Warehouse Safety Tips

Designing a Warehouse

Designing a Warehouse

When designing a warehouse, there are a number of factors to consider. Such things as productivity, safety, and security should all factor into the design of the warehouse and the property on which it stands.

Productivity

In designing the layout of the warehouse, it is essential to use space wisely so that it is possible to store the most product in the smallest space without sacrificing safety or organization. Doing this will enhance the efficiency of the warehouse.

To begin with, use racks to store the inventory. Just as in city planning, there is only so much usable space horizontally, but it is possible to build upward. Be sure to analyze the cost efficiency of these racks - they can be expensive, and it is important not to spend more than the benefit of having them (Wood 1).

Next, it is necessary to examine inventory to determine the most appropriate layout. If the inventory consists of large numbers of the same product, then deeper rows are needed. If it consists, instead, of a variety of products in smaller numbers, then shallow rows are needed. Be sure that the rows are designed with many faces so that all the products are accessible. Be sure that aisle spacing accommodates the type of pallet jack used in the warehouse; making aisles too small will result in damage to inventory and equipment, while aisles that are too large use up valuable space. The best size allows a pallet jack to make a single turn into the row. Similarly, the height of stacked pallets should consider the weight of the product and stability of the packaging (Wood 1). Failure to do so could result in damages to goods or injuries to workers.

Just as designing the layout can enhance or inhibit the productivity of a warehouse, so, too, does the equipment used. Firstly, remove any old or unused equipment - it takes up valuable space and could be a hazard to daily operations (Wood 1). When selecting equipment, make sure that it fits the specific needs of the warehouse, inventory, and function (Wood 2). For instance, stainless steel pallet jacks or pallet trucks are suitable for refrigeration units; often food storage laws require that all surfaces be cleanable, and stainless steel meets this requirement. Then there are low profile pallet trucks which can handle low pallets, with low clearance from the ground. Next are European pallet jacks and pallet trucks. This type of lift equipment is narrower than standard American pallet lifts, which is useful for warehouses with smaller aisles or those handling narrow European pallets. Hydraulic pallet jacks are easier to use, and reduce strain on the user's back and arms, as do quick lift pallet jacks. Pallet jacks with a brake system are ideal for loading areas at an angle. The pallet truck brake system provides better control, preventing accidents and injuries, and a brake that can be locked in place allows the lift equipment to remain stable during loading. Often it is advisable to speak with a reputable dealer and request their recommendations (Wood 2).

Finally, managing inventory is essential to the productivity of the warehouse. One means of maintaining the most profitable inventory is to use JIT (Just in Time) deliveries. This means that the product stored in the warehouse is constantly being moved; there is a reduction in tying up investments in product that just sits in the warehouse (Wood 1). Also, there are a variety of software options available to help manage inventory, but be careful that the software does not take over the operation of the warehouse. It should be a tool assisting in the organization of the inventory, not a slave master that takes up time and personnel. As one expert states, "[B]eware of bells and whistles that sound so good. They can become a cacophony when you try to implement them." Additionally, organizing inventory in a way that allows the easy access to the most commonly used products will enhance productivity and increase accuracy of orders. Specialized equipment is available for selecting and organizing orders; ask for demonstrations and investigate all options before making a final decision (Wood 3).

Safety

The single most important measure for safety is information - make sure that all personnel in the warehouse are aware of safety issues by disseminating information. One way to do this is to post signage announcing various considerations. For instance, mark aisles concerning clearance limits, post floor loading capacity concerning joisted floors, post No Smoking signs in high visibility areas, and identify correct lifting and materials handling techniques through posters and other signage (Warehouse 1).

