Warehouses are important storage and distribution hubs for many different products and employ thousands of Kiwis. However, staff at these sites are often more susceptible to work-place related injuries than those in other industries due to the physical nature of the tasks, materials being handled and machinery used. 

In 2020 the pandemic put the world’s safety systems to the test and encouraged companies to take more responsibility for workers’ health through preventative actions with regards to the spread of the virus. This same approach should be deployed each and every day to protect staff from visible and invisible dangers. Workplace hazards are, after all, an ever-present danger to staff we can fight each day.

A new year brings a fresh start and the opportunity to reflect on the processes that are in place to protect employees and improve efficiencies. In this blog, we’ve compiled a list of important warehouse safety tips that should be prioritised in 2021 to minimise risk and improve safety for all.

Identified Hazard: Slips, Trips, and Falls

Slips, trips and falls can cause serious injury or death and are all too common in New Zealand warehouses with nearly a third of serious harm incidents in the construction industry alone resulting from slips, trips and falls. Losing your footing is especially dangerous when you are carrying a load or working from a height, as it is harder to regain balance. 

Tips for managing this risk:

1. Encourage all staff to take responsibility for keeping the warehouse safe from hazards, including cleaning up spills, removing obstructing items from pathways, keeping cables tidied away, disposing of packaging materials and clearing away equipment not in use.
2. If cables need to be run along the ground, use heavy-duty cord covers to avoid tripping.
3. Ensure that cleaners use appropriate signage when washing floors and encourage them to come outside of normal work hours. Umbrella wrappers can also be used to reduce the potential risk of slips and falls during wet weather by containing the water in the bag dispensers.
4. Train staff to follow working safely from heights best practices. If using ladders, they should maintain three points of contact at all times (e.g. two feet and one hand), stay off the top 3 steps and only work on one for no longer than 30 minutes.

5. Ensure that all floors are level and that steps are easily identified by using visibility products such as the anti-step stair nosing.

Identified Hazard: Vehicle Crashes

Whether it is trucks, forklifts, delivery vans or pedestrians, all drivers within the warehouse need to be involved in implementing the company’s traffic management plan.

Tips for managing this risk: 

1. Maximise visibility by ensuring that the warehouse is well lit, all employees are wearing high-visibility clothing and installing mirrors on corners. 
2. Have speed limit signs clearly displayed and ensure these are enforced for all drivers. Speed calmers can also be used throughout the facility to slow vehicles down. Other signs to encourage correct behaviour should also be used, such as pedestrian crossings, stop signs, and seat belt reminders.
3. Ensure care is taken around reversing vehicles. Reversing should be eliminated where possible by implementing a one-way drive through layout. Alternatively, reversing cameras and ‘beepers’, sensors and corner protection can be used, as well as excluding unnecessary staff from the area and ensuring others (including spotters) are wearing high-visibility clothing.
4. Create exclusion zones in high-risk sections of the warehouse that are restricted to certain personnel. Belts, barriers and fences and our new generation flexible barriers can be used to differentiate these areas.
5. Ensure all staff that are operating vehicles, from trucks to forklifts, are trained and licensed to do so and arrange for regular maintenance and inspection of vehicles.
   

Identified Hazard: Heavy Lifting

Manual lifting is a task regularly carried out in many warehouses, however, muscular stress from lifting, carrying or putting down objects is the leading cause of workplace injuries in New Zealand warehouses.

Tips for managing this risk: 

1. Reduce the need for manual handling in the warehouse by using load moving equipment such as pallet trucks, lifts, belts, forklifts, conveyor belts and trolleys.
2. Ensure staff operating lifting equipment know the maximum safe working load (SWL).
3. Warehouse facilities should be designed with ergonomic principles in mind, for example, frequently used items should be placed on easy to reach shelves.
4. Ensure staff are trained in best manual handling practices in order to avoid injury, such as correct weight limits to lift and techniques for minimising strain. This includes bending at the knees, reducing rotation of the back by facing the object and placing load between the knees and shoulders. 

