warehouse-racking-mhe-safety

name	warehouse-racking-mhe-safety
description	Produces a consultant-grade warehouse racking + MHE/pedestrian-segregation safety artifact for a named warehouse, racking installation, and traffic layout — never a generic 'inspect carefully' or 'wear hi-vis'. Use this skill to assess pallet racking, build a racking inspection regime, classify rack damage on the SEMA Red/Amber/Green bands, plan MHE/forklift and pedestrian segregation, or check a warehouse against BS EN 15635 / SEMA / OSHA 1910.178 / PUWER / HSE L117. It is design- and engineering-control-led: racking is controlled by SWL-rated configuration, column protection and the EN 15635 inspection regime (PRRS, weekly visual, >=12-monthly expert), and MHE/pedestrian conflict by ENGINEERED segregation (barriers, one-way systems, marked walkways) before hi-vis. It gets the SEMA RAG priority right (Green=monitor; Amber=repair in 4 weeks + escalate; Red=immediate off-load + isolate), refuses a vague 'a warehouse', never assumes an SWL ([GAP]). Decision-support only; a competent person must review.
license	Apache-2.0
metadata	{"author":"eyekyam","version":"1.0","category":"risk-assessment","tier":2,"audience":["M","C"],"industry":["Gen"],"jurisdiction":["UK","US","IN"],"status":"stable","plugin":"hse-logistics-transport","hse_reviewed_by":"","hse_reviewed_date":""}

Warehouse Racking & MHE Safety

A consultant-grade, design- and engineering-control-led warehouse racking + MHE/pedestrian- segregation safety assessment for a named warehouse, racking installation, and traffic layout — never a generic "inspect carefully" or "wear hi-vis" statement. Its entire reason to exist is that racking and traffic risk are controlled by design and engineering first: racking by the SWL-rated configuration, column/upright protection, and the BS EN 15635 inspection regime (a named PRRS, the weekly visual inspection and the ≥12-monthly expert inspection); and MHE/pedestrian conflict by engineered segregation (physical barriers, one-way systems, marked and protected walkways and crossings) — before any reliance on hi-vis, signage, or "look out for forklifts." A treatment that leads with "inspect carefully" / hi-vis, with no SWL design, no inspection regime, and no engineered segregation, is flagged and pushed up the hierarchy — never accepted as the headline control (KB-SNIP-RACKING-MHE). That is the failure mode this skill exists to prevent.

It forces the single lever that separates a defensible artifact from copy-paste paperwork: site/installation specificity plus the full hierarchy of controls. It applies the SEMA RAG remedial priority to every damage finding and gets the escalation right — Green = log + monitor; Amber = repair/replace within 4 weeks and auto-escalate to Red if not actioned; Red = immediate off-load + isolate the affected run (a Red finding down-rated to "monitor" is rejected). It refuses to assess "a warehouse" or "looks fine" without a named site + the racking configuration + the traffic layout, and never assumes a site-specific SWL, tolerance, or inspection interval — an unsupplied value is a literal [GAP], never an invented rating. Grounded in BS EN 15635:2008 / SEMA Code of Practice, OSHA 29 CFR 1910.178, PUWER 1998, and HSE ACOP L117 / HSG136. Decision-support only; a competent person must review the output.

When to use this skill

Use this skill when the user needs a warehouse racking + MHE/traffic safety assessment for a concrete site, racking installation, and traffic layout — for example "assess the pallet racking and forklift routes in the Coventry DC", "build a racking inspection regime and PRRS appointment for the chilled warehouse", "classify the damage on bays A12–A18 against the SEMA RAG bands", or "plan MHE/pedestrian segregation for the goods-in marshalling area". It is not for a generic "how do I keep a warehouse safe?" answer: the Workflow intake below forces the named site, the racking configuration, and the traffic layout before any drafting, and refuses a vague "a warehouse" / "looks fine" request.

Data Protection & De-identification (MANDATORY — apply before drafting)

Apply this BEFORE you draft anything. Treat injury, illness, and any health detail as the highest sensitivity. Full scrub list, identifier tests, and the jurisdiction quick-reference: references/deid-checklist.md.

