Warehouse inspection checklist

Warehouse Inspection

This checklist is designed for routine self inspection of warehouse areas. It focuses on housekeeping, access, storage, racking, mobile plant, manual handling, hazardous substances, emergency arrangements and other common warehouse health and safety risks.

Record any problems identified and ensure corrective actions are assigned and followed through to completion.

1. General Warehouse Condition

• Floors, walls and ceilings are in good condition and free from significant damage.
• Walkways and work areas are clearly defined and maintained.
• Aisles are wide enough for the activities and equipment being used.
• Access to work areas is safe and unobstructed.
• Damaged surfaces, floors or structures have been reported and addressed.
• Lighting is adequate for the work being carried out.
• Ventilation is adequate for the warehouse activities.

2. Housekeeping & Slips, Trips & Falls

• Aisles, walkways and work areas are free from rubbish, packaging and loose materials.
• Fire exits and emergency routes are completely clear.
• Spills are cleaned up promptly and appropriate spill controls are available.
• Electrical leads, cords and hoses are positioned to prevent trip hazards.
• Pallets are not left where they create a trip or access hazard.
• Waste and damaged packaging are removed regularly.
• Floor surfaces are clean, dry and suitable for the work being undertaken.
• Changes in floor level are clearly identified and safely managed.

3. Racking & Storage

• Racking is stable, plumb and free from significant damage.
• Uprights, beams, bracing and connections are in good condition.
• Racking shows no significant forklift or vehicle impact damage.
• Racking is properly anchored where required.
• Rack protection is installed where there is a risk of vehicle impact.
• Pallets are in good condition and suitable for the loads being stored.
• Stored loads are stable and unlikely to fall or collapse.
• Loads are positioned correctly and do not create unsafe overhangs.
• Racking load limits are clearly identified and loads are within those limits.
• Heavy or unstable goods are stored appropriately.
• Damaged racking is reported, isolated where necessary and not left in unsafe use.
• Workers do not climb on racking or pallets to access stored goods.

4. Forklifts & Mobile Plant

• Forklifts and other mobile plant are in safe operating condition.
• Pre-start inspections are being completed where required.
• Defective equipment is removed from service or appropriately controlled.
• Forklift travel routes are clearly defined and maintained.
• Pedestrian and vehicle movements are separated where reasonably practicable.
• Speed limits and other traffic controls are in place where required.
• Forklift loads are stable and appropriate for the equipment.
• Operators are trained, competent and authorised for the equipment they use.
• Forklifts are parked safely when not in use.

5. Loading, Unloading & Deliveries

• Loading and unloading areas are clearly identified and kept clear.
• Vehicles are positioned safely during loading and unloading.
• Appropriate controls are in place to prevent unexpected vehicle movement.
• Pedestrians are protected from vehicle movements in loading areas.
• Loading docks and dock edges are maintained in safe condition.
• Loads are secured before vehicles leave the site.

6. Manual Handling

• Storage arrangements minimise unnecessary lifting, carrying and reaching.
• Heavy items are stored where they can be handled safely.
• Mechanical handling equipment is available where appropriate.
• Workers have been provided with suitable manual handling information and training.
• Loads can be moved without excessive twisting, bending or awkward postures.

7. Hazardous Substances

• Hazardous substances are correctly identified and labelled.
• Safety Data Sheets are available for relevant hazardous substances.
• Hazardous substances are stored in suitable designated areas.
• Incompatible substances are appropriately separated.
• Containers are secure, intact and free from leaks.
• Spill kits and other required controls are available and accessible.
• Workers handling hazardous substances have appropriate information and training.

8. Emergency & Fire Safety

• Emergency exits are clearly identified and unobstructed.
• Evacuation routes are clear and accessible.
• Fire extinguishers and other fire equipment are accessible.
• Fire equipment appears to be in place and appropriately maintained.
• Emergency lighting and signage are in place where required.
• Workers know the emergency procedures relevant to the warehouse.

9. Equipment, Machinery & Guarding

• Machinery and equipment are maintained in safe operating condition.
• Guards are fitted and secure where required.
• Emergency stops and other safety devices are accessible and functional.
• Damaged equipment is removed from service or appropriately controlled.
• Only authorised workers operate machinery and equipment.

10. Electrical Safety

• Electrical equipment, leads and plugs appear to be in good condition.
• Damaged electrical equipment is removed from service.
• Electrical leads are protected from vehicle damage and trip hazards.
• Switchboards and electrical isolation points are accessible.
• Portable electrical equipment is appropriately maintained and tested where required.

11. Personal Protective Equipment

• Required PPE is identified for warehouse activities.
• PPE is available, suitable and in good condition.
• Workers are using required PPE correctly.
• PPE storage and replacement arrangements are adequate.

12. Training, Procedures & Records

• Workers receive appropriate induction for warehouse activities.
• Workers are trained and competent for the tasks they perform.
• Relevant safe work procedures are available and understood.
• Training and competency records are maintained where required.
• Incidents, hazards and near misses are reported and followed up.
• Corrective actions from previous inspections have been completed.

13. Critical Findings