Storekeeping Material Handling Principles

STOREKEEPING
PST 04206
BTC.PRO
FELICIAN A.MBWAFU
1
MATERIAL HANDLING
 Materials handling may be defined as
the art and science of movement,
handling and storage of materials during
different stages of manufacturing or
storage considered as material flow
into, through and away from the plant.
 It is in fact, the technique of getting the
goods safely, to the right place, at the

right time and at the right cost.
FELICIAN A. MBWAFU 2
Material handling is important to
efficient storehouse operation.
It supports and improve the

movement of materials into a
storehouse, placement of goods in
store houses, movement of goods
from storage to order picking areas
and eventually to dock areas for
transportation out of the storehouse.
DIMENSIONS OF MATERIAL HANDLING
Material Handling (MH) has four (04) basic
dimensions to consider in designing, purchasing
and installation;
 Movement;
Efficient materials handling means efficient

movement of goods to, from and within the
storage facilities.
Time;
Is concerned with how fast is MH in movement of

goods/materials for production or in fulfilling
customer orders.
The longer it takes the greater the
chance of work stoppage, higher
inventories, increased storage
space, longer order cycles and lower
customer service.
 Quantity;
MH systems are designed to assure

that the correct quantity of product
is moved to meet the needs of
production and customers.
 Space;
MH equipment consumes space in

storehouses and plants. The space
in facilities is always fixed therefore
the MH system must utilize the
space effectively and efficiently.
PRINCIPLES OF MATERIAL
HANDLING
1) Planning Principle
All material handling should be the result of a
deliberate plan where the needs, performance
objectives and functional specification of the proposed
manner are completely defined. Material handling plan
defines the material (what) and the moves (when and
where); together it defines the method (how).
2) Standardization Principle
Material handling methods, equipment, controls and
software should be standardized within the limits of
achieving overall performance objectives and without
sacrificing the needed flexibility. (Standardization
means less variety).
3) Work Principle
Material handling should aim to minimize the work
done without sacrificing productivity or the level of
service required of the operation. Should simplify
work by reducing, combining, shortening or
eliminating unnecessary moves.
4) Ergonomic Principle (designed for maximum

comfort)
Human capabilities and limitations must be
recognized and respected in the design of material
handling tasks and equipment to ensure safe and
effective operations. Ergonomic principle embraces
both physical and mental capabilities. Material
handling must be designed so that they are safe
and user friendly for people. FELICIAN A. MBWAFU 8
5) Unit Load Principle
Unit loads shall be appropriately sized and configured
in a way which achieves efficient material flow at each
stage in the supply chain.
Unit load is the unit of materials that can be moved or
handled at one time.
Less effort and work is required to collect and move
many individual items as a single load than to move
many items one at a time.
6) Space Utilization Principle

Effective and efficient use of all available space must
be made, the equipment should occupy a minimum
space as possible. When transporting loads within a
facility the use of overhead space should be
considered as an option. 9
FELICIAN A. MBWAFU
7) System Principle
MH should be able to be fully integrated to form
a coordinated, operational system which
accommodates receiving, inspection, storage,
production, assembly, packaging, unitizing,
order selection, shipping, transportation and the
handling of returns.
8) Automation Principle
Material handling operations should provide a
room for mechanization and/or automation
where feasible to improve operational efficiency,
increase responsiveness, and improve
consistency and certainty.
9) Environmental Principle
Environmental impact and energy consumption
should be considered as a criteria designing,
selecting or operating a material handling system.
10) Life Cycle Cost Principle

A thorough economic analysis should account for
the entire life cycle of all material handling
equipment.
Life cycle costs to be included in analysis are such
as capital investment, installation, training, repair
and maintenance e.t.c
The life time and long range plan for replacement
of the equipment when it becomes obsolete.
IMPORTANCE OF MATERIAL HANDLING EQUIPMENTS
i. Speed, accuracy and economy in movement

of materials/goods.
ii. Prevention of damage to materials.
iii. It eliminates the factory hazards and thus
increase the safety of operations.
iv. Minimization of fatigue and drudgery (hard
work).
v. Helps in increased production capacity and
maintain constant rate production.
vi. It reduces the idle time of labors and
increase efficiency.
Cont…
vii. Good housekeeping
viii. Reduce cost
ix. Efficient storekeeping and develop effective
working conditions.
x. The factory area is used most effectively.
xi. The quality of materials is maintained
through minimum human touches, elimination
of breakages etc.
TYPES OF MATERIAL HANDLING EQUIPMENT
1.Manual material handling equipment

(Dependent on Physical Effort):
Manual material handling: Is the process of moving or
supporting an object by physical force/effort.
It is used to handle anything which is not heavy. The
equipment used are hand operated and smaller in size.
This level includes all manual driven equipment such as
hand truck, wheel barrows, trolleys e.t.c
Advantages:
 Flexible
 Usefulness and multipurpose
 Minimum investment cost
 They do not require to follow a fixed path of movement
& therefore can be used any where on the floor where

space permits FELICIAN A. MBWAFU 14
Disadvantage:
 More labor intensive
 Some mechanical handling equipment may
not be able to pass through certain
paths/cannot maneuver round certain places.
 Posses several risks to operators
-fatigue
-injury
-damage and defect
2. Mechanical material handling
equipment:
Power instead of physical effort is
used for driving the equipment.
Conveyors & cranes fall into this
level.
Here operators are needed for
operating the equipment.
Advantages:
 Very efficient (is the best option for a company
with uniform product size and volume flow)

 They satisfy for loads which are too heavy to be
handled manually.
 Low operating cost.
 Save time, labor and space
Disadvantages:
 Investment is high
 Often specialized for certain products
 Limited versatility/flexibility
 Require training and operators
3. Automated material handling equipment:
Minimum human intervention is required for

driving & operating the equipment and most of
these functions are performed by computers and
electronic equipment.
No operator is required.
They aid to increased speed and efficiency by
which materials are produced, shipped, stored,
and handled.
Some examples of commonly used
automated materials handling
equipment include robotics in
manufacturing, Stacker cranes.
Automated Guided Vehicles (AGV)