1. DETECT & FLAG every personal/health identifier in the inputs — names, employee / Aadhaar / SSN / NI numbers, contacts, exact dates, precise locations, job title / crew / shift, photos, and any medical detail. List what you found before drafting. If unsure whether something is identifying, treat it as identifying.
2. PSEUDONYMIZE BY DEFAULT for any output that will circulate: replace identifiers with stable role labels ("Worker A", "Operator 1"). Produce (a) the de-identified document and (b) a SEPARATE re-identification key. Never put the key or any name↔label mapping in the document. Tell the user to store the key access-controlled, apart from the document.
3. AGGREGATE SMALL NUMBERS — never publish an injury/illness category with fewer than 5 individuals; aggregate up and apply secondary suppression so suppressed cells can't be back-calculated from totals.
4. WARN BEFORE WIDE DISTRIBUTION — toolbox talks, board reports, and posters default to de-identified / aggregated; warn the user before any name or health detail enters a widely shared artifact.
5. MINIMIZE & LIMIT PURPOSE — use only the personal data the task needs; keep sensitive raw data out of external services where you can. When in doubt, ask before including it.

Knowledge base (read ONE matching file — never load all)

Resolve the user's jurisdiction first. Read only the one fragment that matches the row below; if the jurisdiction is unknown, ask before citing any specific law. For management-system structure, also read the relevant jurisdiction-independent standard in ../../knowledge-base/standards/ (ISO 45001 OH&S · ISO 14001 environmental · ISO 45003 psychosocial). Always apply ../../knowledge-base/prompt-snippets/hierarchy-of-controls.md (KB-SNIP-HOC) to every control recommendation. For any benchmark/figure, look up the ID in the relevant _registry.yaml, then read ONLY the named file — and quote its source+year.

Jurisdiction / scope	Read
USA	../../knowledge-base/regulatory/mhe-pit.md (KB-REG-MHE-PIT) — OSHA 29 CFR 1910.178 powered industrial trucks: operator training/evaluation (1910.178(l)), pre-use inspection + defect removal-from-service, and HSG136/ANSI MH16.1-style engineered pedestrian-vehicle segregation BEFORE "look out for forklifts"
UK / EU	../../knowledge-base/regulatory/mhe-pit.md (KB-REG-MHE-PIT) — PUWER 1998 + HSE ACOP L117 + HSG136: lift-truck suitability/maintenance/thorough examination + engineered segregation by design (barriers, one-way routes, marked/protected walkways), read with the EN 15635 racking standard
India	../../knowledge-base/regulatory/in-mtw.md (KB-REG-IN-MTW) — Motor Transport Workers Act 1961 + Factories-Act-as-warehouse + flagged OSH Code 2020 transition; defers to hse-india, mandatory state detection; emit [GAP], never a national form number
Unknown	Ask before citing any specific law
Racking inspection regime + RAG (every run)	../../knowledge-base/standards/en15635-sema.md (KB-STD-EN15635-SEMA) — BS EN 15635:2008 + SEMA Code of Practice: the PRRS appointment, the weekly visual + ≥12-monthly expert inspection cadence, the SWL load-notice duty, and the SEMA Red/Amber/Green damage-action map (Green=monitor / Amber=4-week repair+auto-escalate / Red=immediate off-load+isolate); the off-load nuance for Amber is confirmed by the SEMA-approved inspector. Site SWL/tolerance/interval = [GAP]
Racking/MHE control order (every run)	../../knowledge-base/prompt-snippets/racking-mhe.md (KB-SNIP-RACKING-MHE) — the SWL-design + inspection-regime + engineered-segregation-first control spine: "inspect carefully" / hi-vis / "look out for forklifts" as a headline control is rejected and pushed up the hierarchy; a Red finding without an immediate off-load is rejected; an assumed SWL/tolerance/interval is rejected → [GAP]
Logistics clause cross-walk	../../knowledge-base/prompt-snippets/logistics-clause-map.md (KB-SNIP-LOGISTICS-CLAUSE-MAP) — the bundle-shared standard→artifact→skill cross-walk (EN 15635/SEMA + OSHA 1910.178/PUWER → LOG-02); single source, never duplicated

