We routinely help industrial and warehousing customers fit their facilities with wire security cages and partitions. They can be built into just about any configuration you want, fit just about any space needed, and can be specified with locks ranging from padlocks to biometric locks.
If you’re paying someone to store a pallet for you, what’s reasonable? Are you overpaying for convenience or location? It’s not easy to compare 3PL vs. 3PL, or even your own warehouse so you know for sure if you are getting value for your money. But there are some basic assumptions you can make to help you understand what you’re dealing with, the costs the 3PL may experience, and reasonable costs for your storage projects.
Sheet metal is one of the most difficult handling challenges out there. It’s simultaneously bulky, heavy, somewhat flexible, and prone to damage if handled incorrectly. It often has sharp edges and corners, making it dangerous to manually move and turn. At higher gauges or in bundles, it requires forklifts, cranes or scissor lifts for safe and effective handling. Even a thin sheet, if it’s 4 x 8, can be too much for a single worker to handle.
Yet, sheet metal is commonly used in manufacturing and fabrication, so finding better sheet metal storage and handling methods is key. What can you do to handle it better?
Pallet racks are frequently subject to abuse, and even the toughest rack will need some cautious handling, processes, guarding equipment, and other help to remain in service. Racks can be overloaded, hit by heavy forklifts, misloaded, and otherwise impacted. These are some tips to help you avoid the frustration, expense, and danger of rack damage.
Take a look at your conveyor – do you think it’s safe? Are there sufficient guardrails? Are operators wearing loose clothing? Are visitors allowed near running lines? Because conveyor seems safe at a glance, it’s an often-overlooked hazard. Used correctly, of course, it is a safe way to increase productivity.
In an industrial environment, intersections can be dangerous. With fast-moving workers who are busy and probably distracted, and fast-moving forklifts that may have loads elevated that can obstruct the driver’s view, corners, ends of rack rows, and intersections can be the cause of many accidents. Whether it’s a worker walking and carrying a load, or a forklift on its way to the next pick, the chances of collisions, injuries, and damages are greater at intersections than most anywhere else. What are your options when it comes to making your intersections safer?
Although this incident took place in a big-box warehouse store, it could have happened in any number of industrial warehouses across the country. The presence of order pickers, shoppers, or others in a rack aisle is a top safety concern, in particular if the aisle on the other side of the rack row is being restocked. Most likely this accident was caused by a push from the opposite side of the racks.
In any case, a tragic accident was narrowly avoided by sheer luck.
If possible, these kinds of accidents should be guarded against with items such as rack safety nets or wire mesh safety panels. This isn’t always possible, since lifts may need access to both sides of a rack aisle.
Another thing you can do is try to remove pickers from aisles where trucks are working the other side. If they are executing each-pick or carton-pick from lower bays, is it possible to move those to their own area of the warehouse, away from lift truck traffic?
In the case of poorly constructed storage, it’s a matter of process. Inspect pallets before they go into the rack. Are they stacked for stability? Shrinkwrap or band them to shore them up. Don’t allow carton picks from those pallets if possible, as that can destabilize the load. If you must pick from them, bring them down, pick, re-balance, and restock them. That’s time consuming compared to a quick carton pick, but given what almost happened here, and what could happen any day in any warehouse, it’s a small price to pay.
You can also clear both sides of a bay when either side is being loaded or unloaded by forklift. This helps you keep people safe even if there is a spill. Of course training lift drivers to avoid these types of “push” accidents is mandatory, but you can’t count on training alone when there is this kind of danger to people in the next aisle.
Since 25% of all warehouse injuries occur at the loading dock, warehousing and manufacturing operations need to pay close attention to this area. Shipping and receiving docks both suffer similar problems in that they are bustling places. At peak times they can get very busy, and when people are pressed for time, they become careless. So, what are the common injury types, and what can you do to avoid them?
At Modex 2012, Hytrol Conveyor’s Boyce Bonham sat down with DCVelocity to discuss distribution center sustainability. We’ve linked the video below, which is worth a few moments of your time. How do initiatives to work greener, smarter, and better affect warehouses and distribution operations? Not surprisingly, these initiatives often save money, at least over the long term.
This note came to us regarding one of our Service & Maintenance clients, a major retailer distribution operation in Dallas, TX, and the experience it had with our technician. With a power conveyor out during the evening, the night before a holiday, he needed fast assistance.
“Tuesday night (July 3) we experienced a significant conveyor failure on night shift. The belt on a straight conveyor section leading into a critical area had broken and wrapped around the drive unit. A huge mess on the night before a holiday.”