Are industrial trucks that can
transport loads without requiring a
human operator. The machine usually
receives instructions from key boards,
pushbuttons & tape or card readers.
Advantages:
 Can function within narrow aisles
 Quick and efficient
 No operator is required
 Good organization of operations
 Labor savings
Disadvantage:
 Capital intensive
 Lack of flexibility
 Vulnerability to downtime whenever there is
breakdown
 Additional maintenance cost
 Cost of auxiliary equipment.
COST ASSOCIATED WITH VARIOUS
TYPES OF MATERIAL HANDLING
EQUIPMENT
Material handling cost: are the
main costs involved in designing,
installing and operating a material
handling system.
Material Handling Cost
Main costs involved in designing, installing &
operating a material handling system are:
1. Equipment Cost; this comprises the purchasing of
equipment, auxiliary components & installation
2. Operating Cost; which include electricity, fuel, &
labor cost, consisting of both wages & injury
compensation, training of operators, insurance etc.
3. Maintenance and breakdown Cost; which is
associated with spare parts, repair and maintenance.
4. Cost due to packaging/unit load equipments;
Some materials require packaging before they can be
moved. E.g the use of pallets in forklifts, wrapping
etc
5. Depreciation on the equipment
COST ASSOCIATED WITH MANUAL
HANDLING EQUIPMENT
1. Equipment Cost;
2. Operating Cost;
- Labor
3. Maintenance and breakdown Cost
COST ASSOCIATED WITH MECHANICAL
HANDLING EQUIPMENT
1. Equipment Cost;
2. Operating Cost;
-Including labor and energy/power (fuel)
4. Training cost
5. Insurance cost
COST ASSOCIATED WITH AUTOMATED
HANDLING EQUIPMENT
1. Equipment Cost;
-Including system installation and auxiliary
facilities
2. Operating Cost;
-Power/electricity as operator is not
required
4. Insurance cost
USE OF MATERIAL HANDLING EQUIPMENTS IN STORE
OPERATIONS
Movement and storage are basic storehouse
operations.
Material handling takes place at different stages

within and beyond stores operation as follows;
Unloading of goods at inwards stores
Loading on to an internal transport
Movement to stores for the purpose of storage
Movement to and from work stations.
Movement to and from finished goods stores.
Movement during packing.
Loading of packed materials on to a external
transport.
Holding materials during storage
CONDITIONS FOR LOADING AND
OFFLOADING OPERATIONS
 To conduct loading and offloading operations a
designated area specialized for loading and
offloading need to be established.
 The designated area must be clearly marked and
sign-posted as a restricted area.
 All employees operating within this confined area
must wear a high-visibility vest or like clothing,
which clearly delineates them from other employees.
 Special loading and offloading equipments as
forklifts, side loaders/lifters, hydraulic lifting jacks,
cranes and mechanical lifting jacks will be selected
for use within this area.
Cont…
The restricted area will have at least the following control
mechanisms in place:
 Designated personnel – Through recruitment, selection,
and training only authorized personnel will be allowed to

enter the designated loading and unloading area.
 Specific Personal Protective Equipment (PPE) – Standard
PPE requirements and in addition a specific high-visibility

vest.
 Radios – the use of radio frequency; those radios
designated for use by crane crews and other personnel

within the restricted area.
 The stores personnel/operator should be trained in the
systems and administrative controls used, as well as

tested for competency in the use of designated equipment
such as cranes and forklifts.
STORAGE EQUIPMENTS
Storage equipment are usually
limited to non-automotive and non
mobile.
Storage equipment is used to hold
materials during storage.
These periods could refer to

temporary pauses during long-term
transportation or long-term storage.
In storage facilities goods are
protected from weather, theft
and deterioration.
The majority of storage
equipment refers to pallets,
shelves or racks onto which
materials may be stacked in an
orderly manner to await
transportation or consumption.
Examples of storage equipments include:
 Racks: such as pallet racks, drive-through or
drive-in racks, push-back racks, and sliding

racks
• Stacking frames
• Shelves, bins and drawers
• Mezzanines
 Containers
 Cabinets e.t.c
Unit Load equipments:
Unit load equipment are equipment
that stabilizes or holds equipment to
avoid tilting during transportation or
storage but themselves do not move.
This equipment also allows more
than one item of the same material
to be held by one unit load. For
example, an egg carton can carry a
dozen eggs at once.
 Pallets, bags, cartons,
containers, crates, straps,
wrapping, bins, baskets and
racks are examples of unit
load equipments.
MOVING EQUIPMENTS
 It refers to any type of material handling
equipment that moves material from one
point to another.
 Involves short distance movement of
materials, goods/products.
 Moving equipments are required to move
goods around the factory for storage and
or transportation.
 Material handling for movement are
categorized in two major types - Powered
and Non-Powered. FELICIAN A. MBWAFU 34
 Powered equipment include trucks,
cranes, conveyors, etc.
 Non -powered equipment include
hand-pallet trucks, order picking
trolleys, stair climbing trolleys, shelf
and cage trolleys.
 Industrial lift trucks/fork lift are used
in warehousing for moving material

over relatively short distances, for
lifting into and out of storage, and for
vehicle loading and unloading.
Examples of moving equipments include:
 Conveyor systems: Are used for moving
material between fixed points, for sortation

and for other industry applications such as
separation, grading, packing etc.
• Cranes are used to move material but
are restricted to certain zones.
• Trucks can move material almost
anywhere
PHYSICAL SECURITY FOR
STOREHOUSE AND STOCKYARD
Physical security:
Is protection concerned with
maintenance of a secure
environment to detect and respond
to intruders and prevent
unauthorized access to
properties/resources.
SECURITY MEASURES IN
STOREHOUSE AND STOCKYARD
i. Entry Controls:
Limit physical access to stores premises by the
use of electronic controls; (biometric punching
or electronic identification cards).
ii. Alarm and Surveillance Systems (CCTV

Cameras):
Utilize intruder alarm systems at storehouses
and other facilities to protect secure areas.
iii. Security Guards and Attendants:
Utilize guard forces and security attendants as
critical components of physical security .
They conduct entry control procedures (for
example, pass checking) and escorting visitors,
monitoring intruder alarm and surveillance
systems (such as Close Circuited Television) and
conduct internal and external patrols.
Introduce administrative procedures (people
must sign, ID and declare belongings) for
controlling entry and exit to secure premises.
iv. Entry and Exit Searches by use of scanners
An important element of an effective access
control system is the capacity to control not just
the movement of people, but materials into and
out of secure areas assisted by the help of
scanners.
v. Electronic Article Surveillance
The use of electronic article surveillance systems
(or electronic tagging) to assist in protecting
against the unauthorized removal of security-
classified information or assets.
vi. Protection of Employees
However, it is important to emphasize that the
physical security arrangements in place are also
extended to provide a high standard of
protection for employees and clients as well.
vii. Custodian of keys.

