Looking at the big picture
August 1st 2010

FLTA chief executive David Ellison examines how big picture decisions can make a real difference to workers' safety in the warehouse

Strategic thinking can make all the difference to safety. There are always important decisions to be made, whether you have a fleet of a hundred trucks, or just one or two.

After all, fork lift trucks are statistically the UK's most dangerous form of workplace transport, so as soon as you introduce one into your operations you introduce a potential hazard that must be fully understood and catered for.

To highlight some of the issues, let's look at an extreme example. You have found your 100 acre plot and you can build your new warehouse. There is so much to think about – finance, architects, planning permission, builders, rules and regulations.

Much of this is outside your comfort zone, but it is exciting.

However, if your operation is going to involve the use of fork lift trucks, then you must also think through how they will be used, right from the start. Questions to ask yourself include: Will storage space be at a premium and will you be thinking of narrow aisle, high rise racking? Will fork lift trucks be used as part of your production process, and will they be required to carry out other tasks? Do lorries (or vans) need to be unloaded and loaded by fork lift trucks? If so will this happen outdoors or indoors, with or without a docking system? Will you be operating single, double or treble shifts? If you are successful, could this change over the next 5-10 years? Will all surfaces where fork lift trucks may operate be smooth asphalt or concrete? If not, what surface will there be and how may this effect traction, wheel loading etc? Are there any unavoidable inclines? If there are, no matter how shallow, do your architects understand the restrictions on gradients for fork lift truck operations? Will you operate enough equipment on site to warrant a dedicated workshop or maintenance bay? If not, where will fork lift truck maintenance and repair take place? A work area needs to be allocated.

There are advantages and disadvantages to different types of fuel.Will you need more than one type of fuel, and if so will you need a charging bay and/or LPG storage or tanks or a diesel tank? How will you be financing the fork lift truck operations? Will you buy the trucks and negotiate a maintenance contact? Will they be new or used? Is contract hire a better option? Will you need extra equipment to cover peaks? Would these be provided on short term hire? The time to consider this is during the design concept, before anything is agreed. Further, unless you are a very large company, you will probably not have the internal expertise to consider all the options available to you. At this early stage of your strategic thinking you should be involving one or more professional materials handling providers.

Similarly, traffic flows inside and outside are critical for productivity, but also for safety.

Vehicle interfaces need to be minimised and controlled. Are one way traffic circuits possible? Would a change to the shape or design of a building improve sight lines? Can you eliminate blind corners? Can pedestrians be completely segregated from traffic, including fork lift truck movements? Do you need barriers, traffic signals, road markings, mirrors, pedestrian crossings? If so, where should they be to increase safety without reducing productivity? Will some areas where fork lift trucks operate need enhanced lighting or ventilation? With a green field site you can include all these items in your plan. Once you have built the complex - changes can be very expensive.

Of course, most of us don't have the luxury of a green field site.

Often we have to move into premises that "will do" or just stay put and change what we have, to "make it do".

This is a different form of strategic planning, and getting everything absolutely right is probably very difficult. Nonetheless, all the issues highlighted above still have to be considered.

For your fork lift truck operations you should consult your service provider as early as possible. It may well be that your existing fleet of trucks is not suited to the new premises or changed concept of operations. You may need more equipment, you may need less, or you may need something totally different.

Over-specified trucks may cost you in the longer term.

The introduction of new or different fork lift trucks will mean additional training for the operators, and probably the supervisors. The cost of this will need to be in the budget.

Detailed arrangements will be needed to ensure that enough operators are trained on the new equipment by the time you intend to start operating it. If you forget or ignore such requirements the result could be catastrophic.

This review begs more questions than it answers.What it should do is alert you to the importance of considering fork lift trucks within your strategic thinking and of seeking professional advice to solve operational challenges before it is too late

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