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Posted By David Bannister
I am attempting to persuade a client that having pedestrians working in warehouse racking aisles where fork lift trucks are operating is poor practice and to be avoided if possible. There is also poor lighting in part. Their response is that the high-vis jackets, driver training and flashing beacons are adequate and we appear to have reached an impasse. The current warehouse management are not prepared to consider any alternative strategies.
I have no intention of involving the enforcement agency and the liability insurers are aware.
Can anyone offer any constructive advice on how to proceed?
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Posted By Dave West
I will be interested to see responses to this post. I worked in this situation for a very large company. When assessed it was not feasible to segregate the two when it came to Reach trucks replenishing stock for the order pickers. so what was looked at was control. Only Reach trucks were allowed in the ailes and they were only allowed to manoeuvre, add and remove stock when there was no pedestrian activity below or around the area.It was also not a non stop activity. I think a certain amount of common sense comes into play here. If you have all your controls in place there should not really be a problem. I was both a driver and a picker by the way. However FLT'S were not allowed in the aisles as we stopped goods inn dropping the pallets directly next to the required location as this was a constant operation and far too risky.
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Posted By John Harrison
The company I work for has to operate like this. Building and site layout doesn't allow us to separate pedestrians and FLTs. Control is important. It is vital that drivers are well trained in their workplace situation, clear rules are set down and enforced e.g. only FLTs allowed in ailes and only allowed to manoeuvre, add and remove stock when there is no pedestrian activity below or around the area. Our Drivers are given authority to instruct pedestrians where to stand etc. for safety and to stop work if they think it is unsafe. Drivers make good use of horns to sound alerts (can be annoying sometimes). We expect pedestrians to give way to trucks. Though one would always prefer segregation, if you have all your controls in place there should not really be a problem. We find the best solutions come when the FLT Instructor, drivers and the department supervisor are involved in the risk assessment process.
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Posted By Merv Newman
David,
Probably impossible in your current situation or for anyone else working with existing racking :
Best practice I have come across is to have "pickers only lanes" alternating with "FLT only" lanes. FLT loads from the back and pickers pick from the front.
One FLT lane can serve two picker lanes.
Merv
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Posted By David Bannister
Thanks, guys. It looks like I may have to accept defeat on this one.
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Posted By Geoff Sanders
I have had warehouse experiences like this in the past.
The only outcome was to diferentiate between essential "picking" staff, and those who are "transitional". The pickers tend to be fully aware of FLT whereas non-warehouse staff often aren't.
Then the sensible solution is to restrict the path on non-pickers so they don't present a risk or hazard, and ensure safe driving and awareness of the drivers relative to the pickers.
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Posted By David Bannister
Thanks, Geoff, you have identified my major concern that transient staff are finding their own way through the racking. Having pickers in aisles with FLTs is bad enough but dispatch office staff returning from lunch etc is unacceptable. I'm working on a solution as you suggest.
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Posted By Chris Jerman
One point not to lose sight of is that once a picker dismounts from their vehicle, they are themselves a pedestrian. That's fine if it's one vehicle per aisle - but if, like many operations there can be multiple vehicle movements per aisle, you cannot prohibit 'pedestrians' from aisles as it will stop the job. You could realistically only probibit the non operational members of the team.
One way to point out to the managers that they may not be controlling activities as well as they may think, is to discuss the function of hi viz. Reflective material only works when it has direct and usually artificial lighting shone at it. If, as you say the lighting is already poor, but there's no way of 'lighting up' the hi viz, it's not really a control. A couple of photos may help them see this frailty. One in poor lighting and one lit up with a lamp or camera flash. Get them to realise that their hi viz is about as effective as wearing a grubby yellow t-shirt. Once you have their attention, you may be able to find an edge.
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Posted By Geoff Sanders
That's a good point re; poor lighting and decent visibility.
Another thing to consider is that (in my experience again)where there is poor lighting, there's signifiant racking damage. The cost of lighting etc could be offset by reduced repairs. At least that's a tangible justification.
I must say though, that if there was an incident, the costs of improvements would seem like very small beer compared to litigation and enforcement costs.
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