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A guide to maximising warehouse safety.

Warehouse safety is a paramount concern for logistics managers as it directly impacts the wellbeing of employees, the protection of goods and the business' overall success. 

Keeping yourself well-informed about warehouse safety is essential for effectively implementing appropriate measures to ensure the smooth operation of your warehouse.

warehouse worker in a warehouse

 

This page aims to keep you updated on the laws and regulations for warehouse safety, what common warehouse hazards you need to know and how you can ensure your warehouse is a secure environment.

Why warehouse safety should be a top priority.

Failing to implement proper safety measures can lead to severe consequences, including accidents, injuries and damaged goods — all of which harm employee retention, company reputation and your bottom line. 

According to industry studies, 123 workers were killed in work-related accidents in 2021/22, with 22 of these happening in the manufacturing sector. 

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To learn how to avoid statistics like this, read our blog, 10 warehouse accident and injury statistics you should know, offering easy-to-implement strategies to tackle the harshest statistics. 

By prioritising safety and investing in comprehensive safety protocols, logistics managers can create a secure and efficient working environment that offers several benefits:

1. Reduced accidents and injuries.
By implementing safety protocols and maintaining a secure environment, the risk of accidents and injuries in the warehouse can be significantly reduced. This not only protects the well-being of employees but also minimises the potential legal and financial implications associated with workplace incidents.

2. Improved employee morale.
Prioritising warehouse safety shows employees that you value their well-being, which can boost morale and job satisfaction. When employees feel safe and supported, they are more likely to be engaged, productive and loyal to the organisation.

3. Enhanced productivity.
A safe working environment promotes efficiency and productivity. When employees are confident in their safety, they can focus on their tasks without distraction or fear of injury. Additionally, well-implemented safety measures help streamline operations, reduce downtime caused by accidents and optimise workflow.

4. Cost reduction.
Implementing warehouse safety measures can lead to significant cost savings for businesses. Fewer accidents and injuries mean reduced expenses related to medical treatments, compensation claims and potential legal battles. Furthermore, insurance premiums can be lower for companies with a strong safety record.

5. Improved customer satisfaction.
Warehouse safety directly impacts the quality of products and services provided to customers. By preventing accidents and damage to goods, you can maintain high-quality standards, meet customer expectations and build trust and loyalty.

6. Attracting and retaining talent.
In today's competitive job market, potential employees consider workplace safety as a crucial factor when choosing an employer. By prioritising warehouse safety, you can attract top talent and retain a skilled workforce who value a safe work environment.

So you can experience these benefits, let us discuss how to create a secure working environment in the following sections:

 

The laws and regulations of warehouse safety.

The warehouse health and safety regulations in the UK are extensive but, with the right motivation and intention, are easy to follow and implement within your warehouse. 

The most important regulations to follow include:

  • The Health and Safety Act 1974.
    This act establishes a general duty for employers to ensure the health, safety and welfare of their employees.

  • The Provision and Use of Work Equipment Regulations 1998 (PUWER).
    These regulations require employers to ensure that work equipment in warehouses is suitable, maintained and used safely by employees.
  • The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER).
    These regulations apply to lifting equipment used in warehouses and require employers to ensure that lifting operations are planned, supervised and carried out safely.
  • The Manual Handling Operations Regulations 1992.
    These regulations aim to protect employees from the risks associated with manual handling tasks in warehouses, requiring employers to assess and reduce the risk of injury from manual handling activities.
  • The Work at Height Regulations 2005.
    These regulations apply to working at height in warehouses and require employers to assess risks, plan work and provide suitable equipment and training to ensure the safety of employees working at heights.
  • The Control of Substances Hazardous to Health Regulations 2002 (COSHH).
    These regulations require employers to prevent or control exposure to hazardous substances in warehouses and ensure that appropriate measures are in place to protect the health and safety of employees.

Of course, you are not expected to know the ins and outs of these regulations. So, we have broken them down in this blog and explain what each regulation means for your warehouse.


Apart from ensuring you remain compliant with the regulations, there are general safety guidelines you can implement to maximise the safety of your warehouse. 

These include:

  • A well-executed warehouse layout.
    An easy-to-navigate warehouse layout will ensure your employees are not putting themselves in risky situations.

  • Using the proper equipment.
    Your employees can only be as safe as their equipment. Ensure appropriate equipment is being used for each task and that it is well maintained.

  • Employee training.
    A well-educated employee is less likely to be involved in an accident. Training is an investment for the whole company. 

Warehouse employees partaking in industry training

We will elaborate on equipment and training further down, but if you want to learn more about these guidelines, read our blog below:


Common warehouse hazards

29 fatal injuries occurred in 2021/2022 due to people falling from heights in the workplace. These injuries accounted for 24% of all worker deaths over the year. 

To avoid warehouse accidents, you must first be aware of which situations are threatening to employees and then become proactive about implementing solutions. 

The most common warehouse injuries you need to be aware of and how to avoid them include:

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Falls from height.

How to avoid: Ensure the use of proper fall protection equipment and barriers, provide training on working at heights and regularly inspect and maintain safety equipment and platforms.

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Slips and trips. 

How to avoid: Maintain clean and well-organized work areas, promptly clean up spills and remove obstacles, use anti-slip flooring, provide adequate lighting and promote employee awareness through training.

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Forklift incidents. 

How to avoid: Implement strict forklift training and certification programs, enforce safe speed limits, ensure clear visibility and pedestrian segregation, conduct regular maintenance checks and establish clear traffic management procedures.

