Protecting Your Resources:
Safety Management in the Loading/Unloading Zone

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Workplace Injuries

As companies around the world continue to feel the need to work faster and more efficient, there is one common aspect they all must keep in mind: the safety of their workforce.

According to research from the Colorado State University Health & Safety Consultation Program nearly 50 workers are injured every minute of the work week. That translates to 120,000 per week or over 6.2 million per year.

Although most companies go through rigorous training efforts regarding how to lift, move and maneuver heavy products and parcels, employees work in fast pace mode and continue to cause injuries to their back, arms, shoulders, hands and elbows. There have even been cases of lifting heavy items in the correct, ergonomic manner causing knee and joint strain.

The question that remains in focus is: how can we prevent these injuries and what mechanisms can we create to significantly reduce injuries to our personnel?

A quick online search revealed several attorneys recruiting potential clients that have suffered from warehouse injuries. As workplace injury costs skyrocket and legal help becomes more easily accessible, it is imperative to be knowledgeable and prepared for accidents in your workplace. There are several types of injuries that can take place in the warehouse as evidenced by the Delius Law Firm’s “Warehouse Injury and Loading Dock Accident” page:

“Warehouse employees can…hurt themselves through overexertion, repetitive stress, or the degenerative effects of heavy lifting over a long period of time.”

Modern Material Handling Magazine also evidenced this in an article entitled “Ergonomic Handling Basics” by Bob Trebilcock in January 2007:

“Some jobs, like unloading parts from a container, require an employee to bend, twist and reach. These jobs can be improved ergonomically with devices that adjust…height and…angle…for easier access.”

There are many examples of various injuries and health hazards that can take place in the loading/unloading zone. According to the OSHA “Warehouse Safety Pocket Guide,” a few of these hazards/injuries include:

• Workers can be injured when they are caught in pinch points or in the in-going nip points, are hit by falling products or develop musculoskeletal disorders associated with awkward postures or repetitive motions.
• Back injuries may occur from improper lifting or overexertion.
• Improper lifting, repetitive motion or poor design of operations can lead to musculoskeletal disorders in workers.

The Canadian Centre for Occupational Health & Safety states that due to the nature of the distribution and warehousing industries, “there are many situations where physical demands involve force, repetition, awkward postures and prolonged activities.” As safety regulations become more stringent and the costs associated with accidents rise, preventing harm to the work force must become management’s top priority.

While working at a conveyor or belt, repetitive motions, reaching, and lifting may be a concern. Safety for the worker is a high priority, as movements are done quickly and tasks are performed for long periods of time. Many studies have been done regarding workplace injuries, specifically repetitive motion injuries.

According to the 2007 Liberty Mutual Workplace Safety Index, there were multiple causes of workplace injury claims in 2005. Overexertion claims totaled $12.7 billion (injuries caused from excessive lifting, pushing, pulling holding or throwing are down from $13.6 billion in 2004), bodily reaction claims totaled $4.8 billion (injuries caused from slipping or tripping without falling are up from $4.7 billion in 2004), and repetitive motion claims totaled $2.1 billion (injuries due to repeated stress or strain are down from $2.5 billion in 2004). These claims, often found in the loading/unloading zone, equal $19.6 billion (down from $20.8 billion in 2004). That equates to 40.7% of the top ten claims (totaling $48.3 billion).

When working in the loading/unloading zone, it is important to remember to be alert and work safely around equipment. Each piece should have its own safe work procedures and precautions. The OSHA “Warehouse Safety Pocket Guide” suggests precautions when working around the different hazardous, and potentially injury causing, loading/unloading zone:

• Inspect conveyors regularly;
• Ensure that pinch points are adequately guarded;
• Develop ways of locking out conveyors and train employees in these procedures;
• Provide proper lighting and working surfaces in the area surrounding the conveyor.
• Provide general ergonomic and task-specific training;
• Test the load to be lifted to estimate its weight, size and bulk, and to determine the proper lifting method;
• Minimize the need for lifting by using good design and engineering techniques;
• Lift properly and get a coworker to help if a product is too heavy;
• If possible, use powered equipment instead of requiring a manual lift for heavy materials;
• Reduce lifts from shoulder height and from floor height by repositioning the shelf or bin;
• Don’t twist while carrying a load, but shift your feet and take small steps in the direction you want to turn;
• Keep floors clean and free of slip and trip hazards;
• Create a Hazards Communication Plan.

While it is impossible to create an entirely safe environment for your workers, there are many things you can do to help prevent injuries. With the suggestions provided above, you can create the safest environment possible with training, precautions, awareness and the correct equipment in your facility.

The Bottom Line

Safety in the workplace and protecting the workforce is the highest priority. At Caljan Rite-Hite, we primarily manufacture products dealing with the loading and unloading zone of the warehouse. This area is where most warehouse work injuries take place, particularly if trailers are loaded and unloaded manually. Repetitive movements of placing parcels in a trailer and attempting to stack them in a manner that will get the most cube has become an ongoing issue for companies. It’s a fact that time and space equal money. What can we do to get the most utilized cube out of a trailer while doing it in the most efficient and safest manner possible?

We believe our equipment will help in preventing ongoing injury issues, and we continue to manufacture our equipment providing the utmost in safety features. We understand that there is a person at the other side of our product line and we have a responsibility to provide a product that is safe and efficient. It’s the responsibility of all industries to continue the effort in making the workplace as safe as possible.

About The Author

Tina Hogel
Account Manager - Midwest Regional Office

Tina Hogel joined the Caljan Rite-Hite team June 2008. She is responsible for developing the Manufacturer and Integrator relationships US market. Currently, she is heading the Midwest Regional Office in Cincinnati, Ohio.

With almost 14 years of experience in the automated material handling industry, her strengths are in high speed distribution utilizing large automated conveyor and sortation systems. She is an expert in building and maintaining customer relationships throughout the material handling industry.

Tina has earned her MBA from Rochville University. She lives in the Cincinnati, OH area where she is an avid girls softball coach and fan.

Resources

Smith, Lee. “Do You Know How Much Accidents Are Really Cutting Your Business?” Colorado State University Health & Safety Consultation Program, 1996.

Delius, Scott. Warehouse Injury and Loading Dock Accident. Delius Law Firm, P.C. 31 July 2008. http://www.deliuslaw.com/CM/WorkersCompensation/Warehouses-Loading-Docks.asp

Trebilcock, Bob. “Ergonomic Handling Basics.” Modern Material Handling 1 Jan. 2007. 4 Feb. 2008 http://www.mmh.com/article/CA6403371.html

“Warehouse Safety Pocket Guide.” OSHA. 27 Jan 2005. 31 July 2008. http://www.osha.gov/Publications/warehousing.html

“OSHA Ergonomics eTool: Solutions for Electrical Contractors.” OSHA. 7 Feb. 2008.

http://www.osha.gov/SLTC/etools/electricalcontractors/glossary_all.html

“Firefighter.” Canadian Centre for Occupational Health & Safety. 32 Mar. 2003. 31 July 2008. http://www.ccohs.ca/oshanswers/occup_workplace/firefighter.html

Liberty Mutual. 2006 Liberty Mutual Workplace Safety Index. Boston: Liberty Mutual, 2007.

Liberty Mutual. 2007 Liberty Mutual Workplace Safety Index. Boston: Liberty Mutual, 2008.