Warehouse Safety Starts with You!

A warehouse is a dynamic workplace where products are constantly being moved, machinery is operated, and workers are scrambling to complete their tasks. However, amidst all the activity, it’s important not to overlook the importance of safety. Accidents and injuries can happen quickly in a warehouse, leading to severe consequences. To mitigate these risks, implementing a warehouse safety checklist can be an effective solution. By identifying potential hazards and ensuring that proper safety procedures are in place and adhered to, warehouse managers can safeguard their employees and assets, while also optimizing operational efficiency.

Importance of Implementing a Warehouse Safety Checklist

Regular maintenance inspections are essential to keep warehouses in good condition and ensure a safe working environment for warehouse workers. A warehouse maintenance checklist can serve as a useful tool for conducting these inspections. By using a warehouse assessment checklist, managers can verify that various components of the facility meet both internal and international maintenance standards. This helps to identify and address any potential hazards or issues before they can cause harm or disrupt operations. By implementing a comprehensive maintenance program, warehouse managers can optimize warehouse efficiency and productivity while promoting the safety and well-being of their employees.

Common Warehouse Safety Checklist (Things you should include on your checklist)

Note: These are general preventive maintenance suggestions that you can add to your company’s approved checklist. Below are only a few very broad items to be aware of when performing or scheduling warehouse safety maintenance. Your specific facility and industry regulations will determine what unique checklists are needed based on your asset\equipment inventory.

Keep in mind that while the aforementioned items provide a foundation, they are not an exhaustive list, and the checklist must be customized according to the distinct attributes and risks associated with the warehouse environment.

General Safety Maintenance

General Safety Measures: Ensure that general safety measures such as signage, lighting, and access to emergency exits are in place and working correctly.
Inspect For Damages: Inspect the building and its surroundings for any damages, including windows, floors, doors, ceilings, and walls. Take note of any identified issues to address them promptly.
Identifying Obstructions: Search for any obstructions, such as packaging blocking fire exits or obstructing aisles. Make sure workstations are free from clutter, and vehicles are parked in their designated locations. Additionally, be aware of trailing electrical cords that could pose a potential hazard.
Vehicle and Pedestrian Traffic: Ensure that there are clear rules and procedures in place for managing vehicle and pedestrian traffic to prevent accidents.
Cleanliness and Safety: Conduct a thorough inspection of hygiene and cleanliness in the warehouse. While it may be challenging to maintain a spotless workplace due to frequent movement and vehicle usage, it is still crucial to eliminate any unnecessary trash or waste that could pose a fire or trip hazard. Moreover, ensure that workstations, break rooms, and bathrooms are clean and hygienic.
Inspections and Audits: Regularly conduct inspections and audits to identify and address any potential safety hazards or issues before they can cause harm.
Pest Control: Verify that measures are in place to prevent pests from entering the warehouse and that proper procedures are in place for their removal.
Safety Maintenance Documentation: To ensure the safety and effectiveness of tools and equipment, regular inspections should be conducted, and it is essential to have a record of these inspections. It’s recommended to include a request to see the documentation of these inspections as part of your checklist.
Contractor Safety: Ensure that any contractors or visitors to the warehouse are aware of safety procedures and hazards and are properly supervised.

Plans & Postings

Material Safety Data Sheets (MSDS) Book: MSDS book is maintained is made readily available to workers who handle or work in the vicinity of hazardous materials.
Emergency Evacuation Map: An adequate visible location has been chosen for posting the evacuation map, and employees have been duly notified about it.
Emergency Action Plan: The Emergency Action Plan is up-to-date and aligned with the current alarm system, exit routes, rally points, and internal shelter arrangements. The plan should be communicated to all employees and reviewed regularly to ensure its effectiveness. The exit routes and rally points should be clearly marked and easily accessible, with no obstructions or clutter. The internal shelter location should be secure, easily accessible, and equipped with the necessary supplies and resources to ensure the safety of the employees in the event of an emergency.
Hazard Communication Plan (HCP): This plan outlines how hazardous materials are identified, labeled, and communicated to employees. Employees should be trained on this and also this should be posted near the hazardous materials.
Material Handling Plan: This plan outlines the procedures for safely moving and storing materials in the warehouse. It should include guidelines for using equipment such as forklifts, conveyor belts, and pallet jacks, as well as procedures for inspecting and maintaining the equipment. This should be posted and easily accessible.

