Checklists are valuable for helping warehouse workers follow the right steps without missing any. However, some safety professionals become overly reliant on these documents. They are useful but much more applicable when combined with improved procedures and relevant training programs. 

Reduce Warehouse Risks with Loss Trend Analyses

An assumption may encourage someone to look deeper into a suspected issue but should not primarily drive their actions. Instead, it’s better to take a data-driven approach to improvement, such as by conducting a loss trend analysis. They reveal how, when, why and where safety incidents happen. People can then use that foundational data to find useful patterns within the information. 

Perhaps the analysis shows that most safety issues involve the least experienced workers. That insight might encourage a manager to change the training program or increase the time employees spend on educational activities. The results help companies create effective risk mitigation strategies with other measurable benefits. 

For example, these investigations may uncover numerous ineffective processes that frustrate workers and make some consider looking for alternative employment. However, if employees feel leaders listen to their feedback about what doesn’t work well and are committed to improving things, that could increase retention and boost morale. 

Help Workers Adopt Safer Habits with Wearables

Many employees unconsciously form risky behaviors, especially related to things they don’t regularly monitor, such as how they move. Most people hardly think about how they walk, reach and bend. However, that lack of awareness could be dangerous in warehouses because workers are physically active throughout their shifts and move in ways that could injure them if not corrected. 

One company dealt with that issue by having warehouse team members use keyfob-sized wearables to prevent spine issues. They vibrated and beeped whenever users made risky movements, teaching them to be safer and encouraging better habits. After only three weeks, 62% of workers reduced their average hourly hazards by at least 50%. Material handling risks also went down by 39%. 

In addition to showing employees which movements to adapt to prevent strain, this study’s data also improved processes. One worker noticed that his wearable notified him during every floor-level task. He dealt with the problem independently by raising the height of the products requiring his attention. However, once his managers noticed the change, they purchased an adjustable lift cart for him. This example highlights how people may not notice unsafe behaviors or practices until they collect information that shows the issues.

Explore Automation Opportunities

Many warehouse decision-makers realize it’s time to automate repetitive or high-risk processes when possible. That can elevate safety while bringing other advantages. One possibility is to use a pallet shuttle to automate storage and retrieval tasks, which can save companies up to 50% in direct labor costs. It can also increase workers’ order fulfillment accuracy rates and overall output. 

The warehouse automation market features numerous technologies, vendors and methods to consider. The solutions leaders choose will depend on factors such as the company’s goals, current challenges, size and product type. Decision-makers should also select metrics to track and timelines for meeting stated milestones. This will keep them focused and reveal whether the technologies already work as well as expected or need tweaks to optimize the outcomes. 

Those overseeing automation rollouts should determine how the selected technologies will change processes and then design new training programs to reflect what’s different. Training specialists should also account for how learners may want to receive content on their mobile devices or only do so because they do not have offices or other dedicated workspaces. One study found that only 19% of people can access training content on mobile devices. However, 60% of respondents would like to receive it that way. 

It may take several weeks or months after the training for people to become comfortable with the new automated equipment. However, they will naturally become more acquainted by spending more time with it. It is also important to emphasize that they should ask questions or report problems as matters arise. People who feel involved in the introduction of automation at their companies are more likely to take ownership of its success and be honest about the downsides they notice. 

Invest in User-Friendly Equipment

Warehouses may also become safer and more efficient when executives find equipment that solves pain points. Such was the case at a coffee company’s facility. Once the business moved to a new place, leaders realized that its narrow aisles and high shelves made it challenging for workers to maneuver forklifts. Plus, employees needed specific certifications to operate that equipment. Not everyone had them, which caused staffing shortages and bottlenecks. 

Executives addressed the issue by purchasing a walkie reach stacker that can lift things 189 inches off the ground and make tight turns. The walk-behind equipment has a 3,000-pound capacity, and people can operate it without earning certifications first. That improved the company’s flexibility. The unit is smaller than a forklift but does everything needed, making it an ideal pick for its current facility. 

Such equipment changes may require training or process updates, but those steps should be worthwhile since the overall result addresses multiple recent challenges. The company’s executives specifically liked how people could use the equipment with minimal training. That meant it should not take them long to learn to work with it safely and efficiently. 

Evaluate Procedures and Educational Methods

Even if decision-makers believe their current methods work well, there may be weak points to improve, or workers may give feedback that would make them more productive and happier in their roles. Those realities make it necessary to continually examine how a company operates and trains its workforce to find opportunities for improvement.