Because they support high-throughput order fulfillment of single product—typically fast movers—some operations utilize pushback rack storage systems as part of their picking process. In order to ensure that pickers are able to perform their assigned tasks safely when working with a pushback system, there are a few recommended best practices.
Pushback Rack Picking Best Practices
These guidelines include:
1. Follow Manufacturer Guidelines.
Always follow the recommended procedures published by the pushback system’s manufacturer. Picking from systems deeper than two pallets is normally discouraged. That’s because the back pressure created by more than a single pallet may become difficult for an operator to control when removing empty pallets.
2. Only Pick at Floor Level.
Picking from a pushback rack should only occur at floor level to ensure operator safety. Likewise, position the system low enough for the operator to safely reach all cases without stepping on a partially empty pallet.
3. Use Beam-Mounted Pallet Stops.
Pushback systems utilized for picking should have beam-mounted pallet stops installed at every pick face. These devices ensure that a partially loaded pallet remains securely in place. This prevents the loaded pallet behind it from pushing it forward, potentially injuring the operator.
4. Remove Empty Pallets with a Forklift.
When a pallet is completely empty, the safest practice is for a forklift to remove it, rather than the operator manually lifting it by hand. This is because the forklift can far more easily control the speed of the pallet’s removal than an operator. In turn, this controls the speed at which the subsequent pallet descends down the lane. Additionally, removing an empty pallet by hand can place a high degree of ergonomic strain on the operator, who must bend down and lift it. Further, if there are any obstructions (such as a lift truck) behind the operator attempting to manually remove the empty pallet, the back pressure of the subsequent pallet might cause him or her to be pinned.
5. How to Manually Remove an Empty Pallet from Pushback Rack.
If an empty pallet must be removed manually (and the loads are not too great), the safest procedure is for the operator to first confirm that the aisle behind him or her is clear. Then, utilize proper lifting techniques to lift the front of the pallet above the pallet stop and slowly walk backward while dragging the pallet on the pushback rail. This allows the operator to use the empty pallet to maintain control of the speed of the descending load behind it.
To learn more about best practices in safe operation of pushback racks, click here.
