Pit Risk Assessment

Warehouse Traffic Analysis
DalTile RDC
Sunnyvale, Tx
Allen King
Safety Manager
Sunnyvale, TX
11/11/2011
Project Objectives
1.
Complete a Warehouse traffic analysis that focuses on:
2.
3.
4.
Warehouse layout & design

Powered Industrial Truck (PIT) traffic flow patterns
Pedestrian (PED) traffic flow patterns
Identify traffic hazard locations and the controls currently in place to reduce those hazards
Prioritize the identified traffic hazards based on the calculation of a Risk Index
Develop new controls and calculate the amount of risk reduction those controls would produce.

Facility Design Layout
Warehouse Layout Drawing

Aisle widths, doorways, stairs,
High Pedestrian Traffic Areas

Offices, break rooms, lockers, restrooms, entrances,
etc
High PIT Traffic Areas

Shipping/receiving docks, warehousing, ramps, etc
Sunnyvale- Warehouse Layout Drawing

SPC Area
Customer
Pick-up
Receiving Office
Restroom-Break
Driver Waiting
LTL
Docks
Receiving
Docks
Aisles
I.C. Office
Restroom
A
Bulk Locations
Bulk
Bulk
PIT
Park
PIT
Park
PIT
Park
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Exit
Bulk
10
Bulk Locations
24
25
35
36
52
53 - 58
Bulk
Bulk
Bulk
60,62,64,66
F
Picking
Pen
PIT
Park
G
Shipping
Docks
Office
RestroomBreak
Maintenance
Battery
Charging
Aisle Ways & Traffic Patterns

All aisles are two way traffic.
Aisle ways 10,24,35,53, B and F are shared
between PITs & PEDs.
Most aisle ways have 4 yellow demarcation lines
The shared aisle way widths vary from 11 to 12
AIAG guideline for shared 2 way traffic aisle ways
is twice the widest PIT/Load plus 36.
Sunnyvale- Warehouse Current Traffic Controls

I.C. Office
Restroom
Customer
Pick-up
SPC Area
Receiving Office
Restroom-Break
Driver Waiting
LTL
Docks
Receiving
Docks
A
Bulk Locations
10
24
25
35
36
53 - 58
52
F
Bulk Locations
S
Picking
Pen
PIT
Park
G
Shipping
Docks
Office
RestroomBreak
Maintenance
Battery
Charging
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Exit
Bulk
PIT
Park
PIT
Park
PIT
Park
Bulk
Bulk
Bulk
60,62,64,66
Current Traffic Controls

PIT Safety Guidelines:
PITs equipped with flashing lights & horns.

PITs have governed speed limits
Sit Down PIT must travel in reverse when the load restricts forward vision.
Reach Truck and O.P. travel cab first.
PITs must sound their horns at blind intersections, corners & aisles.
PITS must sound their horns to alert PEDs on shared aisle ways.
PITs must yield to PEDs
PED Safety Guidelines:
PEDs must make eye contact with PIT operator to ensure right of
way has been given
Sunnyvale- Warehouse Traffic Hazard Areas

I.C. Office
Restroom
Customer
Pick-up
Receiving Office
Restroom-Break
Driver Waiting
LTL
Docks
Receiving
Docks
14
22
Bulk Locations
12
6
10
PIT
Park
PIT
Park
PIT
Park
Bulk
17
Bulk
16
Bulk
SPC Area
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Exit
11
18
13
21
10
24
25
4
7 1
Bulk Locations
Picking
Pen
35
36
53 - 58
52
PIT
Park
60,62,64,66
9
12
15
20
19
Shipping
Docks
Office
RestroomBreak
Maintenance
Battery
Charging
Pictorial Review of Traffic Hazards

Bulk Location Blind Spots
Suggestion:
1.Bulk locations at aisle end should be
limited to two pallets high to permit
visibility of pedestrians.
2.Red STOP blocks and Cross Ways in
Ped. Walkway at bulk locations.
Building A bulk area to pedestrian walkway-blind spots

