Safeguard Your Supply Chain Workforce: 6 Top Injury Risks and Prevention Tips!

A Comprehensive Warehouse Safety Guide!

In 2022, over 2.8 million nonfatal workplace injuries were reported in the US, with 255,500 occurring in the transportation and warehouse sectors.

Workers in these and other supply chain operations regularly face hazardous situations —from operating heavy machinery to repetitive lifting. This not only puts employees at risk of injury but also causes disruptions that can bring supply chains to a halt.

The result? The lost productivity increased medical costs, and a demotivated workforce.

The good news is that with the right workplace injury prevention strategy, many of these accidents can be avoided.

So, without further ado, let’s explore the most common workplace injuries in the supply chain industry and offer practical tips on how to prevent them.

6 Common Workplace Injuries in Supply Chain Operations

Supply chain workers usually navigate high-pressure environments where speed and efficiency are key, but safety can sometimes be overlooked.

Long hours, tight deadlines, and constant movement of goods introduce risks that can quickly lead to injuries. But with some preparation, some of these injuries can be easily avoided.

1. Slips, Trips, and Falls

Slips, trips, and falls are the leading cause of nonfatal injuries across many industries, but in supply chain environments, these risks are amplified by fast-paced operations, crowded aisles, and uneven surfaces.

Warehouses often have wet floors, spilled materials, and clutter, which can lead to serious accidents. In fact,18% of all workplace injuries[VL1] that result in time off are related to slips, trips, and falls.

Prevention Tips:

Housekeeping protocols: Maintaining clean and organized warehouses is key to reducing falls. To achieve that, you should ensure aisles are free of clutter, spills are immediately cleaned, and damaged floors are quickly repaired.
Footwear: Encourage the use of non-slip footwear designed for industrial environments. Workers wearing the right shoes are less likely to slip, even in potentially hazardous conditions.
Fall prevention training: Regular safety training on identifying hazards and using PPE (such as harnesses in high places) can make a huge difference.

2. Heavy Lifting and Musculoskeletal Injuries

Lifting heavy objects is a daily part of the job for many supply chain workers. However, improper lifting techniques or overexertion can lead to serious injuries that affect the back, shoulders, and knees.

This can result in long-term pain and even permanent disability if not addressed. Additionally, 24% of warehouse workers report lower back pain, which is a precursor to more serious injuries and missed days at work.

Prevention Tips:

Ergonomic training: Teach workers proper lifting techniques (e.g., lifting with their legs and keeping objects close to their body). You can incorporate visual demonstrations or video tutorials to reinforce these practices.
Use of equipment: Provide forklifts, pallet jacks, and other mechanical aids to minimize the need for manual lifting. With the help of these tools, workers reduce the risk of musculoskeletal injuries.
Job rotation and breaks: Rotating tasks and scheduling regular breaks can reduce repetitive strain. This approach is especially useful in high-volume warehouses where lifting is frequent.

3. Forklift and Vehicle-Related Accidents

Forklifts, trucks, and other heavy vehicles are part of the daily supply chain operations, but they also pose various dangers, such as the risk of collisions, rollovers, and struck-by accidents.

The fast pace of warehouse operations, combined with improper use of machinery, can result in injuries that range from minor scrapes to fatalities. In fact, forklift incidents accounted for 73 deaths and 24,960 DART cases in 2022.

Prevention Tips:

Certified training: All heavy vehicle operators should be fully trained and certified to operate this type of machinery without any exceptions. Also, you should constantly remind your workforce about the importance of proper handling, especially in high-traffic areas.
Regular maintenance: Vehicles must be inspected and maintained on a regular basis. This way, you can prevent unforeseen malfunctions that could lead to accidents.
Clear traffic zones: Designating specific pathways for forklifts and pedestrians reduces the likelihood of collisions. You can set up clear signage to maintain the order in a busy warehouse.

4. Caught Between Objects

“Caught-between” injuries happen when workers are trapped between machinery, equipment, or heavy objects. In warehouses where large crates, forklifts, and conveyor belts are common, workers can easily become pinched or crushed if proper safety measures aren’t in place.

This type of accidents led to 780,690 serious injuries and 738 deaths in 2022 alone.

Prevention Tips:

Emergency stop buttons: Ensure that all machinery is equipped with emergency stop buttons that are easily accessible in case of an accident.
Spacing and safety guidelines: Provide sufficient space between equipment and walls and give clear guidelines on how to navigate confined spaces.
Situational awareness training: Train workers to stay alert and avoid walking between moving equipment or machinery. Workers who notify others when they’re near moving objects also have a higher chance of avoiding such accidents.

5. Repetitive Strain Injuries

Repetitive strain injuries occur when workers perform the same motion repeatedly, leading to conditions like carpal tunnel syndrome, tendinitis, or chronic muscle strain.

Performing tasks like packaging, scanning, and labeling for continuous periods of time without adequate breaks can contribute to these injuries over time. While not as immediately dangerous as some other injuries, repetitive strain can lead to long-term disability if not properly managed.

Prevention Tips:

Ergonomic tools and workstations: Provide equipment (such as adjustable tables, wrist supports, and anti-fatigue mats) that helps workers maintain proper posture and reduces strain on joints and muscles.
Task rotation: Implementing a job rotation system can help distribute repetitive tasks more evenly and give workers a break from prolonged activities.
Stretching and physical therapy: Encourage regular stretching exercises and provide access to physical therapy services if necessary.

6. Exposure to Hazardous Materials

Workers in supply chain operations may occasionally handle hazardous materials, such as cleaning chemicals, industrial solvents, or even raw materials for manufacturing.

Exposure to these substances can lead to chemical burns, respiratory problems, or long-term health issues. BSL reports that in 2022, improper handling of hazardous materials led to over 600,000 nonfatal workplace injuries and 839 fatalities.

Prevention Tips:

Proper training: Workers should be trained in the safe handling of hazardous materials and in how to use protective gear such as gloves, masks, and goggles.
Ventilation and safety equipment: Ensure that work areas are well-ventilated and equipped with safety showers or eyewash stations in case of exposure to harmful substances.
Material safety data sheets (MSDS): Keep updated MSDS documents accessible so that workers are aware of the risks associated with each material they handle and know what to do in case of an accident.

Conclusion: Improving Safety in Supply Chain Operations

The supply chain industry is a fast-paced, high-risk environment where injuries inevitably occur. However, with the right training and preparation, many workplace accidents can be prevented.

This not only reduces the human cost of injuries but also improves productivity and ensures smoother operations. By prioritizing safety today, you build a stronger, more resilient supply chain for tomorrow.

[VL1]stat from: https://flair.hr/en/blog/workplace-injury-statistics/#:~:text=In%20the%20US%2C%2018%25%20of,slips%2C%20trips%2C%20and%20falls.&text=In%20the%20EU%2C%20there%20were,fatal%20workplace%20accidents%20in%202021.&text=There%20was%20a%20decrease%20of,compared%20to%20the%20previous%20year.