Only authorized person should be responsible
for opening and closing the secured premises
or storehouse.
PHYSICAL SECURITY IN RELATION TO
NATURE OF MATERIAL
i.Entry Controls:
To prevent loss of light consumables and access to
information.
ii. Alarm and Surveillance Systems (CCTV

Cameras):
To prevent loss of medium to large materials and
assets, machinery and equipment.
iii. Security Guards and Attendants:

To prevent theft of all kind of materials
iv. Entry and Exit Searches by use of scanners
To prevent theft of light consumables, materials
and equipment
v. Protection of Employees
To prevent theft of all kind of materials
LOSSES IN STOREHOUSE AND
STOCKYARD
Losses in storehouse and stockyards are
caused by the following:
i. Loss caused by lack of security
measurers:
Lack of security or poor security in the
storehouse and stockyards may create the
room for unauthorized persons to enter in
the store and remove the stored materials.
Theft in the storehouse and stockyards
are the results of the lack of security.
ii. Loss caused by deterioration
Deterioration is the action or process of
becoming impaired or inferior in quality,
functioning, or condition. Deteriorations of
stock can be caused by temperature,
humidity, poor material handling and
storage.
iii. Loss caused by damages to stock
Damages of stock can be caused by failure or
malfunction of handling or storage
equipments leading to stock damage.
iv. Loss caused by overstocking
When the ordered materials exceed
the actual demand; stock can
remain in the store or stockyards
for long period situation that may
lead loss to the stock
(Obsolescence).
v. Loss caused by improper order of issue
(FIFO/LIFO)
Proper issuing principles is very important in the
store and stockyards.
The best proper issuing method is FIRST IN
FIRST OUT (FIFO) especially for perishable items.
FIFO in this matter means the first item received
in store should be the first item to be issued.
For durable items both methods can be used
FIFO and LIFO that means the Last item to be
received in store, be the first to be issued. In the
storage of huge and heavy equipment LIFO can
be used in order to create space for storage of
the incoming materials
vi. Loss of Stock caused by risk of fire
Fire outbreak may cause a huge loss
by destroying materials in the store
and stockyard.
vii. Loss caused by natural calamities.

Natural calamities such as earthquake,
floods/ lightening can be a cause of
loss of stock in store houses.
Measures to prevent losses in
storehouses and stockyards
 By observing security measures, so as to
prevent theft and removal of materials in the
store by unauthorized persons.
 By minimizing materials deterioration -
through dealing with issues that may cause

deterioration of materials.
 Through the use of proper handling equipment
- this equipments should be used properly and

operated by trained personnel to avoid
damage.
 By applying proper stock control measures-
use FIFO during issuing of materials from the
store especially for perishable items.
 Store personnel to communicate with other
departments like procurement, production,

distribution and marketing departments to
avoid overstocking.
Physical safety for a storehouse
Physical safety: Is the condition
whereby an individual is free from harm
or injury from a physical object or
practices that include a physical object.
Physical object can include a person, a

handling equipment, stored materials
(solid, liquid or gas), including a store
house etc
Safety measures in a storehouse
Safety measures: are activities and precautions
taken to increase or ensure safety or protection
from danger/harm/injury.
The following are safety measures in a
storehouse;
i. Ensure Safety Equipment is used at all Times
PPE must be used all the time
ii. Eliminate any Potential Safety Hazards
Safety check is carried out on a regular basis
and keep passages clear all the time.
Cont…
iii. The stacks should not be too high.
iv. Provide sufficient lighting.
v. Familiarize with the location and the
operation of safety equipment including
fire-fighting equipment.
vi. Before operating a machine, make sure it is
in good condition.
vii. Handle chemicals/explosives with care.
viii. Do not drink or take drugs while working.
ACCIDENTS IN STOREHOUSES
Accident: is an unplanned event that happens
suddenly and unwillingly, typically resulting in
damage, injury or death.
Causes of accidents caused by people;

i. Difference in usability and incorrect handling:
E.g Crane controls: the design might contravene
user expectations (pushing the lever down raised
the crane and vice versa) which is different from
the crane he used to.
Cont…
ii. Incorrect use of equipment:
It occurs where machines are being used for
activities other than their primary purpose (e.g
excavator and forklift used instead of crane).
iii. Poor knowledge and experience

Some operators do not have adequate
knowledge in operating handling equipments.
Cont…..
iv. Poor communication.
It is a result of poor or inappropriate
communication among machine operators and
other warehouse workers during operating a
handling equipment.
v. Storage and handling equipment overloaded or

misused against manufacturer’s specifications.
Accidents caused by equipment,
materials and buildings/plants
1. Pallet, Rack/shelf Collapse:
Incidents involving pallet rack or shelf
collapses often arises from materials not
being properly put in a safe and orderly
manner or collapse due to weakening (wear
and tear).
2. Slips & Falls
This can be caused by scattered materials in
store house, wet floor, fall can happen if an
employee climbs a rack to retrieve products
e.t.c
Cont…..
3. Hazardous Material spillage
Production and distribution centers
often receive shipments of harmful or
explosive materials, and accidental
spills out causing accident.
4. Electrical, wiring methods
Sub-standard electrical equipments
and poor wiring, including temporary
wiring, is a major cause of warehouse
accidents.
Cont……
5. Equipment maintenance
deficiencies:
Some equipment parts my not be
functioning well due to lack of
maintenance and repair resulting
to accident.
Accidents caused by weather
1. Excessive heat due to sunlight:
Sunlight heating can cause explosion
especially when storing explosive
materials.
2. Wind
Excessive wind blow can cause handling
and storage materials to collapse
including the store house building.
3. Excessive rain fall
Excessive rain fall may lead to floods,
which may wipe out the store house
causing accidents
4. Storms and hurricanes

