04

Mar

Improved warehouse safety – make your racking a priority task

Safety has to be a priority in any warehouse. They are busy environments. Heavy stock is moving around and you must protect employees while working in the space. However, over recent years with the fast growth in e-commerce, pressures have increased within the warehouse. With a drive for additional storage capacity and faster throughput of stock, are you remembering to maintain warehouse safety?

In the warehouse, the main focus areas for safety are slips and falls, manual handling and keeping your employees safe around moving vehicles. The challenge, especially as our warehouse spaces get busier, is how to minimise the risks. This is where your racking comes into play. Get the design of your storage equipment right, take the correct measures on maintenance and training and it will address many of your safety issues.

Here is our checklist of key points to consider to maximise pallet racking safety.

warehouse safety - pallet racking safety

Warehouse Safety – roles and responsibilities

Before we look at how your pallet racking can make a warehouse safe, you first need to understand your responsibilities towards warehouse safety. Fortunately, serious incidents around racking are rare, but they can and do still happen. This is why there are several regulations and guidance documents in place that any business owner must follow to meet their health and safety requirements. These are:

In addition to these, there are three regulations and guidance documents which specifically relate to increasing warehouse safety. These also cover safety in the design, installation and use of your pallet racking equipment.

Construction Design and Management Regulations 2015 (CDM 2015) sets out the legal duties of everyone involved in a construction project. Although you may not realise it, large pallet-racking projects fall under the category of construction work. CDM 2015 requires the client (anyone who has construction work carried out for them) to make sure their project is suitably managed and upholds the health and safety of anyone involved.

In conjunction with industry unions, associations and employer bodies, HSE produces HSG76 Warehousing and Storage: A Guide to Health and Safety. The document offers advice to warehouse owners in increasing safety and covers general health, safety and welfare, materials handling and storage.

Provision and Use of Work Equipment Regulations, 1998 places the responsibility on employers to uphold safety for their employees by ensuring the work equipment they use is in good working order. The regulations include pallet racking and other storage equipment.

Increase Pallet Racking Safety

Making sure your racking equipment and warehouse space meet industry regulations is essential. However, in an industry with so many different suppliers, knowing who to work with can be a challenge. How do you know they have chosen the right system for your warehouse? Does the design increase warehouse safety standards? Will the structure meet its intended purpose? Are they meeting all the regulations?

Checking the credentials of your suppliers can take a lot of time, especially if you’re not a racking expert! One place to start is by contacting SEMA, a leading voice in the storage equipment industry. Their guidance works through the design, supply, installation, use and maintenance of storage equipment.

To help warehouse owners even further they also work with leading industry suppliers to create a network of approved members. Work with a SEMA Distributor Company such as Teepee and you know they undergo independent audits to ensure they meet all the industry requirements and standards. This provides clear proof to warehouse owners that their new storage system will be correctly designed using new products that are installed by trained and qualified teams to meet HSE standards and that the member is correctly insured. It will save you a lot of time and effort making sure you tick all the health and safety boxes!

warehouse safety - loading

Prioritising pallet racking safety

One of the advantages of working with a SEMA Distributor Company is that you know they are benefitting from the technical expertise available through the group. That means we are kept up to date on the latest industry regulations, technical requirements and design guidance.

To enhance your warehouse safety, we will make sure that your racking considers the following:

