06/04/05 Rack Safety

The diverse range of activities being handled in warehouses across the
Middle East is constantly increasing. Additional tasks such as
packaging and labelling are now taking place alongside traditional
distribution activities, leading to growing numbers of warehouse
hazards. This has resulted in logistics managers re-assessing their
health and safety policies to ensure potential mishaps are kept under
control.
Accidents caused by faulty or damaged racking are normally kept under
wraps in the Middle East, which means official figures on the number of
incidents are currently unavailable. However, despite the secrecy,
these accidents are a reality throughout the region and should not be
ignored.

"Companies tend to keep warehouse accidents outside the public domain,"
says Geoff Wheatley, regional director, SSI Schaefer. "Accidents
involving racking certainly occur in the Middle East but these
incidents rarely hit the headlines because companies fear damaging
their reputations by releasing the information."

The financial impact and potential fatalities resulting from racking
accidents are considerable. A collapsed racking system could result in
property damage, ruined products, personal injury and even death.
However, a handful of simple preventative measures can effectively
reduce the risks.

"Companies always benefit from being proactive rather than reactive to
avoid any possible warehouse accidents," says Walid Tamari, UAE sales
manager, Emirates Specialities Company. "Although logistics managers
can never guarantee an accident-free warehouse, it's important to take
measures towards reducing the numbers of accidents. This is not
necessarily a daunting task and can be easily achieved."

Manufacturers of warehouse racking should follow international
standards, which are implemented to protect customers. These standards,
created by the likes of the Storage Equipment Manufacturer's
Association (SEMA), the Rack Manufacturers Institute (RMI) and the
Federation Europeenne de la Manutention (FEM), are there to ensure
manufacturers abide by stringent safety procedures. All suppliers of
warehouse racking systems should have structural data that backs up
their designs and conforms to industry standards.

"These standards are designed to protect the safety of the operators
within the warehouse environment," says Wheatley. "There are certainly
risks involved in using non-certified racking. Therefore, it's
important for the customer to ask whether the racking has the latest
certification. This gives them peace of mind about the quality of the
racking in the warehouse."

Although higher quality racking is more expensive in the short term,
the return on investment should be better than lower quality
alternatives. However tight warehouse budgets can make cheaper options
more attractive for companies in the Middle East. "Pricing is the most
important decision criteria for the majority of companies purchasing
racking systems," says Tarek Saoud, director, SPAN SCS. "Unfortunately
this means poor engineering or low quality shelving is widely available
and demand exists for such systems. However, purchasing quality racking
that meets recognised international standards is certainly important in
the long term."

Purchasing quality racking is certainly an important first step in
ensuring warehouse safety. However, companies should also conduct
regular inspections of the racking systems, which is a commonly
neglected activity in the Middle East.

"It's important that once the racking is installed in the warehouse,
customers must take precautions to ensure damage does not occur," says
Wheatley. "Regular inspections allow the logistics manager to keep
track of damage and take preventative action."

Logistics managers should replace or repair damaged racking as soon as
possible. Ignoring damaged racking is not only reckless, but it also
sends out the wrong signals, because disregarded damage tends to
promote further racking damage in the warehouse.

There are various causes of damage to warehouse racking systems, which
are often highlighted during inspections. Overloading is a prime
example. Racking is designed to support specific load weights, which
are outlined during the purchasing process. Therefore, when selecting
the system, companies must choose something with adequate strength and
stability, based on the weight of the loads being placed on the
racking. The entire system could collapse as a result of companies
using the racking in a manner other than originally configured.

"The racking systems found in warehouses are carefully analysed during
the design process to meet the requirements stated by the customer,"
says Saoud. "This means the suitability is subject to certain
specifications. For example, the loads being carried by the racking
will contribute either positively or negatively to the system's
structural integrity. If overloading occurs, it can result in
accidents."

The load limits of the entire racking system, as well as each shelf,
should be clearly stated on the racking system to ensure warehouse
staff is aware of maximum load sizes. This information should ideally
be placed once or more in conspicuous locations, such as at the end of
all aisles.

Racking systems are generally produced using lightweight material,
which limits their ability to withstand large amounts of wear-and-tear.
If the forklifts in the warehouse happen to crash into a racking
system, for example, the resulting dents can affect the load-carrying
ability of the racks and create a dangerous working environment for
employees.

"The racking systems can receive structural damage following a harsh
blow," says Tamari. "Although incidental scrapes are normally quite
harmless, anything more serious, like a dent resulting from a forklift
collision, means the damaged component will probably need replacing."

This highlights the importance of careful forklift truck driving within
the warehouse. The skill of these drivers has a great bearing on the
amount of damage likely to be caused. If the operators are reckless
whilst handling vehicles, the chances of mishaps occurring are much
higher. "Damage can be avoided if the company hires good quality
forklift truck drivers," says Wheatley. "If the company notices damage
whilst inspecting the racking systems, it must research the cause and
discuss the situation with the responsible forklift truck driver. If
the damage continues, the company must decide whether to provide some
form of training or whether to take action against the driver, such as
issuing warnings."

There are various different types of forklifts available in the market,
each suitable for different tasks. It is very important that warehouse
operators use the forklift most suitable for the individual task. Using
an inappropriate forklift can also
cause damage to the racking. "Sometimes companies are not educated
enough in using the right forklifts," says Tamari. "A reach truck is
different to a counter balance forklift. They perform different
functions. So if a driver is using the wrong forklift and pushing up
instead of pushing down, it can cause the racking to collapse."

In addition to efficiently driving the right forklift, companies can
also purchase optional tools such as steel or plastic protection
systems to help prevent damage. Impact damage is most likely to occur
at the base of any frame, even more so in the case of the end frames.
The protectors are placed over the front face of a rack upright and
even if serious damage occurs, the protector is replaced rather than
any component of the racking system, which is a cheaper option.

Purchasing quality racking and conducting regular inspections will
bring long-term benefits to companies. Although the safety aspect of
warehouse racking is somewhat neglected, the situation is showing signs
of improvement. Local authorities and companies are becoming more
proactive about reducing the risk of accidents.

"The situation is expected to improve in the future," concludes
Wheatley. "Jafza is very proactive regarding warehouse safety and
conducts regular inspections. Also, more international players are
entering the market and these companies normally have their own inhouse
guidelines regarding health and safety. Companies such as GAC, RHS and
Transworld are very safety conscious in the warehouse environment and
regularly train employees."

Of course, no matter how well storage systems are designed and forklift
truck drivers trained, damage to warehouse racking systems is
inevitable. Luckily, reducing the risk of mishaps and accidents is
relatively simple, saving money in the long term and ensuring the
safety of your warehouse staff.