There’s really no such thing as downtime in a warehouse. When employees aren’t busy stocking materials, retrieving orders, and re-stocking, they are engaged in other important tasks. One such task, and a key to any successful warehouse operation, is maintaining an up-to-date inventory count. While technology can help complete inventory quicker, your people need to be hands-on to get the accurate data you need. And that means you need to pay special attention to fall safety during inventory, especially on elevated surfaces like mezzanines.
Best Practices for Keeping Workers Safe Doing Inventory
Like any other major operation, taking inventory has to be well thought out and planned in order to achieve a successful outcome. A written plan of action that details what each staff member’s responsibilities are for the inventory count is essential.
To address and improve fall safety during your inventory process, be sure to follow these important steps:
1.) Identify Fall Hazards in Your Warehouse
Start by assessing the hazardous areas where workers will be performing the inventory and consider what tasks they will need to execute. Some areas of fall risk in a warehouse are obvious. Others are not, but according to OSHA 1910.28, you have a duty to provide fall protection for your employees in all hazardous situations. Any time workers are exposed to an unprotected edge or side that is 4 feet or more above the previous level, a potential fall hazard exists, and compliant safety equipment is required.
Common warehouse fall safety hazards you want to be on the lookout for in preparation for inventory within your warehouse facility include:
- Stairwells – Uneven steps, debris or items on the stairs, inadequate lighting, and lack of handrails all present serious fall hazards to workers. The entrance to a stairwell can also pose a fall hazard if it is left exposed and unattended.
- Ladders – To reach elevated surfaces like a mezzanine, your employees may use a fixed ladder. During an inventory count, a portable ladder might also be used to reach certain areas. Regardless of the type, ladders pose a serious fall hazard for warehouse workers.
- Loading Docks – Busy warehouses and distribution centers have extremely busy loading docks. Potential fall hazards include the unprotected edge of the dock, ramps, and stairs. Inadequate lighting, loud noises, foot traffic, and equipment like forklifts make loading docks even more dangerous.
- Mezzanines – Warehouses need to take full advantage of every square inch of space and mezzanines are a great way to do that. However, unprotected sides of a mezzanine not only put workers at risk of falls, but it also presents a falling object hazard for employees below.
- Catwalks – Connecting mezzanines and other elevated areas, catwalks are an essential part of providing employees access to those hard-to-reach areas of a warehouse. But because of their height and limited walking/working area, these structures must also be properly outfitted with fall safety equipment.
- Above or Close to Machinery – Pay close attention to elevated areas that are above dangerous machinery and equipment, or which bring them close to moving mechanisms, extreme temperatures, powerful electric currents, etc. Falls and accidental contact with machinery can be extremely dangerous, and it’s your responsibility to prevent them.
- Uneven Floors – Speed is important when it comes to performing inventory in any warehouse setting. But, when employees are in a hurry, accidents are more likely to happen. That’s why it’s vital that you address even the smallest trip hazards and protect workers from them, so you don’t encounter a problem.
2.) Choose Appropriate OSHA Fall Protection Equipment
Understanding that a fall hazard exists is good, put it’s still just the beginning of the process. Once you know about the problem, you need to take action to minimize or eliminate fall hazards as employees perform their inventory checks. Before the inventory activity begins, a qualified safety expert should be enlisted to evaluate the current fall protection systems and to recommend new fall safety equipment such as:
- Guardrail Systems – The most common type of OSHA fall protection equipment is a safety railing or guardrail system. They’re ideal for a variety of applications including protecting elevated platforms, walkways, or uneven surfaces, as well as for guarding machinery and equipment.
- Industrial Swing Gates – While a guardrail will protect elevated edges, access is essential. Properly implemented self-closing industrial safety gates can provide OSHA-compliant fall protection without slowing workers down as they go about the inventory process. These can be used at the entrance to stairways, mezzanines, around loading docks, and in conjunction with guardrails all around your warehouse.
- Mezzanine Safety Gates – During inventory, there’s a lot more traffic than usual on your mezzanines. Protect the entrances to these elevated surfaces with mezzanine safety gates. These specially designed gates close automatically after a worker passes through to minimize fall hazards.
- Ladder Safety Systems – Fixed ladders are a serious fall hazard and need to be protected with a ladder safety system that includes a safety gate, carrier, safety sleeve, lanyard, connectors, and body harness. Keep in mind that ladder cages and wells are not ladder safety systems and do not meet OSHA regs.
- Personal Fall Protection Equipment – Passive fall protection such as railings and gates are good for many areas and activities. But when performing some inventory duties, your employees may need to use active fall protection devices. This may be the case where passive fall protection can’t be used, or you may opt to use a harness, lanyard, and lifeline as an additional form of fall protection.
- Employee Safety Training – No matter how much OSHA fall protection equipment you put in place, if your employees aren’t working safely, it’s a moot point. It’s absolutely essential that safety training takes place during the onboarding process as well as refresher training, such as right before taking inventory.
3.) Make Fall Safety a Priority in Your Warehouse and Throughout Your Company
While you need to evaluate your facility’s fall hazards and safety equipment when you’re performing inventory, the attention and commitment to safety need to start long before then. Creating and maintaining a culture of safety and regulatory compliance in your company is everyone’s responsibility, but it starts with leadership. Ensure that all levels of employees understand that safety is the top priority, and that failing to fulfill this responsibility jeopardizes employee morale and wellbeing, as well as the company’s financial survival.
4.) Choose an Expert Partner for OSHA-Compliant Fall Protection Solutions
Not sure what fall protection equipment and devices are right for your application? Do you need a new guardrail system or mezzanine safety gates, or is your safety railing and safety gate enough? Getting help and guidance from trusted experts is always a good idea.
When it comes to fall protection in your warehouse, you can’t afford to get it wrong. Not only does it put employees at risk; your organization may also face heavy fines and penalties if you’re not in compliance. Not to mention the fact that falls can disrupt productivity and possibly damage your company’s reputation. Contact the safety specialists at Fabenco today to speak to one of our qualified team members. We’ll help you determine what your warehouse’s hazards are, and what your best course of action is to keep your employees safe and your company OSHA-compliant.
