FREE WAREHOUSE
SAFETY CHECKLIST
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Warehouse Safety
A safe warehouse environment promotes both operational efficiency and employee well-being. Incorporating a regular inspection process and preventive measures can mitigate potential hazards in warehouse settings. This introduction to warehouse safety covers the key risks, such as forklift operations and outlines essential safety practices.
Machinery and Equipment Safety
- Regularly maintain and inspect warehouse machinery, provide thorough training to operators, and enforce the use of protective gear to prevent accidents and ensure safe equipment handling.
Preventing Common Warehouse Hazards
- Handling Materials Safely: Use proper lifting techniques and equipment to prevent strain injuries.
- Avoiding Slips, Trips, and Falls: Maintain clean, clutter-free floors and use non-slip mats in high-risk areas.
Regular Safety Training Sessions
- OSHA has established guidelines for training divided into five industry groups. Depending on the industry, the training areas include: Emergency Action, Fire Prevention, Power Platforms (Equipment), Noises Exposure, Hazardous Materials. More information can be found here.
OSHA Guidelines and Compliance
- Ensure adequate space in aisles, loading docks, and passages for safety. Implement visual alerts near dock edges. Adhere to established protocols during the refueling of gas or propane-powered forklifts. Educate employees about the risks linked to forklift operation byproducts, like carbon monoxide.
Creating a Culture of Safety
- According to OSHA, “A strong safety and health culture is the result of positive workplace attitudes – from the chief executive officer to the newest hire; involvement and buy-in of all members of the workforce; mutual, meaningful, and measurable safety and health improvement goals; and policies and procedures that serve as reference tools, rather than obscure rules.”
Record-Keeping and Documentation
- Depending on the industry, companies with over 10 employees are expected to maintain records to validate their inspections and hazard mitigation processes and corrective actions, and are required to post annual summaries of work related accidents and injuries. This documentation is required to be maintained for a period of five years.
Fire Safety Protocols
- Conduct frequent drills to ensure staff are well-versed in evacuation procedures.
- Position extinguishers throughout the warehouse and ensure they are easily accessible.
- Maintain unobstructed pathways to exits, clearly marked with signage.
- Regularly inspect electrical systems to identify and rectify potential fire hazards.
- Install and maintain smoke detectors and fire alarms to provide early warning.
- Develop and communicate a clear plan detailing steps to take in case of a fire.
Essential Safety Equipment in Warehouses
- Safety Helmets: Protect against head injuries from falling objects or collisions.
- High-Visibility Vests: Ensure workers are easily seen, reducing accident risk.
- Steel-Toed Boots: Guard feet against heavy object impacts.
- Protective Gloves: Shield hands during handling of hazardous materials.
- Respirators or Masks: Required in environments with dust, fumes, or harmful gases.
- Safety Glasses: Shield eyes from flying debris and hazardous liquids.
Machinery and Equipment Safety
Preventing Common Warehouse Hazards
Regular Safety Training Sessions
OSHA Guidelines and Compliance
Creating a Culture of Safety
Record-Keeping and Documentation
Fire Safety Protocols
Essential Safety Equipment in Warehouses
Core Elements of a Safety Checklist
Inspection Checklist
Warehouse
General Safety
Exposed or open loading dock doors and other areas that employees could fall 4 feet or more or walk off should be chained off, roped off or otherwise blocked.
Floors and aisles are clear of clutter, electrical cords, hoses, spills and other hazards that could cause employees to slip, trip or fall.
Proper work practices are factored into determining the time requirements for an employee to perform a task.
Employees performing physical work have adequate periodic rest breaks to avoid fatigue levels that could result in greater risk of accidents and reduced quality of work.
Newly-hired employees receive general ergonomics training and task-specific training.
The warehouse is well ventilated.
Employees are instructed on how to avoid heat stress in hot, humid environments.
Employees are instructed on how to work in cold environments.
The facility has lockout/tagout procedures.
Material Handling
Appropriately marked and sufficiently safe clearances for aisles and at loading docks or passageways where mechanical handling equipment is used.
