Warehousing safety: OSHA receives gut punch from OIG
OSHA is set to start inspecting warehousing and distribution operations on October 13, but that did not stop a watchdog from issuing a report that takes a dim view of the agency's efforts to address the high injury/illness rates occurring in warehouses. The recent 42-page report from the DOL Office of Inspector General (OIG) recommends that OSHA make several changes to ensure the safety and health of warehouse employees.
NEWS UPDATE:Since publication of the OIG report, OSHA has issued two Temporary Worker Initiative (TWI) bulletins on warehousing and ergonomics. For details, please see our article, “Temp Worker Bulletins Zero in on Ergonomics and Warehousing.”
Warehouse incidence rates are double the national rate
According to OIG, 1.6 million employees work in 19,700 warehouses nationwide. Another 447,000 employees work in almost 38,800 electronic-shopping and mail-order houses (also known as online retailers). However, warehouse employees face hazards from powered industrial trucks, loaded pallets, and repetitive motion, says the report.
The latest data show that the rate of injuries/illnesses in warehousing was 5.5 incidents per 100 employees in 2021. This is more than double the national rate of 2.7 employees across all industries, the report explains. Yet, warehouses and online retailers were only about 1 percent of the nation's 8 million worksites in 2021.
The rate for days away or restricted duty for warehousing in 2021 was 4.6, more than double the 1.7 rate of all private industry employees. The report argues that this disparity indicates that employees in warehouses are significantly more exposed to serious injury/illness on the job.
Given the high rate of injury/illness in warehousing, OIG studied to what extent OSHA addressed those rates from October 1, 2016, to December 31, 2021.
OIG finds OSHA enforcement falls short
Of the almost 71,500 federal/state inspections performed for all industries on average each year, OSHA performed a limited number of about 750 (or 4.1 percent) at warehouses. Most of these inspections were unprogrammed, primarily driven by complaints and referrals. Surprisingly, while the number of warehouses climbed by 14 percent over the audit period, the number of warehouse inspections OSHA conducted dropped by 10 percent.
OSHA's Site-Specific Targeting Program (SST) has programmed inspections. The program is intended to direct inspectors to establishments with high rates of injury/illness. However, in the last two SST program periods from October 2018 to December 2022, warehouses comprised only 2.8 and 1.4 percent of the total universe of establishments that received SST inspections, respectively.
OIG finds a lack of guidance
The report says it has been a decade since OSHA issued new guidance to help employers identify the hazards of laborers and freight, stock, and material movers. Similarly, the agency has not issued guidance on implementing solutions since 2015. The only warehouse-specific guidance issued by OSHA was in 2004, OIG says.
OIG finds a lack of data
The report estimates that 16 percent of warehousing establishments on average failed to report 300A data annually. Moreover, 300A data reporting non-compliance averaged 46 percent for online retailers, said OIG. Without these statistics, OSHA is unable to identify and appropriately respond to current and emerging worker hazards, according to OIG.
OIG suggests an ergonomics rule
To identify and address injuries/illnesses at warehouses, OSHA uses its own severe injury reports, complaint/referral data, and data from Form 300A and the Bureau of Labor Statistics. These sources each have limitations. Despite this, OIG concludes that, collectively, they show the extent and persistence of certain hazards, such as overexertion and musculoskeletal disorders. The report finds that OSHA has not sufficiently addressed these hazards and suggests the agency could legally issue a "repetitive stress injuries" rulemaking.
OIG applauds NEP
OSHA published a warehouse National Emphasis Program (NEP) on July 13, 2023. In this targeting program, OSHA acknowledged the dangers faced by warehouse workers, including struck-by; caught-in-between; slips, trips, and fall hazards; blocked aisles; means of egress; powered industrial trucks and other material handling equipment; heat; and ergonomic hazards.
The report commended OSHA for kicking off the NEP. Yet, OIG says the program needs:
- A baseline number of establishments OSHA intends to reach,
- A results-oriented approach to measure program success, and
- Clearer guidance on how the agency will assess its effectiveness.
OIG recommendations
Among its suggestions, the report urges OSHA to:
- Change the criteria for the number of establishments to be inspected under the SST program so that the number reflects industry growth and the number of establishments nationwide,
- Develop a strategy to improve employer compliance with OSHA 300A data reporting,
- Assess 300A data categories and gather more information about musculoskeletal disorders, and
- Better analyze 300A data to identify trends among industries and establishments.
For the warehousing NEP, OIG recommends that OSHA:
- Develop measurable inspection goals for the NEP, and
- Provide inspectors with specific training in line with the NEP.
NEWS UPDATE:Since publication of the OIG report, OSHA has issued two Temporary Worker Initiative (TWI) bulletins on warehousing and ergonomics. For details, please see our article, “Temp Worker Bulletins Zero in on Ergonomics and Warehousing.”
Key to remember
An OIG report recommends that OSHA better address the high injury/illness rates at warehouses and online retailer facilities. This may prompt OSHA to act. Regardless, the warehouse NEP starts October 13.