Storms are threats and are major
causes of buildings collapse harming
people and destroying properties.
MEASURES TO PREVENT ACCIDENTS IN
STORE HOUSES
1.The
Warehouse personnel must apply PPE such as
gloves, safety helmet and safety boots during
materials handling. Acids resistant gloves and
goggles should be worn for extra safety during
handling of chemicals and harmful materials.
2. A periodic check should be carried out to ensure
that preventive maintenance is carried out on
material handling and overhead cranes installed in
the main warehouse and other storage areas.
These facilities must be tested at regular intervals
for safe working load and safe working condition.
3. All staff should be properly trained in
using material handling equipment;
Instructions for proper use of material
handling equipment should be
available to all concerned.
4. Only authorized persons and

operators under the supervisor of the
officer, Warehousing section, should be
permitted to operate cranes or forklifts
for material handling inside and /or
outside the warehouse and stores.
Cont….
5. Implement safety meetings at
regular intervals.
6. Implement scheduled and
unscheduled safety inspections
regularly
FIRE FIGHTING EQUIPMENTS
Fire fighting equipment: Is a technical
equipment designed to rescue people
and protect material, valuable goods
and other resources from fire.
Most fires start small but, if left to

develop, they will grow and spread,
causing damage and threatening lives
of those in the surrounding areas.
Types of Fire Fighting Equipment
Fire Fighting Equipments have been categorized
into two groups:
A. Portable/Movable fire fighting equipments:
The function of a portable fire equipment is to
over come growing fires that are detected soon
after ignition.
Portable fire-fighting equipment can prevent a
small fire growing out of control and spreading
beyond the area of origin, affecting the means of
escape and posing a risk to people.
Fire-fighting equipment should be considered as
a means of both prevention and protection.
Portable fire fighting equipments
1. Fire Extinguishers
Most buildings contain a variety of hand-held
firefighting equipment. This range of equipment is
designed to help contain small fires before they
spread and become too large to control. Portable fire
extinguishers are available with a number of different
extinguishing agents to help combat a flame.
A portable extinguisher may contain the following
extinguishing agents:
water
foam
dry powder
CO2
wet chemicals
2. Fire Blankets
Fire blankets are designed for flame
that is fueled by flammable liquids,
cooking oils and fats. Fire blankets
are normally installed in places of oil
reserves.
The blanket is placed carefully over
the burning container or wrapped
around the person with burning
clothes.
3. Fire engine vehicles
 A fire engine (also known as a fire truck) is a
vehicle designed primarily for firefighting

operations.
 The primary purposes of a fire engine include
transporting firefighters to an incident scene,

providing water to fight fire and carrying other
equipment needed by firefighters.
 A typical modern fire engine will carry tools for a
wide range of firefighting tasks, with common

equipment including hoses, ground ladders, hand
tools, self-contained breathing apparatuses, BLS
(Basic Life Support) equipment, thermal imaging
cameras/infra red cameras, first aid kits etc
Cont..
4. Fire fighting aircraft:
Airplanes/helicopters provide means of
supporting the fire fighters on the ground from
aircraft in the air. Aircraft can access steep,
rocky or unsafe areas before ground forces are
able to gain entry.
5. Sand baskets
Prevent access of O2 for growing fire thus
prevents burning
B. Fixed Fire Fighting systems
These are immovable equipments usually installed
in buildings used to extinguish fire before it causes
damage.
Fixed fire protection systems will usually be
required in following circumstances:
◦ In high buildings, or buildings with deep
basements, fixed fire protection systems are
required to assist the fire fighters in the protection
of life and property.
◦Where the consequential loss from the effects of
fire would be very great.
◦In remote/complicated places where firefighters
can not reach quickly and easily.
There are a number of fixed fire-fighting
equipment available, including:
i. Fire hydrants and rising mains
A fire hydrant, also called a fireplug, fire
pump or simply a pump, is a connection
point by which firefighters can tap into a
water supply.
ii. Fire hose reel systems
A fire hose is a high-pressure hose that carries
water or other fire retardant (such as foam) to
extinguish fire. It attaches either to a fire engine
or a fire hydrant.
Indoors, it can permanently attach to a building's
standpipe or plumbing system. 72
FELICIAN A. MBWAFU
iii. Sprinkler systems
Is an active fire protection method,
consisting of a water supply system,
providing adequate pressure and flow
rate to a water distribution piping
system, onto which fire sprinklers are
connected.
In a sprinkler, there is a heat-sensitive
plug designed to open automatically
when fire breaks out, the plug is meant
to break and open the sprinkler as soon
as a fire breaks out.
iv. Water mist systems
A water mist system is a fire protection
system (for detection) which uses very
fine water sprays (i.e. water mist).
The small water droplets allow the
water mist to suppress or extinguish
fires by: cooling both the flame and
surrounding gases by evaporation. The
particles are attracted by the fire and
cool the fire by reducing oxygen
content.
v. Gas systems
The idea behind an gas fire system is to reduce
the amount of oxygen present in the area where
the fire breaks out. This is important because
fires need oxygen in order to spread.
vi. Foam systems (suitable for burning
liquids/fuel)
This prevents the fire re-igniting by creating a
barrier between the liquid's surface and the
flames. Because it is lighter than the burning
liquid, it floats freely over the liquid surface and
extinguishes the fire by prevention of oxygen
action.
vii. Dry powder systems
Dry chemical extinguishers are tanks
of foam or dry powder with
compressed nitrogen. It works by
putting a layer of powder on the fire,
you cut the fuel off from the oxygen
around it, and the fire goes off.
Usually fixed fire fighting equipments

are assisted by heat detectors/smoke
detectors.
CAUSES OF FIRE IN A STOREHOUSE
i. Open flame: Which includes hot work activities
such as welding, soldering and metal cutting
may cause fire.
ii. Electrical distribution equipment: Such as
electrical wiring, transformers and circuit
breakers including various electrical appliances
(heaters)etc, operating in storehouse may
cause fire due to faults → sparks
iii. Chemical reactions between incompatible
chemicals, have also been known to ignite
storehouse fires.
Cont…
iv. Smoking: source of heat when exposed to
explosives/ flammable liquids
v. Poor product disposal practices; such as
burning of perfumes, aerosol spray paints,
chemicals, insecticides etc
Flammable vs Inflammable materials
Flammable: Something which can easily be set
into fire. (it may sometimes require an ignition)
Inflammable: That substance capable of bursting

