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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.

Warehouse Traffic Analysis


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

Pictorial Review of Traffic Hazards


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

Pictorial Review of Traffic Hazards


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

Pictorial Review of Traffic Hazards


Shared PIT & Pedestrian

Suggestion: Remove Pedestrian


Walkway from aisle 24.

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

Pictorial Review of Traffic Hazards


PIT Restricted Pedestrian Only

Suggestion: Stripe according to


drawing and install barricade.

Building B Facing North on the East side of the break


room

Pictorial Review of Traffic Hazards


PIT Parking Area

Suggestion: Re-Stripe PIT


Parking area.

Building B maintenance/battery area

Pictorial Review of Traffic Hazards


Shared PIT Pedestrian

Suggestion: Install Man door in


wall for Pedestrian Walkway.

Building B to C no man door and pedestrian walkway ends

Pictorial Review of Traffic Hazards


Shared PIT Pedestrian

Suggestion:
1.AIAG Standard for docks.
2.Designate PIT Pathway.
3.Designate as authorized Peds.
Only.

Building C dock 53 workstation next to dock

Pictorial Review of Traffic Hazards


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

Pictorial Review of Traffic Hazards


C-Building Re-Work Area/PIT Park Area

Building C at entrance into B


pedestrian walkway opens
into C to B traffic

Pictorial Review of Traffic Hazards


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.

Pictorial Review of Traffic Hazards


Pedestrian Walkways Blocked

Building B at 48,6 trash cans protruding into


ped walkways

Pictorial Review of Traffic Hazards


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.

Pictorial Review of Traffic Hazards


Pedestrian Doorway Under Rack Location

Suggestion:
1.Remove rack above Man door.

Man door to Building A walking under rack

Pictorial Review of Traffic Hazards


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.

Pedestrian & Vehicle Safety Guidelines published by Automotive Industry Action Group

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
Pedestrian & Vehicle Safety Guidelines published by Automotive Industry Action Group

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.

Pedestrian & Vehicle Safety Guidelines published by Automotive Industry Action Group

Restricted Zones
Examples of restricted zones- Shipping, Receiving, Storage

Pedestrian & Vehicle Safety Guidelines published by Automotive Industry Action Group

Solid and
dashed
demarcation
strips
Prominent
posting of
danger signs
around area.
10x 14

Risk Assessment and R3


Calculation
Based on New Controls

Warehouse Traffic Analysis

DalTile RDC
Sunnyvale, Tx

Allen King
Safety Manager
Sunnyvale, TX
11/11/2011

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