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​In today’s ever-growing corporate world, smaller independent dock and door distributors are appointed by larger companies. While there can be advantages to this for the client, there is one disadvantage, especially in today’s supply-chain challenged world. When manufacturer’s own the local distributor, the client’s choice becomes severely limited. Just because the manufacturer offers different models, this doesn’t truly provide the client with multiple choices as the intended applications for those door models are different. See part two of this series for the importance of correct equipment application.

Even if the “lead times” for new equipment are acceptable, what if there is a part failure and the part isn’t available? With high-speed doors and fire doors, this can be a larger issue as there is likely not an aftermarket option due to proprietary parts or regulations not allowing anything but OEM parts to be used.

Partnering with a service and equipment supplier that can offer both the variety of multiple manufacturer choices and the ability to service multiple manufacturer brands will allow your facility to thrive in through supply chain challenges.

What challenges are you facing with your facility? Schedule a call to see if we can help.

A foundational understanding of when to replace equipment is built by having a clear accounting of:

1. Current equipment conditions
2. Equipment quality vs. the application and cycle usage
3. Performance in every environment to determine the life expectancy
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Ideally, a maintenance program is in place that includes a detailed inspection with proper asset configuration. This includes date of manufacture and the needed details to build this foundation of information. “Lead time increases” vary greatly in the dock and door industry, so knowing what to expect is important. For example, many (not all) dock leveler manufacturers are facing “lead times” nearing 1-year, consequently ordering equipment will need to be done much sooner than in the past. In addition, the employee, raw goods, manufacturing shortages, and shipping delays are likely and should be expected. Factoring in the uncertainties listed above for equipment purchases/updates is a great practice.

Typically, you don’t have failure before your new equipment arrives, and if it arrives early that’s OK. If you’re still skeptical about ordering early, ask yourself these questions:

1. What is the cost to your organization caused by down equipment?
2. How does down equipment affect your relationship with your client’s or partners?
   
   

Compare the amounts from the questions above with the cost of buying an asset a few months earlier and consider the total in costs when you don’t take “lead times” into account.

No one likes surprises, why create one more?

P.S. See more tips like this on our LinkedIn page.

As we head into the fall and eventually winter, we start to focus on keeping warm. Keeping the cold air from blowing through our doors. Keeping the temperature in that sweet spot of not too hot and not too cold. But what about water? Not just from fall rainstorms but from melting snow and ice.

We know. It’s September. Are we really talking about snow and ice? Yep. We are.

Winter in the Midwest is hard. It can be brutal on your loading dock equipment and bottom line. It’s cold. It’s warm(ish). It’s sunny. It’s snowing. All of that can cause chaos with your loading dock equipment. Melting (and then refreezing) snow and ice pose serious safety concerns and performance problems at your loading docks.

Safety Concerns
Slippery docks are dangerous to your employees and visiting drivers alike. The potential for someone to slip and fall greatly increases if your docks are not properly sealed and water or ice is present. Forklifts going in and out of trailers will transfer water throughout your facility, creating even more chances for someone to slip and fall. This can lead to injuries, time off, workers comp – all of these can be avoided by paying closer attention to your loading dock and the potential for water infiltration.

Compliance Concerns
Ever smelled a stagnant swamp or bucket of water?  Standing water can become a breeding ground for harmful bacteria.  Bacteria poses numerous threats to the health of your staff and food facilities can be a major violation of the FDA Food Safety Modernization Act (FSMA) requirements.   FSMA requires you to have a food safety plan in place that includes an analysis of hazards and risk-based preventive controls to minimize or prevent the identified hazards.
A pest infestation can be another violation, especially in food and pharma facilities.  Any gaps in your seals or equipment can lead to issues with requirements and compliance.

Performance Problems
Have you ever tried to pry something off the ground that good ole’ Mr. Winter has frozen?  Say your garbage can after it’s been sitting for a week with constant thaw and freeze.  Not a whole lot of fun and sometimes an unsuccessful venture.  Now imagine that at your loading docks.  Imagine melted ice and snow working its way down into your metal loading docks and thawing and refreezing.  Over and over again.  Many repairs we perform during the winter could be prevented by properly maintained and sealed equipment.  A nagging or small issue in July can become a big problem in December

So, what should I do?

1. Be proactive. Schedule your Proactive Maintenance sooner rather than later. Find the small problems before they become big ones. If you don’t currently have a maintenance program in place, now is a great time to set one up – contact us today and we will get you started.  If you are part of our program, work with your Account Manager to address any issues found during your last inspection.
2. Dock seals.  Look at your dock seals.  If you can see rips or tears, they need to be replaced.  If you can see foam, they need to be replaced.  Besides helping (along with dock bumpers) to protect your building from damage they are also an integral part of keeping that opening sealed.  The correct seal or enclosure that is tailored for your facility, your trucks, and your budget are available through us.  Contact your Account Manager for details or check out our website for more information
3. Consider installing HVLS, HVHS, or Dock fans.  Don’t underestimate the value that proper air movement can provide to your facility.  Energy savings, employee comfort, and safety are just a few.
4. Consider snow removal equipment for your fleet and incoming trucks.  The Yeti could be just what you need
5. Rain units provide another level of protection against water ingress.  They help divert waterway from your building and provide excellent barriers to water run-off from the tops of trailers

Check out our other blogs on facility modernization and safety for more ideas on how to improve your facility and your bottom line.

As always, we hope you find this information useful and you find something that you can do in your facility to help prevent the winter blues. Please contact us with any questions or concerns.

Safety hazards exist in every workplace – from the smallest office to the biggest warehouse.  Heavy machinery, distracted walking, water on the floor, heavy traffic areas, etc.  Slips, trips, and falls are a major source of preventable injuries and deaths in the workplace; only motor vehicle incidents cause more worker fatalities. The loading dock area, in particular, is ripe with potential dangers.

