warehouse safety case study

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The Dos and Don’ts of Warehouse Safety: 3 Case Studies and Simple Tips to Avoid Accidents

September 13, 2017

Warehouse Operations

“The fatal injury rate for the warehousing industry is higher than the national average for all industries.” – OSHA

Inadequate training, equipment mishandling, extreme heat. All of these factors can lead to fatal accidents that make up the annual statistics on warehouse injuries – about five injuries per 100 workers in 2015, according to the Bureau of Labor Statistics .

Even though it may not seem like much, a little preparation goes a long way in warehouse safety. Because warehouse workers constantly work with or around heavy equipment and machines, it’s important to provide proper training for all workers – including temporary hires – and maintain optimal working conditions that don’t compromise their health.

Not following safety standards can result in fatal injuries, which comprised at least 10 cases a year between 2012-2015. To avoid such incidents, it’s essential to establish a safe working environment with good training, sufficient ventilation and regular breaks.

Below are three case studies and key takeaways for avoiding preventable accidents.

Provide Proper Training for Heavy Machinery

One of the most unfortunate causes of workplace injuries is inadequate training. When it comes to temporary workers operating heavy machinery, training becomes even more lax and directly results in accidents, particularly in industrial warehouses or manufacturing plants where these equipments are commonly used.

When companies put profit ahead of people and take advantage of temp workers by foregoing the proper training provided to full-time employees, injuries increase because workers don’t know how to handle potentially dangerous equipment. In an industry where 20,000 injuries occur a year due to forklifts alone, this is a problem.

Case Study: The Tribe

In the case of the Tribe , a worker was killed at a hummus plant because he hadn’t been trained on the “lock out/tag out” procedure which shuts down the machine before cleaning the plant. This happened despite a previous OSHA report saying that inadequate safety standards in this area meant “ the probability that a fatality could occur is likely certain within a year’s timeframe.”

The report also stated that the company knew about its deficiencies in safety, yet decided not to change its policies because it would cost too much. Following the death of Daniel Collazo, Tribe paid a $540,000 fine and changed its safety practices.

In 2013, ProPublica found that the rate of injury for temp workers was much higher across five states. Though training temp workers might seem like a waste of time due to their temporary presence, it’s a non-negotiable part of warehouse safety standards. Proper training for all workers increases safety, as well as the likelihood that the workers can return the following season without having to be trained again.

Prepare in Advance of Summer Heat Waves

Some warehouses are located in climates prone to extreme heat. When workers spend all day in an enclosed space with great physical exertion, this can create hazardous conditions. Workers in these environments are in danger of passing out from overheating or even worse.

Case Study: Amazon

In 2015, the Morning Call exposed conditions at an Amazon warehouse in Lehigh Valley, PA, where workers frequently suffered from overheating during summer heat waves, with temperatures in the warehouse exceeding 100 degrees.

A doctor treating these patients reported an “unsafe environment,” while workers revealed that the common practice of leaving dock doors open to circulate fresh air was not observed because the company was worried about theft. After federal regulators got involved, Amazon changed its policies to address these issues.

The combination of heat, lack of policy to combat temperatures and the pressure on workers to work at a certain rate or receive penalties that could get them fired resulted in a subpar working environment that led to workers being burned out and injured.

Proper ventilation and policies set up in advance of the summer could have prevented many of these emergency room injuries, as well as filed complaints and the involvement of OSHA leading to media exposés. Common sense measures to combat heat inside warehouses should always be included in safety regulations.

Implement Regular Breaks and Avoid Mandatory Overtime

Warehouse workers may be used to long shifts, but without frequent breaks, accidents are more likely to occur. In fact, studies have linked workplace injuries and mistakes to overwork during the previous week. Mistakes in a warehouse can be costly and have severe consequences, making it even more necessary to avoid overworking workers.

Case Study: ASOS

Because warehouses are vast by nature, sufficient breaks are important not just for physical and mental reasons but also due to the time it takes to get from one place to another. In an extreme case in the UK, workers at an ASOS warehouse complained that the breaks didn’t allow them enough time to get to the toilets and back, forcing workers to use water fountains.

When coupled with policies such as Amazon’s mandatory overtime , which requires workers to commit to long shifts or risk losing their jobs, insufficient breaks risk workers’ healths and affect productivity for the warehouse in the long run. Research suggests that overtime in particular is not only ineffective but costs companies unnecessary money.

Staying away from stringent overtime policies and providing sufficient breaks for all workers ensures a safer working environment, reduces accidents and increases productivity.

Making Safety a Top Priority

The above case studies show the results of inadequate training, preparation and policy that reveals how companies that prioritize profits can cost workers their health and even lives.

Safety should always be a top priority for warehouse managers to prevent workplace accidents. In an environment where heavy equipment and machines are used on a daily basis, managers need to observe constant vigilance and proper training for all workers to prevent accidents that are avoidable.

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• Warehouse Safety Case Study: How Modular Booths Contribute to a Safe Work Environment

Ensuring warehouse safety is paramount for fostering a safe work environment. The significance of robust safety measures cannot be overstated in this dynamic landscape. Warehouses, often characterized by high-paced activities, heavy machinery, and diverse tasks, require meticulous attention to safety protocols to prevent accidents and enhance overall productivity.

One integral component of warehouse safety is the strategic deployment of modular booths . These designated spaces are pivotal in mitigating potential risks, offering a centralized point for monitoring, communication, and emergency response.

This article dives into the many reasons why modular booths are essential to overall warehouse safety.

Why Warehouse Safety is Important?

Warehouse safety is a paramount concern in industrial settings, encompassing a comprehensive approach to preventing accidents, minimizing injuries, and safeguarding against property damage. Establishing robust safety protocols is not just a regulatory requirement but a fundamental necessity. Here’s why:

• Prevents Accidents: Booths prevent warehouse accidents by serving as vigilant surveillance points equipped with advanced technology. With a bird’s-eye view of operations, booth personnel can swiftly identify potential hazards and unsafe practices with a bird’s-eye view of operations. These booths are also immediate emergency response hubs strategically positioned for rapid intervention during critical incidents. By facilitating quick communication, monitoring, and proactive response, booths contribute significantly to accident prevention in warehouse environments.
• Minimizes Injuries: Booths minimize injuries in warehouses by serving as centralized control centers. Equipped with advanced surveillance and communication tools, they enable proactive monitoring, timely intervention, and effective enforcement of safety protocols. The strategically placed booths enhance visibility and communication, contributing to a safer warehouse environment and minimizing the risk of injuries.
• Protects Property: Booths realistically protect warehouse property by serving as vigilant observation points equipped with advanced surveillance. Positioned strategically, they deter potential threats, promptly detect and respond to security issues, and contribute to a proactive security posture, safeguarding valuable assets.

Key Elements of a Safe Work Environment:

In the context of warehouse safety, booths play a crucial role. They are part of a comprehensive approach that forms a solid framework to protect staff safety and maintain smooth operational processes.

• Training and Education: Regular training sessions for employees on safety protocols, emergency procedures, and equipment operation.
• Clear Communication: Well-defined communication channels, including signage and visual cues, ensure everyone in the warehouse knows potential hazards.
• Proper Equipment Usage: Enforcing guidelines for correctly using machinery, tools, and equipment, coupled with routine maintenance and inspections.
• Ergonomic Design: Designing workspaces with ergonomic principles reduces physical strain and creates a comfortable and safe environment for employees.
• Emergency Preparedness: Developing and regularly practicing emergency response plans, including evacuation procedures and first aid training.
• Continuous Improvement: Regular assessments and feedback mechanisms to identify potential safety hazards and implement improvements.
• Modular Booths for Safety: Integration of modular safety booths to provide centralized points for monitoring, communication, and emergency response.

Prioritizing warehouse safety is essential for protecting workers, securing assets, and ensuring efficient warehouse operations. Focusing on prevention, employee education, and continuous improvement helps build a strong safety culture, benefiting both staff and the overall business.

Next, we’ll delve into the specific role of booth design in warehouse safety, exploring how it contributes to creating a safer and more effective work environment.

Role of Booth Design in Warehouse Safety

Warehouses are dynamic environments where safety is paramount, and the strategic integration of booths plays a pivotal role in fortifying safety measures. These modular structures serve as multifunctional assets, contributing significantly to the overall safety infrastructure of the warehouse.

Here’s we’ll discuss the importance of booth design and how a good modular booth design can help create a safe work environment in a warehouse:

• Control Centers: Proper modular booth design allows safety booths to act as centralized control centers, offering a designated space for monitoring and managing various safety aspects within the warehouse. Equipped with technology such as surveillance systems and communication tools, these booths provide real-time insights into the operational landscape, enabling swift responses to potential hazards.
• Observation Points: With strategic modular booth design and placement across the warehouse, safety booths can be placed on raised platforms to serve as elevated observation points, offering a comprehensive view of activities on the floor. From these vantage points, personnel within the booths can identify potential risks, monitor traffic patterns, and ensure that safety protocols are being adhered to by workers and machinery.
• Communication Hubs: Safety booths function as communication hubs, facilitating the seamless flow of information related to safety protocols, emergency procedures, and real-time updates. Equipped with two-way communication systems, booths enable quick and effective communication between personnel on the floor, management, and emergency response teams, fostering a coordinated approach to safety.
• Monitoring Safety Protocols: These booths contribute to continuously monitoring safety protocols by serving as a centralized location for accessing data from surveillance systems, sensors, and other monitoring devices. Personnel within the booths can promptly identify deviations from established safety norms and initiate immediate responses, preventing potential accidents and ensuring a proactive approach to safety management.
• Integration of Automated Systems: Incorporating automated safety systems within booths, such as fire suppression systems and access controls, enhances the speed and precision of safety responses. These systems can be remotely monitored and controlled from safety booths, allowing for rapid deployment of safety measures in emergencies.
• Floor Operations Oversight Hub: Placing workspaces, including managerial offices, directly on the warehouse floor provides immediate oversight of daily operations. Managers can observe activities in real-time, allowing them to promptly identify and respond to safety concerns or deviations from established protocols. This proximity enables quicker decision-making and intervention, contributing to a more responsive and agile safety management approach.
• Warehouse Collaboration Center: Integrating workspaces on the warehouse floor fosters enhanced communication and engagement between management and the workforce. With managers physically present in the operational environment, there is a more direct and open line of communication. Employees feel empowered to share safety-related feedback, report concerns, and seek guidance, creating a collaborative atmosphere that strengthens the overall safety culture within the warehouse.

Case Study: Implementation of Booths for Safety Enhancement

Ensuring employee safety became paramount in a bustling distribution center handling a diverse range of products. This case study delves into the practical challenges faced in daily operations, the tailored solutions implemented, and the tangible impact achieved through the strategic integration of modular booths.