Identified Hazard: Fires

As warehouses have a lot of open spaces and flammable objects (including excess cardboard), fires are a hazard that should be actively prevented. Fires are not only dangerous to staff, but can also damage goods and the warehouse. Without properly established precautions, this can lead to significant loss of time and production.

Tips for managing this risk: 

1. Create a fire evacuation and emergency plan and review it regularly – this should be approved by Fire and Emergency New Zealand. As part of this plan, designate a fire warden who will be responsible for minimising fire risk in the warehouse and taking control in an emergency.
2. Ensure all employees are prepared for a fire by running regular drills. They should all know the best points of exit and the established safe assembly point. Exits need to be clear of obstacles at all times and not locked, barred, or obstructed when the building is occupied.
3. Regularly check and test fire alarms, smoke detectors and any other fire-prevention equipment in the warehouse, such as sprinklers and extinguishers. Ensure this equipment can easily be located by adding clearly recognisable fire signs and that key staff know how to use them.
4. Exit signs should be easily visible and emergency lighting installed, so that all people in the warehouse (including visitors) can safely navigate their way out in the case of an emergency.
5. Make sure staff know to follow good housekeeping practices. This includes keeping the warehouse tidy, promptly tidying away excess packaging and ensuring that employees are aware of how to handle and store chemicals safely.
6. Any electrical wiring, equipment or appliances used should be in good condition and well maintained. This includes getting electrical equipment tested and tagged by a professional to check it is safe for use.

Identified Hazard: Lack of Training

The Covid-19 related travel restrictions have resulted in fewer migrants working in New Zealand warehouses, therefore, many companies have hired staff from different industries to fill the void. It is essential to have thorough onboarding and training in place to mitigate the heightened health and safety risks associated with new workers.

Tips for managing this risk: 

1. All staff need to be trained in health and safety (this is a legal requirement) and understand the importance of reporting all incidents and near-misses. It’s important to empower employees to raise red flags and take responsibility for themselves and their colleagues as often as possible.
2. When managing warehouse risk, there needs to be a zero-tolerance policy for dangerous behaviour. 
3. It is also important that the health and safety plan within your warehouse has buy-in from the whole team, as staff will need to work together to make the environment as safe as reasonably possible. Selecting a health and safety representative who will be responsible for driving these conversations can help encourage best practice.

Identified Hazard: Pallets and Racking

It is common for staff in warehouses to be involved in unloading, moving and loading goods which typically come on pallets and are placed onto a racking system. Training staff to handle pallets securely is key, as instability may result in pallets falling on people or damaged equipment and products. 

Tips for managing this risk: 

1. Staff should use a wrapping to support the load and stack in a pattern recommended by the manufacturer. Pallets should be stacked evenly with heavier pallets at the bottom, and a safe stacking height and weight capacity should be adhered to. 
2. Ensure pallets are inspected for any cracks or signs of damage, as well as hazards such as loose nails and splinters. 
3. Choose a warehouse racking system with a structural frame and beam profile that is suitable for the loads it will be holding. Consider a suitable height, product weight and potential impact on the racking you are installing.
4. Ensure staff do not climb, lean on, or walk over pallets or racking, and use ladders safely when accessing items stored higher.
5. Encourage staff to wear suitable Personal Protective Equipment (PPE) when possible, as this can prevent exposure to harm when handling stock. This final step in the workplace safety process will help mitigate the harm caused in any incidents. This includes good quality hard hats, high visibility vests, gloves, anti-slip safety shoes, eye protection and hearing protection. 

Warehouses have their own set of unique hazards that need to be planned for to minimise the risk. If these are not controlled, they can result in harm, lost time and property damage. On top of basic compliance, all companies should strive to promote good safety practices throughout the workplace to ensure that staff feel their wellbeing is valued, which in turn helps cultivate trust and improves workplace culture. 

If you would like to assess the risks within your own warehouse, please complete our new Warehouse Safety Checklist. 

Alternatively, if you would prefer to discuss safety solutions for your warehouse directly with one of our experienced staff members, please contact us on the form below and we’ll respond within 60 minutes!