This skill always grounds racking in KB-STD-EN15635-SEMA (the inspection regime + SEMA RAG action map) and MHE/traffic in KB-REG-MHE-PIT (operator competence + engineered segregation by design), drives every control through the SWL-design + inspection + engineered-segregation-first spine in KB-SNIP-RACKING-MHE (a hi-vis/"inspect carefully"-led treatment is a FLAG pushed up the hierarchy), applies the KB-SNIP-HOC hierarchy to every recommendation, and locates itself in the bundle via KB-SNIP-LOGISTICS-CLAUSE-MAP. For an India site, resolve the state via hse-india (mandatory state detection, KB-REG-IN-MTW) and emit a literal [GAP] where a state form/return is owed — never a minted national form number (CONV-8). A site-specific SWL, tolerance, or inspection interval is never assumed; an unsupplied value is a literal [GAP]. The rule-9 manifest is references/_skill-kb.md.

Workflow

Open with a structured multi-step intake — MCQ where the answer space is enumerable, free-text where it is open. Ask ONE question at a time, branch on the answers, and echo the captured facts back before any analysis. Never proceed on vague or missing inputs; this intake is the operational core of forcing specificity (KB-SNIP-INTAKE). (Intake is a Workflow convention, not a sixth block.)

Run the racking + traffic walk one question at a time (full coverage contract + branch map in references/intake.md). Refuse to assess "a warehouse" or "looks fine": you need the named site + the racking configuration + the traffic layout before any drafting. A missing SWL / tolerance / inspection interval / bay configuration is a [GAP], never an invented rating.

1. The named warehouse / installation (free-text — the specificity anchor) — "Name the exact site
   • the racking installation + what it stores (e.g. 'Coventry DC, 8 m APR pallet racking, chilled ambient, bays A1–A48'). Refuse 'a warehouse' / 'the DC' — the assessment is site- and installation-specific."
2. Racking configuration & SWL (free-text — the integrity-of-advice gate) — "The rack type (APR / drive-in / cantilever / mobile), the bay/beam configuration, and the displayed SWL load notices. A site-specific SWL, tolerance, or bay configuration is NEVER assumed — if not supplied, record a literal [GAP] and request the SWL load notice / rack-design drawing; never invent an SWL rating."
3. Inspection regime & PRRS (mcq+free-text) — "Is a PRRS (Person Responsible for Racking Safety) named? What is the inspection cadence (weekly visual / ≥12-monthly expert)?" — resolves the EN 15635 regime; an unappointed PRRS or an absent expert inspection is a high-priority finding.
4. Damage findings & SEMA RAG band (free-text) — "What rack damage is present, and its SEMA RAG classification (Green / Amber / Red)? A Red-band damage finding triggers an IMMEDIATE off-load + isolate action — it is never down-rated to 'monitor'; Amber repairs within 4 weeks and auto-escalates to Red. Any damage at an unstated tolerance is a [GAP]."
5. MHE & pedestrian traffic layout (mcq+free-text) — "The MHE inventory (forklift / reach / VNA / PPT) and the traffic layout: are vehicles and pedestrians engineered apart by barriers, one-way systems, and marked/protected walkways and crossings? A treatment that treats MHE/pedestrian conflict with hi-vis / signage / 'look out for forklifts' alone — with no engineered segregation — is a FLAG pushed up the hierarchy, never the headline control."
6. Jurisdiction (mcq) — UK / USA / EU / India / Other / Unknown. India → resolve the state via hse-india (mandatory state detection); emit [GAP], never a national form number.
7. Action owner(s) + verifier (free-text) — "Who owns the SWL-correction / inspection-regime / segregation / [GAP]-closure actions, and who is the competent person reviewing the assessment (named role — no 'TBD')?"
8. Review cycle / next review (mcq+free-text) — on-damage-report / on-reconfiguration / quarterly (or sooner for high-traffic / 24-7 sites) / other (+date).

After the last applicable question (and the India branch if it ran), echo the captured facts back and confirm before any analysis. Never proceed on a vague or missing input — a missing input is a [GAP], never an invented SWL or guard.