Other precautions concern the design of the structure. Ensure that all aisles provide adequate clearance (Wood 4) and that floor drainage prevents water accumulation, which can lead to slips and other accidents. When designing inventory racks and storage areas, be sure the racks are secure and the materials are stacked in a stable manner, and that they are secured in the event of an earthquake or other natural disaster. Similarly, all storage levels over seven feet should include safety rails (Warehouse 1). Furthermore, it is essential to create a loading dock that accommodates the needs of the warehouse. It will be handling the highest traffic, and as a result, has the highest potential for accidents. Do not skimp on the space provided to the loading dock (Wood 2), and make sure safety rails are installed in the appropriate locations: any space over seven feet high. Finally, all ramps should be designed with a no-slip coating (Warehouse 1).

Security

One of the most important measures for security is garnering a relationship with local law enforcement. Local law enforcement officials can provide a free security survey and make suggestions about the weak points in a building's defenses. They can also recommend alarm system companies and the best alarm system features for an individual property (Security 1). Moreover, know the names of the officers that patrol the area; getting personal with the law enforcement officials can ensure more individualized attention to the property and warehouse. This is especially important for warehouses that are often unoccupied or have a low number of personnel. This also gives law enforcement a contact person in the case that an emergency does occur (Robbery 1). Similarly, invite police personnel, especially those patrolling the area, to view the layout of the building. This will allow them to plan ahead should they need to secure the area. It will also permit them to notice suspicious activity (Carpino 6). Finally, supply the local police department with a list of employees who have authorized access to the property. If the police need to gain entrance, they will need to contact someone with access capabilities (Carpino 2).

The next line of defense is to secure the property. This goes beyond simply locking doors. It is essential to secure the perimeter of the property first - a six foot chain link fence with barbed wire is suggested for the best security (Commercial 1). Immediately around the building, the property owner may want to plant hedges. They should be wide, not tall, and have leaves or other growths that are prickly (Burglary Defense 1). These hedges not only provide a level of protection, but they also beautify the property. One expert points out that the appearance of the property can influence criminals' attitude toward it; a neatly kept building and property gives the impression that there are more eyes watching the property, and so it is a deterrent to criminals (Lockyer 1). It is equally important to provide adequate lighting around the exterior of the warehouse. Visibility should extend to 100' (Parking 1), and the lighting fixtures should be difficult to damage or alter (Small Business 1). It is essential also to ensure that foliage doesn't interfere with lighting (Robbery 1).

After securing the perimeter of the property, it is vital to secure the warehouse itself. This is the final barrier to criminals, so it is very important to be aware of and use as many precautions as possible. One important detail that many people do not consider is that the vehicles they may keep around their property could be used for a forceful entry into the warehouse. For this reason, it is recommended that vehicles be stored away from the building and keys are not left in any vehicles after hours. Another often missed security issue is fire ladders or utility ladders. Criminals will use any entrance, including a roof or ventilation entrance. To prevent this, experts suggest ensuring that ladders are raised at least eight feet about the ground, or have a secured enclosure if they cannot be raised above that level (Commercial 1). In addition to these precautions, it is also recommended that property owners install bars, break resistant film, or mesh on windows (Commercial 2). For safety, as well as quality, it is best to use security equipment, like window bars and grilles, that is UL listed (Security 1). UL listing is very important, because while it is important to protect the business from criminal entry, it is equally important to ensure safety. UL listing is a certification that the product meets safety and quality standards, much in the same way that many fire exit devices are UL listed. Furthermore, it is important to ensure that window locks are not accessible through a broken window, in the case that a criminal attempts to gain entrance by one (Burglary Defense 1).

In addition to these precautions, there is, of course, securing all doors and entrances to the warehouse. Install metal or solid wood doors and tamper-proof hinges on external doors. If there are external glass doors, they should have mesh running throughout, and sliding doors should be secured with a floor rail and vertical steel pin assembly (Commercial 1). It is suggested that doors be locked with a deadbolt lock. If a padlock is used, file off the serial number so that unauthorized keys are not made (Small Business 1). Furthermore, an alarm system may be the final line of defense against criminals (Security 1). Security experts note that prominently displayed warning decals, provided by the alarm company, can be a deterrent to criminals (Commercial 2). Likewise, using clearly displayed signs marking public and private areas, as well as entrances and exits, is an important measure. This will make it easy for employees to determine if someone does not belong (Lockyer 1).