Challenges:

A large-scale distribution center responsible for handling heavy machinery and fragile items faced challenges in effectively monitoring areas that serve various forms of activities.

A large-scale distribution center faces potential safety risks with forklift traffic, including collision hazards and pedestrian safety concerns. Simultaneous forklift operation in their expansive layout increases collision risks, potentially causing damage and injuries. Employees were at risk due to intersecting forklift paths, highlighting the need for safety measures. Limited visibility for forklift operators and challenges in emergency communication during crises further compounded safety issues. A comprehensive approach was essential to mitigate these potential risks and ensure a secure and efficient operational environment.

To address these challenges, the distribution center opted for elevated modular booths strategically placed at high-traffic intersections. The booths, equipped with advanced surveillance cameras and two-way communication systems, provided a centralized control hub for monitoring machinery movement and personnel activities.

Implementation Process:

In-depth risk assessments were conducted to pinpoint high-risk areas susceptible to accidents and near misses within the facility. Based on these findings, the strategic placement of booths was then determined, with a primary focus on optimizing visibility and addressing identified hazards.

As part of the risk mitigation strategy, employees are strategically positioned in booths, and they are tasked with real-time monitoring of activities within these critical zones. This continuous surveillance allows for the swift detection of potential hazards and unsafe practices, enabling immediate intervention to prevent near misses.

In addition, comprehensive training sessions instill a proactive safety mindset and emphasize the importance of real-time reporting and emergency response procedures.

The booths, therefore, serve as communication hubs and intervention points, enhancing the overall safety of activities within the facility. This integrated approach ensures the workforce is well-equipped to respond effectively to emerging risks and actively fosters a secure operational environment.

Impact on Safety Measures:

The implementation of booths has profoundly impacted enhancing safety measures within the warehouse. A notable improvement has been observed in mitigating incidents related to forklift operations, demonstrating the efficacy of the booth placement in optimizing visibility and communication. The strategic positioning of these booths has fostered a more proactive approach to hazard identification and response.

Following the implementation of booths, the distribution center experienced a significant reduction in workplace accidents within the first few weeks of implementation. As an added benefit, booths also contributed to smoother traffic flow, optimizing warehouse efficiency as a result.

This case study demonstrates booth integration’s realistic and tailored application to address specific safety challenges in a busy distribution center. By focusing on the practical aspects of their operations, the distribution center was able to mitigate risksand instill a culture of safety awareness that continues to impact employee well-being and overall operational effectiveness positively.

Why you Should Use Guardian Booths for Your Warehouse Security Needs

Guardian Booth, with a range of innovative modular booth design, offers benefits that significantly contribute to enhancing warehouse security :

Customizable Security Solutions:

Our booths offer customizable security solutions tailored to the specific needs of your warehouse.

Whether your needs extend to surveillance booths, access control points, monitoring stations, or other specific security requirements, Guardian Booth’s modular design ensures high customization. From incorporating advanced access management systems and environmental controls to tailoring layouts for dynamic monitoring, the flexibility in configuration goes beyond the mentioned options.

Guardian Booth offers a comprehensive range of custom logistics booths , ensuring that your security infrastructure is precisely aligned with the nuanced demands of your warehouse facility. This customization ensures that your security infrastructure aligns seamlessly with the layout and requirements of your warehouse facility.

Advanced Technology Integration:

Out booths are equipped with state-of-the-art technology to enhance warehouse security. Integrated surveillance systems, access control features, and communication tools provide a comprehensive security solution. The incorporation of advanced technology not only strengthens the surveillance capabilities but also facilitates quick response times to security incidents.

Durability and Weather Resistance:

Our booths are constructed with durability in mind, designed to withstand the rigors of various environmental conditions. Our booths maintain structural integrity when facing extreme temperatures, heavy rainfall, or other challenging weather elements. Their robust construction ensures long-term reliability, offering a sustainable security solution for your warehouse.

Efficient Emergency Response Planning:

Finally, our booths contribute to efficient emergency response planning within the warehouse. With designated spaces for emergency personnel, these booths serve as on-the-spot coordination centers during critical incidents. Equipped with emergency alarms, first aid supplies, and communication systems, our booths enable a rapid and organized response to emergencies, minimizing potential risks and ensuring the safety of personnel.

Compliance with Regulatory Standards:

Our portable booths for warehouse adhere to industry and regulatory standards for security and safety. By choosing Guardian Booths for your warehouse security needs; you can have confidence in meeting and exceeding necessary compliance requirements. This commitment to standards enhances your warehouse’s overall security posture and mitigates potential risks associated with regulatory non-compliance.

Return on Investment (ROI)

Implementing Guardian Booths in warehouse safety initiatives yields a substantial return on investment, driven by several factors:

• Accident Prevention: Our booths’ proactive monitoring and intervention capabilities significantly reduce accidents and near-miss incidents. The associated cost savings from avoided medical expenses, insurance claims, and potential legal liabilities enhance the overall ROI.
• Improved Productivity: The streamlined communication facilitated by Guardian Booth and their role in preventing accidents improves overall productivity. Reduced downtime from accidents and more efficient emergency responses increase operational efficiency.
• Enhanced Employee Morale: A safe work environment fosters a positive workplace culture. Employees feel more secure and valued, leading to higher job satisfaction, reduced turnover, and increased morale. The resulting boost in employee well-being further contributes to long-term cost savings.

Cost Savings Breakdown:

Explore the tangible benefits of our cost savings breakdown, where Guardian Booth prefab structures plays a pivotal role in reducing medical expenses, lowering insurance premiums, and minimizing legal liabilities for your warehouse operations.

• Reduced Medical Expenses: By providing well-positioned booths that mitigate risks, Guardian Booth contributes to declining workplace injuries, resulting in lower medical expenses for treatments and rehabilitation.
• Insurance Premium Reduction: A safer warehouse environment, supported by Guardian Booths, can lead to lower insurance premiums as the risk of accidents and associated claims decreases.
• Minimized Legal Liabilities: By preventing accidents and ensuring a proactive response to incidents, Guardian Booths contribute to reducing potential legal liabilities, saving on legal costs and settlements.

Take the Next Step: Elevate Your Warehouse Safety with Guardian Booth

Safety in warehouses is crucial, ensuring smooth operational continuity – and the role of Guardian Booth in fostering a safer work environment is evident. Comprehensive risk assessments and strategic booth placements exemplify how Guardian Booth addresses specific safety needs. From serving as surveillance hubs to dynamic monitoring stations, these customizable security solutions offer versatility tailored to the unique demands of warehouse operations.

For warehouse managers seeking to elevate safety standards, the choice of Guardian Booths becomes clear. With Guardian Booth, the emphasis is on proven impact, adaptability, and an unwavering commitment to elevating warehouse safety.

Explore Guardian Booths Modular Booth Design Options

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Assessing and facilitating warehouse safety

Research output : Contribution to journal › Article › Academic › peer-review

Purpose: The purpose of this paper is to investigate how warehouse safety can be assessed and facilitated. Methodology: Through a literature study, we build a theoretical framework to provide insights in how safety in Logistics Service Providers (LSPs) can be assessed and facilitated. We perform a case study at a large Dutch LSP using interviews and questionnaires to determine the relevance of the sub-dimensions to assess warehouse safety. Findings: Using literature, we identify people, procedures and technology related sub-dimensions of safety culture and safety behavior and factors that may affect how safety culture translates to safety behavior. Using a case study our findings indicate which sub-dimensions and influencing factors LSP employees find important and why. We found differences in the importance assigned to safety, which may point to the existence of sub-cultures across warehouses. Research limitations/implications: This paper contributes to the limited existing warehouse safety literature in which the factors that influence safety are not well explored. Although the case study investigates one LSP and as such does not generalize across LSPs, it provides valuable insights in important aspects of safety and how they can be influenced. Practical implications: This paper offers safety managers insights in how to assess and facilitate safety within their warehouses. Originality: Although warehouse safety is important, there is scarce academic research that explores this issue.

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

• 10.1016/j.ssci.2018.02.010

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• Logistics Social Sciences 100%
• Service Provider Social Sciences 100%
• Research Social Sciences 40%
• Behavior Social Sciences 40%
• Safety Culture Social Sciences 40%
• Relevance Social Sciences 20%
• Dutch Social Sciences 20%
• Managers Social Sciences 20%

T1 - Assessing and facilitating warehouse safety

AU - Hofstra, Nienke

AU - Petkova, Boyana

AU - Dullaert, Wout

AU - Reniers, Genserik

AU - de Leeuw, Sander

PY - 2018/6

Y1 - 2018/6

N2 - Purpose: The purpose of this paper is to investigate how warehouse safety can be assessed and facilitated. Methodology: Through a literature study, we build a theoretical framework to provide insights in how safety in Logistics Service Providers (LSPs) can be assessed and facilitated. We perform a case study at a large Dutch LSP using interviews and questionnaires to determine the relevance of the sub-dimensions to assess warehouse safety. Findings: Using literature, we identify people, procedures and technology related sub-dimensions of safety culture and safety behavior and factors that may affect how safety culture translates to safety behavior. Using a case study our findings indicate which sub-dimensions and influencing factors LSP employees find important and why. We found differences in the importance assigned to safety, which may point to the existence of sub-cultures across warehouses. Research limitations/implications: This paper contributes to the limited existing warehouse safety literature in which the factors that influence safety are not well explored. Although the case study investigates one LSP and as such does not generalize across LSPs, it provides valuable insights in important aspects of safety and how they can be influenced. Practical implications: This paper offers safety managers insights in how to assess and facilitate safety within their warehouses. Originality: Although warehouse safety is important, there is scarce academic research that explores this issue.

AB - Purpose: The purpose of this paper is to investigate how warehouse safety can be assessed and facilitated. Methodology: Through a literature study, we build a theoretical framework to provide insights in how safety in Logistics Service Providers (LSPs) can be assessed and facilitated. We perform a case study at a large Dutch LSP using interviews and questionnaires to determine the relevance of the sub-dimensions to assess warehouse safety. Findings: Using literature, we identify people, procedures and technology related sub-dimensions of safety culture and safety behavior and factors that may affect how safety culture translates to safety behavior. Using a case study our findings indicate which sub-dimensions and influencing factors LSP employees find important and why. We found differences in the importance assigned to safety, which may point to the existence of sub-cultures across warehouses. Research limitations/implications: This paper contributes to the limited existing warehouse safety literature in which the factors that influence safety are not well explored. Although the case study investigates one LSP and as such does not generalize across LSPs, it provides valuable insights in important aspects of safety and how they can be influenced. Practical implications: This paper offers safety managers insights in how to assess and facilitate safety within their warehouses. Originality: Although warehouse safety is important, there is scarce academic research that explores this issue.

