Warehouse Safety Checklist examples

In the USA the injury rate for the warehousing industry is the highest in comparison to the national average for all industries according to the Occupational Safety and Health Administration (OSHA). Below you will find the overview of OSHA Safety Checklist recommendations.

Top Warehouse Safety issues by OSHA

  • Failure to use proper personal protective equipment
  • Unsafe use of forklifts
  • Repetitive motion injuries
  • Improper stacking of products
  • Failure to follow proper lockout (tagout) procedures
  • Inadequate fire safety provisions

Top 10 OSHA Safety citations categories

  1. Forklifts
  2. Hazard communication
  3. Electrical, wiring methods
  4. Electrical, system design
  5. Guarding floor & wall openings and holes
  6. . Exits
  7. Mechanical power transmission
  8. Respiratory protection
  9. Lockout/tagout
  10. Portable fire extinguishers

Docks Safety Checklist

Injuries happen here when forklifts run off the dock, products fall on employees or equipment strikes a person.


Warehouse Docks Safety checklist shall cover:

  • Drive forklifts slowly on docks and dock plates.
  • Secure dock plates and check to see if the plate can safely support the load.
  • Keep clear of dock edges and never back up forklifts to the dock’s edge.
  • Provide visual warnings near dock edges.
  • Prohibit “dock jumping” by employees.
  • Make sure that dock ladders and stairs meet OSHA specifications.

Forklifts Safety Checklist

Approximately 100 employees are killed and 95,000 injured every year while operating forklifts


Forklifts safety checklist shall cover:

  • Train, evaluate and certify all operators to ensure that they can operate forklifts safely.
  • Drive safely, never exceeding 5 mph and slow down in congested areas or those with slippery surfaces.
  • Follow safe procedures for picking up, putting down and stacking loads.
  • Examine a forklift for hazardous conditions which would make it unsafe to operate.
  • Properly maintain haulage equipment, including tires.
  • Do not allow anyone under 18 years old to operate a forklift.
  • Ensure that the operator wears a seat-belt installed by the manufacturer.
  • Never drive up to a person standing in front of a fixed object such as a wall or stacked materials.
  • Prohibit stunt driving and horseplay.
  • Do not handle loads that are heavier than the weight capacity of the forklift.
  • Remove unsafe or defective trucks from service until the defect is properly repaired.
  • Maintain sufficiently safe clearances for aisles and at loading docks or passages where forklifts are used.
  • Ensure adequate ventilation either by opened doors/windows or using a ventilation system to provide enough fresh air to keep concentrations of noxious gases from engine exhaust below acceptable limits.
  • Provide covers and/or guardrails to protect workers from the hazards of open pits, tanks, vats and ditches.
  • Train employees on the hazards associated with the combustion byproducts of forklift operation, such as carbon monoxide.

Conveyors Safety Checklist

  • Inspect conveyors regularly.
  • Ensure that pinch points are adequately guarded.
  • Develop ways of locking out conveyors and train employees in these procedures.
  • Provide proper lighting and working surfaces in the area surrounding the conveyor

Materials Storage Safety Checklist

  • Stack loads evenly and straight.
  • Place heavier loads on lower or middle shelves.
  • Remove one object at a time from shelves.
  • Keep aisles and passageways clear and in good repair.

Manual Lifting/Handling Safety Checklist

  • Provide general ergonomics training and task-specific training.
  • Minimize the need for lifting by using good design and engineering techniques.
  • Lift properly and get a coworker to help if a product is too heavy.

Hazard Communication Safety Checklist

  • Maintain a Material Safety Data Sheet (MSDS) for each chemical to which workers are exposed in the facility.
  • Train employees on the risks of each chemical being stored.
  • Train employees to clean up spills, protect themselves and properly dispose of used materials.
  • Provide spill cleanup kits in any area where chemicals are stored.
  • Follow instructions on the MSDS for handling chemical products.
  • Store chemicals away from forklift traffic areas.
  • Store all chemicals safely and securely.
  • Have a written spill control plan.
  • Provide proper personal protective equipment and enforce its use.

Charging Stations Safety Checklist

  • Prohibit smoking and open flames in and around charging stations.
  • Provide adequate ventilation to disperse fumes from gassing batteries.
  • Ensure that fire extinguishers are available and fully charged.
  • Provide proper personal protective equipment such as rubber gloves and eye and face protection.
  • Properly position forklifts and apply brakes before attempting to change or charge batteries. follow required procedures when refueling gas or propane fueled forklifts.
  • Provide conveyors, overhead hoists or equivalent materials handling equipment for servicing batteries.
  • Provide an eyewashing and safety shower facility for employees exposed to battery acids.

Ergonomics Safety Checklist

  • If possible, use powered equipment instead of requiring a manual lift for heavy materials.
  • Reduce lifts from shoulder height and from floor height by repositioning the shelf or bin.
  • Ensure overhead lighting is adequate for the task at hand.
  • Provide employees with task-oriented ergonomic training.
  • Use your legs and keep your back in a natural position while lifting.
  • Test the load to be lifted to estimate its weight, size and bulk, and to determine the proper lifting method.
  • Get help if the load exceeds the maximum weight a person can lift safely without assistance.
  • Don’t twist while carrying a load, but shift your feet and take small steps in the direction you want to turn.
  • Keep floors clean and free of slip and trip hazards.

Contact us to learn how we use computer vision to automate safety monitoring and reporting.

Close Bitnami banner