into flames without the need for any ignition.
Flammable materials
 Petrol/Diesel
 Furniture polish, Kerosene
 Oil-based paints, Fuel oil
 Nail polish remover, Paint thinner, Turpentine
Gasoline
Inflammable materials
 Charcoal starter fluid
 Cigarette lighter fluid
 Spray paints
 Wood stains
Ways to prevent fire/fire precaution
i. Fixing fire warning signs: “No smoking, danger,
explosive, flammable” sign posts must be clearly
placed in all parts of the store, regardless of the
materials being held. One of the major causes of
fires is cigarettes and matches carelessly discarded.
The storekeeper must ensure that the “no smoking”
rule is maintained.
ii. Installation of Fire-fighting equipments: Must be
installed in strategic positions throughout the store
and must be regularly inspected and maintained.
E.g Extinguishers, Hose reels, Sprinkler systems,
Fire Blankets and Fire buckets: The buckets are
usually filled with sand and are to extinguish very
small flame. 82
FELICIAN A. MBWAFU
iii. Paving escape routes and suitable fire exit doors.
Routes and doors must be clearly designed and
marked. Safe routes for people to leave the premises
including the provision of fire resistant walls, doors
and protected routes.
iv. Installation of fire alarm systems including
smoke/heat sensors/detectors.
v. Appropriate training for staff regarding fire prevention
measures, use of fire fighting equipment and provision
of first aid.
vi. Developing a system for maintaining and inspecting
fire safety equipment and systems to make sure they
are working all the time.
vii. All combustible waste materials should be removed
regularly from the storehouse.
viii. Storage building for materials with high fire risk
should be separated from other buildings.
Precaution/ warning signs
 Red is used to denote danger and they
indicate the location of fire fighting
equipments in an emergency situation.
 These signs are installed instantly to show

the location of fire equipment, such as fire
alarms, fire extinguishers, fire hoses and
emergency stop buttons.
FIRE BLANKET
FIRE ALARM
BUTTON
NO SMOKING
DANGER FIRE
RISK
FIRE PHONE FIRE HOSE

LOCATION
SIGN
DO NOT FIRE EXIT SIGN

IGNITE FIRE
IN CASE OF
FIRE USE FIRE
STAIRWAY: DO EXTINGUISHER
NOT USE SIGN
ELEVATORS
EXPLOSIVES
Explosive Substance: Is a substance which is capable to undergo a
chemical reaction by itself producing heat, light, sound, gas or smoke or a
combination of all that could cause injury or damage to people, objects
and surroundings.
CLASSES OF EXPLOSIVE MATERIALS

There are three classes of explosive materials, are as follows:
i. High Explosives: Explosive materials which can explode by loosening the
blasting cap. (for example: grenade etc).
ii. Blasting Agents: Any material or mixture consisting of a fuel and oxidizer
intended for blasting.
The major distinction between high explosive and blasting agents is their
sensitivity to initiation. Explosives are cap-sensitive, whereas blasting
agents require a primer/initiator. For example; ammonium nitrate-fuel oil,
dynamite.
iii. Low Explosives: Are combustible materials, containing within themselves
oxygen needful for their combustion, which burn spontaneously but do not
explode.
They function by producing gas/smoke as a propellant which produces an
explosion for example, gun powder, igniter cords and “special fireworks”
STORAGE OF EXPLOSIVES
Explosives can be stored in three main facilities:
i. Magazine: Is a building or structure intended
for storage of explosives, specially constructed
in accordance with the requirement of
explosives rules and regulations.
ii. Store house: Is an independent building other
than a magazine meant to possess fireworks
not exceeding 05 tones.
Cont….
iii. Storage Box:
Is a heavy duty box for safely holding
explosive substances.
For extra safety it is internally lined with
timber to suppress explosions.
It is secured with a heavy duty internal locking
system and finished with a high build powder
coating.
Cont….
TYPES OF MAGAZINES
There are four types of magazines.
 Type 1 Magazines - Permanent magazines for the
storage of high explosives.

 Type 2 Magazines - Mobile and portable indoor and
outdoor magazines for the storage of high
explosives
 Type 3 Magazines - Portable outdoor magazines for
the temporary storage of high explosives while
attended.
 Type 4 Magazines - Magazines for the storage of
low explosives. Blasting agents may be stored in
type 4 magazines.
SECURITY MEASURES TO STORE
EXPLOSIVES
i. Inspection of Magazines: Any person
storing explosive materials shall inspect
their magazines at least in every seven
days.
This inspection need not be an inventory,

but must be sufficient to determine
whether there has been unauthorized
entry or attempted entry into the
magazine, or unauthorized removal of
the contents of the magazines.
Cont….
ii. Location of Magazines: Magazines
must not be located closer to inhabited
buildings, residence or dwelling,
passenger railways, public highways, or
closer to other magazines.
iii. Construction: Magazine must be

bullet-resistant, fire-resistant, weather-
resistant, theft-resistant and fully
ventilated.
Cont…..
iv. Quantity and Storage Restrictions:
 Different types of explosives shall not be stored in the
same location. Detonators (fataki) are not to be stored

in the same magazine with other explosive materials.
 Every place where explosives are stored shall be
indicated by means of the word '‘Danger - Hatari'' and

underneath the words ''Baruti - dynamite'' or
''Detonators'', as the case may be, displayed in such a
manner as to be clearly visible to any person
approaching such place.
 Restriction on handling explosives - No person shall
handle or cause to be handled any explosive between

the hours of sunset and sunrise.
 Do not exceed storage quantities as indicated in
explosives regulations
Cont…
 Stocks of explosive materials are to be stored
so that they can be easily counted and checked
upon inspection.
 Tools used for opening or closing containers of

explosive materials are to be of non-sparking
materials.
A wood wedge and a fiber or rubber are to be
used for opening or closing wood containers of
explosive materials.
Cont……
v. Lighting: Battery - activated safety lights or
battery-activated safety lamps may be used in
explosive storage magazines.
 Electric lighting must not be used in any
explosives storage.
 All electrical switches, fuses e.t.c are to be
located outside of the magazine.

