Warehouse safety: Practical tips, risks and requirements

Importance of warehouse safety

Unfortunately, transportation and warehousing see a high number of injuries and fatalities. In 2023, businesses in this industry saw 930 fatalities worldwide. 

Injuries and fatalities are the worst-case scenarios. But, they’re not the only reasons why warehouse safety is paramount. Poor warehouse safety procedures can cause:

• Lower productivity: Accidents cause disruptions that lower productivity. Furthermore, these events require investigation, which can lead to stretched resources and time-consuming procedures.
• High turnover rate: Staff may leave if they don’t feel safe. Failing to build a culture of safety in a warehouse may cause employees to seek employment elsewhere.
• Damaged equipment and goods: Failing to maintain equipment and goods puts customer orders and staff at risk, potentially leading to revenue loss and downtime if an incident occurs.
• Environmental factors: Air quality and extreme weather conditions can damage equipment and impact employee health.
• Misplaced stock: An unsafe warehouse can sometimes be unorganized. As a result, goods, equipment and other assets could be lost or misplaced, scuppering order fulfillment.
• Product recalls: Poor safety in warehouses can impact the quality of stored goods at the facility, leading to product recalls and customer complaints. This can be detrimental to the business’s reputation.
• Legal issues and fines: Non-compliance with OSHA’s industry regulations can lead to injured individuals filing lawsuits against the business. Not only does this impact a business’s reputation, but it can also lead to significant fines levied by OSHA.
• Higher insurance premiums: Dangerous conditions and incidents will make your company appear ​“high-risk” to insurance companies, resulting in higher premiums.

Common warehouse health and safety risks

The modern warehouse is as dynamic a workplace as can be. There are high volumes of staff and goods moving around, surrounded by heavy equipment and machinery, all of which create safety hazards.

For successful workplace injury prevention, businesses should be aware of the following common warehouse safety risks:

• Manual lifting: Material handling in warehouses accounts for up to 49% of compensable cases of warehouse injuries. Little warehouse safety training and incorrect handling procedures are a considerable risk.
• Break-ins and theft: Warehouses have an increased risk of intrusion due to the numerous access points on the premises. Areas lacking safety and physical security measures in the warehouse can be vulnerable to vandalism and theft, not only costing the organization but also potentially creating health and safety risks.
• Industrial equipment: Warehouses often have heavy machinery, such as forklifts and conveyor belts, in active use. Many of these vehicles and machines pose health and safety risks due to improper use, lack of protective equipment and incorrect training.
• Slips, trips and falls: There is an increased risk of slips, trips and falls in warehouses due to the nature of the operation. Examples of concerns include slick surfaces, improperly anchored cables, debris and lack of fall protection systems (FPS) on high racking.
• Hazardous chemicals: Industrial cleaning products, pesticides and other stored chemicals can present hazards to warehouse staff. Improper storage or handling can compromise air quality and affect industrial worker health.
• Environmental hazards: Warehouses are also subject to environmental concerns, including fires, flooding and poor indoor air quality (IAQ). Incidents involving these scenarios can increase the risk of worker injury or have long-term health impacts.

12 warehouse safety tips and best practices

When implementing measures to improve the safety in a warehouse, it is important to note that there is no one-size-fits-all solution. Each facility will have different needs and factors that determine the approach to be taken. 

However, as shown below, there are several warehouse safety best practices to follow to minimize the risk of accidents. 

1. Schedule regular training

Warehouse safety training is an ongoing commitment that the organization must deliver to promote greater staff safety. Onboarding training for new starters and refresher courses for long-serving employees are key recommendations.

Employees who do not follow safe working practices or are involved in an incident as a result of their own actions should undergo warehouse safety training to correct their working behavior and help prevent it from happening again. 

It’s also recommended that during these training sessions, employees are shown how to report potential hazards, as it is a legal responsibility to track incidents and near misses. Furthermore, employees should be encouraged to speak up when their safety is at risk.

2. Provide Personal Protective Equipment (PPE)

To help ensure staff are protected and to comply with OSHA warehouse health and safety regulations and requirements, facilities must provide PPE. This equipment minimizes employees’ exposure to hazards that cause serious injuries and illnesses. 

Providing PPE is not sufficient. A best practice to implement is to check that staff are wearing the correct PPE and using it correctly. Clear signage in areas of a warehouse that require it is encouraged, as it’s only human to forget, as well as PPE detection systems.

3. Install warehouse security cameras and sensors

Managers and supervisors can’t be everywhere at once. Warehouse security cameras are a game-changer. They help secure perimeters, improve safety for warehouse workers, boost productivity and alert you if a potential threat is detected. 

