OSHA Announces a New National Emphasis Program for Warehousing and Distribution Centers.

On July 13, 2023, OSHA announced a new national emphasis program to prevent workplace hazards in warehouses, processing facilities distribution centers, and high-risk retail establishments.  State Plans are required to participate in the federal national emphasis program or may opt to develop a similar emphasis program that is at least as effective as the federal directive. Currently, this program is scheduled to terminate in 3 years, but OSHA may elect to extend the program in 2026 as it has with other national emphasis programs.

The growth of this type of facility in the past ten years and the high rate of occupational injuries and illnesses associated with them has contributed to the development of this emphasis program.  While the primary focus will be on powered industrial truck (forklift) operations, material handling and storage, walking and working surfaces, means of egress and fire protection, heat and ergonomic assessments may be included if OSHA identifies them during the inspection. OSHA will also open a national emphasis program inspection at any covered facility when inspecting fatalities/catastrophes, complaints, or referrals.

Sites that are chosen for inspection will come from two lists, those with industry codes covered by the emphasis program and those retail establishments with the highest rates of injuries and illnesses resulting in days away from work, restricted job duties, or job transfer status.  The NAICS codes below for high-risk retail operations are included in this emphasis program.

High Injury Rate Retail Establishments Covered Under this NEP

NAICS Codes	High Injury Rate Retail Establishments
444110	Home Centers
444130	Hardware Stores
444190	Other Building Materials Dealers
445110	Supermarkets and Other Grocery Stores
452311	Warehouse Clubs and Supercenters

What can you do if your facility is covered by this national emphasis program?  First, make sure that your forklift operator’s certifications are current within the last three years.  If they are not, retraining will be needed.  Second, ensure that pre-operation forklift inspections are being conducted and documented on all shifts.  Paper forms or documentation through software such as iWarehouse will be sufficient for this purpose. 

Next, monitor the material handling proficiency of your forklift operators and verify that stored materials are stable inside rack systems.  Stacked material should be limited in height and secure and stable against collapse.  Ensure that aisles have enough clearance for material handling equipment, and that permanent aisles are demarcated.

Task associates with removing banding, carboard, stretch wrap or other items that could contribute to slip, trip, and fall hazards.  Spills should be cleaned up promptly. Ensure personnel are not staging material, even temporarily, in any emergency exit pathway.  Verify associates know where to go in the event of an emergency evacuation and are aware of storm shelters and other emergency practices.  

Review OSHA 300 logs for injury trends and monitor manual material handling for frequent bending, lifting, reaching, or work at or above shoulder level than can contribute to sprain strains and other ergonomic injuries.  If those conditions are identified, look for devices to aid employees and reduce the need for repetitive motion. 

If your facility is not climate-controlled, develop a program to address heat stress and train employees on the signs and symptoms associated with it.  Ensure fans and general ventilation are used to circulate air. Determine what conditions will require potential modification of work tasks, additional breaks, and additional fluids for all staff.  Remember, age, medical conditions, and associates that are not acclimated to the environment can contribute to the potential for heat illness.  The OSHA NIOSH Heat Safety App is available for free and can be used to assist manager and supervisors in making decisions on days when heat hazards are highest.

Above all, engage third parties where support is needed through insurance companies, worker’s compensation carriers, industry resources, and consultants to help strengthen company programs where needed.  

Click here to review the directive for this national emphasis program. 

www.osha.gov/sites/default/files/enforcement/directives/CPL_03-00-026.pdf

Tags: Distribution, OSHA, Resources, Warehousing