Loose/unboxed materials that might fall from a pile are properly stacked by block- ing, interlocking or limiting the height of the pile to prevent falling hazards.
Stack bags and containers in stable, secure tiers.
Keep storage areas clear to avoid tripping and other hazards.
Remove excess vegetation to maintain clear visibility and prevent falls.
Install derail/bumper blocks on rail tracks to prevent collisions.
Covers and/or guardrails are provided to protect personnel from the hazards of stair openings in floors, meter or equipment pits and similar hazards.
Personnel use proper lifting techniques.
Elevators and hoists for lifting materials/ containers are properly used with ade- quate safe clearances, no obstructions, appropriate signals and directional warning signs.
Hazard Communication Safety
All hazardous materials containers are properly labeled, indicating the chemical’s identity, the manufacturer’s name and address, and appropriate hazard warnings.
There is an updated list of hazardous chemicals.
The facility has a written program that covers hazard determination, including Material Safety Data Sheets (MSDSs), labeling and training.
There is a system to check that each incoming chemical is accompanied by a MSDS.
All employees are trained in the require- ments of the hazard communication standard, the chemical hazards to which they are exposed, how to read and understand a MSDS and chemical labels, and on what precautions to take to prevent exposure.
All employee training is documented.
All outside contractors are given a com- plete list of chemical products, hazards and precautions
Procedures have been established to maintain and evaluate the effectiveness of the current program.
Employees use proper personal protective equipment when handling chemicals.
All chemicals are stored according to the manufacturer’s recommendations and local or national fire codes.
Forklift Safety
Forklifts meet ANSI B56.1-1969 standards.
Operator training and certification up-to-date.
Manufacturer approval for any vehicle modifications.
Updated plates/tags for any vehicle changes.
Clear, maintained nameplates and markings.
Hazardous location forklifts are marked accordingly.
Designated areas for battery charging.
Facilities for handling electrolytes and fire safety during charging.
Equipment for safe battery handling and securing.
Use carboy tilters or siphons for electrolytes.
Secure forklifts and apply brakes during battery maintenance.
Ensure vent caps function correctly.
Avoid smoking and sparks near charging stations and propane tanks.
Keep metal away from open batteries.
Maintain safe gas/fume levels.
Regular refresher training and evaluations.
Performance reviews at least every three years.
Secure forklifts when unattended.
Maintain safe distance from edges on elevated surfaces.
Adequate overhead clearance for forklifts.
Overhead guards to protect operators from falling objects.
Adherence to traffic and speed regulations.
Clear visibility and safe speeds.
Secure dock boards for loading/unloading.
Prohibit stunt driving and horseplay.
Ensure load stability within truck capacity.
Refuel with engine off and use safe parts.
Inspect trucks for safety before use; remove unsafe trucks from service.
Personal Protective Equipment (PPE)
Adequate supply and use of PPE.
Ergonomics
Workstations designed to reduce strain.
Training on proper lifting techniques.
Emergency Preparedness
Regularly conducted fire and emergency drills.
Accessible and well-marked first aid kits.
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Stay Compliant and Save Time - Go Digital
Above is a simplified Safety Audit Checklist designed to cover key areas of safety in a warehouse environment. We have converted this checklist into an easy-to-use digital format that comes with visual inspection assistance, making it easier and faster for operators. It can be customized or expanded based on the specific risks and safety needs of your warehouse operations.
ROO.AI Improving Warehouse Safety
The Power of Visual Instruction
Guide workers through inspections, receiving and loading processes with quick, easy visuals to ensure the job is done correctly every time including image verification and worker signatures.
Encouraging Safety Mindfulness
Accelerate onboarding and engage your employees with easier more effective safety training. Equip new team members with the essential skills and standard procedures through clear visual guidance. Provide on-the-spot training and integrate safety into standard operating procedures
The Role of AI
Transform your traditional documents into dynamic digital workflows with ROO.AI. Effortlessly convert forms, checklists, PDFs, and spreadsheets into optimized, user-friendly digital formats. Plus, our AI technology can turn any process video into detailed digital instructions and inspections, streamlining your workflow like never before.