Warehouse Safety: A Practical Guide to Preventing Warehouse Incidents and Injuries

Table of Contents......Page 5
List of Figures and Tables......Page 13
Foreword......Page 17
Preface......Page 19
About the Author......Page 23
Acknowledgements......Page 24
Disclaimer......Page 25
A NATIONAL CONCERN FOR SAFETY IN THE WORKPLACE......Page 27
WAREHOUSE SAFETY STUDY......Page 29
SAFETY NEEDS FOR WAREHOUSES......Page 31
OSHA CONSIDERATIONS......Page 34
REFERENCES......Page 35
DUPONT CORPORATION AS A LEADER......Page 37
UNSAFE CONDITIONS......Page 38
SAFETY ROLES FOR EVERYONE......Page 39
RATING SUPERVISORS' PERFORMANCE IN SAFETY......Page 40
USE OF THE RATING FORM......Page 41
ELEMENTS OF SUCCESSFUL SAFETY PROGRAMS......Page 44
DELIVERING THE PROGRAM TO EMPLOYEES......Page 48
MANAGEMENT RESPONSIBILITY......Page 49
Benefits of VPP......Page 51
The Application Process......Page 53
Site Document Review......Page 58
REFERENCES......Page 60
3 New Employee Orientation......Page 61
SUGGESTED DISCUSSION AND TOUR TOPICS......Page 62
ADDITIONAL PROGRAM ELEMENTS......Page 63
WAREHOUSE SAFETY RULES......Page 64
NEW EMPLOYEE ORIENTATION CHECKLIST......Page 66
REFERENCES......Page 70
PALLET SAFETY......Page 71
RACKING......Page 73
Additional information on racking......Page 76
MEZZANINE SAFETY......Page 79
SUMMARY......Page 80
REFERENCES......Page 81
FIRE STATISTICS......Page 83
WAREHOUSE FIRES......Page 84
UNDERSTANDING FIRE AND FIRE EXTINGUISHERS......Page 86
Fire Extinguishers......Page 87
SPRINKLER SYSTEMS......Page 93
FLAMMABLE AND COMBUSTIBLE LIQUIDS......Page 97
WAREHOUSE STORAGE......Page 99
Fire Considerations in High-Rack Storage......Page 100
SUMMARY......Page 101
REFERENCES......Page 103
6 Safeguarding of Hazards......Page 105
WHEEL CHOCKS1 TRAILER RESTRAINTS......Page 106
GUARDS FOR MOVING HAZARDS......Page 108
Conveyors......Page 109
Forklift Moving Parts......Page 110
FIXED LADDERS......Page 111
TRASH COMPACTORS......Page 112
SKYLIGHTS......Page 113
BARRIERS FOR GUARDING......Page 114
POWERED HAND TOOLS......Page 116
USE OF COLOR CODING......Page 117
REFERENCES......Page 118
7 Lockout/Tagout Procedures
......Page 119
Steps for Restart......Page 120
OSHA Requirements......Page 121
EXAMPLES OF LOTO IN WAREHOUSES......Page 123
TRAINING......Page 126
SUMMARY......Page 127
REFERENCES......Page 128
PRACTICAL HOUSEKEEPING TIPS......Page 129
BENEFITS OF GOOD HOUSEKEEPING......Page 133
SLIPS AND FALLS......Page 134
REFERENCES......Page 135
INJURY DATA......Page 137
SAFE DOCK DESIGN......Page 141
VEHICLE RESTRAINTS......Page 143
DOCK SAFEGUARDS......Page 146
REFERENCES......Page 148
OSHA STATISTICS......Page 153
TIPOVER......Page 155
Narrow-Aisle Trucks and Tipover......Page 157
FORKLIFT TRUCKS-GENERAL SAFETY GUIDELINES......Page 163
STABILITY OF POWERED INDUSTRIAL TRUCKS......Page 171
Stability Triangle......Page 172
Dynamic Stability......Page 174
FEATURES OF POWERED INDUSTRIAL TRUCKS......Page 175
Operator Training......Page 176
WALKIE TRUCKS......Page 179
While Operating a Walkie......Page 180
While At the Dock......Page 181
Elevators......Page 182
FINE-TUNING OPERATOR TRAINING......Page 183
OSHA CITATIONS......Page 185
Attachments Require Training......Page 186
WHEN FORKLIFTS MAKE THE HEADLINES......Page 187
PEDESTRIAN SAFETY......Page 188
Additional Pedestrian Safeguards......Page 191
Operator Guidelines......Page 192
REFERENCES......Page 193
Back Injuries......Page 195
Back Belts......Page 196