KW - Case study

KW - Safety

KW - Warehouse

U2 - 10.1016/j.ssci.2018.02.010

DO - 10.1016/j.ssci.2018.02.010

M3 - Article

AN - SCOPUS:85042069107

SN - 0925-7535

JO - Safety Science

JF - Safety Science

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Warehouse Safety: It’s No Accident

Careful planning and a dedication to safety are top priorities for keeping warehouse workers injury-free. Here is your no-slip, no-trip, ergonomically correct guide to warehouse safety.

Where most warehouse visitors simply see shelves, pallets, and boxes, Dixie Brock sees danger. In fact, Brock glimpses danger wherever she looks.

It’s not that she is easily frightened or overly cautious. Brock sees danger because it is a key part of her job as national safety and workers compensation manager for APL Logistics, an Oakland, Calif.-based transportation services provider that manages more than 100 warehouses worldwide.

“I constantly analyze accidents,” Brock says. “I study them, search for causes, and try to find ways to prevent them.”

More warehouse operators need to think like Brock, says Gary Gagliardi, vice president of Safety Resources, a safety consulting firm located in Indianapolis. While companies tend to focus their safety efforts on manufacturing sites and transport vehicles, warehouses also require attention, he says.

Yet, when it comes to warehouse safety, employees and management often tug in different directions. “Workers concentrate on going home with their fingers and toes intact,” Gagliardi says.

“Managers are also concerned about safety, but they focus more on where the company is headed, and how profitable it can be.”

To make sure that a warehouse is both safe and efficient, managers and workers need to pull together to spot dangerous practices and plan ways to eliminate threats.

“Companies need a culture of safety,” says Gagliardi. “Creating a safe work environment requires a good deal of effort, but it brings benefits to both workers and management.”

Adding Insult to Injury

Warehouse mishaps tend to be less severe than most manufacturing- and transportation-related accidents. Yet a series of relatively minor incidents can still seriously injure employees and lead to lost productivity, higher insurance bills, and government fines.

“The primary injuries occurring in a warehouse stem from lifting, straining, and turning,” says Joel Anderson, president and CEO of the International Warehouse Logistics Association, a non-profit organization based in Des Plaines, Ill., that represents more than 500 third-party warehouse and logistics service providers.

Similarly, APL reports these top three injury categories at its warehouses:

• Slips, trips, and falls.
• Ergonomic-related pains such as lifting, reaching, pulling, and pushing.
• Material handling incidents such as dropped boxes and forklift accidents.

Although not particularly severe, warehouse accidents are numerous—the warehousing and storage industry experiences nearly 15,000 injuries and illnesses each year, according to the U.S. Bureau of Labor Statistics.

To keep a lid on accidents, warehouse operators should stress worker training and establish safety best practices, says Bob Shaunnessey, executive director of the Warehousing Education and Research Council (WERC), an Oak Brook, Ill.-based organization dedicated to warehouse management and its role in the supply chain.

For most warehouses, forming a safety committee is the first step toward implementing enhanced safety procedures.

A safety committee’s members are usually selected from specific organizational groups—including warehouse floor workers, shift supervisors, and department managers. This approach gives everyone a voice, but keeps the committee’s size to an effective number of participants.

“Safety committees are a common practice,” says Shaunnessey. “In most cases, when management supports the committee, workers are likely to gain a safe work environment.”

Safety committees should not be confused with safety meetings. A safety meeting usually includes all floor employees, as well as a management representative, to ensure that key issues are addressed.

“Typically, a safety committee is an effective safety management tool for large employers, and safety meetings are effective for small employers,” notes Shaunnessey.

OSHA’s Impact

One pivotal player in warehouse safety is the U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA), the federal agency responsible for ensuring safe workplaces.

OSHA exists to make sure businesses that do not take safety seriously won’t imperil their employees. Many warehouse operators take a skeptical view of OSHA, believing they can maintain a safe working environment without government oversight.

Warehouse operators that maintain a safe workplace generally have little to fear from OSHA, says Alex Sierra, health, safety, and environmental manager for Fluor Constructors, the construction arm of Irving, Texas-based engineering, procurement, construction, and maintenance service company Fluor.

“Warehouse managers need to realize that investing in OSHA compliance, and safety in general, is a smart move,” says Sierra. “The average cost of a recordable injury in the United States is $35,000, according to the U.S. Department of Labor. This expense directly impacts a company’s bottom line, as well as workers’ compensation and productivity costs.”

The best way to avoid becoming entangled with OSHA is by not attracting attention to your organization.

“If companies report recurring accidents, or other problems that attract OSHA’s attention, they are usually inspected,” Shaunnessey says. “During an inspection, OSHA may find unsafe practices and require the employer to correct them. If inspectors find egregious safety violations, they often impose fines.”

Warehouse operators who comply with OSHA safety guidelines don’t have much to worry about, says Gagliardi of Safety Resources.

“Generally, unless a ‘red flag’ pops up, OSHA does not have the manpower or the time to inspect a lot of warehouses,” he explains.

While OSHA wields enormous clout, worrying constantly about a run-in with the agency won’t enhance warehouse safety and can actually be counterproductive.

“OSHA should not be a warehouse manager’s main safety concern,” says Gagliardi, who believes warehouse operators should view OSHA safety regulations as benchmarks to exceed. “Companies with advanced warehouse safety programs rise well above OSHA standards.”

APL’s Brock points to forklifts as one area where it pays to enact company policies that go above and beyond OSHA requirements.

“OSHA enforces forklift seating requirements, but its regulations do not mandate that forklift operators stay inside the cage, for example,” she explains.

And, the fact that OSHA doesn’t regulate a particular area or practice doesn’t let a warehouse operator off the hook if a related accident occurs.

To discover whether exceeding OSHA requirements in a particular area is a good idea, safety committees must identify weaknesses in current practices. Warehouse operators also need to analyze the reason for past accidents rather than simply recording their outcome.

“Knowing an employee suffered a fractured arm doesn’t tell the manager how to correct the operating procedures that caused an injury,” says Brock.

“But if the manager knows the elbow was fractured when it was outside the cage and the forklift driver turned a corner too sharply, it becomes obvious that the employee needs to be retrained on driving speed, leaving enough room to safely turn corners, and keeping their body inside the cage.”

Staying on top of safety incidents is another guaranteed way to steer clear of OSHA’s tender mercies. Managers must stress the importance of taking immediate action whenever a safety hazard is identified.

“If managers pass the same slippery oil spot on the warehouse floor every day without taking action, for example, what message are they sending employees?” asks Sierra.

Resistance is Futile

Perhaps the biggest mistake warehouse operators make when dealing with OSHA is fighting agency rulings—a futile pursuit, according to Gagliardi. “It does no good to argue with OSHA compliance officers. Companies will not win the battle,” he notes.

Despite the criticism directed at OSHA, most of the agency’s regulations make sense, says WERC’s Shaunnessey. After a rough start in the 1970s and 1980s, the agency has evolved to the point where it now works closely with businesses to create guidelines that are fair to both workers and employers.

“OSHA has become more proactive in its efforts, and is trying to be more practical,” Shaunnessey says.

OSHA, however, is not the only safety regulator that warehouse managers have to pay attention to. The federal government has become increasingly concerned about hazardous materials transportation, including how these substances are handled at origin and destination sites. As a result, U.S. Department of Transportation (DOT) inspectors show up routinely at warehouses.

“It’s not uncommon for our facilities to receive a walk-in DOT visit,” Brock says. “Ten years ago, DOT officials never visited warehouses. They were often involved in the transportation sector of the business, but not in warehousing.”

Another concern among warehouse operators is the growing influence of state regulators; most states now have some type of worker safety agency.

“Many states merely adopt federal warehouse safety standards,” says Brock. But a few states actually strive to exceed OSHA mandates. California, for example, boasts rules that are more stringent than federal OSHA, says Sierra.

To cope with state safety agencies, warehouse operators should follow the same practices as they do when dealing with federal guidelines, say the experts: know and follow the rules, aim high, and don’t attract attention.

“If a company complies with the toughest state regulations, it usually is in compliance with other states as well,” says Sierra.

Creating a Safety Culture

Creating a safe warehouse does not happen by accident, it happens by planning to prevent accidents. Although forming a safety committee is a good first step toward building better worker safety practices, warehouse operators also need to work toward creating a “safety culture” inside their facilities.

“Warehouse managers are accountable for safety. They need to be aware of that, and lead by example,” says Sierra. “All company employees should feel that safety is their responsibility—that is part of building a safety culture.”

“Maintaining an efficient safety culture is a continuous effort,” Gagliardi agrees. “Safety is not a one-time deal; companies cannot accomplish a culture of safety with one or two yearly meetings. But emphasizing safety throughout the company has a positive influence on its success.”

Unfortunately, the benefits derived from safety training and practices are hard to directly quantify. As a result, many companies work to meet only basic government requirements. But such shortsighted thinking can burn companies over the long haul.

“Because safety efforts are not direct activities that generate profit, people tend to forget them,” says Shaunnessey. “But ultimately, having a safe workplace puts companies in a position to be more profitable.”

Safety Savings

An emphasis on safety can generate cost savings—both direct and indirect. Warehouse operators who take the time to analyze their safety training and practices can reap financial benefits, says Patrick Floyd, senior executive vice president of operations for Total Logistic Control (TLC), a third-party logistics provider headquartered in Zeeland, Mich.

TLC, which operates 83 distribution centers nationwide, implemented a comprehensive safety plan that generated fast and measurable results.

“TLC reduced its recordable incident rate from 11.5 in 2000 to 3.63 in 2006,” notes Floyd. “This helped reduce workers’ compensation costs from $2.53 per man-hour to 30 cents per man-hour.”

The 3PL also makes safety an essential responsibility of its facility managers, office managers, and other supervisory personnel.

“Our managers’ annual key performance indicators are based upon how well their facilities comply with OSHA, safety, and process improvement,” Floyd says. “They cannot ignore safety concerns. If they do, it affects their performance as a leader and it affects their compensation.”

To keep safety top of mind for employees, training needs to touch on all key areas that affect warehouse safety, notes Brock. APL, for instance, offers separate programs on topics including slips and falls, forklift operation, heat exhaustion, ergonomics, and hazardous materials.

“Safety is not separate from what warehouse employees do every day,” she says. “Safety is a key aspect of how they do their job, and that’s the mindset they must have.”

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THE ULTIMATE GUIDE TO WAREHOUSE SAFETY: BEST PRACTICES AND REGULATIONS

Warehouse safety is of utmost importance in maintaining a healthy and productive work environment for employees. Accidents and injuries in warehouses can lead to costly downtime, legal complications, and a negative impact on the company’s reputation. Therefore, understanding and implementing warehouse safety procedures and best practices is crucial for every organization.

