Many pallet manufacturing facilities have operated for many years – as have many of the employees and supervisors working in these facilities. Though this experience in the industry is tremendously valuable, it can also be dangerous. Let’s face it – when we get comfortable doing something, we often start working on autopilot or sometimes even cutting corners. Often the longest-term employees feel the most confident in executing their duties. While taking shortcuts can ramp up production, these actions can also lead to tragic accidents.
In this article, we’ll discuss common workers’ compensation claims in pallet manufacturing and the causes of these accidents. We’ll outline how a single claim can have a trickle-down effect resulting in more major problems, as well as offer tips on how pallet facility management can mitigate risk.
Top Seven Pallet Manufacturing Claims
1. Material handling accidents are the most common workers’ compensation insurance claim we see reported by pallet manufacturing facilities. These accidents typically stem from less automated plants as more advanced facilities leave most of the handling to machines rather than people. Typically, material handling incidents comes into play when workers need to remove materials from machinery, and/or manually stack boards or pallets. The lifting and turning motion required to do this can result in back injuries, which can persist for years.
2. Punctures related to nailing boards together in less automated facilities can also lead to both minor and serious accidents and can keep employees out of work.
3. The removal of safety guards on the equipment, poorly maintained automatic shutoff systems or older equipment without safety measures can lead to injured or lost limbs, among other issues. While some may say the machine operates faster and with more precision without the safety mechanisms in place, the removal of these is a leading cause of accidents.
4. Eye injuries are also the basis of frequent claims as sawdust and various flying debris are commonplace in a pallet facility.
5. Stacking pallets too high can and has led to falling pallets and crushing accidents. We’ve seen tragic claims, where building materials stacked too high led to debilitating limb loss and even death.
6. Forklift accidents resulting from inadequately trained drivers can lead to injuries involving other employees or falling material.
7. Commercial auto accidents are a major source of insurance claims in workers’ compensation and beyond often caused by inadequately trained drivers or distracted driving. Injuries related to improperly loaded cargo are also a source of workers’ compensation claims especially during the loading and unloading processes.
The Trickle-Down
While pallet workers’ compensation claims may not be frequent, when they do occur, they can be severe, or even tragic. Workers’ compensation claims can not only be debilitating for the employee involved but can also lead to costly problems for the business owner or managers. A badly injured employee may be out of work for an undetermined, and sometimes very long, period of time – sometimes years – and the business likely won’t be able to replace the worker due to the disability laws of the state. This, in turn, can lead to a slowdown in production. This could be particularly difficult for a pallet facility owner in today’s bustling economy.
Additionally, the injured worker could have been a long-time employee, and for the staff, his absence could hit home, causing a slump in morale or concerns about their own safety. The injury could also lead to a costly and reputation-damaging lawsuit in addition to an increase in workers’ compensation insurance premium due to the claim. Lawsuits and comp claims can also affect pricing, claims, coverages or eligibility on other lines of insurance like auto, general liability or umbrella.
Workers’ Comp Risk Mitigation Tips
The following tips can help supervisors and management at pallet manufacturing facilities keep their facilities safe for their employees:
• Use automated material handling where possible.
• Ensure that safety guards are not removed from machinery and that equipment is properly and regularly maintained and cleaned.
• Require employees to wear eye protection and maintain a clean facility to reduce sawdust and debris buildup.
• Train employees on proper lifting and stacking techniques and ensure they wear a belt when lifting. Define a maximum height for stacking and ensure that rule is followed. Use mechanical lifting devices or two-man lift techniques for any weight over 50 lbs.
• Provide regular training for forklift drivers and make sure equipment is updated with safety features and is properly maintained.
• Check motor vehicle records of drivers regularly and implement training to keep drivers safe on the road. Consider a driver monitoring solution to encourage safe driving and identify poor driving habits.
Finally, another way a pallet manufacturing business can take action to prevent future workers’ compensation claims is to talk to their insurance carrier, particularly one specializing in the wood niche. The loss control team at a good insurer can assist with employee training and share other risk management tips to help prevent workers’ compensation claims affecting your business. Making safety a priority is always a smart business decision.
Editor’s Note: Genevieve Ventiere is brokerage marketing manager at Allied Building Material Agency, a wholesale brokerage for workers’ compensation insurance owned by Pennsylvania Lumbermens Mutual Insurance Company. An insurance professional for more than 15 years, Genevieve places all lines of insurance for the wood industry business. She can be reached at Genevieve@abmbrokerage.com.