Ramp at 24G shared PIT & Pedestrian
Suggestion: Bypass alarm at Door

#6 and make door #7 PIT only.
Building A facing North overhead door and man door. Man

door tied into security system

Shared PIT Pedestrian
Suggestion:
1.Install man door in wall.
2.Install barricade at aisle end to
limit PIT Traffic.
This area showed the highest risk
level at 125. Interim containment
was to limit traffic out of lane by
use of cones until a permanent
fixture can be installed.
Building A to B access Pedestrian and PIT

Shared PIT & Pedestrian
Suggestion: Remove Pedestrian

Walkway from aisle 24.
Building A- Aisle 24, Pedestrian walkway along rack in aisle

PIT Restricted Pedestrian Only
Suggestion: Stripe according to

drawing and install barricade.
Building B Facing North on the East side of the break

room

PIT Parking Area
Suggestion: Re-Stripe PIT

Parking area.
Building B maintenance/battery area

Suggestion: Install Man door in

wall for Pedestrian Walkway.
Building B to C no man door and pedestrian walkway ends

Suggestion:
1.AIAG Standard for docks.
2.Designate PIT Pathway.
3.Designate as authorized Peds.
Only.
Building C dock 53 workstation next to dock

C-Building Bulk Areas
Suggestion:
1.STOP Signs at cross ways.
2.Stop Box on floor or if not feasible, 24 Stop
Sign.
3.Enforce STOP at cross aisles policy.
Building C Row 64, 3 facing South blind spots in

area. Have 360 degree mirrors no signage and
operators not stopping

C-Building Re-Work Area/PIT Park Area
Building C at entrance into B

pedestrian walkway opens
into C to B traffic

B-C Building PIT Doorways
STOP
STOP
Building B to C signage on one side and

none on the other
Suggestion: Hang STOP Banner above
door ways.

Pedestrian Walkways Blocked
Building B at 48,6 trash cans protruding into

ped walkways

Shipping/Receiving Docks mixed PIT/Pedestrian
PIT h
Pat
y
wa
Building B at aisle 32, 7 Pedestrian and forklift

traffic. Pedestrian also wearing black shirt in area.
Suggestion:
1.Flags on Checker Carts.
2.Cones at aisle ends where checkers are working.
3.PIT Pathway for through traffic.

Pedestrian Doorway Under Rack Location
Suggestion:
1.Remove rack above Man door.
Man door to Building A walking under rack

Pedestrian only in SPC Packing Stations
Suggestion:
1. AIAG Standard for PIT restricted.
SPC Area
Area is currently PIT Restricted but has no visual
demarcations.
Traffic Hazard Risk Assessment

R3 Residual Risk Reduction
R3 is a risk assessment technique used to
qualify and quantify hazards and demonstrate
risk reduction from interventions
The Nature of Risk
Risk
Frequency
Likelihood
(Exposure Opportunity)
(Chance of Occurrence)
Probability
(Occurrence Opportunity)
Severity
(Degree of Harm)
Risk Assessment Matrix

Parameter
Level 1
Level 2
Level 3
Level 4
Level 5
Frequency
Exposure to the
hazard exists
less than once
per month
Exposure to the
hazard exists
less than once
per week
Exposure to the
hazard exists
less than once
per shift
Exposure to the
hazard exists
more than once
per shift
Exposure to the
hazard exists at
all times
Likelihood
Highly Unlikely
Unlikely
Possible
Probable
Highly Likely
Severity
Injuries are
likely to involve
first aid only
with no lost time
from work
Injuries are
likely to involve
medical
treatment but
no lost time
from work
Injuries are
likely to involve
medical
treatment and
lost time from
work but with
full recovery
Injuries are
likely to involve
medical
treatment, lost
time from work,
and some
permanent
impairment
Injuries are
likely to involve
death or
permanent
disability
New Traffic Control Options
Sunnyvale- Warehouse New Controls

A
10
24
25
35
36
52
53 - 58
G
Authorized PEDS ONLY
Aisle Gates/Barriers
Crosswalk
Stanchions
Shared Aisle
PIT Restricted
Kiosk Barrier
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
Bulk
60,62,64,66
Guidelines for Suggested

Control Measures
Shared Aisle Designs

guidelines
One-way Traffic
widest load handled or
powered industrial truck,
whichever is greater,
plus 3 feet (18 clear on
either side of load).
Two-way Traffic
2 times the widest load
handled or powered
industrial truck,
whichever is greater,
plus 3 feet (18 clear on
either side of load).
Pedestrian & Vehicle Safety Guidelines published by Automotive Industry Action Group
Pedestrian Walkways
guidelines
Dedicated pedestrian only
Shared vehicle & pedestrian
> 3 feet in width.