In this comprehensive guide, we will cover various aspects of warehouse safety, including the importance of safety in a warehouse, safety standards, personal protective equipment, occupational safety, fire safety, and more.

Why is Safety Important in a Warehouse?

Safety in a warehouse is vital to ensure the well-being of employees, protect valuable assets, and maintain efficiency in operations . A safe warehouse environment can lead to:

Improved Employee Morale and Productivity

A safe warehouse environment can boost employee morale, as warehouse workers will feel more secure and cared for by the organization. This, in turn, can lead to increased productivity, as warehouse employees are more likely to be focused and engaged in their work when they feel safe.

Reduced Absenteeism and Turnover

A workplace with a strong safety culture tends to experience lower levels of absenteeism and employee turnover. When warehouse employees feel that their well-being is a priority, they are less likely to miss work due to injuries or illnesses and more likely to stay with the company long-term.

Lower Insurance Premiums and Workers’ Compensation Costs

By maintaining a safe warehouse environment and reducing the frequency of accidents and injuries, businesses can potentially lower their insurance premiums and workers’ compensation costs. This can result in significant cost savings for the organization.

Compliance with Regulatory Requirements

Warehouses must comply with various safety regulations and standards, such as OSHA  and state regulations in the United States. Ensuring a safe work environment helps organizations avoid fines and penalties for non-compliance, as well as the potential for legal action and liability.

Enhanced Company Reputation

A strong commitment to warehouse safety can enhance a company’s reputation among customers, suppliers, and potential employees. Companies that prioritize safety are often seen as responsible and trustworthy, which can contribute to their overall success and profitability.

Warehouse Safety Standards

To maintain a safe warehouse environment, it is essential to follow industry standards and regulations. Some of the key warehouse safety standards include:

OSHA Warehouse Regulations

The Occupational Safety and Health Administration ( OSHA ) is the primary regulatory body for workplace safety in the United States. OSHA has established numerous regulations related to warehouse safety, covering areas such as walking-working surfaces, personal protective equipment, material handling, powered industrial trucks, and hazard communication. Compliance with these regulations is essential for maintaining a safe warehouse environment and avoiding penalties.

Some key OSHA regulations that apply to warehouses include:

• 29 CFR 1910.22 – Walking-Working Surfaces.
• 29 CFR 1910.132 – Personal Protective Equipment (PPE).
• 29 CFR 1910.176 – Handling Materials.
• 29 CFR 1910.178 – Powered Industrial Trucks.
• 29 CFR 1910.1200 – Hazard Communication.

ANSI/ASSP Z359.1 – Safety Requirements for Personal Fall Arrest Systems

The American National Standards Institute ( ANSI ) and the American Society of Safety Professionals ( ASSP ) have developed the Z359.1  standard, which outlines safety requirements for personal fall arrest systems, including harnesses, lanyards, and anchorages. Warehouses that require employees to work at heights should implement fall protection measures that meet or exceed these safety requirements.

NFPA 13 – Standard for the Installation of Sprinkler Systems

The National Fire Protection Association ( NFPA ) has developed the NFPA 13  standard, which specifies the minimum requirements for the design and installation of fire sprinkler systems in warehouses and other structures. Properly designed and installed sprinkler systems can help prevent fires from spreading and minimize property damage and injuries in the event of a fire.

ISO 45001 – Occupational Health and Safety Management System

The International Organization for Standardization ( ISO ) has developed the ISO 45001  standard for occupational health and safety management systems. This standard provides a framework for organizations to develop, implement, and maintain a comprehensive safety management system that can help reduce workplace hazards and improve overall safety performance. Adopting this standard can demonstrate a commitment to warehouse safety and contribute to a safer work environment.

Warehouse Safety Procedures

Effective warehouse safety procedures play a significant role in reducing accidents and ensuring a safe work environment. Some essential procedures include:

Implementing a Comprehensive Warehouse Safety Program

A comprehensive safety program should encompass all aspects of warehouse operations, including hazard identification, risk assessment, and control measures. This program should be regularly reviewed and updated to reflect changes in operations, equipment, or regulations.

Conducting Regular Safety Training and Drills

Training employees on safety procedures, equipment use, and hazard recognition is essential for maintaining a safe warehouse environment. Regular safety drills, such as fire and emergency evacuation drills, can help ensure employees are prepared to respond effectively in case of an emergency.

Establishing Clear Communication Protocols

Clear communication is crucial for maintaining worker safety in a warehouse. Establish protocols for reporting hazards, near-misses, and incidents, as well as for sharing safety information and updates with employees.

Performing Routine Safety Inspections and Audits

Regular safety inspections and audits can help identify potential hazards and areas for improvement. These inspections should be conducted by knowledgeable personnel and should cover all aspects of warehouse operations, including equipment, storage, housekeeping, and work practices.

Identifying and Addressing Potential Hazards

Proactively identifying and addressing potential hazards is critical for preventing accidents in the warehouse. Encourage employees to report hazards and implement a process for evaluating and addressing reported concerns in a timely manner.

Personal Protective Equipment (PPE) in Warehouses

Personal Protective Equipment (PPE) is a crucial component of warehouse safety procedures. Providing appropriate PPE and ensuring employees wear them properly can significantly reduce the risk of injuries. Some common types of PPE used in warehouses include:

• Safety footwear: Steel-toed boots or shoes protect warehouse employees from falling objects, punctures, and slips.
• Protective eyewear: Safety glasses or goggles protect workers’ eyes from debris, chemicals, and other hazards.
• Gloves: Protective gloves shield hands from cuts, abrasions, and chemical exposure.
• Hearing protection: Earplugs or earmuffs protect employees from excessive noise levels, which can cause long-term hearing damage.
• Hard hats: These provide protection against falling objects, bumps, and electrical hazards.
• High-visibility clothing: Reflective vests or jackets make employees more visible, reducing the risk of accidents involving vehicles or machinery.

Training warehouse employees on the proper use, maintenance, and disposal of PPE is crucial to ensure its effectiveness. Regularly inspect PPE for damage or wear and replace it as necessary.

Occupational Safety in Warehouses

Occupational safety in warehouses involves implementing measures to protect employees from work-related hazards and ensuring compliance with relevant regulations. Some key aspects of occupational safety in warehouses include:

• Ergonomics: Implement solutions that incorporate proper ergonomics to reduce the risk of musculoskeletal disorders caused by repetitive motions, awkward postures, or heavy lifting. Examples include adjustable workstations, proper lifting techniques, and frequent breaks for employees.
• Chemical safety: Store and handle hazardous materials according to regulatory requirements and manufacturer recommendations. Train employees on the proper handling, storage, and disposal of chemicals, and provide appropriate PPE.
• Electrical safety: Ensure all electrical installations and equipment meet applicable codes and standards. Train employees on electrical safety procedures, such as lockout/tagout, and how to respond to electrical emergencies.
• Fall protection: Implement fall protection measures, such as guardrails, safety nets, or personal fall arrest systems, for employees working at heights. Train employees on the proper use of fall protection equipment and conduct regular inspections to ensure its effectiveness.
• Vehicle and equipment safety: Train employees on the safe operation of vehicles and equipment, such as forklifts and pallet jacks. Establish traffic management plans and enforce vehicle maintenance schedules to reduce the risk of accidents.

By incorporating these elements into warehouse safety procedures, operators can create a safer work environment and promote occupational safety in warehouse operations.

Fire Safety in Warehouses

Fire safety is a critical concern in warehouses due to the potential for significant property damage, injuries, and even fatalities. Key elements of fire safety in warehouses include:

• Fire detection and suppression systems: Install fire alarms, smoke detectors, and sprinkler systems to provide early warning and control fires.
• Fire extinguishers: Provide accessible fire extinguishers throughout the warehouse and train employees on their proper use.
• Emergency exits and routes: Ensure that emergency exits are clearly marked, unobstructed, and easily accessible. Establish and maintain clear emergency routes for evacuation.
• Fire safety training: Provide regular fire safety training for employees, including the use of fire extinguishers and evacuation procedures.
• Proper storage and handling of flammable and combustible materials: Store flammable and combustible materials in designated areas, away from ignition sources, and follow proper handling procedures.

By implementing these fire safety measures, warehouse operators can help prevent fires, minimize damage, and protect employees in the event of a fire.

Warehouse Safety Policy and Procedures

A well-defined warehouse safety policy is crucial for setting expectations and providing guidance to employees. Key elements of a warehouse safety policy should include:

Management Commitment to Safety

The safety policy should emphasize management’s commitment to maintaining a safe work environment and outline the responsibilities of managers and supervisors in supporting safety initiatives.

Employee Responsibilities and Accountability

The policy should clearly define the safety responsibilities of all employees, including following safety procedures, wearing required PPE, and reporting hazards or incidents. Employees should also be held accountable for their safety performance through regular evaluations and disciplinary actions, as needed.

Hazard Identification, Assessment, and Control

The safety policy should outline the process for identifying, assessing, and controlling hazards in the warehouse. This includes conducting regular risk assessments, implementing control measures, and evaluating the effectiveness of these measures.

Training and Competency

The safety policy should emphasize the importance of safety proper training for all employees and outline the requirements for maintaining competency in their respective roles. This includes providing initial training for new employees, ongoing refresher training, and specialized training for specific tasks or equipment.

Incident Reporting and Investigation

The safety policy should establish procedures for reporting and investigating incidents, including near-misses, accidents, and injuries. Investigations should aim to identify the root causes of incidents and develop corrective actions to prevent recurrence.

Emergency Preparedness and Response

The safety policy should include provisions for emergency preparedness and response, such as developing and maintaining an emergency response plan, conducting regular emergency drills, and ensuring that employees are trained in emergency procedures.

Warehouse Safety Best Practices

Implementing warehouse safety best practices can help reduce the risk of accidents and create a safer work environment. Some key best practices include:

Maintain a Clean and Organized Warehouse

Good housekeeping is essential for preventing slips, trips, and falls. Keep aisles and walkways clear of debris and clutter, and ensure that materials are stored properly to prevent falling objects.

Implement Clear Signage and Markings

Use signage and markings to clearly indicate hazards, such as forklift traffic zones, pedestrian walkways, and storage areas for hazardous materials. Ensure that signs are visible and easy to understand.

Develop and Enforce Safety Rules and Procedures

Establish and enforce safety rules and procedures for all warehouse operations, from material handling to equipment use. Ensure that employees are trained on these rules and procedures and held accountable for following them.

Provide Appropriate Personal Protective Equipment (PPE)

Ensure that employees have access to and use the appropriate PPE for their tasks, such as safety glasses, gloves, hard hats, and steel-toed shoes. Train employees on the proper use and maintenance of PPE.