Environmental

Environmental Conditions: Verify that the warehouse is free from any environmental hazards such as extreme temperatures, high humidity, or chemical fumes.
Check the ventilation: Due to the prevalence of dust in packaging warehouses, it is essential to maintain proper ventilation to ensure the safety of workers.
Ventilation and Air Quality: Check that the ventilation system is working correctly, and the air quality is within acceptable limits to prevent respiratory illnesses.
Hazardous Materials: Verify that all hazardous materials are properly labeled, stored, and disposed of according to safety regulations.
Noise Levels: Check that noise levels are within acceptable limits to prevent hearing damage.
Chemical Handling: Ensure that proper procedures are in place for handling, storing, and disposing of chemicals, including the use of personal protective equipment.

Building

Structural Integrity: Check that the building’s structure, including walls, ceilings, and floors, is stable and free from any signs of damage or deterioration.
Electrical Safety: Check that all electrical equipment is properly grounded and that any exposed wires or cables are insulated and out of reach.
Electrical Supply:
* Service panels are unobstructed and in good repair.
* Service labeled inside and voltage label on the exterior of the panel door.
* Emergency shut-off switches are easily accessible and labeled clearly.
* Power cords are in good condition with no splices or broken insulation.
* Lockout/Tagout program in place; training conducted for authorized and affected.
* Electrical tools are used according to the manufacturer’s instructions and kept in good condition.
* Regular electrical safety audits are conducted to identify potential hazards and to ensure compliance with safety standards.
First Aid and Emergency Preparedness: Verify that first aid kits and emergency response plans are in place and that workers are aware of their location and procedures to follow in case of an emergency.
Eyewash Stations: Are easily marked and in good condition; regularly inspected.
Stairs: To prevent workers from tripping and ensure their safety, it is vital to compare all staircases and ensure that they have a consistent design and height, especially while climbing to walkways and platforms. Additionally, it is important to check whether guardrails have been installed to prevent falls.
Warehouse Lighting: Warehouse lighting is a critical safety factor that should not be overlooked. Adequate illumination should be provided in workstations, corridors, fire exits, offices, loading docks, lunchrooms, and even bathrooms. Insufficient lighting can create a hazardous environment, making it challenging for workers to navigate safely and potentially leading to accidents and injuries.
Emergency Lighting: Verify that emergency lighting is working correctly and is available in case of a power outage.
Loading Dock Safety: Confirm that loading dock areas are adequately lit and that proper procedures are in place for loading and unloading trucks.
Loading Dock/Storage Racks/Conveyors:
* Dock plates and levelers are in good repair.
* Dock doors and lightings operate properly.
* Storage racks are marked with load limits and in good repair.
* Storage rack content does not extend beyond 6” and safety netting is in place if needed.
* Conveyors have appropriate guards where needed.
* Dock bumpers are installed and in good condition to prevent damage to the building and vehicles.
* Dock plates and levelers are rated for the load capacity and are properly secured in place.
* Trailer wheels are properly chocked before loading and unloading.
* Loading and unloading operations are properly supervised to prevent accidents or incidents.
* Pallet jacks and forklifts are in good condition and properly maintained, and operators are trained and authorized to use them.
* Storage racks are installed and anchored properly to prevent tipping, and aisles are wide enough for the safe maneuvering of equipment.
* Overhead clearance is adequate and clearly marked to prevent collisions with forklifts and other equipment.
* Storage racks are regularly inspected for damage or signs of stress, and any damaged racks are promptly repaired or replaced.
* Heavy items are stored on lower shelves to prevent tipping or collapse, and lighter items are stored on higher shelves.
* Conveyors are regularly inspected for damage or signs of wear, and any damaged or worn parts are promptly repaired or replaced.
* Conveyor belts are properly tensioned and aligned to prevent slippage or jams.
* Emergency stop buttons are installed at appropriate intervals along the conveyor line for quick and easy access.
* Conveyor control panels and electrical equipment are properly grounded and installed in accordance with safety standards.
* Conveyor operators are trained and authorized to operate the equipment, and appropriate safety guards are in place to prevent injuries.
* Conveyor Checklist……

