Boosting Warehouse Productivity: A Guide to Upkeep

Worn and weary warehouse barriers slowing down your operation are as much a part of the job as splinters from broken pallets. Yet it doesn’t have to be this way. New technical advances mean your warehouse protection can be impact-absorbent and maintenance-free. So say “ta-ta” to time-wasting repairs and “hello” to our toolkit of damage-deflecting solutions designed to keep your warehouse productivity on track. We’ve got you covered faster than a forklift on a straight stretch.

The Importance of Looking After Your Warehouse

Prevent Damage

The best way to look after your warehouse is to ensure you have the best damage prevention in place. Broken or damaged steel bollards, metal column guards, rails, or steel angle (RSA) can impact the daily operation of your warehouse resulting in wasted time and additional costs. New barrier solutions are designed to deflect impacts and reduce maintenance.

Increase Productivity

Damaged barriers lead to reduced warehouse productivity. Replacing or repairing barriers takes time away from core operations. Installing high-quality barriers that prevent damage in the first place is key to maximising productivity. Modern barriers absorb impacts and don’t chip or scratch easily so you spend less time on repairs and replacement.

Reduce Costs

Barrier damage is expensive. Repairing or replacing damaged barriers costs money and reduces your bottom line. High-performance barriers are more durable so they last longer and don’t need frequent repairs or replacement. While they may cost slightly more upfront, they save money in the long run through reduced maintenance and a longer lifespan.

Ensure Safety

Damaged barriers can pose safety risks in a warehouse environment. Jagged edges or unstable barriers may cause injury to staff or damage to vehicles and equipment. Well-maintained, high-quality barriers keep everyone and everything in the warehouse safe by doing their job properly – absorbing impacts and preventing damage.

Warehouse protection is a key part of efficient operations. Investing in high-performance barriers designed for the challenges of a warehouse environment will boost productivity, reduce costs, prevent damage, and ensure safety for the long term. Your warehouse and your bottom line will thank you.

Maximising Warehouse Efficiency With Preventative Maintenance

Preventative maintenance is key to maximising efficiency in your warehouse. Regular inspections of your warehouse protection barriers like bollards, guardrails and columns will ensure any damage is identified quickly. Annual inspections should be carried out independently by a SEMA approved SARI inspector

Schedule Routine Checks

Set up a schedule to check barriers, guardrails and columns at least once a month. Look for any dents, cracks or damage that could weaken the structure or cause injury. It’s much more cost-effective to repair or replace damaged parts before they fail.

Train Staff in Barrier Safety

Make sure all forklift drivers and warehouse staff are trained to properly use barriers and warehouse equipment. Go over safe operating practices and the importance of reporting any damage right away. Supervisors should also keep an eye out for any barrier damage during regular warehouse activities.

Invest in Protective Padding

Adding protective padding like rubber or polyurethane sleeves and bumpers to steel barriers and columns is an easy way to prevent damage from minor impacts. The padding absorbs energy from glancing blows that might otherwise dent or scratch the surface. Padding also prevents paint chipping which helps barriers last longer.

Repair or Replace Promptly

Once the damage has been identified, schedule repairs or replacement parts as soon as possible. Severely bent, dented or damaged barriers won’t properly protect your warehouse or equipment. Temporary fixes may seem convenient in the short term but won’t provide the level of security your warehouse needs.

With a proactive preventative maintenance plan in place, you can feel confident your warehouse barriers are in top shape and contributing to an efficient, productive work environment. Keeping on top of regular inspections and repairs will save you time and money in the long run.

Common Areas Requiring Regular Inspection and Repair

Warehouse doors

The doors of your warehouse experience some of the heaviest traffic and impacts, so inspect them frequently for any dents, scrapes or damage. Steel doors in particular can become misaligned or fail to close properly if bent or dented. Check that doors are firmly on their tracks and closed securely to maintain temperature control and security.

Column protectors and guardrails

Guardrails, bollards and column protectors prevent vehicles and machinery from hitting key structural supports in your warehouse. Inspect them regularly for any signs of damage or impact, and repair or replace them as needed. Even minor dents or scratches reduce their effectiveness and put your building structure at risk.

Loading docks

Your loading docks should have bumpers, guardrails and column protectors to prevent impacts during loading and unloading. Inspect the edges and surfaces of the docks themselves for any cracks or damage, and check that dock levellers and lifts are functioning properly. Worn or damaged docks can lead to injuries for staff operating forklifts and other equipment.