Promote a Safety-First Culture

Encourage a safety-first culture by involving employees in safety initiatives, recognizing and rewarding safe behaviors, and fostering open communication about safety concerns.

Warehouse Rules and Regulations Sample

A sample set of warehouse rules and regulations might include:

• Follow all safety procedures and guidelines, as outlined in the safety policy and training materials.
• Wear required PPE at all times while in the warehouse.
• Report any hazards, near-misses, or incidents to a supervisor immediately.
• Keep aisles, walkways, and workspaces clean and free of debris and clutter.
• Use proper lifting techniques and equipment when handling materials.
• Operate equipment and machinery only if properly trained and authorized.
• Do not block emergency exits, fire extinguishers, or safety equipment.
• Follow proper procedures for handling and storing hazardous materials.
• Participate in safety training and drills as required.

Warehouse Hazards

Identifying and addressing warehouse hazards is essential for maintaining a safe work environment. Some common warehouse hazards include:

• Slips, trips, and falls.
• Falling objects and materials.
• Forklift and vehicle accidents.
• Manual handling and ergonomic hazards.
• Chemical and hazardous substance exposure.
• Fire and explosion risks.
• Electrical hazards.
• Noise and vibration hazards.
• Confined spaces and poor ventilation.

Steps to Creating a Safe Warehouse

As we’ve discussed, creating a safe warehouse involves implementing various safety measures and best practices to minimize risks and protect employees. Some key elements of a safe warehouse include:

Well-Designed Layout

A well-designed warehouse layout  can help prevent accidents by providing clear pathways for pedestrian and vehicle traffic, adequate space for material handling, and proper storage areas for different types of materials.

Comprehensive Warehouse Safety Programs

A comprehensive warehouse safety program should cover all aspects of warehouse operations, from hazard identification and control to employee training and incident reporting.

Employee Training and Competency

Ensure that all employees are properly trained in safety procedures, hazard recognition, and the safe use of equipment and materials. Regular refresher training and specialized training for specific tasks can help maintain employee competency and reduce the risk of accidents.

Personal Protective Equipment (PPE)

Provide employees with the appropriate PPE for their tasks and ensure they are trained in its proper use and maintenance. PPE can help protect employees from various hazards, such as falls, impacts, and exposure to hazardous substances.

Develop and maintain an emergency response plan, and ensure that employees are trained in emergency procedures. Regular emergency drills can help ensure employees are prepared to respond effectively in case of an emergency.

Owning a Warehouse

Owning a warehouse comes with significant safety responsibilities, including ensuring compliance with regulations, maintaining a safe work environment, and providing adequate resources for safety initiatives. Warehouse owners should prioritize safety in their operations and promote a safety-first culture to minimize risks and protect employees.

Warehouse Safety Inspections

Regular warehouse safety inspections are crucial for identifying potential hazards, ensuring compliance with regulations, and promoting a safe work environment. Key aspects of warehouse safety inspections include:

• Inspection frequency: Conduct safety inspections at regular intervals, such as monthly or quarterly, depending on the size and complexity of your warehouse operations.
• Inspection scope: Inspections should cover all aspects of warehouse operations, including storage and handling of materials, equipment maintenance, housekeeping, and employee work practices.
• Inspection checklists: Use standardized checklists to guide your inspections and ensure consistency in identifying hazards and assessing safety performance.
• Inspection personnel: Assign knowledgeable personnel to conduct safety inspections, such as safety managers or external safety consultants.
• Follow-up actions: Address identified hazards and issues promptly, and implement corrective actions to prevent recurrence. Document inspection findings and track progress in addressing safety concerns.

By conducting regular safety inspections, warehouse operators can proactively identify and address potential hazards, helping to prevent accidents and maintain a safe work environment.

Warehouse Safety Training

Effective safety training is essential for ensuring that employees understand their safety responsibilities and are competent in their tasks. Key aspects of warehouse safety training include:

• Initial safety orientation: Provide new employees with an orientation on warehouse safety, including safety rules and procedures, hazard recognition, and the use of PPE.
• Task-specific training: Provide specialized training for employees who perform specific tasks, such as forklift operators, handling hazardous materials, or working in confined spaces.
• Refresher training: Conduct regular refresher training to reinforce safety knowledge and skills, and to keep employees up-to-date on changes in safety procedures or regulations.
• Emergency response training: Train employees in emergency procedures, such as evacuations, fire extinguisher use, and first aid.
• Training records: Maintain records of employee safety training, including dates, topics covered, and trainer information.

By providing comprehensive safety training and ensuring employee competency, warehouse operators can reduce the risk of accidents and create a safer warehouse  work environment.

Warehouse Safety Metrics

Monitoring warehouse safety metrics can help organizations track their safety performance, identify trends, and make data-driven decisions for improving safety. Some common warehouse safety metrics include:

• Total Recordable Incident Rate (TRIR): The number of recordable incidents (injuries and illnesses) per 100 full-time employees, calculated over a specified period.
• Lost Time Incident Rate (LTIR): The number of incidents resulting in lost work time per 100 full-time employees, calculated over a specified period.
• Near-miss reporting rate: The number of near-miss incidents reported by employees, which can help identify potential hazards before they result in accidents.
• Safety inspection findings: The number of hazards identified during safety inspections, as well as the progress in addressing these findings.
• Safety training completion rate: The percentage of employees who have completed required safety training.

By monitoring these and other safety metrics, warehouse operators can gain valuable insights into their safety performance and make targeted improvements to reduce the risk of accidents and injuries.

Warehouse Safety Communication

Effective communication is essential for promoting safety awareness and ensuring that employees understand their safety responsibilities. Some strategies for fostering effective safety communication in the warehouse include:

• Safety meetings: Hold regular safety meetings to discuss safety topics, share updates on safety procedures or regulations, and address employee safety concerns.
• Safety signage: Use clear and visible safety signage to communicate important safety information, such as hazard warnings, emergency exits, and designated pedestrian walkways.
• Safety bulletin boards: Provide a central location for posting safety information, such as safety policies and procedures, training schedules, and safety performance metrics.
• Open-door policy: Encourage open communication between employees and management regarding safety concerns, and provide multiple channels for reporting hazards or incidents.
• Safety feedback: Solicit employee input on safety initiatives, and involve employees in the development and review of safety policies and procedures.

By fostering effective safety communication, warehouse operators can help ensure that employees are well-informed and engaged in maintaining a safe work environment.

Warehouse Safety Technologies

Leveraging modern technology can help warehouse operators improve safety and reduce the risk of accidents. Some examples of warehouse safety technologies include:

• Collision avoidance systems: Implement collision avoidance systems on forklifts and other vehicles to help prevent accidents involving pedestrians or other vehicles.
• Automated guided vehicles (AGVs): Use AGVs to automate material handling tasks, reducing the risk of human error and manual handling injuries.
• Fall protection systems: Install fall protection systems, such as guardrails or harnesses, to protect employees working at heights.
• Safety monitoring software: Utilize safety management software to track safety metrics, manage safety inspections and audits, and streamline incident reporting and investigation.
• Wearable technology: Implement wearable safety devices, such as smart helmets or vests, that can provide real-time feedback on hazardous conditions or worker behavior.

By incorporating safety technologies into warehouse operations, operators can enhance safety performance and create a safer work environment for employees.

Warehouse safety is an essential aspect of maintaining a productive and efficient work environment. By understanding the importance of safety, implementing best practices, and complying with relevant regulations, warehouse operators can create a safe and efficient work environment for their employees. This comprehensive guide has provided you with the knowledge and strategies needed to improve warehouse safety and maintain compliance with industry standards. By prioritizing safety and fostering a safety-first culture, your organization can reduce the likelihood of accidents, minimize downtime, and ensure a healthier and more productive workplace.

To learn more about implementing warehouse safety guidelines as well as how Cadre Technologies warehouse management solutions  can help you maximize safety and streamline operations in your warehouse, contact us  today. Our team of warehouse experts are here to help you create a safe and compliant work environment.

Warehouse Safety Frequently Asked Questions and Answers

In this section, we will address some common questions related to warehouse safety and provide answers and guidance to help improve safety in your warehouse.

What are the common warehouse hazards?

Some common warehouse hazards include:

• Slips, trips, and falls
• Falling objects and materials
• Forklift and vehicle accidents
• Manual handling and ergonomic hazards
• Chemical and hazardous substance exposure
• Fire and explosion risks
• Electrical hazards
• Noise and vibration hazards
• Confined spaces and poor ventilation

How can we prevent accidents in the warehouse?

Preventing accidents in the warehouse involves a combination of proactive measures, including:

• Implementing a comprehensive safety program
• Conducting regular safety training and drills for employees
• Establishing clear communication protocols for reporting and addressing hazards
• Performing routine safety inspections and audits
• Identifying and addressing potential hazards before they result in accidents

What is the role of management in warehouse safety?

Management plays a crucial role in warehouse safety by:

• Demonstrating commitment to safety and leading by example
• Providing adequate resources for safety initiatives, including training, equipment, and personnel
• Setting clear expectations for employee safety performance and accountability
• Encouraging open communication about safety concerns and issues
• Regularly reviewing safety performance and making improvements as needed

What are some essential warehouse safety tips?

Some essential warehouse safety tips include:

• Prioritize housekeeping and organization to reduce clutter and trip hazards
• Ensure proper storage and handling of materials to prevent falling objects and accidents
• Train employees on the safe use of equipment, tools, and chemicals
• Use appropriate safety equipment and personal protective equipment (PPE)
• Establish and enforce safety rules and procedures for all warehouse operations

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An Integrated Approach to Workplace Safety and Wellness: Case Studies of Warehouse Communication System Design

Workplace safety is closely related to staff’s wellness, but they have been mostly approached as separate initiatives due to organizational conventions and operational constraints. Thanks to the rising awareness of health and wellness as well as advanced technology capabilities, corporate attempts are increasing for creating a safer work environment by monitoring employees’ physical and emotional conditions in relation to potential workplace hazards. This paper will present an integrated design approach to workplace safety and wellness based on the case studies of communication system design projects that explored digitally augmented warehouse work environments. The projects were carried out in an interdisciplinary design studio course in the school of design at University of Cincinnati with 16 enrolled students from industrial, communication and fashion design programs across 15 weeks. Students collaboratively conducted trend research about emerging technology and social issues, secondary research focusing on warehouse work conditions and safety regulations, and primary research by visiting a warehouse and interviewing managers and staff. Based on the research insights, possible scenarios for enhanced lift-truck driving experience were explored to satisfy the warehouse staff’s demands for staying informed , connected and supported. The paper will showcase conceptual communication system scenarios in the warehouse environment and speculate on how individual operators could be empowered by augmented information sharing and display, leading to positive impacts on safety as a result. In the end, design implications for integrated safety and wellness promotion will be discussed to leverage the communication and experience potential of digitally augmented work environment.

