How to Prevent Products from Falling in a Warehouse

Warehouses are notoriously high-risk work environments because of the machinery, heavy lifting, and operational speed involved. One basic yet pervasive risk in this industry is falling items. Warehouses usually have rows of tall racking and shelving to store products for shipment. But if these systems fail or are improperly installed, it can result in falling objects that can harm employees. Here, we’re discussing how to prevent products from falling in a warehouse so you can uphold safety standards and protect your merchandise.

1. Use Proper Storage Practices

The easiest and best way to prevent the issue is to store all items in accordance with their weight, size, and packaging stability. Heavier items should always go on lower shelves, while lighter, less frequently accessed products should go higher up. When stacking items, factor in height and stability. For example, to safely stack and store gaylord boxes, the largest, widest designs should form the base to avoid instability and tumbles.

2. Regularly Inspect Racks and Shelves

Damaged or faulty shelving is a key cause of product falls. This is why you must inspect your racks and shelves regularly. Look for bent beams, missing bolts, or signs of overloading (such as sagging). Additionally, hire professionals to properly install new shelving systems. DIYing it is an easy way to make mistakes that compromise the structure’s integrity.

3. Implement Load Limit Labels

Overloading racks is a common mistake in warehouses. Avoid it by setting clearly visible weight limit labels on all shelves and racks to prevent excessive loads. Training staff on these limits is equally important.

4. Train Employees on Safe Practices

Train your employees on more than just reading and adhering to load limits. When you onboard new workers, make sure they learn how to properly load, remove, stack, and store products during general safety training. Employees play a vital role in executing safety measures, so send out regular reminders and updates to discourage complacency.

5. Add Safety Barriers

Total prevention includes planning for the unexpected. Safety barriers, such as netting or rack guards, catch items that shift or fall. This precautionary measure is especially important for high-rise racking or shelving, but it’s good to incorporate everywhere in your warehouse.

6. Maintain an Organized Warehouse

A cluttered warehouse is more likely to be the scene of accidents. Keep up with the following organizational tasks:

• decluttering the floor
• storing pallets securely
• adjusting the layout for maximum maneuverability
• partnering with waste-removal companies for scheduled pickups

Create a Safer Warehouse Today

Preventing products from falling in a warehouse is possible with some planning, employee training, and maintenance. By adhering to these best practices, you can protect both your inventory and your employees from harm.