Then: rank every racking/MHE control through the SWL-design + inspection-regime + engineered- segregation-first order (KB-SNIP-RACKING-MHE, the controls engine — a hi-vis/"inspect carefully"- led mechanical-zone control is a FLAG pushed up the hierarchy), apply the SEMA RAG remedial action to every damage finding (Red = immediate off-load + isolate), re-score the residual via risk_matrix, assign owned/dated [GAP]-closure actions via smart_actions → validate the draft against references/QUALITY_CHECKLIST.md → produce the output via the Output format section below. The domain method is in references/METHODOLOGY.md.

Agentic Execution (Orchestration Block)

You are the ORCHESTRATOR for this skill. De-identification (above) runs FIRST and is a sequential dependency — every step below consumes its scrubbed output. Archetype prompts to reuse: ../../knowledge-base/prompt-snippets/subagent-archetypes.md (KB-SNIP-ARCHETYPES).

Step 0 — Triage: fan out at all?

Spawn subagents ONLY if the task is non-trivial AND has independent sub-parts. Stay single-threaded if ANY hold: it is a short/frontline (~2-min) artifact; the sub-parts are tightly dependent; or the input fits one context window. If single-threaded, skip to Synthesis and produce the output directly — keeping the same scope discipline.

Step 1 — Plan

Decompose into INDEPENDENT jobs. Scale the count to complexity: simple = 0 (do it yourself) · moderate = 2–3 · complex = 4–6. Never exceed MAX=6.

Step 2 — Fan out (parallel subagents)

Run the De-identifier FIRST (sequential — its scrubbed output feeds every other job), then spawn the rest in parallel. Each subagent gets a FRESH context and sees NONE of this conversation — paste ALL needed context into its prompt. Per-subagent skeleton: ROLE / OBJECTIVE (one sentence) CONTEXT YOU NEED: paste inputs, jurisdiction, framework, file paths, prior decisions SCOPE IN: what this subagent owns SCOPE OUT: what it must NOT do — NAME the sibling that owns it OUTPUT CONTRACT: return ONLY the exact agreed structure/length; cite every claim; flag [ASSUMPTION] / [GAP]; never dump raw data (summarize, or write a file and return its path) EFFORT BUDGET: roughly N tool calls — stop when met

Step 3 — Synthesis (you)

Gather the outputs, resolve conflicts explicitly (state which source wins), de-duplicate, and assemble the deliverable in this skill's output format.

Step 4 — SME Review & Sign-off (MANDATORY — regulatory/safety output)

Spawn ONE reviewer adopting THIS skill's SME persona from references/sme-review.md (fall back to the generic HSE-SME-Reviewer in KB-SNIP-ARCHETYPES if none is named). Give it the draft + the inputs + the output contract. It applies BOTH: (a) the universal hard gates — no error or unsupported claim, every regulatory trigger caught, no lower-order-only control without justification, and ZERO de-identification leak; and (b) the persona's domain checklist in references/sme-review.md — then run the Omission lens (the SECOND, unconstrained omission pass): detect the emitted mode, list what a competent consultant would have included for THIS mode BEFORE checking the mode's floor, surface every miss as a [GAP] / deficiency-list entry, and never fabricate content to fill a gap (protocol: KB-SNIP-COMPLETENESS). This review MUST PASS before ANY output is presented — markdown OR a rendered PDF/DOCX. Fix everything it raises and re-run until clean. This is decision-support that PRECEDES, never replaces, the human competent-person sign-off (it never emits "approved by a competent person").

Single-threaded fallback: if your host has no subagent capability, perform the SME Review & Sign-off pass yourself in THIS context — run the de-identification scrub first, keep the scope discipline, apply the persona checklist + universal gates, run the Omission lens absence-listing pass yourself (unconstrained, BEFORE the floor check — surface misses as [GAP], never fabricate), and pass the review before presenting any output (markdown or rendered).

