Page 10 - OHS, January/February 2022

INDUSTRIAL SAFETY
For example, an interlock system disables the use of a hydraulic leveler, overhead door or dock barrier until the vehicle restraint has achieved a safe engagement. Advanced systems also can tap into IIoT when enabled to provide facility managers insight about potential safety risks or areas for improvement.
Visual safety features are available on some control panels, as well. Exterior camera views of the vehicle restraint and landing gear for spotted trailers deliver real-time trailer status to the embedded monitor, helping to keep boots off the ground outside on the drive approach.
Clear Communication at the Loading Dock
Red/green interior and exterior dock lights are the most ubiquitous tool for communication and safety at a loading dock. A green light on the control box inside indicates to a forklift that the trailer is locked and safe to enter, while the corresponding red light outside tells the truck driver it is not safe to pull away (and vice-versa). However, these interior lights are not always visible, as stacked pallets can obscure a lift driver’s view. Thankfully, advancements in LED light communication systems have addressed this issue and more.
Hazard recognition systems that incorporate the newest technologies can offer safety solutions inside the loading dock area and outside the loading dock area on the drive approach. This combination of components uses motion detection, line-of-sight notification and audible alarms to provide hazard recognition and communication to people on and off forklifts. Working in tandem, these safety tools help create a safer, more productive loading dock environment, both inside and outside, by keeping people a step ahead of the potential dangers in their path.
Outside the dock opening, from a fixed location above the dock door, a sensor detects the motion of a tractor-trailer backing into a dock position. A visual and audible alarm located in the vehicle restraint, or mounted as standalone box, alerts dock workers and pedestrians in the drive approach of the impending danger. This multisensory alert system is particularly important because ambient noise often masks the sound of a cab’s noisy engine, which can be 70 feet or more from the back of the trailer.
Inside the dock area, motion-sensing technology can trigger a bright blue light that projects onto the dock leveler when it detects material handling equipment or a pedestrian’s presence inside the trailer. An advanced system also will work in conjunction with the vehicle restraint to alert any dock worker or forklift that enters an unsecured trailer. An integrated vehicle restraint will keep a trailer secured if motion is detected inside the trailer. A blue light flickers as an audible alarm alerts the unsuspecting dock worker that they have entered an unsecured trailer, while the external light system simultaneously changes to red, warning the truck driver that there is activity inside the trailer.
Also on the inside of the loading dock are safety lights located on the upper corners of dock opening. These LEDs provide a clear line-of-sight to trailer restraint status, even if the control box lights are obscured by pallets. LEDs located in the corners of the leveler let workers inside the trailer know the trailer restraint’s engagement status, warning them to leave immediately if the restraint becomes disengaged.
While LED communication at the loading dock is not new, it
is oftften a good starting point for any facility that simply has a red light/green light on the inside and outside of the loading dock.
Upgrading to smart equipment in this part of the facility today can reap benefifits in the future if a move to IIoT is made down the line.
Traffic Control Inside the Facility
Blind intersections present another safety challenge for facilities. There are several products that address this issue. Instead of the big convex mirrors that obscure reflections in ways that are not to scale, there are a few LED light communication systems designed for blind corners.
There is ceiling-mounted system that plays the role of a traffic light, alerting workers with a red LED stop signal and an amber LED yield signal when something is approaching from another direction. It works by using unidirectional microwave sensors to pick up approaching traffic in all directions, whether it is a four- way, three-way, or two-way intersection. When an object is within sensing range, the other directions on the device show an amber yieldsignal.Theworkerapproachingtheintersectionwillnotbe presented with any lights. However, when two or more objects are approaching from multiple directions, those workers will see red LED lights on the device. The remaining directions will show amber LED lights. Advanced models can be enabled with smart technology to capture intersection traffic data, which can be used to develop safety enhancements such as modified traffic patterns or floor layouts.
The ends of rack aisles can create similar blind areas in facilities. For this challenge, smaller units that can mount to racks, walls and door jambs can sense traffic moving to protect workers who are using a main thoroughfare to transport goods. Instant communication on possible collision risks allows workers to avoid danger and work more efficiently when they know traffic is not approaching.
Safety Done Right
Making inherently dangerous operations safe is not easy. However, with all the technological advancements being made at the loading dock and inside the facility, there are ways to improve worker safety in the present and help ensure safety in the future.
While cost may be an impediment to safety upgrades for some facilities, many of the products mentioned here are offered as standalone options or can be added as retrofit—providing those facilities with an incremental, budget-friendly equipment integration option. From inside the loading dock and outside on the drive approach to inside the facility, these solutions can help improve safety in the dock operations of any factory, warehouse or distribution center.
Walt Swietlik has more than 35 years of experience in the material handling industry, with more than 30 of those dedicated to the area of loading dock and door safety and improved productivity. For the past two decades, Walt has managed Rite-Hite’s popular “Customer Fly-In Program,” where he works closely with a variety of customers to address the challenges associated with shipping and receiving areas. Walt has spoken at a variety of local, regional and national forums, including ProMat and MODEX.
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10 Occupational Health & Safety | JANUARY/FEBRUARY 2022 www.ohsonline.com