Preparing Warehouses for OSHA’s Workplace Safety National Emphasis Program

Warehouses are busy environments, and all this activity often comes with significant risk. To address potential safety issues, the Occupational Safety and Health Administration (OSHA) rolled out a new National Emphasis Program (NEP) in July 2023, focusing specifically on warehouse safety.

The program aims to reduce injuries and fatalities in the industry. For operators, this is an essential initiative. Understanding the ins and outs and preparing your facility can mean the difference between a smooth inspection and a costly compliance issue later.

Below, we explore the ins and outs of preparing warehouses for this OSHA NEP and what it means for you and your facility.

What Is the New OSHA National Emphasis Program?

OSHA’s new NEP initiative focuses on reducing and eliminating hazards, injuries, illnesses and fatalities in warehousing and related industries. It’s a direct response to the troubling rise in injury rates.

The program gives inspectors a framework to conduct random, unannounced inspections in large and small warehouses. These inspections primarily focus on the following:

• Forklift safety
• Material handling equipment
• Ergonomics
• Fire protection and exits
• Walking-working surfaces
• Heat-related hazards

If your facility handles e-commerce or third-party logistics, you may be especially at risk for inspection, as these sectors have seen sharp increases in incident rates.

Why This Matters

For owners, noncompliance can be expensive. Fines can be costly, including the reputational and operational costs of violations. However, beyond compliance, there’s an opportunity to make your warehouse safer, more efficient and overall better for your workforce.

According to the United States Bureau of Labor Statistics, there were 4.7 injury and illness cases and 28 fatalities for every 100 full-time workers in 2023. Being proactive can mean fewer accidents and less downtime. It also positions your business as a responsible, safety-conscious operation, something your employees, partners and customers will appreciate.

How the New OSHA National Emphasis Program Works

The new warehouse safety NEP is available nationwide, but its enforcement varies depending on whether your state follows federal OSHA regulations or operates under a state plan. All state programs must adopt this federal NEP or implement an equivalent state emphasis program that meets OSHA’s requirements.

Facilities are selected for inspection via two randomized lists:

• Warehousing, distribution and parcel processing centers
• Select high-risk retail sites with elevated Days Away, Restricted or Transferred (DART) rates

Some states use a trigger-based approach, where inspections occur in response to complaints, accidents or fatalities, rather than randomly.

Preparing Warehouses for OSHA’s New Safety Program: A Step-by-Step Plan

Ensuring your facility meets the new OSHA guidelines for warehouses is relatively straightforward. You’ll need to focus on the following key areas.

1. Conduct an Internal OSHA Warehouse Safety Audit

Start by conducting a comprehensive audit. This assessment gives you a clear understanding of current warehouse conditions and helps you spot potential hazards.

Look at:

• Forklift operation zones
• Loading docks
• Racking and shelving systems
• Emergency exits and signage
• Walkways and trip hazards
• PPE usage and accessibility
• Heat zones, especially in the summer

2. Request a No-Risk Consultation

Federal and state OSHA programs offer free, confidential on-site consultations. These consultations come with no fines, citations or reporting to inspectors. They can help you identify areas of improvement and give you time to make the necessary adjustments to your operation.

3. Review Forklift and Lift Truck Safety

Lift trucks are often central to warehouse operations, but they can contribute to serious injuries. Some common forklift incidents include:

• Tip-overs from elevated loads or even ground
• Collisions with pedestrians due to poor visibility or a lack of traffic control
• Falling loads from improper stacking or damaged equipment
• Misuse of forks to lift personnel
• Falls from docks or trailers due to unstable platforms
• Equipment impacts from speeding or distraction

To improve safety, you can ensure:

1. All forklift operators receive certified training on specific vehicle types and site conditions.
2. Daily inspections are being documented.
3. Forklifts are being maintained according to manufacturer guidelines.
4. Load capacities and stability principles are communicated.

4. Address Heat-Related Hazards

Warehouses can get hot, especially during the summer or in regions with extreme temperatures. OSHA’s new NEP includes heat illness prevention as a key focus, particularly in areas where ventilation is limited.

To stay compliant, you’ll need to:

1. Provide access to water and shaded rest areas.
2. Educate employees about the signs of heat exhaustion.
3. Implement work and rest cycles during peak heat.
4. Use ventilation fans or HVAC systems where possible.

5. Ensure Proper Ergonomics

Musculoskeletal injuries are common in warehouses due to repetitive motion, heavy lifting and awkward postures.

To protect your team, you can invest in:

• Lift-assist tools and adjustable-height workstations
• Anti-fatigue floor mats
• Ergonomically designed material handling equipment
• Ergonomic training as part of onboarding

You might also consider robotic solutions. For example, Hyster Yale forklifts and tow tractors can help reduce the strain on workers while maintaining productivity. 

6. Maintain Clear Exits and Fire Protection

A fire can be catastrophic, but regular checks and basic training can prevent one from occurring. Creating effective warehouse health and safety regulations includes checking for blocked exits, broken emergency lighting and outdated fire extinguishers.

For this, you’ll need to make sure:

1. All exit routes are marked, unobstructed and well-lit.
2. Fire extinguishers are inspected monthly.
3. Exit doors remain unlocked.
4. The staff knows evacuation procedures.

7. Train and Involve Your Team

Your safety plan requires the involvement of your people. You can involve your employees in identifying hazards and creating solutions. You can also host regular meetings, offer refresher training and encourage open communication. Remember, keeping your team safe isn’t a one-time fix. You’ll need to create a workplace culture where every team member understands and values it.

How Burns Industrial Equipment Can Help

At Burns Industrial Equipment, we believe the best way to support you is by helping you stay ahead. Whether it’s by offering high-performance forklifts, robotics or warehouse layout consulting, our goal is to deliver the best solutions, including:

• Certified forklift operator training
• Fleet management services with proactive maintenance
• Telemetry and safety tech integrations
• Hyster-Yale robotic and operator-assist technologies

Whether your facility needs assistance in preparing for an OSHA inspection or a fleet upgrade, we can help you ensure your operations stay safe, productive and compliant.

Let Burns Industrial Equipment Help You Stay Compliant

The new OSHA warehouse safety program isn’t meant to overwhelm you. It’s simply a turning point that signals operations can no longer afford to treat safety as an option. With the right preparation, your operation can meet and exceed these new standards. This means fewer accidents, lower costs and a better working environment for everyone on the floor.

If you’re unsure where to start, Burns Industrial Equipment is here to help. From safety-first equipment to operator training and expert support, we’re ready to assist you. Contact our dedicated team today and let us create a safer and more compliant workplace for your team.