  1. Safe working spaces
    Keeping your employees safe when working in areas with pallet racking has a lot to do with the layout of the equipment. Of course, optimising the racking must address how to increase storage capacity, processing order timescales and productivity. But good design and layout will also help reduce accidents, keep your employees safe from moving vehicles and minimise the risk of slips or trips. This includes creating clear pathways, designated loading and unloading zones, and ensuring stock is accessed safely.
  2. Moving vehicles
    In the modern warehouse, you will inevitably see some form of vehicle moving around the space. Forklift trucks are the most common but, with the increase in automation and robotics, the requirements are changing. However, with warehouse workers also using the space there needs to be constant management to prevent accidents. Traffic routes around the racking should allow pedestrians to see the vehicles and drivers to operate safely. Where possible, employees should be kept separate from the vehicles.
  3. Racking designed for stock profiles and picking methods
    As warehouse spaces become larger, so too do the size and height of the racking structures. It is not unusual for workers to work above floor level on mezzanine or multi-tier structures or through the use of forklift trucks. Keeping everyone safe on the shop floor requires a design that includes enough space between the beams for the picking methods, equipment used and stock profiles. The racking aisles must also accommodate safe access to goods, use correct racking protection products and incorporate the moving space of fork-lift trucks and robotics.
  4. Pallet racking – weight limits
    The design of your racking includes limits on the weight the structure can hold and how to load it correctly. The precise details can be different for each bay or racking run depending on the stock you carry. Important guidance when you consider that, in its simplest form, your racking is a basic metal frame. Ignore the weight-carrying specifications and it can lead to a potential failure of the racking. You can’t expect everyone to remember the different weight-carrying capacities which is why your employees need to pay attention to the Load Notice. This key warehouse safety sign clearly shows the correct loading and weight procedures for the structure.
  5. Pallet racking safety equipment
    If you have the optimal design for your racking it should keep everyone safe. However, it can only meet its intended purpose if everything is working correctly. Your supplier should also build in safety equipment that protects the racking from damage including rack guards and post protectors. Finally, for correct installation of the structure you must use a SEIRS installer who has trained to meet SEMA and industry standards. That way you will know pallet racking safety pins are correctly securing beams in place. Locks are in place to ensure adjustments are not be made by unauthorised members.

warehouse safety - rack protectors

Improving Safety

The racking is in place and stock is moving through the space seamlessly. Stock efficiency has increased to minimise order timescales and increase your profitability.

Now the biggest challenge – how to keep it all working correctly!

The answer lies in equipping your employees with the knowledge of how to work in areas with racking. It may seem easy to dismiss racking training as an unnecessary step, but it does provide you with two clear advantages. First, and perhaps most importantly, it will keep your employees safe. Second of all, it will help to maximise the lifespan of your racking (which is ideal for maximising the ROI).

That is why we run our Rack Inspection Training. The course equips your employees with the skills and knowledge they need to work safely in areas where racking is present. It also provides them with the tools they need to recognise damage on racking. After all, the sooner damaged racking is reported, the sooner it can be fixed and the safer everyone stays. Finally, our course will help you in meeting your PUWER responsibilities by training a member of your team to perform the HSE and SEMA recommended weekly inspection.

warehouse safety - inspection

Ongoing Warehouse Safety

The final step is to ensure your racking keeps everyone safe for as long as possible. You can only achieve this if the structure is subject to an Expert inspection at least once a year. This inspection must be undertaken by a professional with the correct qualifications. Their role is to conduct racking and storage assessment reports on the racking and recommend if repair work is required.

Ideally, you want an approved racking inspector who uses a traffic light reporting system according to SEMA guidelines. Their report will indicate where damage is present and action requirements over what timescale.

  • Green areas indicate where damage falls within SEMA limits and is considered safe and suitable for use, but it will need reviewing at the next inspection.
  • Amber shows where the damage is severe enough to require remedial work, but you don’t need to offload the racking immediately. As pallet positions empty, you must not refill the area. Repairs not completed within four weeks automatically become a red risk.
  • Red risk areas indicates a dangerious level of damage and the racking requires immediate offloading. At this stage, you must isolate the racking and not use it until the repair work is complete.

If you need an expert inspection, get in touch with Teepee and we can arrange for one of our fully qualified and insured racking inspectors to visit your site. They will produce an electronic report that adheres to SEMA inspection guidelines. The report will detail specifications, conditions, damage list by location and photographic evidence for remedial works by your approved supplier.

Need help in upholding warehouse safety?

At Teepee, we’re more than just creating and delivering the perfect storage solution. We place safety and high standards at the forefront of every racking design and installation we fulfil.

If you’ve got a warehouse storage project planned, why not contact Teepee? Our experience within the racking and warehouse industry means that we can help deliver a project that promises safety, quality and reliability throughout the lifetime of your racking.

