The project kicked off with a three-day facility assessment that included:
- A high-level walkthrough of the facility.
- Multiple physical walkthroughs during several shifts of all areas of the facility where racking activities occur.
- Real-time evaluation and discussion of possible control measures at each of the areas of concern, which were identified during the walkthroughs either upon visual observation or at the suggestion of the client.
- Interviews with associates from every shift to better understand their concerns and perspectives and to solicit feedback for continuous improvement.
Antea Group presented potential controls to address the identified hazards related to racking safety. The detailed description of each control option included:
- Control effectiveness
- Cost to implement at one distribution center, and an extrapolation to understand cost investment for all locations
- Delivery timeframe
- Ease of installation (i.e., can this be easily installed or will manufacturer support be required?)
- Limitations of the control
- Impact on overall distribution center operation
The proposed controls followed the hierarchy of controls prioritizing effectiveness, ranging from elimination and substitution to engineering controls, administrative measures, and personal protective equipment (PPE). Engineering controls to preventing material from falling off racks and enhanced forklift attachments for rider safety and improved material handling accuracy were suggested. Administrative controls, including training, targeted hiring practices, and workspace inspections, were also evaluated. Additionally, recommendations for PPE were provided for workers operating in rack aisles.
