How can you design a safer warehouse?

In the organization of work in the warehouse space, one of the main focuses from the point of view of safety is traffic flows and, if possible, avoiding their crossing. In all cases, pedestrian paths must be protected with physical protectors, marked and indicated. In addition to light and sound signaling, transport and lifting equipment should be equipped with a pedestrian detection system.

I actually miss in the article Risk assessment of current and future activities in the given layout/area to develop. Identify all loading/unloading points - current and future, of all goods, raw materials, finished product, waste etc. consider optimizing workflows and traffic flows towards less / no pedestrian in these.

Not all warehousing uses forklifts to store their wares. Care needs to be used to ensure items places above are secured with plastic wrap or are banded together. Also keeping heavy items off the top shelves can be advantageous to avoid injuries. For our team communication is key and training our new team members is a a constant reminder that missing important steps can be hazardous. A place for everything and everything in its place philosophy goes a long way to ensure our successes...

It is important to optimize the layout and space of the warehouse before designing a safer warehouse. Ideally, a layout should ensure smooth traffic flow, adequate lighting, and easy access to emergency exits and fire extinguishers

In planning and designing the layout, consider what access is required to allow safe maintenance and repair; design in space and routes to safely remove plant / equipment for planned renewal, and have an idea how you would remove a large/complex piece of equipment if you had to when it breaks long before expected. Don't expect people who need to carry out planned maintenance on the roof (either outside or inside) to have to climb ladders to do so

In warehouses we are still far from the levels of maintenance that you can find in an industrial site, and this is essential for the life of equipments but also for safety. This topic is becoming obvious for logistic automation, where robots are involved, but it is as important when you use conventional equipment such as lifttrucks, racking, or cranes. And as it is mentioned below, it is not only a matter of norms and rules, but most of internal culture in every firm.

Consider the fact that in a modern warehouse, automation, Automated warehouse systems, AGV, robotics etc actually turn safety from 100% pure logistics flows safety into machine safety, guarding, etc. Powered pallet trucks and FLTs give way to machine, which in majority of cases will be new new to people designing, managing, operating these areas. New to contractors, truck drivers, third parties. As such maintenance and automation expertise are a must.

Equipamentos e Manutenção: Utilize equipamentos adequados e mantenha-os em boas condições. Isso inclui desde empilhadeiras até equipamentos de proteção individual. A manutenção regular previne acidentes.

Priorizar equipamentos munidos de tecnologias de sinalização, sensores e controle nas operações, é crucial para um armazém mais seguro, sendo que, o fator humano, no caso, operadores de máquinas e equipamentos, e demais envolvidos na atividade, devem estar em inteira sintonia quanto ao planejamento da atividade, prezando pela comunicação assertiva e controle prévio à possíveis desvios.

Making a safer warehouse is much dependent on the selection of machinery & automation. It needs to be carefully assessed that the machines used should be as per load capacities & should have a preventive maintenance plan on hand. A preventive maintenance schedule should also be followed as per plan.

A safe warehouse design should prioritize efficiency, clear signage, proper lighting, safety equipment, fire prevention, emergency preparedness, regular maintenance, training, security measures, and continuous improvement. It should be organized to minimize hazards, provide comprehensive training, and implement security measures to prevent theft and unauthorized access.

Consider physical areas capacity while configuring operations queuing algorithms set by procedures or used in your WMS - which units and when exactly will get their commands at the shared working area. Not only mileage shortening is the reason for deliberate separation of material and personnel flows, but operation safety is a significant purpose as well. The safest yet effective method may differ from the fastest.

Removing paper work and physical documents handover to create areas free of pedestrian that gives opportunities for improving loading productivity and organization.

SOPs for warehousing should reflect on the three key functions of a warehouse ie Receiving, Storing and Dispatching/Shipping. From these key functions other minor functions that create these main ones can be documented too like assembly, packaging etc.

Create regular employee safety training program, especially on the use of warehouse equipment and their maintenance. You cannot afford to ignore the concept of Theory X and Theory Y in terms of an employee's response and adherence to workplace safety SOPs. The cost of a workplace injury suit is higher than a simple regular workplace safety training program

In addition, fostering a culture of safety among warehouse staff is paramount. A culture of safety goes beyond rules and regulations; it instills a mindset where every employee prioritizes safety as an integral part of their daily work. Encourage open communication among your team members, where they feel comfortable reporting near misses or potential hazards without fear of reprisal. Recognize and reward safe behaviors to incentivize a proactive approach to safety. By promoting a safety-conscious culture, you not only reduce accidents but also boost morale and productivity among your workforce.