 Light fittings shall be strong and protected
against dust.
Cont…..
vi. Repair of Magazines: Before repairing the
interior/exterior of magazines, all explosive
materials must be removed.
Cont….
vii. Housekeeping: Magazines are to be kept clean, dry and
free of dust, paper, empty packages (containers) and
rubbish. Floors are to be regularly swept. Brooms and
other utensils used in the cleaning and maintenance of
magazines must have no spark-producing metal parts,
and may be kept in magazines.
Floors stained by leakage from explosive materials are to
be cleaned according to instructions of the explosives
manufacturer.
When any explosive material has deteriorated, it is to be
destroyed in accordance with the advice or instructions of
the manufacturer.
The area surrounding magazines is to be kept clear of
rubbish, brush, dry grass or trees.
Volatile materials are to be kept a distance of not less
than 50 feet from magazines. FELICIAN A. MBWAFU 96
Cont…..
viii. Inventories must be kept on all explosives:
Inventory entries must be made in ink, and
include:
a) date received,
b) material and quantity
removed/returned/resupplied,
c) name of manufacturer,
d) lot number and date of manufacture
e) name of person issuing/receiving materials
f) expire date etc
Cont…….
ix. Measures to prevent fire or explosion:
(a) excluding naked flame;
(b) excluding sources of electrical energy which could
produce sparks or otherwise initiate explosives;
(c) excluding sources of electromagnetic radiation
such as radio transmitters, mobile phones, walkie-
talkies, etc., from areas where explosives are stored;
(d) preventing accidental initiation from frictional or
impact energy;
(f) preventing accidental contact between explosives
and exposed hot surfaces;
(g) preventing contamination of explosives and other
ingredients (including contamination by water);
(h) prohibiting smoking or possession of smoking
materials. FELICIAN A. MBWAFU 98
Cont....
(i)maintenance of required separation distances
appropriate to the permitted explosives limits;
(j)minimizing the number of people permitted
to enter areas where explosives are held so as
to ensure that limits on persons permitted to
be present in the store are not exceeded;
(k) ensuring that other dangerous goods,
including flammable or toxic materials, are
excluded from areas where explosives are
stored;
Cont…
x. Measures to ensure safe systems of work:
(a) measures to ensure that personnel entering
explosives stores or handling explosives are
competent, suitably trained and have
appropriate tools, clothing and equipment;
(b) that stock is rotated so as to prevent build-
up of old stock, and
(c) shelving and stacking systems are stable
0
PETROLEUM
Petroleum (crude oil): Is a naturally occurring,
toxic, flammable liquid consisting of a mixture
of hydrocarbons and other organic
compounds, that are found in nature beneath
the Earth‘s surface.
1
PETROLEUM PRODUCTS
I. Gasoline or Petrol: Is a petroleum-derived
liquid flammable mixture consists mostly of
hydrocarbons.
Gasoline is primarily used as a fuel. Depending
on use, it can be classified as:
 Automobile gasoline
 Aviation gasoline
 Technical solvent
2
Cont….
II. Mineral Spirits: Is a petroleum distillate.
Commonly used mineral spirits are paint
thinner, nail polish remover and mild solvent.
Mineral spirits are especially effective in
removing oils, greases, carbon, and other
material from metal.
3
Cont…
III. Kerosene or paraffin oil: Is a colorless, oily,
flammable liquid with a strong odour, distilled
from petroleum.
It is burned in lamps, heaters and furnaces and
is used as a fuel or fuel component for diesel
and tractor engines, jet engines, rockets and as
a solvent for greases and insecticides.
Kerosene is sometimes used as an additive in
diesel fuel to prevent gelling or waxing in cold
temperatures.
4
Cont….
IV. Diesel fuel: Is a type of Fuel oil in diesel engines.
V. Motor oils: Are derived from petroleum-based

and non-petroleum synthesized chemical
compounds.
Most motor oils are made from a heavier, thicker
petroleum hydrocarbon base stock derived from
crude oil, with additives to improve certain
properties.
The main function is to lubricate moving parts.
Motor oil also cleans, inhibits corrosion,
improves sealing and cools the engine by
carrying heat away from moving parts.
5
Cont…
VI. Hydraulic oil/fluids: Is a non compressible fluid
that is used to transfer power within hydraulic
machinery and equipment.
It can be synthetic or mineral based oils based
on mineral oils or water.
It is used in machinery equipment ranging from
brakes, hydraulic cylinders, power steering and
transmissions.
Other are used for special applications, such as
in extreme temperatures.
6
SAFETY AND SECURITY MEASURES TO STORE
PETROLEUM PRODUCTS
I. Separation distances:
 Separation Distances between tanks / offsite

facilities: Reasonable separation distances
between above or ground tanks storing
petroleum products need to be maintained.
7
Cont…
II. Ladders, stairs and Handrails
Individual tank (above ground tanks) shall be
provided with access to the roof.
A platform with railing should be provided from
the top to bottom to provide easy access in case
of emergency.
8
Cont….
III. Tank inlets/outlets

The number of inlet/outlet connections to the
tank should all be kept minimum . Safety valve
on inlet, outlet and recirculation line shall be
installed.
9
Cont…
IV. Breather Valve
Breather valves shall be provided. The tank
breathes - in air when the tank pressure is
lower than the atmospheric pressure and
breathes - out when tank pressure is greater
than the outer pressure.
0
Cont…
V. Temperature and Insulation alarms
When product storage temperatures are likely to
be higher than 100 degree C, a remote
temperature indicator with alarm should be
provided in addition to local indicators.
1
Cont…..
VI. Electrical Safety Equipment
(a) Earthing Installation
The tanks shall have an earthing network with
required number of earth electrodes connected to
it.
Earthing system shall be designed for the
following:
1. To neutralize the system by earthing.
2. Protection against Static discharges.
3. Lightening Protection
Lightning Arrestor (LA)
The Grid of LA shall be distinct and shall not be
connected to any other earth Grid.
2
Cont…..
vii. Measures to prevent fire or explosion:
(a) excluding naked flame;
(b) excluding sources of electrical energy which
could produce sparks or otherwise initiate
explosives;
(c) excluding sources of electromagnetic radiation
such as radio transmitters, mobile phones, walkie-
talkies, etc., from areas where explosives are stored;
(d) preventing accidental initiation from frictional or
impact energy;
(e) prohibiting smoking or possession of smoking
materials.
3
OBSOLETE AND REDUNDANT STOCK
 Obsolete Stock: Is a term that refers to inventory
that has reached the end of its product lifecycle.
In this stage, there is no market demand
anymore.
It refers to items that are replaced due to their fall
in functionality as a result of the availability of
cheaper and better products.
 Redundant stock: Is also called Non Operating
Stock usually occur when organization makes
transition from manufacturing one product to
another in which stock for previous product
remains in surplus or excess.
Or as a result of Government restrictions or
change in manufacturing policy.
4
HOW TO PREVENT MATERIAL TO FALL UNDER
OBSOLETE AND REDUNDANT STOCK
Material can be prevented to fall under obsolete/
redundant by observing the following;
 To keep working stock level low enough to
reduce the risk of obsolete/redundant stock

 Constantly reviewing stock movement
frequencies
 Being aware of changes in techniques/technology
and demand within the industry

 Maintain close communication between stores
and the other departments involved in product

development to ensure customer satisfaction and
pro longed product life cycle.
5
Cont….
 Clear up the Excess Stock
 To sell the remaining stock promptly, before
incurring excess cost.

