When warehouse management is managed correctly, it will deliver the best-case scenario. You will enjoy the efficiency of stock moving in and out, nothing being broken or dropped from a height, and no stock going missing or being misplaced. The time invested will deliver happy customers/clients and an equally contented workforce.

Poor design and implementation, in contrast, may result in serious costs. These include the financial cost of missing/broken/delayed stock, customer/client loss or delays to major projects further afield, potentially leading to financial penalties. In the worst-case scenario, someone may be hurt or even lose their life as a result of incorrectly implemented or managed warehouse storage and systems.

Three Key Principles for a Safe and Efficient Warehouse

To achieve the best-case scenario and pre-empt a wide range of risk factors, a warehouse should follow three key principles.

1. Safety first, always

There's no end of safety requirements in a warehouse if you are to minimise injury risk. They range from the dangers inherent in driving a forklift around shelves full of heavy or dangerous goods, falls from height, trapping fingers or toes in equipment and even the basic slips, trips and falls. In Britain, the fatal injury rate in the transportation & storage sector to March 2024 was approximately 0.91 per 100,000 workers, about 2.2 times the all-industry rate, reinforcing the need to make a warehouse a safe place to work.

The challenge here is in instilling the importance of a health and safety first culture. This can be a really long and difficult process, as most workers just want to get the job done and will, even if subconsciously, cut corners at the expense of their own safety in order to do so. That's why a warehouse should be designed with both safety and efficiency in mind, so the default becomes to work compliantly and safely.

2. Professional Grade Warehouse Storage

Warehouse rack design is the focal point of a well-oiled warehouse. It should be expertly designed and installed. Not only should it meet industry standards, but it should maximise space and make the working day a little easier for every team member. If racking is weak or unbalanced, workers are inherently at risk, even when merely in proximity to it. The Health and Safety Executive (HSE) reports that in 2023/24, there were 15 fatalities in the transportation and storage sector, including warehousing, highlighting the importance of having safe warehouse racking.

There are many different shapes and sizes of warehouses, each with different needs. Creating a warehouse rack design to complement the space ensures that it works safely and efficiently from the outset and avoids remediation later on, when the warehouse is in full operation, adding to the complexity and cost of any adjustments.

If stock changes often, then adjustable pallet racking is something to consider. Bulk storage is supported by drive in racking, but this has some inherent disadvantages for those wanting to pick up items swiftly. If a warehouse contains a wide range of randomly sized objects such as beams, pipes or really oversized stock, then a cantilever system may be beneficial. Whatever rack design a warehouse management team opts for, balance is essential. If weight is unevenly distributed, beams can become stressed, leading to damage over time that may not be noticed until it's potentially too late. In these cases, a simple nudge from a forklift in a hurry could be enough to make the entire set up fail.

To ensure that the installation is optimised and meets both company and industry standards, soliciting professional input from warehouse design consultants adhering to Storage Equipment Manufacturers' Association (SEMA) standards is a sure way to keep everything compliant.

3. Inspect and Maintain

It's essential to look after warehouse equipment with regular maintenance and inspections, not merely because SEMA indicates that inspections should be undertaken at least once a year, but also because ample industry evidence shows that racking collapse can cause serious injury or death when systems are poorly maintained, overloaded or struck by forklifts. It's not just about the racks, either; lights, fire exits, and ventilation all require regular attention. If anything appears damaged, loose, or unsafe, it should be fixed straight away.

Keeping a record of inspections is vital in confirming that your warehouse storage systems meet safety standards, and by using warehouse design consultants, your people and your clientele are kept safe, accidents are prevented, and your warehouse runs smoothly every day.

In conclusion, warehouse storage solutions and their design considerations go far beyond merely the handling of stock. Their design is about keeping people safe and making everyone's job easier. When racks are sturdy, layouts make sense, and there's room to adapt, the entire facility runs like clockwork. If you adhere to these three principles (safety first, professional warehouse rack design, and frequent inspections) your warehouse will not only stay compliant but will also be a nicer, safer place in which to work.

Contact Us for Expert Racking and Storage Solutions

Here at DC Space & Storage Solutions, we offer expert support across all areas of warehouse safety and efficiency, including professional racking design, installation, inspections, and repairs. Our team works with businesses of every size to create storage systems that are safe, compliant, and built to perform. Get in touch with us today to discuss your warehouse needs and find the right solution for your operation.