Since safety measures come in all shapes, sizes, and forms, what can you as an employer do to make your facility as safe as it can be for yourself, your employees, and visitors?

Let’s look at each situation and how you can help prevent injury and equipment damage.

Slips

Fall Protection
We talked about fall protection in our blog Hazard Recognition – 3 commonly overlooked serious situations and it is a serious problem.  In fact, it’s one of OSHA’s Top 10 violations (see here, Fall Protection – Top 10 on OSHA’s violation list, for the remaining 9 – and notice that fall protection training is in there too).

Fall protection at your loading dock can be as simple as having enough of the right size and capacity ladders to installing safety netting or gates to adding truck restraints at every dock position.  There are so many options to fit every situation, every need, and every budget, it’s a no-brainer to investigate what you can do to ensure your safety, the safety of your employees, and protect your equipment and products.

Employee Training
Proper training is crucial for the prevention of slips, trips, and falls.  This includes equipment training for all employees, common-sense procedures, regular and thorough general housekeeping, and policies that enforce and enhance your safety practices.  The old adage: an ounce of prevention is worth a pound of cure most certainly applies.

The NSC’s Make Fall Safety a Top Priority article has some very simple and great tips for fall protection.

How can we help?
As always, we hope this has given you some helpful information, as well as some things to consider checking or adding to your facility to improve your safety systems.
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We are here to help if you have any concerns or questions please Contact Us today for a no-obligation safety and OSHA compliance check.

We see hazards every day in our personal lives – the texting driver, the kid running across the street, the unsecured cargo in the back of a pickup.  But do we see the hazards at our warehouse?  Or have we gotten so used to things just working that we don’t see the dangers they pose if they don’t?

About 25% of all industrial accidents happen at the loading dock.  For each reported accident there are as many as 600 near misses…that’s a scary number.  Forklifts, pedestrians, debris and other hazards, faulty equipment, human error, and countless other reasons are to blame.  Many of these can be avoided by developing and enforcing clear and comprehensive safety practices, providing top-notch employee safety training,  and repairing or replacing old or faulty loading dock equipment.

As we visit our clients the most common hazards we see are:

1. No truck restraints or wheel chocks at all loading docks
Lack of truck restraints, be it wheel chocks or mechanical restraints,  can cause a multitude of very serious problems; trailer creep being the biggest and scariest of them.  Trailer creep is when the trailer of the truck “creeps” away from the dock.  This can cause separation between the dock lip and the trailer itself.  Once that separation gets big enough the weight and constant back and forth motion of the forklift could cause the lip to fall down or break, taking the forklift and the driver with it.  This could result in serious injury or death and major equipment damage.
Impatient drivers or unclear communication between drivers and dock workers can cause early truck departure – resulting in the same situation or worse.

Wheel chocks can certainly help but are not always the best choice.  They have drawbacks that can make them an unreliable means of securing a trailer in your dock.  But they are better than nothing.  If you are using wheel chocks only, make sure to train your staff on how to properly use them and how to safely and effectively communicate with your truck drivers.  You also need to have a process in place for inspecting your chocks and assessing their condition so you know when its time to replace them.  Broken, missing, or misused wheel chocks are as bad as not having any at all.

Check out the articles below for some basic information and facts on loading dock safety and the crucial role that vehicle restraints can play.

Prevent Trailer / Dock Separation Incidents (MH&L)
Stay Safe: 8 Tips to Ensure Loading Dock Safety (Load Delivered)
5 Loading Dock Catastrophes (and How to Prevent Them)  (safeopedia)

2. Missing or improper entrapment devices on doors
As the name states these devices prevent someone from becoming entrapped under your door.  Overhead door systems are frequently overlooked as safety hazards, even in companies with excellent safety programs.  Quite simply, if they are working, we kind of forget about them.  Commercial doors are heavy, many hang high in the air, and in the interest of efficiency can operate quickly.   Besides being an OSHA safety violation, missing or improper entrapment devices is an opportunity for a serious accident to occur.  A person or even a forklift can easily get trapped under a door that isn’t set up correctly to prevent entrapment.

There are different options and different devices that can prevent this from happening, depending on how your facility and equipment are set up and used.  The proper entrapment devices can save thousands in equipment damage and prevent a serious injury from happening.

3.  Missing fall protection
This is a commonly overlooked safety component because we usually don’t see the docks empty and the doors open.  But what about those beautiful spring & summer days when you open the doors to let a nice breeze in.  What protects your employees and equipment then?

While it may be a simple thing to ignore, OSHA standard 29 CFR 1910.23(b) relating to protection for wall openings and holes requires fall protection for openings where there is a drop of 48″ or more.   We recommend fall protection wherever you have an opening that a forklift, person, or other equipment could fall from and cause injury.  As with most things, there is a wide variety of fall protection equipment available depending on your facility, your budget, and the frequency of use.

OSHA Requirements
Many times we reference OSHA standards in our industry and while it is a great tool and great organization, we consider their requirements to be the bare minimum.  Your facility and your industry may have standards that far exceed the OSHA requirements and that is a very good thing.  Make sure when laying out your safety plans or adding safety equipment that you take into consideration how it will be used, what equipment is going to be affected by it, and how your employees can easily and safely implement your safety practices.   Keep the bare minimum in mind, but plan and build for the reality of your situation.

We hope this has given you some helpful information, as well as some things to consider checking or adding to your facility to improve your safety systems.

Check out our other blogs on Loading Dock Safety and Risk Assessment for more helpful tips.
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We are here to help if you have any concerns or questions please Contact Us today for a no-obligation safety and OSHA compliance check