 Have effective Stock Management Policies
 Use an Inventory Management Software (IMS)
The use of IMS will minimize inventory costs

and maximize sales & profits through improved
efficiency and productivity operations leading to
consistent customer satisfaction.
↑sales = ↓obsolete/redundant stock
6
HAZARDOUS MATERIALS
Hazardous materials: Is any substance that, can
cause harm to people, property or the
environment because of its chemical, physical or
biological properties.
The term collectively describes “dangerous

material/substances” etc.
7
Cont…
Hazardous materials are often found in
a warehouse. These materials can be
either raw materials or finished goods.
A hazardous material is one that is

capable of producing harmful effects
such as a fire, sudden release of
pressure and explosion or short term
(acute) health effects, such as burns,
tremors and long term (chronic) effects
such as organ damage and cancers. 11
FELICIAN A. MBWAFU
8
Cont….
 For example, exposure to
hazardous substances can cause
adverse health effects such as
asthma, skin rashes, allergic
reactions, allergic sensitization or
cancer and other long-term
diseases/effects.
9
Cont….
 Hazardous materials includes many
commonly found industrial, commercial,
pharmaceutical, agricultural and
domestic materials/chemicals.
Many of which are found in mining, fire

works (metal fumes), metal
concentrates, solvents, cleaning agents,
petroleum products, compressed gases,
biocides etc
0
Cont…
A
majority of household chemicals and
materials are hazardous including;
Paints, motor oil, antifreeze,

insecticides, herbicides, fungicides,
cleaning agents, adhesives (cement),
aerosol cans, gas cylinders, insects
repellents, batteries, televisions, cell
phones, laptops etc
1
Cont….
Materials are considered hazardous when they
display one or more of hazardous properties which
are harmful on materials, environment and human
health including;
-explosive,
-radioactive
-flammable,
-irritant, harmful, toxic, carcinogenic
“Hazardous,” a broader term, refers to all materials

that are dangerous for any reason.
A hazardous material may impose the effect
intrinsically or extrinsically.
2
General characteristics of
hazardous materials
Any material that exhibits one or
more of these characteristics is
termed as hazardous materials:
• Ignitable
• Corrosive
• Reactive
• Toxic
3
Cont….
i. Ignitable: Materials that could cause fire during
transportation, storage or disposal. Many solvents,
thinner, paints are ignitable.
ii. Corrosive: pH as an indicator of corrosivity;

Materials with high or low pH can react
dangerously with other materials or cause toxic
contaminants to migrate from containers.
Materials are capable of corroding steel and
escape from their containers causing harmful
effect.
Examples of corrosive materials include acidics,
base etc
4
Cont….
iii. Reactive: Reactivity is a characteristic used to
identify unstable materials that can pose a
danger such as explosion.
A material that exhibits any of the following
properties is considered as hazardous due to
its reactivity:
• Reacts violently with water
• Generates toxic gases, vapors or fumes when
mixed with water
5
Cont…
• Capable of ignition if heated under confinement

or subjected to strong initiating source
• Capable of detonation/ignition at standard

temperature and pressure
Examples of reactive matter includes industrial

gases and various explosives.
6
Cont….
iv. Toxic: Refers to poisonous substances which
cause death or serious injury to humans and
animals by interfering with normal body
functioning (physiology).
The term is properly used to describe a
substance, whether or not it has become a waste
(i.e., “toxic substance” or “toxic chemical”).
A toxic effect is imposed intrinsically.
7
CLASSIFICATION OF HAZARDOUS
MATERIALS
Hazardous materials/substances
are classified on the basis of their
effects (health effects) whether
immediate or long-term,
particularly in relation to
workplaces.
8
Cont….
Hazardous materials are assigned to one or more of the
following classifications:
i. Flammable Liquid - any liquid having a spark point
below 38 degrees C .
ii. Combustible Liquid - any liquid having a flash point
between 40 degrees C and 80 degrees C and the
liquid produces enough vapors to ignite if exposed to
an ignition source.
iii. Flammable Solid - a substance that can cause a fire
through friction, absorption of moisture or
spontaneous chemical reaction and when ignited will
burn vigorously that it creates a hazard.
Flammable material
9
Cont…
iv. Oxidizer - a substance that readily yields
oxygen to stimulate the combustion of
organic matter.
Oxidizer/oxidizing
agent/organic
v. Corrosive
peroxides - a liquid
that corrodes steel or
has a pH less than 2 or greater than 12.5.
Corrosive
0
Cont…
vi. Organic Peroxide - an organic compound
containing the chemical bond, oxygen joined to
oxygen.
vii. Poison - a substance so toxic that it
presents a risk to life or health.
Poison/Toxic
substance
1
Cont….
viii. Compressed Gas - a substance in gas or
liquid form contained in a vessel under
pressure.
This includes cylinders, aerosol cans etc. These
substances may be flammable, non-flammable,
or poisonous. E.g tear gas
Compressed gas
2
Cont…
ix. Cryogenics - Substances that are extremely
cold such as liquid nitrogen, liquid helium
and dry ice. These substances may cause
suffocation (asphyxiation) if spilled in non-
ventilated areas.
Cold/low
temperature
3
Cont…
x. Radioactive/Ionizing Radiation:
Radioactive materials emit one or more of
harmful radiation: alpha particles, beta
particles, gamma rays, x-rays.
Radio
active/ionizing
radiation
xi. Biomedical hazard- tissues, organs,

blood, drugs and medicine
Biohazard
etc
4
Cont….
Biomedical Hazards: The AIDS epidemic has brought
the management of biomedical products/wastes
sharply into the forefront.
Products/wastes from health care, research and