1. Introduction

Warehouse is a complex work environment where physical materials are received, documented, stored and delivered within and out of a company. Warehouse staff are exposed to dynamic and potentially dangerous work conditions that require constant attention to human and material traffics as well as expertise to operate heavy lifting equipment. Especially, lift truck operators, although they may feel confident about driving equipment once the work becomes their daily routine, still need to pay careful attention to keep their work environment safe. A careless mistake or too much confidence could lead to a fatal warehouse accident. It has been reported that many warehouse accidents are caused by operator’s carelessness or underestimation of potential dangers, and that drivers could avoid fatal human injuries or material damages by simply complying to basic safety regulations (Motorola, Inc., 2013). The studio project presented in this paper was motivated to increase lift truck operators’ attention to safety and to improve their work experience in warehouse.

Traditionally lift truck industry has been mostly concerned with hardware performance of lifting equipment and ergonomics to increase operators’ work efficiency. However, recently with growing interest in human wellness in various personal and public areas of our society, warehouse safety requires different approaches beyond safety regulations or risk management strategies. In addition, nowadays we are observing huge leaps in capabilities of advanced technologies including big data, automation, and wearable tracking, which can be used cooperatively to collect data about personal condition and work environment. It has become more common to consider workplace safety in the continuum of personal health and wellness instead of as a separate goal to achieve with safety policy and regulation (Ozer, 2013; Rath and Harter, 2010). There have been many attempts to identify key factors of workplace safety and wellness in relation to fundamental human needs from an integrated perspective (Putman, 2015). And design explorations are further encouraged to imagine possible system scenarios by connecting various experiential factors and leveraging environmental and cultural prompts to enhance employees’ work experience. In particular, it is critical to devise a program that could support individual engagement by raising awareness about safety and wellness conditions, providing positive reinforcement for behavioral changes, and sustaining intrinsic motivations based on employees’ participation instead of imposing top-down safety regulations and monitoring their compliance to them (Figure 1; Putnam, 2015).

Figure 1. Diagrams redrawn from Putnam (2015) to illustrate an integrated perspective toward fundamental human needs, workplace wellness and safety and to identify key factors to explore workplace wellness programs: Imagine What’s Possible Pyramid (page 31) and Maslow Meets Mallory Culture Audit (page 72).

In consideration of emerging technological capabilities and increasing demands for physical and emotional wellness at work, this project aims at exploring design interventions for improving warehouse safety from an integrated perspective. In particular, we focus on engaging and empowering employees in nurturing a corporate safety and wellness culture through workplace systems. The project presented in the paper was carried out as a junior level interdisciplinary design studio in the school of design at University of Cincinnati.

2. Methodology and Design Process

Sixteen students from different design programs—Industrial, Interaction, Graphic and Fashion Design—worked in four teams over sixteen weeks. The studio followed the double diamond process that was developed by the Design Council in 2005. The process consists of four stages by mapping the divergent and convergent thinking modes that designers use: discovery (identifying needs and inspirations), definition (interpreting these needs to business objectives), development (forming design-led solutions through iterative revisions and tests) and delivery (finalizing resulting product or service).

2-1. Discovery: trend survey + literature review + primary research

The first phase is to understand the problem by conceptualizing the meaning of safe and smart lift truck experience based on initial research. Questioning about “how to make a lift truck experience safer and smarter?” , students investigated warehouse work conditions and lift truck drivers’ responsibilities from secondary sources, while in parallel surveying creative inspirations from emerging sociocultural and technological issues before delving into primary user research through interview and contextual inquiry. Each team developed their initial design strategy based on the keywords emerged from their trend research: connected work experience by location-based information sharing ; personalized workspace in a lift truck ; seamless integration of physical and virtual dimensions of the work environment ; intelligent use of technology for engaging work experience . These initial strategies set out from the trend research served as a shared vision for the communication within each team. Students also conducted primary research by visiting a warehouse, observing the real work context, and interviewing lift truck operators and other warehouse staff. Mind mapping method was employed to summarize research findings and corresponding conceptual design spaces (Figure 2).

Figure 2. Mind maps for conceptualizing warehouse safety and operator empowerment

2-2. Definition: synthesis of insights + initial sketches and scenarios

The second phase is to define design requirements based on the problems and opportunities identified in the previous phase. Initial solution scenarios were explored and quickly simulated in forms of idea sketches and storyboards. Proposed solutions range from new dashboard and display interfaces to wearable and embedded tracking devices. Simple photographic sketches, which graphically overlay the conceptual interfaces on real photographic images of the warehouse environment (Greenberg et al., 2011), were efficient to simulate pervasive technological interventions and to receive constructive feedback from weekly critique sessions (Figure 3). Through iterative ideations and critiques, concrete design requirements and scopes of design interventions were defined by prioritizing problems and possible approaches to them.   

Figure 3. Photographic sketches for simulating initial ideas

2-3. Development: specification of system components

The development phase is to translate the initial concepts into feasible systems with multiple touch points that consist of physical, interactive, and informational design components. Emerging information and interaction technologies—from embodied and embedded tracking to big data and automation—were applied to develop conceptual scenarios in consideration of their experiential value propositions. It was challenging to demonstrate the systemic, experience-oriented concepts because their forms are not contained by a single, static device but involved with various intangible dimensions of work conditions and interaction flows. Planning how to best communicate systemic and experiential design concepts was another design decision by itself besides resolving the defined problems. Students were encouraged to come up with their own format to best illustrate the intended user experience and related value propositions of their concepts (e.g., system diagram, interactive prototyping, video demonstration). They spent much more time in planning out scenarios by highlighting all significant problematic situations and sequencing them in a temporal order like making a movie (Figure 4).

Figure 4. Initial ideation for use case scenarios in storyboard

2-4. Delivery: final demonstration + documentation

The final phase is mostly about documenting the design proposals and the process work. Each team documented the inventory of their initial concepts, final design goals and statement revised based on their design explorations. The final solutions of each team were documented with the following components: system overview (interaction flows and/or information architecture), design theme (style and/or interaction guidelines), form explorations (hardware and interface sketches), and final experience scenarios .

3. Design Considerations for Warehouse Safety

Below are four main considerations for designing safe lift truck experience defined based on our primary and secondary research. In addition to the research about general warehouse accidents and safety regulations, we investigated lift truck operators’ training programs, responsibilities, social dynamics in their workplace, and personal aspirations. In this course, the meaning of safety was reconstructed in terms of proactive self-protection and emotional support for building a safety culture beyond passive prevention of accidents or monitoring driving behaviors for penalties. Below is the list of design considerations prioritized based on our research:

3-1. Pedestrian visibility : Visibility is a continuing issue for lift truck drivers. It is important for pedestrians to make themselves stand out in a warehouse environment. A pedestrian can never assume that a driver can see him or her. Currently, drivers are instructed to use eye contact and check before crossing aisle and honk their horn to alert others of their presence. Pedestrians have the option of wearing high visibility vests, but this is not a requirement in all warehouses. Pedestrians cross walks and lanes presently exist in warehouses, but in order for them to be effective they need to be well maintained and designated.

3-2. Warnings and notifications : In busy and loud warehouse environment, both lift truck drivers and pedestrians can be easily distracted, losing their focus on significant tasks or important notifications. Appropriate warnings may substantially reduce the probability that the regulator loses control of the situation altogether. Warnings are useful in situations where a regulator or leader needs to maintain control. However, if a regulator or leader continuously responds harshly to those whom violate the rules or conditions, the effect of the rule or condition is weakened, adding more stress to lift truck operators.

3-3. Learning and training : Surprisingly there are many lift truck drivers who operate trucks without taking training sessions due to practical reasons including time and cost. It is more problematic that they do not get proper feedback about their driving behaviors until an accident happens. Research has shown the importance of positive feedback in the practice of expert tutoring (Knippen and Green, 1997; Lu and Roto, 2015). Positive feedback can relieve learner’s uncertainty towards a task, thus allowing them to make corrections within the process. The effect of positive reinforcement in learning and changing behaviors has been critically considered during our concept exploration with three questions: What did the operator do correctly? What is the outcome of the incorrect action? How can the operator correct his or her action and avoid an unsafe situation?

3-4. Motivation and empowerment : Most importantly warehouse safety is largely dependent on individual drivers’ intrinsic motivation to comply with safety regulations and professional work ethics. Driving lift truck could be easily considered as a temporary job with a relatively low professional barrier as well as insufficient payment. Personal empowerment is critical for drivers to stay focused at work and to keep their environment safe. Instead of a regulator or manager monitoring their performance, fundamental programs to sustain their motivation need to be devised by challenging them in constructive ways and rewarding their performance.

The four considerations listed above highlight different aspects of warehouse safety both at individual and organizational levels, but they are closely related with each other, influencing drivers’ performance and safety habits. Based on these considerations, each of the four student teams explored conceptual scenarios with different design strategies, which will be describe in the next section:

1. Connect drivers through augmented reality interfaces by geo-tagging safety information;

2. Build a sense of community in a warehouse through a mentoring and supporting system;

3. Attach a user more effectively to his truck and use the truck as a platform for learning and training;

4. Enhance interactions in the operator workflow through ambient intelligent notifications.

4. Conceptual System Scenarios

In exploring different scenarios, we commonly focused on the bond between a driver and his lift truck as a basis to specify design components, specifically by leveraging its potential in tracking the driver’s behaviors, enhancing his workflows with minimal distraction, providing real-time safety feedback to change his behaviors, protecting him in dangerous situations, and connecting to other operators to share useful information. In what follows, four concept scenarios are presented to showcase different technological interventions and their corresponding value propositions based on the aforementioned design considerations.

Scenario 1: augmented reality for geo tagging safety information

The design goal of this scenario is to create a set of augmented reality interfaces for keeping drivers alert and interested in their work. The scenario aims to archive and share useful information throughout the warehouse by leveraging augmented reality technology with its simplified user interfaces and display flexibility. In the proposed solution, the current vehicle dashboard is removed in favor of an entirely projectable system. Simple projections are seamlessly blended into the warehouse environment, reducing the need for multiple screens as well as distractions and allowing information to be seen where it is needed (Figure 5). In particular, the idea of geo-tagging is applied to improve warehouse communication and find a more efficient and proactive way of reporting and measuring safety metrics. When there is an accident, spill or pothole, or if someone has a question or pro-tip, an icon can be dropped at the location of the event, hazard, or question. If a pothole is repeatedly reported, superiors will be able to see that information and fix the pothole or make sure that drivers who run over it are not docked for collisions. This readily available knowledge shared and updated in real time will contribute to creating a smarter and safer work environment.

