Our Blogs How to Prevent Common Accidents with Material Handling Equipment

Date Posted:19 November 2024

By creating a safe working environment and investing in the right tools and training, businesses not only protect their employees but also improve overall operational efficiency.

Material handling equipment plays a critical role in transporting, lifting, and moving goods in warehouses and other workplaces. However, improper use of such equipment can lead to accidents, resulting in injuries or damaged goods. Preventing these accidents requires a combination of safe practices, proper training, and regular maintenance.

1. Employee Training

One of the most common causes of accidents with material handling equipment is operator error. Employees should undergo regular and thorough training on how to properly use trolleys, forklifts, conveyor systems, and other handling devices. Training should cover operating procedures, load limits, and safety protocols. Operators should also be familiar with the specific equipment they are handling.

In addition, training programs should cover:
•   The importance of understanding the equipment's capacity.
•   How to inspect equipment before use.
•   Handling emergencies or unexpected malfunctions.

Regular refresher courses are also essential, especially when introducing new equipment into the workspace.

2. Proper Equipment Maintenance

Routine inspections and maintenance are crucial to ensuring the safe operation of material handling equipment. Equipment that is not regularly checked may develop issues such as worn-out parts, malfunctioning controls, or faulty brakes, all of which can cause accidents.

Create a maintenance schedule that includes:
•   Checking wheels, brakes, and steering mechanisms.
•   Inspecting load-bearing components for wear and tear.
•   Testing any electrical components (for electrically powered trolleys, lifts, or conveyors).

If any defects are found, the equipment should be taken out of service immediately for repairs. Maintenance logs should be maintained to track repairs and inspections.

3. Overloading and Improper Stacking

Overloading equipment or stacking items improperly is a significant risk factor. Each piece of material handling equipment has a specified weight capacity, and exceeding that limit can lead to equipment failure, tip-overs, or even collisions.

To prevent these issues:

•   Ensure employees understand the weight limits for each type of equipment.
•   Load items evenly to prevent imbalances.
•   When stacking, make sure the items are secured and the height is within safe limits.

Providing clear signage around the workplace about load limits can act as a constant reminder for employees.

4. Clear Pathways and Proper Space Utilisation

Accidents often occur due to cluttered pathways or improper space utilization in warehouses. Clear and marked pathways allow operators to navigate freely without the risk of bumping into objects or other workers.

To ensure safe movement:

•   Keep all aisles and pathways free from obstructions.
•   Mark pedestrian zones to avoid collisions between equipment and workers.
•   Use mirrors at intersections to improve visibility.

In tight spaces, use material handling equipment suited for the area, such as smaller trolleys or foldable lifts. This reduces the chances of accidents in confined spaces.

Ergonomics plays a critical role in preventing accidents, especially those related to manual handling. Employees should be taught proper lifting techniques to prevent injuries such as strains, sprains, or back injuries.

To reduce ergonomic risks:

•   Provide height-adjustable workbenches and lifting equipment.
•   Use equipment like scissor lift trolleys for loading and unloading tasks.
•   Encourage frequent breaks and ensure proper posture when operating machinery.

Additionally, having equipment with ergonomic designs—such as padded handles, smooth wheels, and adjustable features—can help reduce operator fatigue and prevent accidents caused by loss of control.

6. Proper Use of Personal Protective Equipment (PPE)

Providing and enforcing the use of personal protective equipment (PPE) is another key step in accident prevention. Depending on the type of material handling equipment, employees may need to wear safety helmets, gloves, steel-toed boots, or high-visibility vests.

Additionally, ensure that:

•   PPE is well-fitted and comfortable for long-term use.
•   Employees know when and how to wear their PPE correctly.
•   Supervisors regularly check that PPE is in good condition and properly used.

7. Installing Barriers and Safety Guards

In busy workplaces with heavy machinery and material handling equipment in use, barriers and safety guards are essential to protect both workers and equipment. Barriers can help keep equipment within designated zones and reduce the risk of accidents involving pedestrians.
Install safety guards around:

•   High-traffic areas.
•   Loading docks.
•   Conveyor systems with moving parts.

Safety barriers also prevent damage to equipment and infrastructure, which can occur when equipment accidentally runs into shelving or walls.

8. Utilising Automated Systems

Automation has been a game-changer for improving safety in material handling. Automated systems, such as conveyor belts and robotic forklifts, reduce the need for manual handling and, consequently, the risk of accidents due to human error.

Automation solutions:
•   Lower the risk of back injuries from lifting.
•   Improve precision in loading and unloading.
•   Increase efficiency in transporting goods.

However, it's essential that automated systems are well-maintained and regularly tested to avoid malfunctions that can lead to accidents.

9. Monitoring and Reporting Systems

Encouraging a culture of safety starts with proper monitoring and reporting systems. Workers should be empowered to report hazards, unsafe equipment, or near-misses without fear of repercussions. Implement a system where employees can report hazards immediately, and ensure quick corrective action.

In addition:
•   Conduct regular safety audits and inspections.
•   Establish a safety committee to review accident reports and recommend improvements.
•   Involve workers in safety planning and decision-making processes.

Preventing accidents with material handling equipment requires a proactive approach. From proper training and maintenance to using ergonomic equipment and enforcing PPE usage, workplaces can significantly reduce the risks associated with handling heavy loads. By creating a safe working environment and investing in the right tools and training, businesses not only protect their employees but also improve overall operational efficiency.

By adhering to these safety measures, workplaces can prevent common accidents and ensure the smooth and safe operation of material handling equipment.