Is your warehouse safe? Not likely, according to OSHA, who cite forklifts, electrical wiring methods and guarding floor and wall openings and holes among the hazards most frequently cited in warehouse operations.

For the more than 145,000 people who work in the 7,000+ warehouses across the United States, warehouses may be hazardous – but visual communications can play an important role generating greater awareness of these dangers.

Warehouses are often crowded with inventory stacked high on pallets and forklift trucks and foot traffic coming and going. When warehouses are disorganized, profitability suffers, which should be a huge concern.

Lisa Van Straten, vice president of Human Resources and Safety for WOW Logistics stated, “At WOW Logistics, warehousing is our business, but safety is our priority. In our hectic fast-paced world, it is easy to take short cuts to get a job done faster. We communicate to all our employees on a daily basis the importance that safety plays in creating a true efficient and effective operation for our clients. We train our employees to ‘think safety’ whether they are on a forklift, picking an order, or simply cleaning up.”

Often, placement of a few key signs can help. Forklifts and areas that surround loading docks present carbon monoxide hazards. Aisles should be kept clear.

About 100 employees die and 95,000 are injured each year while operating forklifts in all industries. Tip over accidents account for a significant percentage of these fatalities. Some forklift safety suggestions follow:
• Label forklifts with operating information
• Do not allow anyone under 18 years old to operate a forklift
• Properly maintain warehouse vehicles, including tires
• Do not handle loads heavier than the weight capacity of the forklift
• Label forklifts with inspection checklists
• Ensure adequate ventilation by opening doors or windows
• Provide covers or guardrails to protect workers from the hazards of open pits, tanks, vats and ditches
• Train employees on the hazards associated with combustion such as carbon monoxide

Used throughout plants and warehouses, falls from ladders are involved in 8% of occupational fatalities. Ladders slip, tip, slide and break. While human error causes most ladder falls, steps can be taken to minimize injuries.
• Place the ladder on an even, stable surface
• Clear obstructions within the path of the climb
• Verify the ladder’s maximum weight capacity
• Know the difference between a step ladder, a single ladder and an extension ladder and their appropriate applications

“We use labels of all shapes and sizes to designate areas for storage, high traffic areas, safety warnings and overall warehouse definitions. We have multiple communication boards showing warehouse performance, 5S and safety standards. The boards are easily accessible to all work areas and provide quick updates for all warehouse employees and management,” said Clay Fuller, Komatsu America Corp.

Careful consideration should be given to signs and labels in industrial environments as they may be exposed to harsh weather, chemical spills and forklift traffic.

Vinyl supplies are resistant to most environmental conditions, but in some cases specialized materials may be needed to attain optimum label performance. Innovative sign and label materials have been developed to make labeling faster and easier. One such solution is floor marking tape which is cost-effective, highly visible and withstands the abuse of warehouse traffic.

Warehouse floor marking creates better organization and safety on the inventory floor by clearly indicating where inventory should be stored, which aisles and pathways to keep clear and directing traffic flow. When people, vehicles and goods flow in an orderly fashion, profits are optimized.

But all floor marking tape is not created equal. Forklift trucks destroy inferior tape. For heavy duty facility traffic, DuraLabel has introduced a family of floor marking supplies that will take daily punishment from vehicles, enhancing safety communications and directing foot traffic.

Floor marking or floor striping is used to define loading and unloading areas for inventory, safety and hazard zones, wayfinding or directional communications. When spills occur, floor marking visually warns us to avoid wet and slippery floors which may cause injuries. Despite the name, floor marking is not limited to floors. Floor marking supplies line hand rails and step landings and outline doorways.

One indispensable tool for warehouse managers is a thermal transfer printer. With a thermal transfer printer, you can print signs and labels on polyesters, polyimides, reflective films and vinyls which are all resistant to chemicals, water, abrasion and UV. Where safety is critical, thermal printers produce labels with crisp, clear text and images – improving the clarity and readability of the label.

The DuraLabel Toro thermal transfer printer is one of the first totally stand-alone industrial label printers with a built-in keyboard and touch-screen. With free label creation software, OSHA-compliant templates and an extensive symbol library, Toro makes code compliance easy. Toro can run on battery power which means you can work outdoors or anywhere an outlet isn’t accessible.

Docks also present potential hazards. Injuries may occur when equipment is run off the dock or equipment strikes a person.

Here are a few possible preventatives:
• Operate equipment slowly on docks and dock plates
• Secure dock plates and verify the plate can safely support the load
• Keep clear of dock edges and never back up equipment to the dock’s edge
• Provide visual warnings, including appropriate signage near dock edges
• Make sure that dock ladders and stairs meet OSHA specifications
• Prohibit “dock jumping”

Manual lifting and handling may cause back injuries at warehouses. Consider the following:
• Provide ergonomics training and task-specific training
• Minimize the need for lifting by using good design and engineering techniques
• Obtain assistance with heavy objects
• Use signs and posters to remind workers of proper lifting techniques

Improperly stored materials may fall and injure warehouse workers. Warehouse managers are advised to:
• Stack loads evenly and straight
• Place heavier loads on lower or middle shelves
• Remove one object at a time from shelves
• Keep aisles and passageways clear and in good repair

Moving products on conveyors has its own set of potential hazards in the warehouse. Workers can be injured when they are caught in pinch points, ingoing nip points or in the conveyor system. It is advisable to:
• Inspect conveyors regularly
• Ensure that pinch points are adequately guarded and have appropriate warning labels and signs
• Provide proper lighting and working surfaces in the area surrounding the conveyor
• Keep clothing, fingers, hair and other body parts away from the conveyor
• Develop procedures for locking out conveyors

Inadequate fire safety provisions, improper use of lockout procedures and failure to wear personal protective equipment also create hazards in the warehouse environment. Discouraged? Don’t be. Follow these guidelines and suggestions and you can create a safer warehouse culture.

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