Safety achieved with a combination of technology and process

However, taking additional safety precautions should not have to involve a compromise on the speed and efficiency of operations. Measures can be taken to improve both safety and productivity in the warehouse as well as looking at the technology available to assist with this.

The majority of businesses have procedures in place to reduce the chances of an accident, but even with thorough training, operational safety can still be open to human error. While eliminating danger entirely is not possible, technology and straightforward designed-in solutions can play a significant role in minimising the risk.

From an equipment point of view, it’s all about ensuring the right products are supplied to suit the site and the vehicles in use there. Visual cues for drivers and loading bay staff are essential. Traffic lights on both sides of the loading bay door can be used to signal when it is safe to load, unload and move the vehicle. The best versions will include high-level visibility LED traffic light systems with arrows to aid continental drivers.

Most of the latest developments in loading bay safety are a combination of technology and process. Control systems can be programmed to ensure activity takes place in a specific order to reduce the risk of accidents. These reinforce and complement the practices already in place at many warehouses. For example, some systems prevent the door from opening until the vehicle is properly docked and the wheel chocks are securely in place.

Built-in sensors are another feature to look out for in intelligent docking systems and are proving increasingly popular in busy warehouses where operations need to be both safe and fast moving. Similarly, these systems can be connected to traffic lights which help the driver to reverse into the correct position by signalling the distance between the rear of the trailer and the dock buffers.

At Hörmann we’ve also seen an increase in demand for our key chute system, which requires the driver to deposit the vehicle’s keys after docking. These are then pulled through the chute by the internal operator, who places them on a hook on the loading bay door. This means that the keys cannot be accessed while the door is open, so there is no risk of the driver accidentally pulling away early.

Innovative control systems such as these, not only minimise the risk of accidents around moving vehicles but can also reduce unloading time by ensuring processes happen in the necessary order. Another option that can be incorporated is a recess in the ramp that allows a vehicle’s doors to open fully after it has docked in the loading bay. This also means that the goods can remain well protected in the trailer until they are ready to be unloaded.

Dock levellers play an extremely important role when reducing loading bay hazards; however, it’s important to ensure levellers are suitable for the type of vehicles being used on site. Manufacturers will be able to advise on the weight limits for their products, which should be carefully considered before installation.

An anti-twist platform is one functionality worth looking out for when choosing a dock leveller. This will help to compensate for any lorry tilting when loads are unequal, reducing the chance of slips or falls. Similarly, the lift mechanism of the dock leveller can improve stability. Hydraulic platforms with two or more legs will offer more stability than single lift designs, and will bear uneven weights more securely.

Regular maintenance and inspection should not be forgotten. Keeping up with service schedules will ensure that equipment is replaced prior to failure, thereby reducing downtime and increasing operational efficiency, while also adhering to safety requirements.

If you suspect a fault in any machinery or mechanisms, get it checked out as soon as possible. A good maintenance package will include an emergency call out service, which will ensure that equipment is repaired swiftly. Hörmann, for instance, offers a 24/7 support service that features a number of total preventative repair and maintenance packages.

Safety in the warehouse has improved significantly over recent years but we should not become complacent. Warehouse managers must implement correct procedures and pressure should be put on manufacturers to develop products and systems that help design-out hazards. As long as the right safety enhancements have been implemented to suit the site and thorough risk assessments are completed, reaching equilibrium between safety and efficiency is an achievable goal.