I have found that training is one of the most steps an organization can take in preventing loss in a warehouse. All to often the need for updated training is overlooked due the idea that "It's just a warehouse. What could happen?" that is held by upper level leaders that are looking to cut cost. If education is not a priority I hope your workmans comp insurance is up to date.

Training & education is the most critical part for warehouse safety. People should be frequently given training related to safety & should be encouraged to participate in various knowledge sharing activities to incidents or learning.

Treinamento e Educação: Proporcione treinamento regular aos funcionários sobre práticas de trabalho seguras, uso de equipamentos e procedimentos de emergência. Uma equipe bem treinada é fundamental para um ambiente de trabalho seguro.

Always keep the lines of communication open between management, employees and the company to the public. This transparent atmosphere assures that everyone is on the same page safety-wise and can move toward common goals. Open communication also assures that when problems do arise, they can be solved quickly and efficiently.

Cultura e Comunicação: Fomente uma cultura de segurança onde os trabalhadores se sintam responsáveis e capacitados para agir de maneira segura. A comunicação aberta sobre questões de segurança é essencial.

I think this is by far the a critical part not only with designing a warehouse but all operational infrastructures. It sounds played out but empowerment is key. We should lead by example. Attitudes and efforts trickle downhill. I strongly believe It is the sole responsibility of company management to set the firm’s tone, culture and expectations. Employees on the floor live and breathe losses and wins on a daily basis.

Including all workforce from the warehouses to contribute to safety discussions. Is a fantastic way to build positive culture within the team. It also aids with building policies and procedures that will be actioned by the team as they have ownership of them and fully embed them into their working practices.

Communication is everything from the part time workers to the office staff to the supervisors and managers It does not cost much to speak to your staff every day and make sure they are ok Staff meetings every morning are important to let everybody know what is going on and how the company is progressing and when staff complete courses they should be commended and encouraged to keep training up to date and that goes for all staff from management to the shop floor

Seems to me that many observations are not design related. Architects, m & e design engineers, fire engineers, etc a have responsibility for designing with safety in mind. Access, egress, space for ongoing maintenance, maintenance free equipment, are amounst a wide range of key aspects. Training, although very important is not specifically a design issue. Design to meet building regulation and standards. Design to meet health and safety standards. Complete design risk assessments at each stage of design. Consider the principles of prevention. Consider Fault Tree Analysis and design with potential failures in mind. Just a few thoughts....

In addition, it's crucial to incorporate sustainability practices into your design. A sustainable warehouse not only benefits the environment but also contributes to long-term cost savings and a positive brand image. Consider using energy-efficient lighting systems and natural ventilation to reduce energy consumption. Integrate eco-friendly materials in your shelving and racking systems, and explore the use of solar panels or other renewable energy sources to power your warehouse. Implementing sustainable practices not only aligns with global environmental goals but can also attract eco-conscious customers and partners.

A warehouse is a place where you keep anything. For designing the warehouse, you must understand the space and product specifications especially dimensions and nature. Basic fundamentals are considered to design the warehouse as under: Capacity Easy access Flow Identification Safety Storage is made considering techniques as under: High frequency and Low frequency Heavy and light weight Fragile items etc During operation you must realise your available resources to make your warehouse effective and modernized.

Designing a safer warehouse involves several key considerations: 1. Layout and Flow 2. Safety Signage 3. Adequate Lighting 4. Fire Safety 5. Storage 6. Forklift Safety 7. Equipment Maintenance 8. Emergency Response 9. Personal Protective Equipment 10. Training 11. Security 12. Material Handling 13. Regular Audits 14. Compliance 15. Employee Involvement 16. Continuous Improvement

Before jumping in the warehouse and thinking about yellow helmets, we need to think about: 1. What commodity do we want to store/manipulate in our warehouse? It's not the same as building a dry warehouse or a frozen commodity warehouse. ADR warehouse requires an additional set of safety measures deepening the commodity class. 2. Environmental risks depending on storage location can contribute a lot to general operational safety once the storage is running. 2. Basic logistics planning data will give us a clear guideline about capacity, labor, machinery, and storage technology that needs to be implemented. 3. Protocols for escalations and deescalations in emergency situations. Common sense does not mean common practice!