reasonable levels.
If your insurer won't help, try "The Rewards of Managing Risk: A Guide for Entrepreneurs and Managers," published by the Chubb Group of Insurance Companies. Get a free copy by calling 1-800-36CHUBB. Although this booklet is designed for small business use, the safety tips apply in any business where material is handled.
Management must establish best practices for safe materials handling. Says Thom Garrison, president, Garrison Service Company, "The culture of the company is improved when safety is a focus of the company, and that starts from the top down. Some companies are proactive and will deal with safety issues before an accident. However, many wait until an accident occurs before showing an interest. The liability of a lost life accident runs in the millions. How does that compare to the cost of a little training?"
Thomas Beach, Corporate Sales Manager, Handling Specialty Inc., agrees that "safety pays." He says, "The advantages of a thorough safety plan are two-fold. First, there's a reduction in lost time injuries. And second, there's a marked increase in worker morale."
Defining Problem Areas
Materials handling safety issues can be broken up into three basic categories: the materials themselves, moving the materials, and the people handling the materials.
Storing materials is a key element to warehouse safety. How are your materials stored?
Do you store hazardous or bio-hazard materials at any time? Are they clearly identified? Do all personnel understand the safety procedures involved in handling haz-mats? Do personnel understand the difference between acids, caustics, etc., and clean-up procedures? Do they know where to find MSDS (Material Safety Data Sheets) for guidance?
Is shelving or palletizing sufficient to hold the loads required? Is shelving properly anchored to walls and floors? If you are in an earthquake zone, does your shelf system meet requirements for earthquake safety? Says Mike Gorski, General Manager/Sales for Equipto, "There is a correct storage format, or mezzanine format for every situation. We depend on our sales staff to know what is required to create a safe warehouse environment. At the same time, installers subcontracting with Equipto are expected to undergo safety training. We try to cover the shelving/mezzanine safety issue from two sides."
Is personal protective equipment provided, used, maintained and accompanied by appropriate training? Do personnel working at heights wear safety harnesses?
Is waste material disposed of in a timely and safe manner, including broken or damaged cartons and broken containers?
Do you handle combustible materials? Are personnel trained on fire safety? Do you run fire safety drills?
"Many distributors pay employees by the pallet instead of by the hour," explains Garrison, whose company sells and services Toyota lifts. "While that increases productivity, it also increases the likelihood of accidents. Operators cut corners, speed through aisles, and frequent collisions or overturns result."
Perhaps the most popular or commonly used materials mover is a fork lift. Bob Koch, vice president of sales/marketing for Minnesota Supply Company, a distributor of Caterpillar lifts, claims safety is not a primary factor in purchasing a fork lift, because "buyers expect all lifts to meet ANSI standards on safety features: Overhead guards, load back rests, warning lights and alarms for back up, forward or both, and ergonomic seating. Safety is not a 'sale' feature because safety is a requirement."
Charles F. Haywood, president, Hyster New England, Inc., agrees that safety is in-built in lifts, but adds that "buyers should specify certain features, including lift height, lowered height, free lift, side shift, type of tires, seat restraints or belts, harness for narrow aisle equipment, strobe lights and back-up alarms, and a proper battery charger for electric trucks." He adds that the turning radius of the vehicle vs. the actual aisle width is an important consideration.
Attention managers: Safe equipment does not equal a safe environment! "It's surprising," says Thom Garrison, "how many initially safe lifts become unsafe because operators personalize their vehicles. They disconnect safety alarms and strobes, ignore use of safety belts or truck speed requirements."
That's where a close bond between maintenance and management comes in. Your maintenance department has scheduled maintenance checks every 200 hours for lifts. At that time, trucks should be checked for fluids, fuel supply, brakes and emergency hand brakes, back-up alarms and strobes, ties, forks, chains, and general mechanical condition. Mechanics should not only repair any safety device that has been disconnected, but report the infraction to the department supervisor.
"In addition," states Haywood, "there are types of equipment that can help ensure safe, productive operation of vehicles, like hour meters, chain gauges, fork gauges, battery discharge indicators, safety glasses and gloves, eye wash units, rack guards, and safety clothing."
"Visibility is also an issue," states Beach. He suggests employers use high-visibility warning stickers on lifts and apparatus to increase visibility.
There's more to moving materials, however, than fork lifts. Handling Specialty, Inc. makes lift equipment of all varieties that are used in all industries like automotive, assembly lines, aerospace - even theater productions. Says Beach, "We're in the business of moving heavy items around people, and conversely, people around heavy items."
W. F. Myette Corporation is also a work-station lift manufacturer which places an emphasis on ergonomics in lift design. The company produces Gorbel Work Station Cranes that allow 99 percent of a standard workforce to safely handle a two ton load. In a report appearing on their website, Myette states, "since physical strength becomes less of an issue with work station cranes, you can better utilize your work force."
For smaller tasks, like loading and unloading pallets, Bishamon offers the E Z Loader. Bishamon's director of marketing, Bob Clark, explains, "The pallet positioner keeps the load at the proper height for the worker. You can set the proper work height prior to starting work, then the E Z Loader adjusts to accommodate the employee. It turns so employees don't have to reach while loading or unloading a pallet. We've found the E Z Loader increases productivity while reducing repetitive stress injuries, back or lifting injuries and compensation claims."
The Human Element
No matter how good the equipment or how safe the layout of the warehouse or conveyor assembly, the critical factor in safety is people. At the top level, it's people implementing and following through with a safety plan. At the department level, it's people overseeing safe work habits and ensuring a safe work environment. At the maintenance level, it's people ensuring safe equipment.
The most significant avenue for safe materials handling lies with the operator. You can manage every hazard to the maximum, but if your people are not sufficiently trained you'll have accidents.
Says Haywood, "There are ways to ensure a safe environment, but the key is training your people. Use yellow safety striping to mark off walkways and pedestrian areas, and remind employees that pedestrian safety is dependent upon both the truck operator and the pedestrian."
Remind operators that the number one fatality accident is overturned vehicles. This is a result of turning too quickly. Adds Garrison, "Training is a key issue. People with less experience are at greater risk for an accident. Put your money in training. Make sure every lift has belts and that they're used. Enforce safety practices. Don't allow people to negate safety devices."
Since roughly 90% of accidents occur due to unsafe actions of people, make sure your people stay safety aware and safety alert. Don't allow lax safety issues to become lost-time safety issues.
Repetitive stress injuries and back injuries are common workers' compensation claims. Clark suggests training on proper lifting techniques, and "ensuring that employees have the proper equipment to reduce lift-related injuries."
Beach adds, "Don't wait until a safety issue forces safer practices. A customer had a situation where a man was crushed under a fork lift while doing a routine maintenance check. We produce a safe hydraulic lift designed for this purpose, and while we sold the customer one for each plant location, it was not the way we'd like to make a sale."
"The operator is responsible for safe operation, first and foremost," says Bob Koch. "They're the ones closest to the situation. Train, train, train, then empower your people to create a safe environment."
Koch adds, "The most significant story in safety is when there are 'no stories about safety' that I can tell."
One final word about safety: No one has ever found a better safety tool than common sense. Encourage your employees to use theirs!
EDITOR'S NOTE: Barbara Somer-vill is a freelance writer who lives in South Carolina. She can be reached at 864-963-8662.
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