Analysis Of Hazards and Control At Workplace

1. Identification of Site of Survey

The purpose of this report is to present a comprehensive and critical assessment of the workplace hazards at a selected site of survey. The workplace which will be evaluated and assessed for the purpose of this report is that of Costco Wholesale Docklands which is a large-scale publicly traded retailer which deals in a wide range of products including appliances, electronics, jewelry, foods and beverages, outdoor living and furniture amongst other products and services. Costco initiated its operations in Seattle in 1983, however, the origins of the company date back to 1976 with the formation of Price Club which later merged with Costco. The company operates under the retail warehouse club concept whereby shoppers can purchase a large quantity of goods at attractive prices by paying a membership fee which grants them the right to shop at the specific location (1).

Similarly, access to Costco Wholesale Docklands is only provided to members which is similar to the business model of other Costco outlets. This implies that shoppers who wish to purchase products and services at Costco can only do so if they maintain their annual membership. Costco Wholesale Docklands is spread over a large area and the interior portion of the retailer is designed as a warehouse with stocks thousands of SKUs. The sheer space of the warehouse allows hundreds of shoppers to be present in the store at one time along with multiple staff members that are present on the floor in addition to retail staff,, cleaners, floor supervisors, salespersons and cashiers. The warehouse is structured in a format where similar items and product categories are placed in the same location, however, there are no specifications or markings on aisles to help shoppers navigate through the warehouse. This decision has been taken from a marketing and sales point of view as the absence of aisles encourages customers to explore other parts of the warehouse and come across items that they had not intended to purchase, this in turn helps increase sales revenues (2).

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A typical Costco warehouse is spread across a floor space of more than 140,000 square feet. The items that are present in the warehouse are generally available in bulk in large quantities or family sizes which makes it an attractive destination for small-scale business owners as it allows them to purchase items at competitive prices. As is the case with standard retailing operations which require a series of activities to align together in order to meet customer demands, Costco’s sheer scale of operations and its warehouse model presents a range of workplace hazards and safety concerns which need to be mediated.

This reports presents a selection of the workplace hazards that were commonly identified at the site of the survey while showcasing the degree of risk that these hazards pose to the individuals who are exposed to them including staff and customers. In line with the discussion conducted in the report, the analysis also presents effective interventions which can be implemented to manage and control these risks in an effective manner by applying the relevant principles and standards associated with occupational hazards and their management.

2. Identification and Selection of Hazards

Workplace safety hazards can be categorized into six types. These include chemical hazards, biological hazards, physical hazards, safety hazards, ergonomic hazards and psychosocial hazards. When exposed to biological hazards, a person may experience adverse health symptoms. Accordingly, chemical hazards can have a negative physical impact which may includes blindness and irritation to the respiratory system. Moreover, physical hazards do not require a direct exposure to the hazard but are a consequence of environmental components such as pressure noise and heights. Safety hazards are created in a workplace when working conditions are not suitable for employees or individuals who are present at the site. Examples of safety hazards include slippery floors and exposed wiring. Ergonomic hazards are most commonly present in spaces where individuals are working in a sitting position for continuous hours or are continuously exposed to the computer screen. Long-term exposure to such a hazard can result in musculoskeletal injuries. Furthermore, psychosocial hazards have can negatively affect the well-being or mental health of an employee including workplace violence and sexual harassment (3). Based on the site survey of Costco Warehouse Docklands, the workplace hazards that were assessed have been categorized and evaluated as follows.

Narrow Aisle Space

Costco Warehouse Docklands is spread across an extensive area and is designed as a warehouse space whereby, thousands of SKUs are placed in pallets and shelves according to their categories or specifications. The space between the warehouse tracks is designed to enable several shoppers and staff members to walk between the area and haul their carts. Even though there is sufficient space between two racks, safety hazard which was witnessed at the survey site was the presence of unsupervised carts that are often left by customers who no longer wish to use the items. This is a physical safety hazard because it increases the chances of accidents by limiting the aisle space and creating issues for smooth movement. Another physical hazard which was witnessed at the site survey was the presence of in-store product placement and specific aisles where certain products are marketed on separate shelves that are placed in the middle of the aisle.

Trip and Slip Hazards

Another critical workplace hazard which was witnessed at the survey site and can potentially harm the employees may occur during the handling of materials as improper lifting of heavy items can cause serious injuries and strain the back muscles (4). The potential risks which may aggravate this issue include the presence of pre-existing conditions and limited physical capabilities. Slips and trips are one of the leading causes of safety concerns in warehouses. Overcrowding in an aisle because of the presence of several customers and staff members can further increase the chances of experiencing this safety hazard at the site.

Furthermore, this safety hazard can also emerge because of the presence of slippery surfaces. For example, temperature changes in the meat and poultry and fresh produce section of the warehouse can contribute to the floor becoming slippery thereby, leading to accidents caused by falling and tripping on such surfaces. The warehouse style layout of Costco is also one of the reasons why the workplace safety hazards at the retail store are different from its competitors which do not adhere to a similar floor plan (5). The presence of towering warehouse shelves and heavy pallets increases the risk of being struck by products which may fall off from the shelf especially because thousands of customers touch the product placements everyday. Some products that are stored on the upper shelves and are present on the pallet maybe slightly misplaced from their original space which can further increase the chances of falling. The severity of such injuries is often high because the products may fall at a fast speed. The size and dimensions of the product may also influence the extent to which an individual gets injured if such an accident takes place.