CONVEYOR SAFETY......Page 201
Conveyor Noise......Page 205
Crane Safety Guidelines......Page 206
HOISTS......Page 208
SUMMARY......Page 209
REFERENCES......Page 210
POWERED INDUSTRIAL TRUCKS......Page 211
Pre-Use Inspections......Page 212
FACILITY INSPECTIONS......Page 215
WAREHOUSE ITEMS TO INSPECT......Page 219
SAFETY AUDITS......Page 222
Audit Content......Page 224
When Audits Are Conducted......Page 226
SUMMARY......Page 227
REFERENCES......Page 229
UNDERSTANDING ERGONOMICS AND ITS COSTS......Page 231
BLS Statistics......Page 232
BASICS OF ERGONOMICS......Page 233
Carpal tunnel syndrome......Page 234
ERGONOMIC ISSUES-ARMS AND SHOULDERS......Page 235
ERGONOMIC ISSUES-THE BACK......Page 236
METHODS TO IMPROVE ERGONOMICS......Page 239
Powered Industrial Trucks......Page 241
Negative Ergonomic Factors......Page 242
ERGONOMICS IN THE OFFICE......Page 243
SUMMARY......Page 244
REFERENCES......Page 246
THE HAZARD COMMUNICATION STANDARD......Page 247
MATERIAL SAFETY DATA SHEETS (MSDS)......Page 248
PRODUCT WARNING LABELS......Page 250
EMPLOYEE TRAINING......Page 251
HANDLING AND STORAGE OF CHEMICALS......Page 252
EVIDENCE OF CO EXPOSURE......Page 254
Measurements and Guidelines......Page 256
REFERENCES......Page 257
TYPES OF EQUIPMENT......Page 259
HARD HATS......Page 260
EYE AND FACE PROTECTION......Page 262
SAFETY GOGGLES......Page 263
Face Shields......Page 266
Cutting Goggles/Welding Helmets......Page 267
GLOVES......Page 268
RESPIRATORY PROTECTION......Page 270
Written Program Requirements......Page 271
Respirator Selection......Page 272
New Filter Choices......Page 273
HEARING PROTECTION......Page 274
TYPES OF EQUIPMENT......Page 275
FALL ARREST SYSTEMS/FALL PROTECTION......Page 278
SUMMARY......Page 280
REFERENCES......Page 281
Work Interruption......Page 283
Contact......Page 284
CAUSES OF INJURIES......Page 286
Unsafe Acts......Page 287
UNSAFE CONDITIONS......Page 289
INJURY INVESTIGATION......Page 293
INCIDENT REPORTING......Page 298
REFERENCES......Page 301
17 Job Hazard Analysis......Page 303
DEFINING THE WORD "JOB"......Page 304
DEVELOPING A JHA LIST......Page 305
SELECTING THE JOB TO BE ANALYZED......Page 307
STARTING THE JHA PROCESS......Page 308
FORMS USED FOR JHA......Page 310
IDENTIFYING POTENTIAL HAZARDS OR INJURIES......Page 313
COMPLETING THE JHA......Page 314
TAKING THE PROGRAM FURTHER......Page 315
ECONOMIC CONSIDERATIONS FOR JHA......Page 316
SUMMARY......Page 317
REFERENCES......Page 318
18 Warehouse Emergencies......Page 319
WRITTEN PROGRAM......Page 320
REFERENCES......Page 324
ELECTRIC TRUCK BATTERIES......Page 325
Changing the battery......Page 330
GENERAL SAFETY GUIDELINES......Page 331
COMPRESSED NATURAL GAS (CNG)......Page 333
GASOLINE AND DIESEL FUELS......Page 335
SUMMARY......Page 336
REFERENCES......Page 337
Types of ladders......Page 339
INCENTIVE AND RECOGNITION PROGRAMS......Page 342
Confined Space Hazards......Page 344
Types of Hazards in Confined Spaces......Page 345
Flammability Testing for Confined Spaces......Page 346
Employee Training......Page 347
ELECTRICAL SAFETY......Page 348
Electrical Injuries......Page 349
Toxic Gases and Fumes......Page 350
General Safety Guidelines......Page 352
Torch-Cutting Operations......Page 353
Hot Work Permits......Page 354
JSO Benefits......Page 356
How JSO Works......Page 357
Key Points of JSO......Page 359
REFERENCES......Page 360
Appendix A......Page 363
Appendix B......Page 367
Glossary......Page 369
Index......Page 379