4 ways to improve DC safety and increase productivity

Increasing pick rates and throughput is a great first step. But don’t underestimate the impact of a safe working environment on morale and productivity.

By Bob Trebilcock, Editor at Large -- Modern Materials Handling, 8/1/2007

“When it comes to improved productivity, safety is an overlooked area,” contends Michael Davis, a manager with Sedlak Management Consultants. “A lot of times, you don’t realize how much a workmen’s compensation claim costs or the hit you take to morale and productivity if someone gets hurt on the job.”

Given that lift trucks are involved in about 10% of the injuries in a warehouse or distribution center, that’s one of the first areas Davis looks at when he walks through a facility. Davis says there are at least four easy fixes that can reduce accidents and create a safer, more productive work environment.

1) Create a walkway

The simplest solution is to create a pedestrian walkway, outlined by yellow paint and protected by a guard rail. “This is a low cost and effective solution that’s often overlooked when you’re designing a new facility,” Davis says.

2) Install mirrors and alerts

Aisleways can get congested. In some picking areas, it’s not uncommon to have order pickers on foot along side order pickers with walkies while lift trucks replenish pick faces. Mirrors are one solution to this congestion. Another concept is a mirror system with sensors and alerts.

“Even if you can’t see if someone’s coming in the mirror, the sensors will pick it up and alert you to an oncoming vehicle and to what direction it’s traveling,” says Davis. He adds that the $1,500 to $4,500 investment is a fraction of a workmen’s compensation claim.

3) Put a safety gate on mezzanines

OSHA requires a protected gate for mezzanine areas. Most of the time, those are manually operated. “They work great, as long as someone doesn’t forget to close the gate,” says Davis. A better solution is a safety gate that automatically closes after it’s been opened. 

4) Install sensors around automated equipment

Automated systems, like robotic pickers and palletizers, are an effective way to improve productivity in picking and shipping operations. They can also result in serious injury if workers are careless around them. “That’s why we suggest the installation of a light curtain around automated equipment,” says Davis. “That’s a system of photo electric eyes that create a barrier around the equipment. If the beam from the photo electric eye is broken because someone is in that area, the equipment automatically shuts off.”