Threats, including intrusion, overheating equipment, individuals in restricted areas and forklifts moving in the wrong direction, can be detected by security cameras with AI video analytics technology.

The benefits of AI security cameras and sensors can also help streamline warehouse operations. From identifying bottlenecks and analyzing occupancy levels to detecting poor air quality and abnormal noises, these powerful devices enhance situational awareness, enabling managers to be proactive in minimizing risks and preventing incidents from occurring.

4. Install safety signs, appropriate flooring and hygiene stations

To mitigate safety risks and enhance employee awareness, installing clear signage throughout the facility can help. Signs displaying speed limits for vehicles, high-risk areas, emergency exits, first-aid points, load limits and more can lend to greater safety.

It’s also important to install non-slip flooring to avoid trips and falls, as well as provide easily accessible hygiene stations for workers to wash their hands, collect supplies to clean up any spills or mess and access first aid kits.

5. Ensure appropriate lighting

Areas with good lighting reduce the risk of incidents occurring, improving industrial worker safety. With appropriate lighting, staff can clearly see hazards that could harm their safety. It also has the added benefit of boosting productivity and well-being, lending to a more organized and successful warehouse operation.

6. Assign a safety marshal

During busy periods, it is common to see some employees forgetting to wear the appropriate PPE or carry out a task in an unsafe manner. 

Assigning a designated safety marshal in a warehouse is a key step. They can review that warehouse safety standards are being adhered to and spot issues early to avoid any incidents. 

7. Restrict warehouse access

Warehouses should only house those who are required to be inside. This helps ensure that any individual in a busy facility is appropriately trained and aware of the warehouse safety procedures they must follow.

Restricting access to unauthorized people and those not fully trained in warehouse safety helps to mitigate risks. Implementing an access control system can help achieve this.

8. Create an Emergency Action Plan (EAP)

Developing an EAP is essential for businesses to prepare for emergencies. It details to managers and staff the steps and warehouse safety procedures to be taken in the event of an emergency. This plan contains the exit routes to follow, communication channels, roles and responsibilities, contact details and more.

9. Test equipment and systems

To ensure all systems and equipment are functioning safely, it is advised that managers test equipment to identify potential issues. A thorough maintenance process will help ensure that all machinery and equipment are safe to operate, reducing the risk to workers using them, and are reliable, helping to keep warehouse operations running smoothly.

If any system or machine is identified as unsafe to operate, clear signs or tags should be applied to it to stop employees from operating it.

10. Ventilate areas

Warehouse environments can be detrimental to health and safety for warehouse workers. From exhaust fumes to dust and debris, maintaining a clean, healthy space is vital. 

Good ventilation can help achieve this by removing unhealthy air and preventing the accumulation of dust piles. Pumping in fresh, clean air not only leads to greater employee health but it can also raise their satisfaction levels and productivity.

11. Ensure correct vehicle credentials

Warehouse operations involve forklifts and delivery trucks, posing health and safety risks to both those operating and working with them. Accidents involving forklifts result in 75 – 95 deaths and approximately 9,000 injuries requiring days off every year, demonstrating why correct vehicle operation and loading/​unloading procedures are a substantial part of warehouse safety.

Managers and supervisors must ensure that personnel operating vehicles possess the correct credentials in accordance with local law and understand the corresponding warehouse safety procedures regarding their use. Check for valid licenses and conduct regular training, updating on any workflows, compliance requirements or safety practices that may change during a given period.

12. Conduct regular safety audits

Even a minor lapse in judgment by a staff member can pose significant safety risks in a warehouse. Administrators, managers and supervisors should conduct safety audits to help ensure that all applied safety measures are optimal and mitigate risks of injury or illness.

While warehouse security systems can help support health and safety oversight, human inspections can help bolster safety by identifying any anomalies on the floor. Audits should include reviewing the correct operational equipment procedures, proper use of PPE, analyzing environmental metrics and reaffirming safety markers. When the audits are completed, the warehouse health and safety policy should be updated with any required changes.

Improve warehouse safety with a comprehensive strategy

Warehouse administrators and managers prioritize safety on the premises to not only facilitate a more secure working environment for staff but also boost productivity and mitigate risks to both staff and equipment. Using the warehouse safety tips in this guide can help curate a safety strategy that meets those organizational goals.

Pairing security technology with a robust warehouse health and safety policy can form the basis for an improved operation, offering the flexibility needed to adapt to today’s continually changing industry conditions. They can also help develop a unified approach to ensure a comprehensive and scalable warehouse safety strategy that aligns with business objectives.