Figure 5. Augmented reality for tagging and sharing safety information (Student team: Kerri Morabito, Minkyu Song, Ryan Bahm, and Taylor Spencer)

Scenario 2: mentoring and supporting system

The main focus of this scenario is a mentoring system through which novice operators can learn driving tips from experienced ones. The scenario envisions how a personalized truck and incentive program for rewarding mentoring effort could support individual drivers. The proposed system consists of three interface components: a wrist band (that carries the driver’s data and syncs up with his truck to allow more reliable driver identification); a truck (whose main light is color coded to indicate the driver’s expertise and status to those around him); and a safety vest (that lights up to increase visibility within the warehouse). The light on the truck corresponds to the lighting of the vest (Figure 6). In case of an emergency, the light will begin to blink red to alert others of a safety hazard. The safety vest lights up to increase visibility within the warehouse. The final system focuses on the relationship between a mentor and a mentee, and how that system can then reinforce teamwork and safety within the whole warehouse community. The mentoring system is supported by positive reinforcement through a parallel achievement system. Drivers can gain points from safe driving, volunteer work, and communication with their mentor/mentee. These points can be exchanged for rewards such as a day off or free lunch. The ultimate goal of this proposed scenario is to build a sense of community and support network in the warehouse through tangible incentives, thus to support and protect each other from potentially dangerous situations.

Figure 6. Mentoring and supporting system with color coded truck and vest indicating operator’s safety status and expertise: yellow for notice, green for expert, red for emergency (Student team: Eunsol Byun, Jensin Wallace, Paul Harris, and Tobias Dreifke)

Scenario 3: In-truck training system

This scenario focuses on the intimate connection between an operator and his truck as an effective learning and training platform (Figure 7). The main touch point of the proposed system will be a tablet attached to a truck, which consists of three modes: in-truck training (that offers an unobtrusive interactive learning experience, complete with light-up indicators, step-by-step illustrated instructions, and positive feedback); custom tutorials (that allows operators to show off their proficiencies; if an operator does something particularly well, he or she is offered the opportunity to participate in the creation of a tutorial); and personal profile (that gives operators the gift of credibility, recording credentials such as truck safety records, work experience, training history, and tutorial creation). If an operator makes an error, his truck provides a safety pulse , a warning message to alert and give a chance to correct the error. If the operator does something particularly well, the truck can sense his or her level of expertise and will prompt the operator to participate in the creation of a tutorial by using cameras attached to his truck. The driver and the truck develop their performance together and also protect each other in emergent situations. A long-term vision of this scenario is to archive the operator’s performance as his personal profile, which could certify his expertise as well as safety work ethics for future warehouse job application.   

Figure 7. In truck training system for exchanging driving tips and a display wall for sharing community news (Student team: Bennett Nestok, Dane Mayson, Lei Xin, Necia Disse, and Soojin Kim)

Scenario 4: ambient lighting system for safety alert

The objective of this scenario is an intelligent enhancement of interactions in the operator workflow by minimizing distractions with a pervasive lighting system. The focus lies on communicating important information to the driver through the use of multiple senses in unison. The system consists of four display components: the LED ring surrounding a driver’s seating area; the transparent screen projection for the dashboard; the exterior lighting indicator on the top of a truck; and graphic signals projected on the ground from a truck. Colors of the LED ring are designed to easily communicate four types of notifications consistently: red for danger, yellow for warning, blue for neutral alert, and green for positive feedback (Figure 8). When operator driving into the intersection, the exterior indicator will signal directions to surrounding lift trucks and passers-by to raise their awareness. Arc is projected on the ground to indicate an approach from around corner. The use of simple geometric shapes and lines was selected to ultimately communicate to the truck operators both on the truck screen as well as in the projected signals on the ground. Turning different surfaces into convenient screens and projecting necessary information in the direction wherever the drivers are looking can further reduce the drivers’ mental stress of having to constantly check screens for incoming information.

Figure 8. Pervasive lighting system for multi-sensory communication with other drivers and pedestrians (Student team: Chenxi Sun, Christopher Wells, Chunhui Xie, and Jingyao Xu)

5. Reflection

In this project we explored conceptual scenarios for safer warehouse work experience through smart technological interventions by employing different research and ideation methods. A broad range of conceptual scenarios was proposed from a simple, low-tech system of color-coded trucks and vests to a futuristic one for ambient lighting communication. The proposed systems do not involve novel technology invention nor feasible implementation, but the contribution of this project lies on contextualizing emerging (and currently feasible) information and interaction technologies in lift truck work experience and re-framing warehouse safety into the dimension of emotional support through intelligent systems. In particular, environmental and cultural prompts were actively explored through design approaches to develop an organizational program for sustaining operators’ intrinsic motivation. This front-end design ideation of workplace systems and crafted visualization of their use cases enabled constructive discussions between the students and the stakeholders throughout the project. Receiving positive feedback from warehouse staff and managers, we believe that our framing of the core problem of warehouse safety—operators’ motivation and empowerment in their workplace—and our exploratory design approach for it have broader implications for integrated safety and wellness programs in other workplaces, especially by leveraging environmental and cultural prompts rather than imposing administrative regulations (Figure 9). At the same time, we also learned pedagogical lessons that could inform the curriculum of system-oriented design studios with key learning objectives and methods that are distinct from those of product-focused design studios. In what follows, we reflect on these implications.

Figure 9. Reflecting on value propositions and design implications of proposed system scenarios

5-1. Exploratory Approaches to Workplace System Design

Information and interaction technology pervades every aspect of human life, quantifying our personal, social, and professional experiences into data that can be archived and shared as meaningful information. With the current speed of advancements in the technology sector now is an exciting time to push forward into new and unexplored areas in industry. Information systems at workplaces have mostly concerned with monitoring employees’ performance or compliance to regulations or automating repeated, labor-intensive tasks (NY Daily News, 2013). These approaches might be efficient in some aspects, but hard to influence employees’ intrinsic motivations and empowerment, which we found more critical factors in this project. We believe that design approaches could bring in more human values to organizational information systems by promoting employees’ emotional health and self-development (Schulte et al., 2015). At the same time, the application of social network to build a sense of community in workplace was repeatedly proposed across the four student teams in our studio project. This illustrates that the technology-mediated social connection is pervasive in millennials’ tendency to be constantly connected and actively exchange useful information (American Press Institute, 2015; Apple, 2011). It is expected that such technology mediated communities will enable operators to get to know their fellow operators and grow useful relationships not only for their work but for friendship as well. Especially when combined with personal data tracking technology, its influence would become more significant by facilitating social connections based on personal behaviors and interests. Considering the millennials as a new generation of employees, investments in individuals and their emotional wellness are becoming a major priority and under explored frontier. Big companies are taking a new interest in their employees stressing engagement and satisfaction in the workplace. Our proposed scenarios envisioned some of these human-centered approaches to workplace system design (Kaasinen et al., 2015) in contrast to technology-oriented approaches.

5-2. Graphic Design Issues with Emerging Technology

Amongst this roaring interaction and display technology simplicity is taking center stage on just about all fronts. With intelligently enhanced interactions in the operator workflow and connectivity at workplace, we expect to increase safety by enabling drivers exclusively focus on the most meaningful tasks while the system prioritizing and layering different pieces of information. Here the mastery of basic design principles cannot be emphasized more in achieving the simplicity of user interaction with complex systems. Color is utilized as one of the simplest but strongest visual communicators in various forms of system components in proposed scenarios including a vest, graphic/lighting alerts, or projected signage. It is always important to follow the standard meanings of colors (i.e., red for danger, yellow for warning, blue for neutral alert, and green for positive feedback), while reinforcing their meanings across multiple touch points of a system is left for creative ideation. It is important to note that a same message can be more efficiently conveyed when combined with multi-sensory media to create a more compelling communication. In addition, harsh lighting or overwhelming sensory notifications in these distracting industrial environments can have negative effects on a person’s mood and by adjusting their levels the visibility of pedestrian and operator status could be increased in addition to making the operator feel more immersed in the ambient communications.

5-3. Pedagogical Issues for System Design

Although information system design has matured in technology and engineering disciplines, there is not enough pedagogical resource in design education to guide through an exploratory ideation process that reflects emerging technological opportunities beside analytical user-centered approaches (Stickdorn and Schneider, 2012). And we believe that sharing various exploratory design cases will have a meaningful contribution to enriching human-centered system design approaches. The combination of top-down lifestyle as well as technology trend forecasting and bottom-up user-centered research worked out successfully in exploring innovative, still grounded design interventions. We also experienced challenges in defining required design components of system-oriented forms and visualizing conceptual scenarios of new systems that involve multiple touch points of user interactions and rich experiential values. By experimenting with various means of visual communications, we have learned that realistic photographic sketches are effective for discussing initial scenarios than drawn sketches focusing on specific product forms, while static system overviews that list all interaction flows and design components (as in Figure 8 and 9) are more time-efficient for delivering the final scope and structure of a system than video demos, although this may be different in other projects.

Another issue to underscore is that information system design requires domain specific knowledge for professional tasks. We spent much time at the beginning in understanding main tasks of lift truck operators, their workflows, and organizational issues in warehouses (Monk and Howard,1998). The learning curve was steep, but through the conversations with truck operators and warehouse managers we could discover some problematic issues as well as opportunities, which might have not been noticed by those who are already in the system. We consider the communication of this discovery to be more important than final solutions in this front-end system design project. This implies that the role of designers is evolving in this field from making final forms of artifacts to communicating current status of design problems and envisioned scenarios, which could inform and inspire stakeholders to initiate innovative changes. We hope that our detailed report of the project process and reflection could be useful resource for other system design projects and studios.

Acknowledgements

We thank all the students who contributed to this project, and study participants who provided valuable insights about their warehouse work experience.  