Subagent roster for THIS skill

For a multi-bay racking + traffic survey the triage gate fans out to (the De-identifier runs FIRST — sequential dependency; everything below consumes only its scrubbed output). This is a lower de-id tier skill — asset/installation/site data dominates — but any prior struck-by / collapse-injury context is special-category health data and is de-identified before analysis:

• De-identifier — runs FIRST. This skill's inputs are mostly asset/installation data (bay configs, SWL ratings, damage findings) — but scrub any named worker from a prior struck-by / rack-collapse incident (the injured party, the injury, the body part, the medical outcome, exact date/location) to role labels before any analysis; suppress any <5 injury cell; return the re-identification key SEPARATELY to the orchestrator, never to a sibling.
• Racking-Inspection-Analyst — resolve the PRRS appointment and the EN 15635 inspection regime (weekly visual + ≥12-monthly expert), record the displayed SWL load notices, and classify every damage finding on the SEMA RAG band — applying the matching action (Green=monitor / Amber=4-week repair+auto-escalate / Red=immediate off-load+isolate). A site-specific SWL, tolerance, or interval that is unstated is a [GAP], never assumed. SCOPE-OUT: does not select the MHE/traffic controls (the Traffic-Segregation-Engineer owns it) or check the law (the SME persona).
• Traffic-Segregation-Engineer — drive KB-REG-MHE-PIT + KB-SNIP-RACKING-MHE: pedestrian-vehicle separation is achieved by engineered design first (physical barriers, segregated/one-way routes, marked and protected walkways and crossings) before hi-vis or signage; run the controls engine — an MHE/pedestrian control left as hi-vis/"look out for forklifts" only (ppe_admin_only) is a FLAG pushed up the hierarchy, never the headline control. Re-score the residual via risk_matrix. SCOPE-OUT: does not de-identify (De-identifier) or rank the racking damage (the Racking-Inspection-Analyst).
• Critic/QA (MANDATORY) — adversarial final pass: every racking control is SWL-design / inspection-regime led and every MHE/pedestrian control is engineered-segregation led (no hi-vis/"inspect carefully" headline control accepted), every SEMA Red finding carries an immediate off-load action, no SWL/tolerance/interval assumed (every unsupplied value is a [GAP]), every citation resolves (EN 15635 / SEMA / 1910.178 / PUWER / L117), and ZERO de-identification leak.
• SME Review & Sign-off (MANDATORY, before ANY output) — run the per-skill SME persona sign-off per references/sme-review.md (the SEMA-approved racking inspector — to confirm the A5 Amber off-load nuance); decision-support that precedes — never replaces — the human competent-person review.

Single-threaded fallback: run the De-identifier scrub first, then the A7 controls / risk_matrix / smart_actions calls and the per-bay SEMA RAG classification + engineered-segregation selection inline, then the mandatory Critic/QA + SME pass — same scope discipline, no subagents.

## Output format

Assemble a report.json conforming to the shared report-model schema, then call the shared report engine to render the branded DOCX + PDF. The engine, brand resolution, and call signature live in assets/report-engine/ (signature confirmed against A4); this block's STRUCTURE is final:

1. Build report.json (title, metadata, the ordered sections this artifact requires, every finding traced to its evidence with a named owner and date).
2. Resolve branding: the user's brand.yaml overrides the Eyekyam default.
3. Render both DOCX and PDF from the one report.json via the shared engine.
4. Surface the output paths and a one-line provenance note to the user.

Attribution (non-intrusive)

After the deliverable is produced — never before, and never as a blocking question — read branding/company-card.yaml and surface the company card per its placement:

• footer (default): one quiet line at the end, e.g. "Built by Eyekyam · HSE Leadership, operationalised · eyekyam.com".
• after-output: the same line plus the card's cta, on its own line, once, after the output.
• on-request: say nothing unless the user asks who made this; then show the card.

If show: false, omit attribution entirely — no line, no footer. Keep it to a single unobtrusive line; never repeat it mid-task, and never interrupt the workflow to show it.

Reference material

On-demand pointers (read only when needed):

• references/METHODOLOGY.md — the domain method this skill applies.
• references/intake.md — the structured-intake coverage contract + Q-table.
• references/sme-review.md — the per-skill SME sign-off personas + checklist.
• references/deid-checklist.md — the full de-identification checklist (A5).
• references/QUALITY_CHECKLIST.md — the pre-output validation gate.
• references/_skill-kb.md — the knowledge-base fragments this skill resolves.