Unstable Load and Broken Pallets

One observation which was made during the site survey was that of unstable load and a lack of secure storage. This was noticeable in the case of certain products such as drinks and liquid detergent which was placed in cardboard pallets that were stacked over each other but seemed to be unstable on the topmost pallet. The height of the materials was also a primary concern as it enhanced the risk of unstable load because it was stored on the upper side of the warehouse shelf. OSHA’s guidelines for retail stores specify the importance of ensuring that pallets are stacked properly and that they are inspected before moving them to another location or loading them (6)(7).

Cuts and Lacerations During Unpacking and Restocking

The warehouse club model of Costco attracts customers because of the discounts that they can obtain due to bulk purchases. This implies that the retail store has a high sales turnover and employees must restock products that run out of stock quickly because of high demand. Opening new product packages entails the use of sharp items such as box cutters and knives which exposes staff members to the risk of lacerations or cuts. Such injuries are often the result of ineffective or incomplete training which does not provide employees with the necessary information and knowledge about how to unpack products and avoid preventable injuries.

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Congested Pathway

The spacious floor plan of Costco Wholesale Docklands is marked with exit and entry doors, however, the design of the floor space and the placements of shelves and racks limit the ability of customers and staff members to navigate through the exit doors in case of a fire emergency. This is also an alarming concern in case of an unforeseen event as individuals who are inside the store may not be able to make the way outside the retail establishment successfully. The pathways within the warehouse often become congested because of the presence of several customers at the same time which is a critical workplace hazard.

3. Assessment of Degree of Risk

Narrow Aisle Space

The presence of narrow aisle spaces due to the placement of shelves in the middle of the pathways and the entry of multiple customers and staff members at once poses critical safety risks. One of the risks caused by this hazard is the increased chance of collision which can result in accidents. Moreover, if multiple customers are present in the aisle at once there is a risk that the carts being handled by the customers may cause injuries to other individuals who are present within the aisle by stepping over them. However, the probability of such accidents is low because customers have control over navigating the carts through the aisles and when shopping carts are left in a state of immobility, they do not move ahead on their own. More the severity of the injury caused by this safety hazard would be low as the injury would potentially require first aid treatment.

Trip and Slip Hazards

The warehouse style layout of the retail store exposes workers to potential slip and trip hazards. Temperature changes in the meat and poultry section often lead to a slippery floor in the area which can cause customers and staff members to slip and increase the chances of injury. The probability of this risk is medium because generally the temperature in the section is maintained and remains stable however, if any changes do take place the floor is not wiped immediately. The severity of the risk is also classified as medium because slipping on the floor can cause a sprain which may keep staff members off work due to injury.

Unstable Load and Broken Pallets

The stacking off products on the top portion of the warehouse shelves increases the risk of unstable load. Moreover, the products which are placed within the lower half of the shelf are already accessible to customers which can result in broken pallets especially in the case of cardboard pallet boxes. The probability of the workplace hazard occurring is low however, the severity rating for this risk is high because if a product falls on a worker from a height, it may result in major fractures and serious head injuries.

Cuts and Lacerations During Restocking and Unpacking

The workers at Costco Warehouse Docklands undergo extensive training in workplace safety which involves the proper usage of PPEs and equipment which are a part of their job description. Any cuts and lacerations during the process of restocking by using knives and box cutters have medium risk of occurring because the activity takes place several times during a workday. Accordingly, the severity of risk associated with the activity is low because it would only require first day treatment.

Congested Pathway

The presence of congested pathways is a critical safety hazard because it increases the chances of not being able to contain the fire hazard in case of an emergency because of the presence of several customers who may not be able to navigate through the emergency exit doors and make their way outside the warehouse. This risk has a low probability of occurring, but it has a high severity rating because it can lead to serious injuries and loss of life.

4. Suggested Means of Control of Risk

The means of risk control which should be implemented in order to address the risks at the facility includes several measures. The hazard concerning the presence of narrow aisles and congested pathways can be addressed through the implementation of stringent and effective administrative controls whereby staff members are thoroughly explained and trained in the standard operating procedures which need to be followed in case of emergencies. This entails teaching staff members about the best course of action which would have to be undertaken in case of an emergency situation. The training should also feature the mechanisms which would have to be adopted in order to ensure that the situation is controlled especially with the presence of hundreds of customers at the same time.

Accordingly, the safety hazard pertaining unstable load in broken pallets can be addressed through the implementation of engineering controls which involve modifying pallet design and making shelves more secure (8). This process would involve a revamp of the shelving system which is adopted by Costco in addition to identifying the maximum load that the racks can bear and the maximum height of stackable pallets which should be permitted during storage (9).

Accordingly, enforcing engineering controls to maintain the temperature of the meat and poultry and fresh produce zones would ensure that the slipping and dripping hazard in the area is reduced or eliminated. The risk controls which can be adopted at the warehouse would enable the retail store to ensure the safety of its workers and its customers while reducing the risk of exposure. Moreover, it is imperative to develop and continuously promote a culture of safety whereby employees are able to practice safe work ethics and adhere to policies and regulations which are put into place to control hazards in the workplace. A safety culture can be maintained in the organization by performing a comprehensive workplace risk assessment and identifying the root causes of incidence and near misses that have taken place in the store (10). Once these issues have been identified the next process is to inform workers about the changes and work standards and processes which have been implemented to ensure that such incidents do not occur in the future (10). The implementation of safety culture involves strengthening the shared values, perceptions and patterns of behavior to guide the organization towards a culture where the safety, well-being and health of all employees is valued. Enforcing such a culture is particularly important during the prevailing COVID-19 situation (11). The presence of a safety culture will also promote a proactive approach where employees will be able to handle unforeseen situations that may increase safety risks or have potentially hazardous consequences.

References

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