Equipment

Equipment and Machinery: Inspect all equipment and machinery for any signs of wear or damage and ensure that all safety guards and emergency stop buttons are in place and working correctly.
Industrial Power Equipment:
* Operators have had appropriate training and carry licenses.
* Industrial power equipment is maintained and serviced on a regular basis, and any issues or malfunctions are addressed promptly.
* Pre and post-inspections are conducted; inspection sheets are maintained.
* Load capacities are clearly marked and are not exceeded.
* Equipment is stored properly when not in use, to prevent damage or accidents.
* Batteries are properly charged and stored according to the manufacturer’s recommendations.
* Emergency stop buttons and other safety controls are clearly marked and easily accessible.
* Safety guards, shields, and other safety features are in place and functioning properly.
* Operators of industrial power equipment are trained in safe operating procedures and are aware of potential hazards and risks associated with the equipment.
* All equipment is used according to the manufacturer’s specifications and recommendations.
* Pickers/Turrets/Clamp PIT Operators properly trained.
* Pallet Jack properly inspected and training in place.

Inspections

Regular Inspections: Set up routine inspections to check the warehouse for potential hazards.
Issues: Address any issues promptly.
Hazard Reporting: Encourage workers to report any hazards they encounter.

Employees

Material Handling: Ensure that proper material handling procedures are in place, such as proper lifting techniques, proper storage procedures, and the use of protective equipment.
Personal Protective Equipment (PPE): Ensure that workers have access to the required PPE and that they are properly trained in its use.
Training and Safety Procedures: Confirm that workers have been adequately trained in all safety procedures and are aware of any specific hazards related to their job duties.
Loading and Unloading: Train workers on the proper techniques for loading and unloading goods and materials. Ensure that all lifting equipment is used appropriately.

Fire Safety

Fire Safety: Check that fire prevention systems such as smoke detectors, sprinkler systems, and fire extinguishers are present and functioning correctly.
Sprinkler Heads. Are clean, and in good repair, and no storage within 18”
Fire Extinguishers:
* The appropriate number of fire extinguishers and specific types are available and working.
* Locations identified and unobstructed.
* Monthly and annual inspection plans are in place
* Fire exits clearly marked and unobstructed.
Fire Doors: Ensure that all fire does are kept closed and unobstructed, and any holes or gaps are repaired.
Emergency Lighting and Exit Signs: Are installed and tested regularly to ensure they are in working order.
Employees Trained: Employees have all been trained in fire prevention and emergency response procedures, including evacuation routes and procedures for reporting fires or other emergencies.
Fire Drills: Plans are in place to conduct regularly scheduled fire drills to ensure all employees are familiar with evacuation procedures and to identify any potential issues with the emergency response plan.
Warehouse Inspections: Regular routine inspections for potential fire hazards, and any hazards are addressed promptly.
Warehouse Designated Fire Marshal: Someone responsible for fire safety inspections and procedures.
Fire Safety Policies and Procedures: These need to be reviewed regularly and updated as needed to ensure they remain current and effective.

Security

Security: Check that proper security measures such as access control, video surveillance, and security alarms are in place to prevent theft and unauthorized access.
Proper Lighting: Have a well-lit facility with adequate lighting inside and outside the warehouse.
Security System: Install a security system with cameras, alarms, and access controls.
Authorized Personnel: Control access to the facility by using locked doors and gates, and limiting entry to authorized personnel only.
Inventory Control: Keep inventory control and track all incoming and outgoing shipments to prevent theft and loss.
Employee Training: Train employees on security procedures, such as what to do in case of an emergency or how to report suspicious activity.
Secure Windows & Doors: Ensure that all windows, doors, and other entry points are secured and locked properly.
Grounds Inspection: Regularly inspect and maintain the perimeter of the facility to ensure that it is secure, such as checking for broken fences or holes in walls.
Background Checks: Conduct background checks on all new employees and contractors before they are hired.

Benefits of Using CMMS Software for Maintenance Operations

Utilizing a computerized maintenance management system (CMMS) is the ultimate way to efficiently manage, automate, and systematize maintenance operations. CMMS is specifically designed for this purpose.

To achieve streamlined maintenance operations in a warehouse setting, consider the following requirements:

An efficient method of reporting asset issues.
Knowledge of asset locations and their current condition.
Constant monitoring of PPE, tools, and spare parts inventory.
Coordination of work orders and collaboration among multiple teams and technicians.
Creation and optimization of maintenance schedules for assets and pieces of equipment.
Compliance with safety requirements.
Monitoring costs related to vendors, contractors, equipment, parts, and labor.
Adherence to a maintenance budget.
Detailed reports.
Managing Warehouse KPIs and performance efficiency.