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Handling heavy materials.

How to avoid: Provide proper manual handling training, encourage the use of mechanical aids and equipment, ensure clear pathways and adequate lighting, implement weight limits for manual handling tasks and promote the use of team lifting techniques when necessary.

And that is only half of them. View more common injuries, their staggering statistics and helpful tips to prevent them by clicking below. 

 

The reasons these injuries occur are plenty. Of course, some accidents are simply accidents but most occur due to a lack of planning and preparation, including lack of signage, irregular equipment maintenance and improper training.  

Read our blog below for a complete list of warehouse hazards and how to avoid them. 



Ultimately, the most effective strategy for logistic managers to avoid warehouse accidents is to be informed and spread their knowledge. By staying well-informed about safety protocols and enforcing training procedures, you can create a culture of safety and awareness among your workforce.


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To help you achieve your health and safety goals, we have listed 10 important warehouse safety tips you should consider implementing.

1. Optimise your warehouse layout.
Helps improve safety by creating efficient traffic flow, minimizing congestion and reducing the risk of collisions or accidents.

2. Supply and wear personal protective equipment (PPE).
Supplying and wearing appropriate PPE, such as safety helmets, high-visibility vests, protective gloves and safety shoes, helps protect employees from potential hazards in the warehouse.

3. Regularly run training sessions.
Conducting regular training sessions ensures that employees are well-informed about warehouse safety procedures, hazards and best practices.

4. Inspect your equipment.
Regular equipment inspections help identify any potential faults, damage or wear and tear that could compromise safety in the warehouse. 

Click the link below for further explanation and to discover the rest of the 10 tips. 


Warehouse safety equipment.

Your employees’ safety is only as safe as their equipment. If they are driving a damaged forklift or not wearing a safety hat, they are putting themselves at unnecessary risk. 

You can significantly reduce the risk of accidents, injuries and property damage by prioritising the implementation of safety equipment, such as personal protective gear, signage and emergency response systems. 

Such proactive measures safeguard employees' physical and mental health, enhance productivity and minimise costly disruptions. 

To further improve warehouse safety, you should adopt various actionable safety tips that promote a culture of safety awareness and adherence among the workforce:

1. Conduct a comprehensive safety equipment assessment.
Assess the warehouse to identify the necessary safety equipment required for different areas and tasks. This assessment should consider fire safety, personal protective equipment (PPE), emergency response equipment and more.

2. Ensure proper signage.
Clearly label the location of safety equipment such as fire extinguishers, first aid kits, emergency exits and eye wash stations. Use highly visible signs and ensure all employees can easily understand them.

3. Regularly inspect forklifts.
Establish a schedule for routine inspections of forklifts to ensure it is in proper working condition. 

Learn why it is so important to continuously service and maintain your forklifts in this helpful blog:

 

As a general note, logistics managers should ensure the following safety equipment is available in a warehouse:

  • PPE.
  • Fire safety equipment.
  • First aid kits.
  • Safety signage.
  • Safety barriers and guardrails.
  • Material handling equipment safety features.
  • Spill containment kits.
  • Emergency lighting.
  • Safety training resources.

Warehouse safety training.

The final step to maximising your warehouse safety is promoting a culture of safety and awareness through employee safety training. 

Employees should learn the importance of following proper procedures, adopting safe work practices and correctly using equipment, enabling them to effectively prevent accidents and injuries. 

With heightened awareness of their surroundings, employees become more attuned to potential hazards in the warehouse environment and take prompt action to address unsafe conditions. This proactive approach fosters a strong safety culture where employees actively contribute to maintaining a safe work environment.


Consequently, accident rates decrease, leading to improved safety records and reduced financial losses associated with workplace incidents. 

Furthermore, comprehensive safety training instils employees with a sense of confidence, empowerment and ownership over their well-being, promoting a positive work environment. 

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It also enhances productivity and efficiency as employees can work with a focus on safety, minimising disruptions and downtime caused by accidents. 

Ultimately, investing in effective warehouse safety training benefits both employees and businesses by creating a safer, more productive and more successful work environment.

You can further discover the importance of training, when and how often you should offer training and what the training should cover by heading to our blog post below.



At Toyota Material Handling UK, we focus highly on forklift training since improper use can lead to serious accidents and injuries. Training ensures operators have the knowledge and skills to operate forklifts safely and efficiently. 

Forklift training covers essential aspects such as understanding the forklift's controls and functions, load capacity and stability, safe manoeuvring techniques, appropriate stacking and unstacking procedures and awareness of surrounding hazards. 

Training also emphasises the importance of pre-operation inspections, regular maintenance and compliance with safety regulations.

We cover all of these important lessons in our range of forklift training courses. Discover them by clicking the link below.

Secure your warehouse safety with our helpful resources.


Warehouse safety is of utmost importance for logistics managers, ensuring the well-being of employees and protecting goods from damage. 

Logistics managers can create a secure environment in their warehouses by adhering to safety regulations, implementing practical tips and strategies and prioritising training. 

Failing to do so can lead to accidents, injuries and legal consequences. It is crucial for logistics managers to take proactive steps to prevent accidents, reduce risks and promote a safety culture within their organisations. 

To get you on the right track to maximising your warehouse safety, sign up for our free safety resources.

Our extensive library of resources includes safety guides, checklists and posters promoting best practise in the industry that you can share with your team. 

To access your copy of free safety resources, click below.

Request free safety resources