Loading docks are very busy places in both human food manufacturing and pet food manufacturing facilities. Trucks and forklifts, people, and other lifting devices are constantly moving in and out of the dock area. This activity creates an atmosphere ripe for injuries. When dock doors are open, pet food manufacturing facility safety rules require that owners and managers install safety gates, guardrails or another type of protection barrier against falls from loading docks.
In the US, loading docks usually run between 46 inches to 55 inches high. OSHA loading dock safety rules require that open docks four feet or more above ground level or the platform floor have standard safety gates, guard railings or their equivalent to prevent serious worker injuries from falls. In addition, manufacturers must make sure that workers maintain a safe distance from the edge of:
- Ramps or platforms on an elevated dock, or
- Platforms or freight cars.
Loading dock gates are a primary protection against employee falls from loading docks. Loading dock gates typically come in widths from 8 feet to 10 feet (though custom sizes are often available) and are easy to install using basic tools. Included gas struts make opening and closing easy, too.
In addition to installing loading dock gates, owners/managers must ensure that the leading edge of the loading dock and any swing gates and railings reflect a noticeable safety color and that warning signs are plentiful.
Loading dock gates come in a variety of different styles that meet all OSHA loading dock safety standards, including:
- Standard vertical lift loading gates – These basic lift gates protect loading dock areas that don’t have a limited height clearance. Ideal for guarding platform openings in small spaces, they’re simple to operate and close using tapered guides for easy alignment.
- Dual vertical lift loading dock gates – These specialized safety gates provide extra-wide protection against loading dock falls, while maintain a limited height clearance for those areas with low ceiling issues. Perfect for compliance with OSHA loading dock safety standards, these gates often feature gas struts to make their operation easy for one worker.
OSHA Issues Hefty Fines
OSHA issues significant fines for manufacturer non-compliance with safety regulations. Just ask the Purina Animal Nutrition Center in Wichita, Kansas. In the past, OSHA cited the popular pet food company for multiple violations for not maintaining proper pet food manufacturing facility safety, such as lacking guardrails on platforms and floor openings which exposed workers to falls from 6-12 feet. The proposed fine exceeded $40,000.
OSHA has six categories of violations, each with its own penalty amount:
- Serious or High Gravity — This type of violation occurs when an owner or manager knows there is a risk of serious bodily injury or worse from a safety hazard and does nothing about it. OSHA bases violations in this category on the level of risk. Fines can reach as high as $16,653 for each violation.
- Moderate Gravity or semi-serious — Fines range from $7,802 to $11,703 for each violation.
- Low Gravity or less serious — $5,851 for each penalty sustained.
With respect to a hazard that does not result in an injury or death but does threaten an employee’s health or safety at a serious level, OSHA has the option to issue a citation or reduce the penalty by 95%.
In addition, minimal-only violations result in warnings but no financial penalty. More substantial minimal-only violations face financial penalties that range from $1,000 to $13,653 each violation.
Violations repeated within three years are considered willful violations and face stiffer penalties up to $13,532. Willful violations are subject to reduction based on the size of the workforce, as follows:
- 10 or fewer employees — fine reduced 80%
- 11-20 employees — fine reduced 60%
- 21-30 employees — fine reduced 50%
- 31-40 employees — fine reduced 40%
- 51-100 employees — fine reduced 20%
- 101-250 employees — fine reduced 10%
- 251 or more employees — fine reduced 0%
Companies that do not resolve the violation by the OSHA imposed data face the maximum penalty per day after the due date.
Note: OSHA does not impose fines against employees who violate workplace or job site safety rules.
Given the potential for facing the severest OSHA fines, it is advisable for pet food manufacturers to take a proactive stance regarding OSHA safety compliance. Owners and safety managers should consider internal inspections of their facilities’ loading docks and other fall hazard areas on a regular basis. It is also prudent to lay out a mechanism for workers to report safety hazards and violations to management without fear of reprisal. In the event that OSHA’s inspectors find violations, it is prudent for owner/operators to take immediate steps to correct the problems.
The Crux of the Safety Protocols
Pet food manufacturing facility safety rules recognize that these facilities and their loading docks are among the riskiest environments for workers. OSHA’s guidelines go a long way to helping employers minimize those risks. Maintaining compliance with OSHA’s standards for eliminating fall risks saves companies from the imposition of substantial penalties. It also improves worker safety, which enhances productivity.
Worker safety is a critical issue and one that is difficult for safety managers to do alone. It helps to partner with an industry expert who can help your firm identify fall safety hazards, assist with OSHA compliance, and create a safer work atmosphere for your employees.
Fabenco is an industry-leading expert in fall safety and the manufacturer of gate systems that comply with OSHA loading dock safety standards, as well as other types of fall protection equipment. We invite you to contact us for suggestions on how we can help you improve your safety compliance.
To learn more about OSHA safety regulations that may apply to your facility, you might be interested in the August 2020 article from ohsonline.com entitled “Understanding Key Safety Regulations for Materials Handling.”