01

Feb

Warehouse Trends 2024 – How to Plan Warehouse Racking Systems

Warehouse Trends 2024 – How to Plan Pallet Racking Systems

Is your warehouse ready for 2024? At this early stage of the year, it is the ideal time for businesses to review their warehouse and work on a plan that will boost productivity and increase efficiencies. Maybe you’ve run out of storage space? Do you need to review your warehouse racking systems or your picking and packing timescales are too slow? Do you need to upgrade your warehouse management, or do you want to analyse changes in customer behaviour? In this new era of increased e-commerce, the warehouse and logistics industry is rapidly changing. However, new warehouse trends and developments are arising that could provide the answers.

So where is the best place to start? With so much noise, it’s hard to pinpoint the changes that will provide the best Return On Investment. If you’re worried about the affordability of new technologies, not sure how easy they are to implement or concerned about disrupting warehouse life, this blog is just for you.

With over 30 years of experience working in the storage equipment and warehousing industry, we know a thing or two about how you can give your warehouse a push in the right direction. Our complete guide will give you some pointers. We look at ways to improve the agility of your supply chain, and how you can future-proof your warehouse for this new revolution in warehouse trends.

Warehouse Trends - add workable space with a mezzanine floor

Warehouse Trends – Optimising Your Space

Before looking at new warehouse trends and what to invest in, let’s start off your 2024 plan with something you already have – your warehouse space. With the cost-of-living crisis challenging our year ahead and warehouse space at a premium, how can we make changes without breaking the bank?

In recent years, warehouse owners have faced the problem of not having enough storage capacity. This could be due to rising costs or a lack of availability of suitable units. Moving doesn’t always have to be the answer. Instead, look at making the best use of your space and invest in a new warehouse racking system. You may not realise it, but your racking could be the key that unlocks a lot of the problems you may experience in your warehouse.

  • Lack of storage?
    Choose warehouse racking systems which increases the density and capacity of your space. For example, a multi-tier structure adds additional storage space and maximises the full height of your building. Or create additional floor space within the same unit with a warehouse mezzanine floor. If you haven’t got the height opt for a VNA (Very Narrow Aisle) which decreases the aisle width and allows more racking within the same space.
  • A need for speed?
    Ensure your layout works for the throughput of your stock. Its journey from the moment it arrives in the warehouse until the moment it leaves should be seamless. To speed up the process, the design of your warehouse racking systems should enhance the flow of the stock, making it easy to locate and removing sticking points. You could even opt for a system such as push-back racking. This operates on a FILO (first in, last out) system which provides less need for manual stock rotation to increase picking and packing timescales.

Warehouse Trends - warehouse racking systems

Future Proofing: Keeping up with Warehouse Trends in 2024

Is your warehouse ready for the future? Can it maximise your business for years to come? Although your warehouse might have supported your business performance in the past, there is no guarantee it will do so in the future. This is especially true when you look at the rise of e-commerce and the demands it places for faster delivery times and multifunctional spaces.

Of course, installing the best warehouse racking systems for your space can help, but to stay competitive in 2024 it is also critical to understand what the new warehouse trends are and how they can improve your business. To help you out, here we share what we believe the future holds. Not that we are psychics or anything.

Warehouse trends - automation

Warehouse Trends – Automation:

Even though we have just stepped into 2024, the warehouse industry knows that the advancements in warehouse automation and AI will continue to be a hot topic. After all, integrate these technological advances and it can improve productivity, increase the flow of stock, deliver consistent results. However, for a lot of smaller logistics, cost has been a prohibitive factor. As the growth and uptake of automation continue, prices are expected to come down and, with the efficiencies it can deliver, should offer a high Return On Investment for businesses.

Of course, any new technology must be the right fit for your warehouse and work with your space. To be successful, the new solutions have to be harmonious with the traditional – your warehouse racking systems. Get advice from industry experts on how automation, robotics or AI will work for you and whether the design of your racking accommodates key elements. For example, does it provide clearance for the movement of automation or build on the improvements the new technology can deliver?

Warehouse Trends – Data is King!:

Warehouse Management Systems (WMS) are not new in the modern warehouse and most businesses have one in place to improve efficiencies. However, as technology advances, now might be the time to address whether your WMS still works for your business.

