Don’t Let Your Warehouse Become a House of Cards: Your Safety Guide
Guest blog by MHI member Damotech
Imagine stepping into your bustling warehouse, where forklifts zip by, and employees are hard at work. The energy is high, but so is the risk. Maintaining a safe environment isn’t just about keeping operations smooth—it’s about protecting your people and assets.
That’s where rack safety comes in! Solid and secure racks are the backbone of any warehouse, but even the sturdiest rack can get damaged if not correctly cared for. Damaged or improperly maintained racks can pose a serious threat, jeopardizing the safety of your employees, potentially leading to lawsuits, and causing significant business disruptions. OSHA identifies rack collapse as a leading cause of warehouse accidents in the US, resulting in costs of an estimated $36 billion annually.
Here’s the good news: you can prevent all that by following a rack safety program! Think of it as a roadmap to keeping your warehouse safe and efficient. Let’s discuss why prioritizing rack safety is crucial and how you can establish a solid safety program to keep your warehouse running efficiently.
Why Rack Safety Matters
Why is rack safety so important? Let’s say a forklift bumps a rack, and a beam gets bent. That bent beam might not seem like a big deal initially, but it could lead to a bigger problem, like a whole shelf collapsing over time. That could injure someone, damage products, and shut down your warehouse for repairs. Not to mention the cost of replacing the damaged rack and other products.
However, with a rack safety program, you can catch these minor problems before they become big.
What exactly is a rack safety program?
Think of it like a game plan. It has a few key moves.
Regular inspections by your staff or a rack safety expert can help identify any damage before it becomes a safety hazard. Think of it as a preventative maintenance check for your warehouse, just like taking your car to the mechanic. Monthly inspections by your staff can catch minor problems before they escalate. During these inspections, they should be vigilant for issues like dents, cracks, signs of corrosion, compromised welds, detached braces, loose or missing anchors, and any missing load capacity labels.
In addition to monthly checks, a third-party expert should perform a deeper inspection once a year. They’re trained to spot hidden damage and use proven methods to assess your entire racking system. They can also ensure your racks meet safety standards and calculate safe weight limits for all your stored goods.
After an inspection, you need to understand what’s going on. Maybe a forklift bent a beam, or a brace is missing. The inspector’s report will help you figure this out. Once you know what’s wrong, it’s time to fix it! Sometimes, you might need to replace a damaged part. Other times, you can repair it with a special kit.
A good rack safety program also includes training for your staff. This training covers the fundamentals of racks, the risks associated with damaged or overloaded racks, and the relevant safety regulations. Your employees will learn how to spot potential hazards, use equipment safely, and what to do if they see something wrong with a rack. The more informed they are, the safer your warehouse will be.
However, the best way to deal with problems is to avoid them in the first place. That’s where rack protection comes in. Think of it like bumpers for your racks: it shields them from everyday bumps and scrapes caused by forklifts. These guards come in various forms, protecting uprights, aisle ends, walkways, and even building elements. They’re a smart investment, keeping your employees safe and saving you money on repairs and replacements in the long run.
Finally, a rack safety program can help you stay current with the latest regulations. Warehouse safety standards are constantly being updated, and a program can help you ensure you’re always meeting the requirements.
The Myths of a Rack Safety Program
Implementing a safety program might raise concerns about cost and time investment. Let’s address some of these misconceptions and highlight the long-term benefits that outweigh the initial investment.
Myth #1: It’s too expensive.
True, there’s a cost, but it’s way less than what happens if a rack fails. Imagine an accident—injuries, repairs, and a stopped warehouse cost a lot more! Regular checks and maintenance help prevent these problems and save you money in the long run.
Myth #2: It takes too much time.
A well-planned program can be quick and easy. Your staff can do monthly checks, and yearly expert inspections are short and don’t disrupt your work. In the end, you save time by avoiding accidents and repairs.
Myth #3: It only helps workers.
Everyone benefits from a strong safety program! It protects your employees, your inventory, and your profits. Following safety rules means you avoid fines and shows you care about a safe work environment. This can even lower your worker’s compensation costs and keep your employees happy.
The Benefits of a Rack Safety Program
Implementing a comprehensive rack safety program brings numerous benefits:
• Accident Prevention: Regular inspections and maintenance help prevent accidents before they happen.
• Cost Savings: Investing in safety can save money in the long run by reducing the need for costly repairs and avoiding fines.
• Employee Morale: A safe work environment boosts employee morale and productivity.
• Operational Efficiency: Well-maintained racks ensure smooth and efficient warehouse operations.
• Regulatory Compliance: Ensuring your warehouse meets safety regulations, such as those set by OSHA, reduces the risk of fines and legal liabilities. This demonstrates your commitment to a safe work environment and the long-term health of your warehouse infrastructure.
Conclusion: Invest in Peace of Mind, Invest in Rack Safety
By implementing a rack safety program, you’re not just protecting your employees, you’re making a smart business decision. Regular inspections and proper maintenance prevent costly accidents, minimize downtime, and ensure your warehouse operates efficiently. Plus, you’ll gain peace of mind knowing your facility adheres to safety regulations.
Don’t wait for an incident to occur. Partner with rack safety experts—they’ll be your trusted advisors, helping you establish a program that keeps your warehouse running smoothly and safely for years to come.