> 4 inch demarcation strip
pedestrian side provides best
out-of-aisle escape route.
One pair of Footprints should
be located in the center of and
parallel to the pedestrian
walkway, every 20-30 feet.
Shared walkways footprints
should be Target Yellow and
dedicated walkways Industry
Safety Green.
Footprints reinforce pedestrian
use of a walkway and provide
clarity for pedestrians who may
be colorblind.
Crosswalks/Intersecting Aisles
guidelines
Crosswalk boundaries striped yellow with internal crosshatches.

Crosshatch spacing should measure 24 inches, center-to-center of demarcation lines
painted Target Yellow
Stop Box on floor or if not feasible, 24 Stop Sign
10x14 caution sign suspend above pedestrian entrance to intersection
Blind Corner Application

guidelines
Materials within 8
feet of an aisle
intersection used
by pedestrians
should be stored
no higher than 4
feet to preserve
visibility for
equipment and
personnel in the
area.
Where blind
intersections exist,
an overhead
domed mirror
should be provided.
Restricted Zones
Examples of restricted zones- Shipping, Receiving, Storage
Solid and
dashed
demarcation
strips
Prominent
posting of
danger signs
around area.
10x 14
Risk Assessment and R3

Calculation
Based on New Controls
DalTile RDC
Sunnyvale, Tx
Allen King
Safety Manager
Sunnyvale, TX
11/11/2011

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What is the purpose of the traffic analysis?

What is the purpose of the traffic analysis?

What areas of the warehouse were analyzed?

What areas of the warehouse were analyzed?

Warehouse Traffic Analysis

Complete a Warehouse traffic analysis that focuses on:

Warehouse layout & design

Warehouse Traffic Analysis

Warehouse Layout Drawing

High Pedestrian Traffic Areas

High PIT Traffic Areas

Sunnyvale- Warehouse Layout Drawing

Aisle Ways & Traffic Patterns

Sunnyvale- Warehouse Current Traffic Controls

Current Traffic Controls

PITs equipped with flashing lights & horns.

PED Safety Guidelines:

Sunnyvale- Warehouse Traffic Hazard Areas

Pictorial Review of Traffic Hazards

Building A bulk area to pedestrian walkway-blind spots

Pictorial Review of Traffic Hazards

Suggestion: Bypass alarm at Door

Building A facing North overhead door and man door. Man

Pictorial Review of Traffic Hazards

Pictorial Review of Traffic Hazards

Suggestion: Remove Pedestrian

Building A- Aisle 24, Pedestrian walkway along rack in aisle

Pictorial Review of Traffic Hazards

Suggestion: Stripe according to

Building B Facing North on the East side of the break

Pictorial Review of Traffic Hazards

Suggestion: Re-Stripe PIT

Building B maintenance/battery area

Pictorial Review of Traffic Hazards

Suggestion: Install Man door in

Building B to C no man door and pedestrian walkway ends

Pictorial Review of Traffic Hazards

Building C dock 53 workstation next to dock

Pictorial Review of Traffic Hazards

Building C Row 64, 3 facing South blind spots in

Pictorial Review of Traffic Hazards

Building C at entrance into B

Pictorial Review of Traffic Hazards

Building B to C signage on one side and

Pictorial Review of Traffic Hazards

Building B at 48,6 trash cans protruding into

Pictorial Review of Traffic Hazards

Building B at aisle 32, 7 Pedestrian and forklift

Pictorial Review of Traffic Hazards

Man door to Building A walking under rack

Pictorial Review of Traffic Hazards

Traffic Hazard Risk Assessment

The Nature of Risk

Risk Assessment Matrix

New Traffic Control Options

Sunnyvale- Warehouse New Controls

Guidelines for Suggested

Shared Aisle Designs

Dedicated pedestrian only