WMS are essential for providing real-time analytics and insights into the movement of your stock and managing your supply chain fulfilment. Combine the system with AI, especially with hybrid operations, and it can improve the process even further. This will increase the efficiency of your warehouse by avoiding the chance of stockouts and enabling quick response times. Get the right warehouse racking systems in place to support your WMS and it can transform your warehouse.

Warehouse trends - inspection

Warehouse Trends – Sustainability:

As transparency becomes a big factor, customers are expecting businesses to share their contributions to reducing carbon emissions. As the new generation becomes more conscious about environmental impacts and methods towards achieving net zero targets, sustainable efforts by businesses have become a major factor that has influenced buying behaviour/ purchasing decisions. Warehouse owners must prioritise the integration of sustainability at an early stage.

It can be challenging to implement sustainability in the logistics industry. Yet even small changes can be implemented that can make significant savings on carbon emissions. Whether it’s implementing energy-efficient lighting, HVAC or increasing the number of recyclable materials used in your packaging. Also, examine the credentials of your warehouse racking systems. Look at where it has been manufactured and the journey it makes to your warehouse. Alternatively increase the lifespan of your equipment by adopting a rigorous inspection regime

Warehouse trends - work environment

Warehouse Trends – Quality Work Environments:

With rising mental health issues over the past 10 years, the focus on well-being in the workplace has become an important factor. Fostering a positive work environment has proven to have a great impact on employee engagement and organisational performance.

You can support your team by introducing a positive work culture. Specify designated break areas that are comfortable and relaxing. Equip them with the knowledge to perform their job correctly. When it comes to your racking this has the added benefit of keeping them safe! Send them on a training course like our Rack Inspection Training course. Delivered by our expert instructors, the course provides them with the knowledge to work safely around warehouse racking systems. They will also learn how to recognise damage to the equipment. Training is a great way to bring peace of mind to any work environment.

How can Teepee help?

We hope this blog gives you a better understanding of how to give your warehouse a boost in 2024.

Need some help? Why not get in touch with Teepee and see how we can help to upgrade your business in 2024? As a SEMA Distributor Company and through our experience with a wide range of industries, we can provide a full turnkey solution that delivers everything you need to maximise your performance and increase safety:

  • Start with our free site visit to establish the best design solution for your space.
  • Project managing from start to finish. We oversee a smooth and seamless delivery with all works meeting required quality and safety standards.
  • Supplying a flexible storage solution to meet the unique needs of your business, including warehouse mezzanine floors.
  • Installing the highest quality standards with very little interruption to your business
  • Providing aftercare: maintenance, repair & inspection.
08

Jan

Your Complete Guide to Understanding Warehouse Racking Repairs

Warehouse racking repairs, we hate to say it, are inevitable. In the busy day-to-day environment that is your warehouse, it’s natural for your storage equipment to be at risk of knocks and bumps. No matter what racking you have, eventually all that wear and tear is going to need some repair work. To keep your warehouse running smoothly and your workforce safe, ensuring it’s in the best condition is extremely important.

In this blog, we look at how you can minimise accidental damage and reduce ongoing repair costs. We’ll also look at what you can do to minimise maintenance costs and the best approaches to address racking repairs.

Racking Safety Regulations

warehouse racking repairs - safety regulations

When addressing warehouse racking repairs, the first place to start looking at the relevant safety regulations. Under the PUWER (Provisions and Use of Work Equipment Regulations 1998) you, as the warehouse manager must ensure that any work equipment is in good working order. What you may not be aware of is the fact that your racking is classified as work equipment.

PUWER requires you to check whether any equipment is:

  • Suitable for the intended use
  • Safe to use
  • Inspected
  • Maintained in a safe condition

Failing to correctly do so can result in serious consequences. If an investigation by the HSE discovers you have failed in due diligence it can result in hefty fines. This doesn’t even take into account the potential impact on lives after a serious accident.

Inspections and Warehouse Racking Repairs

To meet PUWER it is recommended that you inspect your storage equipment. The design of your racking does allow for some wear and tear but there is a limit to what it can take. Even minor damage can limit the load-carrying capacity of the structure and quickly develop into a serious issue if not addressed.