Finally, another important security issue is fire - a fire could be disastrous to inventory in a warehouse. Studies have shown that arson is often connected with robbery (Garrow 3). As important as it is to secure the property against entrance, it is as important to secure it against arson. Keep flammable material away from the fence or edge of property to prevent criminals from starting a fire from outside the property (by throwing a match or some other incendiary onto the flammable material). Similarly, secure trash bins away from walls and stop up gaps under doors (Garrow 3). Make sure that address numbers are clearly visible from the street so firefighting personnel can easily find the location if necessary (Fire 1). Additionally, all emergency exit doors should be unlocked from the inside at all times (Fire 5). The easiest way to do this is to install a fire exit bar on each emergency exit. Panic exit bars are designed to remain unlocked at all times, so no one is ever caught inside a burning building without an exit. These emergency exit devices are also a secure means of preventing unauthorized entrance to the warehouse. Many fire crash bars do not allow entrance from the outside of a building without specific accessories. For warehouses that have emergency exits that are rarely used, this design is ideal, since the door is always secure from the exterior, but is always unlocked from inside. For those warehouses that use emergency exits for regular business purposes, like deliveries, panic crash bars are often equipped with dogging, which locks the fire exit bar in a depressed position so the door is accessible from the exterior. By adding fire door hardware like handles, the emergency exit door can become a functioning door. Furthermore, many emergency fire exit bars come with a cylinder lock for additional security from the exterior of the building. Other fire door hardware can make a building more convenient for business needs. For instance, certain door closers are designed to slow the opening or closing of doors to accommodate the entry of a person carrying or maneuvering a large load. Thus, by installing the proper emergency fire devices, a property owner can secure the building, protect inventory and employees, and accommodate business needs.

Sources:

"Commercial Building Security Tips." Loss Prevention Bulletins. The Co-operators General Insurance Company. 27 November 2008. http://www.cooperators.ca/static/pdf/en/LP014.pdf

Carpino, John M. "Commercial Burglary & Robbery Prevention Tips." SafetyCops.com. 30 November, 2008. http://www.safetycops.com/commercial_burglary.htm

"Fire Safety for Small Business." Plainville Fire Department. 30 November, 2008. http://plainvillefire.us/firework.htm

Garrow, K. "Fire Safety Tips - How to Protect Your Business from Arson." Ezine @rticles. 30 November, 2008. http://ezinearticles.com/?Fire-Safety-Tips---How-to-Protect-Your-Business-From-Arson&id=1644458

Lockyer, Bill. "Burglary Prevention." Crime and Prevention Center. California Attorney General's Office. 29 November, 2008. http://crc.losrios.edu/~police/Resources/burglary.pdf

McGoey, Chris, CPP, CSP, CAM. "Parking Lot Security." Crime Doctor. 29 November, 2008. http://www.crimedoctor.com/parking.htm.

Montaldo, Charles. "Business Burglary Prevention Tips: Keep Your Business Safe." About.com. 29 November, 2008. http://crime.about.com/od/prevent/qt/burglary_tips.htm

Montaldo, Charles. "Robbery Prevention Tips for Businesses: Make Your Business Safer." About.com. 29 November, 2008. http://crime.about.com/od/prevent/qt/prevent_robbery.htm

"Security Tips for Small Business." 27 November, 2008. http://www.lunaweb.com/buscrime.htm

"Small Business Security Tips." Security World. 27 November 2008 http://www.securityworld.com/ia-389-small-business-security-tips.aspx

"Small Business Security Tips: Burglary Defense and Prevention." ADT. 29 November, 2008. http://www.adt.com/wps/portal/adt/small_business/learn_about_security/security_tips

"Warehouse Safety." Web Direct Brands, Inc. 11 February 2009 http://www.palletsonthego.com/safety.asp

Wood, Leslie. "Planning a Warehouse." March 2002. Material Handling Management. 11 February 2009 http://www.estonian-warehouse.com/failid/18876266.pdf