Five tips for a safer warehouse: How to manage the workplace's “most dangerous machine”
The warehouse is one of the most accident-prone environments, with the forklift being one of the most hazardous machines. Forklift accidents account for a significant number of workplace fatalities and life-changing injuries in the UK. However, with the right precautions in place, it's possible to improve safety while also making the warehouse a more efficient place to work.
Every day, thousands of online orders are placed across the UK - everything from furniture and food to clothing and electronics. But most products share one thing in common: before reaching the customer, they’ve passed through a warehouse and been handled by warehouse staff.
Distribution and goods receipt play a vital role in ensuring that much of what we take for granted in everyday life runs smoothly. But there’s a darker side. Statistics show that warehouse workers and forklift drivers are among the most frequently affected occupational groups when it comes to work-related injuries.
Safety at the core
But not all warehouses operate in the same way. At AJ Products’ warehouse, the number of incidents and workplace accidents is low. Warehouse Manager Fredrik Emilsson believes that a strong focus on safety is essential to keeping things running smoothly.
“Safety runs through everything we do” he explains.
In our 54,000-square-metre central warehouse, over 100 employees work each day to receive, pack, wrap and dispatch thousands of packages from a range of more than 15,000 products.
“It’s the sheer variety of products that makes the job so challenging" Fredrik adds, “at the same time, we’re mindful of the environment - we don’t want to be packaging, storing or shipping air. It’s like an ongoing game of Tetris to make the most of every inch.”
A personal commitment to safety
Fredrik Emilsson has experienced firsthand the tragedy a workplace accident can bring. Last October, his son died following an accident on a farm. Naturally, this has brought immense grief, but it has also deepened his understanding of just how vital safety is.
“Although I’ve always prioritised safety, losing my son Casper has given it a whole new meaning. It’s about preventing accidents before they happen - no matter the workplace” he explains.
Fredrik used to speak regularly about safety, but now it’s a conversation he has even more often – and in more meaningful ways. Despite the heartbreaking loss, he’s determined to find purpose by helping others, including through his involvement with a charity that promotes organ donation.
“No parent should outlive their child. But my son’s organ donation saved five other lives” he says.
Involving all employees
Fredrik Emilsson attributes the smooth running of machinery at his own workplace, along with the low number of accidents, to diligent safety efforts that involve all employees.
“Sustainability is the key word - not just when we talk about products, but also people. It’s about the environment, of course, but just as much about safety. Many of our staff have been with us for over 20 years. You can’t retain people if you’re constantly pushing and pressuring them.”
One of the improvements introduced in recent years has been to ensure that, wherever possible, deliveries from Asia arrive on pallets rather than being loosely packed in containers.
“Loose picking is hard on the body, and we want to reduce that as much as possible” says Fredrik Emilsson.
How the forklift was tamed at AJ Products
In any warehouse, the forklift is arguably the most essential tool – but also one of the most dangerous. Across the UK, forklift-related incidents remain a leading cause of workplace injuries.
At AJ Products’ warehouse, however, incidents involving forklifts are rare. A number of targeted safety improvements have made a significant difference in recent years. For instance, clear floor markings now indicate main routes and right of way, helping both drivers and pedestrians navigate the space more safely. Each forklift is also fitted with access controls, so only authorised personnel can operate the vehicles.
“We’ve also added lights to the forklifts that shine onto the floor ahead of them” explains warehouse manager Fredrik Emilsson, “so colleagues can spot a vehicle approaching, particularly at junctions.”
Fredrik and his fellow supervisors regularly step away from their desks to spend time on the warehouse floor. Being visible and involved helps them spot potential risks early and support the team directly.
“Serious accidents don’t happen in the office” he says. “Businesses benefit in the long run by listening to and investing in their people. Of course, keeping up the pace matters - but at the end of the day, our goal is to deliver quality in a safe and sustainable way.”
Fredrik's 5 tips for a safer warehouse
- Be proactive, not reactive
“You’ve got to work preventatively – not just respond when something goes wrong. For example, if you’re redesigning or rebuilding your warehouse, carry out a proper risk assessment and sort out any potential hazards before they become problems.” - Share, don’t shelve, incident reports
“Incidents shouldn't be brushed under the carpet. If something happens, everyone needs to know about it so we can prevent it happening again. That’s why we hold monthly meetings with our full team – over 100 people – so the same message is shared clearly and consistently.” - Get your team involved
“Staff need to feel confident that their concerns will be listened to, especially when it comes to safety. That’s why my supervisors and I spend a lot of time out on the warehouse floor.” - Keep it clean – for safety’s sake
“Cleaning isn’t just about appearances. We have dedicated staff who handle cleaning full-time because loose pallets or wood scraps can be real hazards if left lying around.” - Look after your body – and lift properly
“Warehouse work is physically demanding. Some people assume it replaces regular exercise, but your body still needs care to last over time. When we expanded the warehouse, we also built a wellness centre for all staff, with generous opening hours, to encourage long-term health.”
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