Every facility has its heroes like the shiny conveyor systems, towering pallet racks and state-of-the-art automation that seem to draw all the safety focus. But just like in any good action movie, even the heroes have a few weaknesses. Warehouses and manufacturing facilities are no different! These “weak links” are the areas that, if overlooked, can cause big safety issues. You can create a stronger, more resilient facility by paying attention to these sneaky trouble spots.

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Sometimes the right tool for the job is not the flashiest. The humble ball transfer isn’t high-tech, but does a great job of minimizing reaching and straining that endangers workers. Ball transfers punch above their weight class in a warehouse ergonomics and safety program.

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In this month’s employee spotlight, we talk to Markus Green, a safety specialist in our Dallas office. Markus leads our safety automation group in solving forklift/pedestrian interaction issues with advanced solutions. With June being National Safety Month, we talked with him about how he approaches safety for his customers.

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Palletizers are great for higher-volume operations. They increase palletizing speed, increase safety, and build solid, consistent pallets without human intervention. In today’s tough labor market, palletizing is one of the best places to automate and reduce manual involvement. Fully-automated systems come in two basic varieties: conventional and robotic, either of which could be the right fit for your operation.

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There are many ways to transport products vertically in a warehouse or manufacturing operation, each with its distinctive advantages and limitations. These methods can range from extremely basic – a forklift and a pallet – to fully-integrated, automated systems. Vertical conveyors are one of the most common methods for certain loads and situations. What are some of the integration factors for these conveyors, and how can you handle them?

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Insufficient safety measures in warehouse and distribution centers can have severe repercussions, including injuries, operational downtime, product losses, property damages, and potential legal actions. Of particular concern are accidents involving collisions between forklifts or other vehicles and employees or visitors.

Within busy operations, a forklift or other vehicle may eventually run into existing rack. While the rack may not require immediate replacement, storage capacity and product throughput may be compromised for some time. If overloaded, or loaded incorrectly, a rack can also collapse, spilling the inventory to the ground. Employees and visitors must also be protected from vehicle traffic.

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Improving the ergonomics of any warehouse operation may be the single easiest way to improve productivity – and that’s aside from the obvious safety and labor force protection aspects. Consider all the ways people move and work every day, every week, every year. Those repetitive motions take a toll both on the people doing the work and overall productivity. Ergonomics and productivity are not only related: they’re essential to each other.

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As we enter 2024, it’s no secret that manufacturing is growing at a nearly unprecedented rate. This cycle has been on the rise for years, and is now accelerating. Beneath the surface, some regions and sectors are growing faster than others. What are the trends we can anticipate in 2024 and beyond?

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Above: pallet racks are installed both to the side and in front of dock doors in tight space. Palletized loads are floor-staged nearby, further squeezing space.

Warehouse shipping docks are one of the busiest areas in any warehouse. You have the buzz of constant activity as shipments are received or processed out the door, with a mixture of people on foot, forklifts, carts, floor scales, pallets and storage areas. There may be extendable conveyors or other equipment in the same relatively compact footprint. During busy times, it gets more congested and less workable.

It’s also a popular area for palletized storage on, near and around the area. Here’s what to keep in mind:

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Creating a culture of safety is a high priority (and always ongoing) in any facility that values its operations. Whether it is safer forklift/pedestrian interactions, ergonomic improvements, or machine protection, every warehouse is constantly working to improve the conditions within its walls.

But what about the area outside, say, in the parking lot? Sure, it’s not a glamorous area, but you want to keep your workers safe and secure there too!

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