Flooring

Warehouse floors experience extremely high impacts, loads and traffic, so inspect them regularly for any damage or wear and repair as needed. Cracks, holes or uneven surfaces can cause injuries, disrupt material handling equipment and reduce storage density. High-visibility floor markings, lines and hazard warnings also need to be reapplied or repainted as they fade to ensure a safe working environment. It is important to remember that when under impact, bolts will damage and pull up parts of the concrete slab, leaving the barriers/protection anchored allowing impact to the systems or pedestrians

Your warehouse protection and damage prevention measures require ongoing inspection and maintenance to function properly. Developing a regular schedule for checking high-impact and high-traffic areas of your warehouse, as well as keeping spare parts for quick repairs, will help minimise downtime and ensure the safety of your staff, vehicles, and inventory.

Protecting Racking and Storage From Damage

To avoid damage and downtime in your warehouse, you’ll want to invest in high-quality protection for your racking, storage areas and barriers. As a warehouse owner, you know that forklifts and other machinery can easily cause chips, dents and scratches if left unprotected.

Bollard and Guardrail Covers

Cover exposed metal bollards, guardrails and steel angles with protective padding. Look for covers made of durable, impact-resistant materials like high-density polyethene (HDPE) that can handle the constant bumps and knocks from forklifts and pallet trucks without showing damage. These covers absorb impacts to prevent scratches and dents in the metal underneath. They also come in a range of diameters to suit different-sized bollards and rails.

Rack Protectors

Instal rack protectors, like steel rack upright covers or end-of-aisle protectors, on exposed rack uprights and corners where impacts most frequently occur. These protectors shield the racking from damage while still allowing easy access for forklift operators. Look for rack protectors that are specifically designed for warehouse use, as they’re made of ultra-high molecular weight (UHMW) polyethene plastic which is impact, scratch and chemical resistant.

Bumper Blocks

Place bumper blocks in areas where forklifts frequently turn, brake or load/unload. These large rubber blocks absorb much of the force from forklift impacts to prevent damage to racking, shelving and barriers. They come in a range of sizes so you can choose blocks appropriate for the size of your forklifts and the forces in your warehouse.

By installing high-quality protection like bollard covers, rack protectors and bumper blocks around your warehouse, you can avoid costly damage to your storage equipment and ensure maximum uptime and productivity. Your forklift operators will also appreciate guidance for manoeuvring in tight spaces, allowing them to focus on their work. Keeping your warehouse safe and damage-free pays off through lower costs, less downtime and a more efficient operation.

FAQs on Looking After Your Warehouse

How often should I inspect my warehouse barriers?

It’s recommended to perform routine inspections of your warehouse barriers, rails, and column guards at least once a month. Have your warehouse manager or safety officer walk the perimeter and spot-check for any damage like cracks, dents, or chips. Early detection of damage means you can schedule repairs before the problem worsens and impacts your operations.

What’s the best way to prevent damage in the first place?

The most effective approach is to install high-quality, impact-resistant warehouse barriers in high-traffic areas in the first place. Look for steel barriers, column guards and rails specifically designed for warehouses, with reinforced construction to withstand repeated knocks from forklifts and other vehicles. While more expensive upfront, these options last longer and save money in the long run through reduced maintenance and replacement costs.

What if my budget is tight? Are there more affordable options?

If funds are limited, look for ways to improve your existing setup. Apply protective padding like rubber or foam guards onto metal uprights and rails. Use visual cues like high visibility paint, reflective tape or warning signs to clearly mark potential hazards for equipment operators. You might also restrict traffic flow to essential vehicles only in high-risk zones.

How do I keep maintenance costs under control?

Carefully monitor any repairs made to ensure problems do not quickly reoccur. Schedule and budget for the replacement of older barriers and rails over time to avoid unexpected costs from emergency repairs. Provide regular training for forklift and vehicle operators on safe driving practices to minimise future damage.

Keeping your warehouse properly protected and maintained does require an ongoing time and financial commitment. However, by taking a proactive approach with high-quality equipment, routine inspections, and driver education, you can significantly reduce costs from downtime, repairs, and replacement over the lifetime of your warehouse. Focusing on damage prevention will boost productivity and keep your operations running smoothly.

Conclusion

Don’t let your warehouse productivity suffer from damaged barriers and safety hazards. Check out our toolkit for advanced warehouse protection solutions to keep your operations running smoothly. Installing top-quality barriers engineered for impact resistance will save you time, money, and worry in the long run. The small upfront investment is well worth it to boost productivity and ensure your warehouse is a safe, efficient place to work. Take control of your warehouse damage prevention today for big rewards tomorrow. Get in touch to discuss.