A rigorous inspection regime will address any damage before it becomes serious. For industry guidance on inspections, there are two places to go. The HSE has produced ‘HSG76 Warehousing and Storage: A Guide to Health and Safety’ or you can head to the website of SEMA who are the leading voice on safety in the storage equipment industry. Both recommend following a three-tiered process for inspecting warehouse racking.

How Often Should You Inspect Racking?

warehouse racking repairs - installation

  1. Every day your staff should be aware of any damage on the racking. Provide training for your employees, like our Rack Inspection Training course, and it will give them the tools they need to understand what classifies as racking damage. It is far more cost-effective to catch damage early before it develops into a more serious problem.This training also has the benefit of guiding them through safe working practices. Damaged racking can cause downtime for your business. Minimise unnecessary costs by making sure your employees know how to correctly work around the racking. Not only will it keep them safe but it should also reduce accidental damage to the structure.
  1. At least once a week, a member of your staff must undertake a more thorough inspection. This includes checking the loading is correct for the load notice and if there are any components that are missing or damaged. It will also check that everyone is using the equipment correctly. Again, our Rack Inspection Training course will guide them through the process.
  2. Finally, at least once a year, you must have an Expert Inspection by a qualified approved racking inspector. Their detailed inspection report will cover the suitability and compatibility of your equipment, and rack configuration type and classify any damage using a traffic light system to indicate actions required and the recommended timescale to address them.

If you’re overdue for your inspection or have not had one before, why not give us a call and we can arrange for one of our experienced racking inspectors to visit your site.

How do I know if I need warehouse racking repairs?

You know you have damage to your racking but does it need repairing every time? The first thing to understand is the level of the damage. If your racking inspection uses the traffic light system, it should be very easy to understand.

A ‘Green Risk’ shows that there is damage, but it falls well below SEMA allowances. This will be recorded for follow-up at the next inspection.

Next, is the ‘Amber Risk’. This is damage which requires repair work but not at a level that requires immediate offloading. However, you should be aware that as you empty the bays, they should not be refilled. This does not mean you can leave the repair work. SEMA advises that if you don’t get the ‘Amber Risk’ areas fixed within four weeks it will immediately become a ‘Red Risk’.

Now on to the worst type of damage ‘Red Risk’. This is an area with a high level of damage and must be immediately offloaded and isolated. You may only use the racking again once it has been repaired.

Protect your racking investment

warehouse racking repairs - installation

Before you jump online and book a company to come out and repair your racking, take caution! Not all repair work is valid. SEMA has produced guidance on what repair work they recommend and what should be avoided.

For example, your racking company should never undertake welding to the structure because there is no way to test the result of the weld and guarantee strength. If there is damage to an upright, you should never bend it back into shape – it’s far safe to cut out the affected area and splice in a new section. If you need to replace non-structural elements you should only use the correct manufacturer’s part according to their specification. Always check they are replacing the part with the correct one!!

Finally, check with the racking manufacturer on whether the repair work will affect your warranty. Any warehouse racking repairs using third-party materials or unqualified installers could alter the original specification and verification of the product and impact its integrity. The company undertaking the work must provide a warranty to confirm that the repairs are covered by the manufacturer.

How to choose a company to conduct your warehouse racking repairs

warehouse racking repairs - choose a supplier

If you’re looking to protect your investment, you need to work with a company that is approved by the manufacturer of your equipment. However, knowing which companies to trust can be a time-consuming process.

One solution is to work with a SEMA Distributor Company like Teepee. As a member of SEMA, we work closely with the manufacturing members and can access their documentation to conduct repair work. Any warehouse racking repairs will be approved by the manufacturer and protect your warranty.

To become a SEMA Distributor Company, we have been able to successfully demonstrate a high level of commitment to adhere to over 40 regulations, industry standards, Codes of Practice, and legislative requirements. We also have to submit to a three-yearly audit process which checks that we have technical sign-off and traceability for any racking repair work or modification. It will save you a lot of leg work and reassure you.

Need repairs to your racking?

As a member of SEMA, we are also committed to using SEIRS-trained racking installers. The programme run by SEMA ensures that all SEIRS installers have been through their rigorous two-stage training programme and instructs on the correct and safe industry practices for working on racking equipment.