biomedical manufacturing facilities may contain a
variety of other infectious and/or pathogenic wastes.
Blood Samples can contain disease-causing
organisms or matter.
Materials/wastes that are infectious or contain
infectious materials pose a hazard to handlers and
the public if they are not isolated and/or disposed of
in a manner that destroys the viability of the
infectious matter.
5
SAFETY AND SECURITY MEASURES TO
STORE HAZARDOUS MATERIALS
In order to safely and properly handle and store
hazardous materials, it is important to know the
hazards of those materials.
Proper handling and storage reduces the risk of

accidents involving hazardous materials.
In Controlling of Hazardous Substances

storekeeper must ensure dangerous substances
are stored and handled in a way that minimizes
the risks and limits people's exposure to them.
6
Precautions/measures needed to handle and store hazardous materials:
i. Labelling all containers of hazardous

substances. All dangerous materials should be
appropriately labelled to allow them to be
easily visible and used safely.
ii. Storing chemicals according to the

manufacturer's instructions on the safety
data sheet. Follow all the storage instructions
on the product label.
7
Cont…
 Place liquid hazardous materials above
ground where they are unlikely to be
damaged.
 avoid overfilling containers
 supervise deliveries
 maintain gauges, valves of all hazardous
devices
8
Cont…
iii. Keeping minimum quantity of hazardous
substances where necessary
Reduce the amount of hazardous materials

you keep in storage.
Purchase only the amount necessary to
complete your current job.
You may find it better to discard leftover

product rather than storing it. Just make sure
you follow the proper process for disposing of
hazardous materials.
9
Cont…
iv. Store incompatible substances separately
v. Taking immediate steps to prevent release

or leakage of dangerous substances
- Keeping a spill kit near to storage areas,
and ensuring staff are trained in what to do
in the event of a spill
- Cleaning up any leaks or spills that occur
0
Cont…
vi. Using the right safety measure when handling
hazardous substances. For example; wearing
protective clothing (PPEs) and ensuring
adequate ventilation etc
For example; Concentrated acids is classified as a
corrosive and would require the following
preventive measures:
 Do not breathe its vapour it causes severe burns
 Never add water to this product
 Wear suitable protective clothing
 Wear suitable gloves
 Wear eye/face protection
1
Cont…
vii. Control Fire and explosion risks
Ensure that flammable substances are correctly
stored in suitable containers and are not stored
near to a source of ignition such as a heater.
 Lighting and Electrical Equipment. Use only
electrical lighting recommended. Wiring and all
electrical equipment must meet the requirement
standards.
 Flame and Ignition. Do not permit open flame,
smoking, or other sources of ignition. Post

approved “No Smoking” signs in all areas.
Abide to all fire precautions including rapid

availability of fire fighting equipment. 14
FELICIAN A. MBWAFU
2
Cont…
viii. Ensuring employees who store and handle
dangerous substances are properly trained.
The training should include:
a. Recognition of hazardous materials.
b. Information about the health or
environmental effects of the material
c. Symptoms of overexposure to the material
d. First aid and emergency procedures
e. Safe handling procedures and personal
protective equipment requirements.
f. Environmental clean-up procedures
3
Cont…
ix. Isolation:
Isolation may be by a physical or a distance
barrier.
Isolation controls include:
- Remote storage of hazardous materials (for
example; explosives, fuel tanks)
-The separation of materials that could create
hazards by coming into contact with each
other by accident (for example; oxidants and
fuels).
4
Cont..
x. Ventilation: It is one of the main methods to
control airborne chemical hazards, particularly
contaminants.
Especially materials emitting toxic fumes, gases
and dust.
 Be sure to store all volatile products in well-
ventilated areas. Fumes can be toxic to humans

and animals.
 Make certain you store flammable products in
the recommended temperature range.
5
Safety measures cont……
xi. Storage of high-risk hazardous materials,
such as cyanide and explosives, needs to be
organised so that access is only authorized staff
has access, strict inventory control and regular
inspections.
xii. Products must be kept with safety lids

at all times.
6

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STOREKEEPING

goods safely, to the right place, at the

It supports and improve the

Efficient materials handling means efficient

Is concerned with how fast is MH in movement of

MH systems are designed to assure

MH equipment consumes space in

4) Ergonomic Principle (designed for maximum

6) Space Utilization Principle

10) Life Cycle Cost Principle

i. Speed, accuracy and economy in movement

1.Manual material handling equipment

& therefore can be used any where on the floor where

with uniform product size and volume flow)

Minimum human intervention is required for

Automated Guided Vehicles (AGV)

Material handling takes place at different stages

and training only authorized personnel will be allowed to

PPE requirements and in addition a specific high-visibility

designated for use by crane crews and other personnel

systems and administrative controls used, as well as

These periods could refer to

drive-in racks, push-back racks, and sliding

in warehousing for moving material

material between fixed points, for sortation

ii. Alarm and Surveillance Systems (CCTV

vii. Custodian of keys.

ii. Alarm and Surveillance Systems (CCTV

iii. Security Guards and Attendants:

vii. Loss caused by natural calamities.

through dealing with issues that may cause

- this equipments should be used properly and

departments like procurement, production,

Physical object can include a person, a

Causes of accidents caused by people;

iii. Poor knowledge and experience

v. Storage and handling equipment overloaded or

4. Storms and hurricanes

4. Only authorized persons and

Most fires start small but, if left to

vehicle designed primarily for firefighting

transporting firefighters to an incident scene,

wide range of firefighting tasks, with common

Usually fixed fire fighting equipments

Inflammable: That substance capable of bursting

 These signs are installed instantly to show

FIRE PHONE FIRE HOSE

DO NOT FIRE EXIT SIGN

CLASSES OF EXPLOSIVE MATERIALS

storage of high explosives.

This inspection need not be an inventory,

iii. Construction: Magazine must be

same location. Detonators (fataki) are not to be stored

indicated by means of the word '‘Danger - Hatari'' and

handle or cause to be handled any explosive between

 Tools used for opening or closing containers of

located outside of the magazine.

V. Motor oils: Are derived from petroleum-based

 Separation Distances between tanks / offsite

III. Tank inlets/outlets

reduce the risk of obsolete/redundant stock

and demand within the industry

and the other departments involved in product