American Press Institute (2015). How Millennials use and control social media. Retrieved from https://www.americanpressinstitute.org/publications/reports/survey-research/millennials-social-media/ Apple, Inc. (2011). Challenge Based Learning: A Classroom Guide. Retrieved from http://www.apple.com/br/education/docs/CBL_Classroom_Guide_Jan_2011.pdf     Crown Equipment Corporation (2015). InfoLink Fleet Management Solutions. Retrieved from http://www.crown.com/content/us-en/fleet-management/infolink.html     Davis, M. (2002). The New Culture of Desire: 5 Radical New Strategies That Will Change Your Business and Your Life. Free Press. Design Council (2005). A study of the design process. Retrieved from http://www.designcouncil.org.uk/sites/default/files/asset/document/ElevenLessons_Design_Council%20(2).pdf Holmquist, L. E. (2012). Grounded Innovation: strategies for creating digital products. Morgan Kaufmann. Greenberg, S., Carpendale, S., Marquardt, N., and Buxton, B. (2011). Sketching User Experiences: The Workbook. Morgan Kaufmann. Johansen, B. (2007). Get There Early: Sensing the Future to Compete in the Present. Berrett-Koehler Publishers Kaasinen, E., Roto, V., Hakulinen, J., Heimonen, T., Jokinen, J. P., Karvonen, H., … & Tokkonen, H. (2015). Defining user experience goals to guide the design of industrial systems. Behaviour & Information Technology , 34(10), 976-991. Knippen, J. K. and Green, T. B. (1997). Asking for positive reinforcement. Journal of Workplace Learning, 10(5), 163 – 168. Ljungblad, S. and Holmquist, L. E. (2007). Transfer scenarios: grounding innovation with marginal practices. Proceedings of the SIGCHI Conference on Human Factors in Computing Systems , 737 – 746. ACM Press. Lu, Y., & Roto, V. (2015). Evoking meaningful experiences at work–a positive design framework for work tools. Journal of Engineering Design, 26(4-6), 99-120. Monk, A. and Howard, S. (1998). The Rich Picture: a tool for reasoning about work context, ACM Interactions 5 (2), 21 – 30. Motorola, Inc. (2013). Top 10 Losing Warehouse Strategies – And How To Avoid Them. Retrieved from http://www.motorolasolutions.com/content/dam/msi/docs/business/solutions/manufacturing/_documents/_staticfiles/top_10_losing_warehouse_strategies_and_how_to_avoid_them.pdf Norman, D.A. (2004). Emotional Design: Why we love (or hate) everyday things. New York, NY: Basic Books. NY Daily News. (2013). Can smart machines take your job? Retrieved from http://www.nydailynews.com/news/national/smart-machines-job-article-1.1246522 Ozer, I. (2013). Safety and Wellness: The Critical Connection. Retrieved from https://ohsonline.com/Issues/2013/09/September-2013.aspx Pink, D. H. (2011). Drive: The Surprising Truth About What Motivates Us. Riverhead Books. Putnam, Laura (2015). Workplace Wellness that Works: 10 Steps to Infuse Well-Being and Vitality into Any Organization (p. 31 and 72). Wiley. Kindle Edition. Rath, T. & Harter, J. (2010). Wellbeing: the five essential elements. Gallup Press. Roto, V., Uibo, E., Vienamo, T. 2012. Experience design for forklift e-learning tool. Eds. Väätäjä, H. et al. How to Utilize User Experience Goals in Design workshop in conjuctions with NordiCHI’12 conference, October 14, 2012, Copenhagen, Denmark, pp. 28-32. Stickdorn, M. and Schneider, J. (2012). This is Service Design Thinking: basics, tools, and cases. Wiley. Schulte PA, Guerin RJ, Schill AL, Bhattacharya A, Cunningham TR, Pandalai SP, Eggerth D, Stephenson CM. (2015). Considerations for Incorporating “Well-Being” in Public Policy for Workers and Workplaces. American Journal of Public Health, 105 (8), 31-44.

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4 Warehouse Management System Case Studies

• July 23, 2020

Successful WMS Implementation Case Studies

Warehouse Management Systems (WMS) represent a major investment in your supply chain and operational efficiency. While it can be difficult to gauge your estimated time to value, these four cases featuring enVista clients provide a warehouse management system business case and showcase outcomes after successful WMS implementations.

In this post, we’ll cover four examples of WMS implementations and how they helped companies to optimize warehouse operations :

• Nature’s Best
• Performance Bike
• Bradshaw International
• Men’s Wearhouse

Four  WMS Implementation Examples

1. nature’s best.

*Note: Since project completion, Nature’s Best has been acquired by KeHE.*

Leading the market of health and natural foods distribution, Nature’s Best serves Certified Organic products in over twelve states. Nature’s Best was experiencing high labor costs based on time and manpower to transport temperature-controlled food products between four buildings on its DC campus. The company’s zones were organized to suit either small or large clients – a key competitive differentiator. Because of the facility layout, the overall distribution process was inefficient; each product was touched 18 times on its way to the customer. Nature’s Best technology, distribution processes and buildings also needed updating to keep pace with growth projections.

enVista was called upon to address and resolve the challenges Nature’s Best was facing and did so using its consult, implement and operate (CIO) methodology to create a customized solution.

Phase One: Consult

A supply chain strategy that met Nature’s Best’s business goals was developed. enVista conducted a material flow analysis and redesigned the internal flow processes to increase efficiencies. As a result, a global WMS was selected that addressed all of Nature’s Best’s concerns and determined construction needs for the distribution center (DC). Operations would be consolidated to one DC, and enVista designed the new facility with various temperature-controlled zones.

Phase Two: Implement

As Nature’s Best began construction, enVista supervised the integration and implemented a Manhattan Associates WMS including interface design, configuration, training, facility preparation and labor standards among other features. Nature’s Best shifted from a mechanized to non-mechanized system and from paper to radio-frequency (RF) devices with voice-based technology. enVista managed the move of $25 million of inventory and trained the company team on new system processes.

Phase Three: Operate

During go-live, enVista ensured a seamless transition into Nature’s Best new facility, systems and processes. Throughout the Consult, Implement, and Operate phases, sales were steady – even growing – and upon completion, the project was delivered on time and within budget. The chosen system required few modifications for Nature’s Best’s business model, which would lower costs and allow for easier upgrades in the future.

The new system reduced labor costs by over 30 percent and more than doubled productivity. Ninety-seven percent of full-time employees were retained, and temporary and non-value-added positions were eliminated. Nature’s Best went consultant-free only four weeks after go-live.

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Example 2: Performance Bike

Performance Bike is a privately-held, specialty retailer focused on bicycles and accessories. The company had expanded to over 110 retail locations since its founding in 1982. Performance Bike had a DC in Chapel Hill, NC, with over 60 associates and partners with a 3PL in Long Beach, CA.

Due to compliance issues with the U.S. Postal Service barcodes, Performance Bike had to make system changes to its Manhattan PkMS WMS. The company’s experience with Manhattan Associates gave it a flexible approach when considering an upgrade. enVista’s enABLE methodology was used for the upgrade, and many of the roles typically filled by software or consulting companies were completed by Performance Bike.

Because of the prior experience and flexibility of Performance Bike and enVista, the WMS implementation was under budget and on time. Team members from both enVista and Performance Bike worked together to complete and implement the WMS. The vice president of warehouse operations for Performance Bike noted enVista’s customer-centric approach and flexibility.

The WMS upgrade was implemented in less than 6 months. There were very minor changes to the user experience, so trainings were seamless and increased productivity. Performance Bike experienced a pick per hour increase of 50 to 100 units per hour, exceeding the company’s executives’ expectations.

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Example 3: Bradshaw International

Bradshaw International’s Good Cook™ brand is sold in over 30,000 U.S. retail stores. Bradshaw is a leading marketer of kitchenware products and launched Good Cook to incorporate quality, value and service into every product. This philosophy has allowed Good Cook to achieve the best position for kitchen tools and gadgets with 43 percent of the market.

Bradshaw was asked to participate in Wal-Mart’s direct store delivery consolidation (DSDC) program as Good Cook is distributed in the stores. The program was designed to allow shippers to directly replenish Wal-Mart stores in less-than-case-pack quantities. To do so, Bradshaw had to make changes to several parts of its current distribution systems.

Changes to electric data interchange (EDI), order management, and a pick/pack operation integrated with a new WMS would be required to handle the new variable volumes. enVista was asked to help design and integrate the DSDC program. To meet Walmart’s DSDC objectives, the team had to design and build a new pick/pack module, select the technology to be used by the picking team, and integrate it with the WMS. The order management software , EDI software and billing system had to be modified to accommodate the structures required by Walmart’s DSDC program.

The team profiled SKU movements, identified pick and storage mediums to model replenishment rates, and formulated labor plans and proper work flows. Bradshaw IT and enVista worked together to make configuration changes to the RedPrairie WMS and integrate it with the Pick from Light System and EDI software. The joint team also specified data maps from order capture to order management to WMS through EDI transmissions to move the infrastructure to industry standards.

With enVista’s help, Bradshaw successfully integrated the DSDC program into operations. Shipping volumes increased beyond expectations, but the new WMS has allowed Bradshaw to keep up with demand. The program was implemented with almost no customer disruption.

Example 4: Men’s Wearhouse

Founded in 1973, Men’s Wearhouse is one of the country’s largest specialty retailers of men’s apparel with over 700 stores. The stores carry a full selection of high-end men’s clothing and accessories.

Men’s Warehouse’s main DC was a 1.1-million square foot facility in Houston, Texas. It is the core retail distribution center for Men’s Warehouse retail stores, as well as 60 percent of merchandise from K&G Retail stores, acquired in 1999. A significant percentage of its garment-on-hanger merchandise is shipped by dedicated fleet to regional hubs across the country. enVista’s main objective was to consolidate retail and e-commerce systems to run all operations on a single platform and a central material handling equipment (MHE) integration point.

enVista acted as the program management role for supply chain execution and MHE software functions for all facilities. The implementation of the new systems platform occurred in two distinct phases.

The first phase focused on using the new systems platform to more efficiently meet Men’s Wearhouse’s growing e-commerce business needs. A new WMS and distributed order management system were implemented and integrated to an e-commerce web platform. These systems allowed strategic decision making regarding e-commerce order fulfillment and room for growth, along with the accuracy and flexibility necessary for seamless execution and delivery.

Phase two focused on implementing the new WMS and a consolidated warehouse control system (WCS) in Men’s Wearhouse’s Retail Distribution Operation. The WMS replaced the retailer’s legacy system, and the WCS consolidated the management of several operations into one system. Men’s Wearhouse now has the ability to dynamically change product flow, unit allocation, and achieve more effective utilization of Case Level ASN receiving with the new WMS. The system’s ability to recognize and execute on cross-docking opportunities created improved throughput and lower overall processing costs.

With the implementation of a common WMS and standardized processes, Men’s Wearhouse was able to share recourses across operations and respond to seasonal increases in workload more effectively. The implementation of WMS and WCS gives the company the ability to consolidate its distinct Men’s Wearhouse and K&G distribution operations to reduce costs and increase overall processing efficiency.

Download Men’s Wearhouse Case Study

Conclusion: enVista’s WMS Expertise

Getting your WMS right and making sure it’s integrated properly across your supply chain technology stack is critical to realizing quick ROI and improved operational efficiencies. 

enVista has completed hundreds of WMS implementation projects in its nearly two decades of experience, and our vendor agnostic approach to consulting and implementation ensures you get objective help for your most critical projects. We’re passionate about supply chains and delivering solutions that are the right fit for our clients and would love to help you optimize your supply chain.

If you have a WMS project on the horizon or want to learn more about how we can help you, let’s have a conversation .

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