A warehouse must strictly comply with safety standards. Facilities must be designed by professionals for optimal operation to avoid key errors in warehouse configuration. This is important both for the protection of workers and for the smooth running of the business.
Poor design, lack of clear signage or failure to comply with internal regulations and official legislation can compromise worker safety. According to the US Occupational Safety and Health Administration’s (OSHA) Pocket Guide to Warehouse Safety (pdf), up to 95,000 forklift-related accidents occur each year in the US alone.
The key to a safe start of operations in a warehouse is advance planning, so properly designing facilities and establishing clear rules in each space should be a priority. Separating areas, using proper signage in the warehouse, maintaining consistency and establishing standards help to avoid errors in warehouse organization.
In addition, it is important to keep employees trained and up to date on safety program standards. Good warehouse planning from the outset also helps companies to continue to grow sustainably in the event of the need to expand facilities and thus minimize key errors in warehouse configuration.
Key errors in the configuration of warehouses: design
Poor planning, inadequate design, lack of space or mishandling of materials can cause damage to facilities. The following tips are important to avoid key mistakes in warehouse configuration and thus minimize risks in the workplace.
1) Lack of signage
Signage is particularly important in the operation of a warehouse, as it serves to warn personnel of potential hazards that may be present in certain areas. Signs alert to the location of safety equipment, such as fire extinguishers, as well as hazards. These may include flammable substances, corrosive materials, fall hazards or loading and unloading docks.
2) Lack of lighting
A warehouse should have all its areas illuminated. Staff must be able to clearly see any area and be aware of potential hazards they may encounter, such as objects on the floor, overloaded shelves, spilled substances or operating machinery. Regularly checking lighting installations and reporting any faults as soon as they occur is important to maintain the safety of everyone working in the warehouse.
3) Management of hazardous substances
Warehouses may use substances that are considered potentially harmful and therefore subject to legal restrictions and regulations. In such a case, they must always be stored in suitable containers that comply with these regulations. Failure to designate appropriate areas for storing such substances is one of the key errors in warehouse design that must be avoided.
Key errors in the configuration of warehouses: preparation
Hazard control and accident prevention are key considerations when designing a warehouse or distribution center, so among the most important key warehouse configuration mistakes to avoid are those that do not adequately minimize these risks.
4) Fire hazards
Fires or explosions may occur in areas with flammable materials or substances. Extreme caution should be exercised and smoking should be prohibited in appropriate areas. Higher risk areas should be clearly marked. Personnel must know where fire extinguishers are located and be trained to use them in the event of fire. In addition, it is important to have a good ventilation system throughout the building.
5) Power failures
Mistakes in the installation of the electrical system can lead to short circuits, power outages or even fires. It is important to check plugs and sockets regularly to ensure that they are kept in good condition and are not overloaded.
6) Rack overloading and falling objects
A common source of errors in warehouse configuration occurs when setting up facilities to store materials. This means choosing the warehouse racking that best suits your needs and ensuring that loading and picking areas are designed to allow adequate access for people and vehicles, such as forklifts.
Key personnel-related errors in warehouse configuration
Some of the key warehouse setup mistakes to avoid are those that put people at risk, while others are those that do not adequately prepare personnel for the risks and other hazards present in the facility.
7) Lack of staff training
Key errors in warehouse configuration are not limited to infrastructure alone. Failure to properly train personnel is an omission that can be costly. Employees who know the correct regulations in each area can prevent accidents from occurring, helping the warehouse run in an organized and efficient manner.
8) Provision and storage of safety equipment
In a warehouse, hard hats, boots, gloves and other protective clothing will often be needed, and ensuring access to them for anyone using the space is important. Failing to install facilities for proper storage and ease of access to that gear another key warehouse setup mistake to avoid.
9) Fall prevention
Falls can be due to objects on the floor or materials spilled on the floor. Therefore, an important part of the warehouse setup is to provide access to signage to alert others of such hazards, as well as the opportunity to cordon off areas that should not be accessed.
10) Collision avoidance
Accidents such as collisions can occur if workers do not follow correct procedures when moving through designated machinery areas or due to operator distraction. To avoid collisions, it is important that areas where people and vehicles will be sharing space are properly marked.
Serviap Logistics offers warehouse picking services
At Serviap Logistics we supply and install elements for warehouses in Brazil, Mexico and the United States.
These include shelving, labels, signage, floor marking and collision protection. We also offer project management services and can oversee the installation, refurbishment or relocation of your warehouse from start to finish.
We count some of the world’s largest companies among our satisfied customers and partners, covering a wide range of industries such as automotive, e-commerce and wholesale, among others.
As a company that has grown internationally after starting in Mexico, we are committed to service excellence and pride ourselves in offering personalized service to each client.
We are also dedicated to maintaining the highest safety standards wherever we operate, including OSHA certification in the United States.
Contact us at for more information on how we can help you with your warehouse shelving.
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