If you are in the manufacturing, logistics, or distribution industry, you know that a well-run warehouse is an important part of a successful business. Proper and regular warehouse maintenance can boost productivity and is a crucial step in keeping your employees and inventory safe.
As busy as warehouses can get, being able to fit regular maintenance items into the schedule can certainly be a challenge. That is why maintenance items such as inspections, cleanings, and safety checks should be a part of a routine schedule. In this article, we will cover how to set up a warehouse maintenance plan as well as a guideline for maintaining your pallet rack.
Getting Started with a Warehouse Maintenance Plan
A warehouse should ideally have two levels of maintenance: preventive and emergency. Preventive maintenance is a great way to avoid incidents, ensure OSHA compliance, and boost productivity at your warehouse. But you also need a plan for emergency repairs. First, let’s discuss how to get started with a preventive maintenance plan.
Preventive Warehouse Maintenance
Preventive warehouse maintenance refers to scheduled maintenance activities to keep your warehouse organized, keep your equipment running, and ensure that proper safety precautions are in place. Creating a maintenance checklist is a good way to keep track of maintenance activities.
A warehouse maintenance checklist is an overview of all of the maintenance items that need to be completed as part of your preventive maintenance. Although the checklist you create will be specific to your business, you can start by considering the following items:
-
Evaluate the safety gear and protocols; this includes checking PPE and replacing any that are no longer intact, making sure that emergency exits are clear, and all the necessary safety equipment is available and intact.
-
Ensure that storage areas are properly labeled and there is sufficient space allocated for the products that are being stored.
-
Make sure to include specific maintenance plans for warehouse equipment and have a way to keep track of repairs.
-
Evaluate your floor plan and update it as necessary.
-
Schedule regular warehouse cleaning and pest control.
-
Inspect key structures such as alarms, lighting, electrical, etc. for damage and schedule repairs as needed.
-
Update training guidelines and operational authorizations for machines.
-
Conduct safety and fire drills in the warehouse.
-
Check the software systems such as the Warehouse Management System and ensure that it is updated regularly.
-
Maintain the cooling and heating systems and ensure that there is proper ventilation in the building.
Standardize Procedures
Warehouse management includes many reoccurring tasks. Create Standard Operating Procedures (SOP) to standardize the process. You can use your checklist as a starting point to create more detailed manuals that will be shared with employees. Stay on top of your SOPs and make time to regularly review them.
Prioritize Employee Training
Once you have a procedure for maintenance, training your employees on it should be your priority. When employees are trained and tasked with maintenance items relevant to their positions, they are more likely to stay on top of their assigned tasks.
Create and Keep Your Schedule
You have spent all of the time assessing your needs and creating a maintenance plan. Not you need to put it in motion. Create a clear and comprehensive schedule, and include checkpoints to stay on it; make maintenance a part of employee schedules. One idea to encourage employees to stay on top of maintenance tasks is to offer perks and incentives for keeping a safe work environment.
Emergency Maintenance
With all the different moving parts and equipment used in a warehouse, unexpected repairs can be needed at any time. It’s important to have an emergency maintenance plan in place so you can take care of the issue without having to delay your operations for too long. Your emergency maintenance procedures should be highly personalized to your business. Consider the different emergency situations that can arise and the different equipment that could need repairs, and be prepared for any other disasters. Also, make emergency maintenance procedures available and easily accessible to employees and include these in your training materials.
Pallet Rack Maintenance
Pallet rack is one of the most commonly used pieces of equipment in a warehouse and one that is subject to a lot of wear and tear. Staying on top of your pallet rack maintenance will allow you to get more out of your investment, and protect your employees against accidents.
One of the key parts of pallet rack maintenance is regularly scheduled inspections. During the inspections, make sure to check the following components:
-
Uprights: Inspect the front and back of each upright for any damage, and ensure that the frame is not twisted.
-
Bracing: Inspect for damaged or missing bracing and broken welds, and ensure that the anchors are secure.
-
Cross Beams: Check all of the beams for missing safety clips or bolts, and ensure that the beams are structurally sound.
-
Decking: Ensure that the load capacity of the decking (and pallet rack in general) is not exceeded. The load should be evenly distributed across the deck. Inspect for any damage to the decking.
-
Accessories: If you are using any pallet rack accessories ensure that they are structurally sound.
-
Baseplates: The baseplates should be anchored to the concrete floor. Make sure that the anchors are intact.
If you find any problems during your inspection, secure them as soon as possible. Unload the pallet rack with caution and make the necessary repairs. Do not continue using the pallet rack before the repairs are complete. Learn more about pallet rack safety in our article: How to Increase the Safety of Your Pallet Rack.
Pallet rack safety accessories are a cost-effective way to prevent damage. Check out our entire collection on our website.
Warehouse Maintenance Challenges
Before you start implementing a warehouse maintenance plan, it’s a good idea to evaluate your warehouse and operations for challenges that may stand in the way of maintenance. Here are some of the top challenges to look out for:
Poor Warehouse Layout: Evaluating your warehouse design and layout should be your first step. All parts of the warehouse should be accessible and unobstructed. If you don’t have assigned areas for different equipment and product, clutter zones can arise. Compartmentalizing your warehouse with the use of signage, labels, maps, etc. will make it easier to carry out maintenance tasks.
Scheduling Issues: Warehouses are constantly busy, which makes it hard to find time for maintenance activities. Finding dates and times for maintenance that work with all of the different activities that take place in a warehouse can be a challenge. A good way to tackle this issue is by scheduling maintenance for smaller sections of the warehouse instead of as a whole.
Improper Training Procedures: Employee training is a key part of warehouse maintenance. All employees should be knowledgeable when and what maintenance procedures should be followed and how to respond in an emergency situation.
American Storage & Logistics Can Help With Your Warehouse Equipment and Design Needs
American Storage & Logistics has been a leader in new and refurbished warehouse equipment sales for over 50 years. Our entire inventory, including pallet rack, is available online for shipping and next business day local delivery or pickup. We also offer warehouse design services to help you figure out the most efficient layout for your warehouse. We can help you figure out how to get the most out of your existing space. Contact us today to get started with your project!
