Running a successful warehouse means juggling many priorities, and often, safety and efficiency seem to be at odds.

It is important to challenge the misconception that prioritising safety slows down operations.

Prioritising speed and output over safety can be incredibly costly—not just in terms of potential fines and legal fees but also lost productivity, low morale, and a damaged reputation. The good news is that safety and efficiency aren’t mutually exclusive; they go hand in hand. In reality, a safe workplace is also a more efficient one.

The truth is if you have people off work due to injury, or you have wasted floor space due to bad layout, operations become inconsistent, and you are ultimately putting your company profits at risk.

Let’s explore how a commitment to safety can enhance your warehouse operations, boost productivity and improve your profits.

The relationship between safety and efficiency

In warehousing and logistics, efficiency means using resources well. This includes time, labour, space, equipment, and energy. The goal is to move and store goods effectively while reducing waste and boosting output.

It’s about doing things right and doing the right things. 

Crucially, efficiency can never come at the expense of safety.  In fact, a strong emphasis on safety often increases efficiency.

Take for example, a warehouse using forklifts for material handling. An inefficient approach might involve:

• Forklifts criss-crossing each other without designated lanes (creating a high risk of collisions)
• Workers walking through active forklift areas without defined pedestrian walkways (increasing the chance of incidents)
• Poorly organised storage areas forcing workers to search for items (causing delays and potentially unsafe lifting manoeuvres)
• Neglecting regular maintenance on forklifts (leading to potential equipment failure and injury).

This approach is inefficient and unsafe, wasting time, increasing the risk of incidents and injuries, and ultimately costing more in the long run (due to repairs, downtime, insurance claims, etc.).

An efficient approach, on the other hand, would incorporate:

• Clearly marked forklift lanes and pedestrian walkways (reducing the possibility of collisions).
• Designated storage areas for materials (minimising search times and providing clear pathways for movement).
• Regular forklift maintenance (to prevent breakdowns and ensure safe operation).
• Safety training and protocols for all warehouse staff.
• Using technology, such as warehouse management systems, to optimise workflows and reduce material handling times.

This approach is efficient and safe as it streamlines the workflow, reduces the risk of incidents, and improves overall productivity.

The improved safety directly translates to efficiency.

The Human Factor: Benefits of a Safe Working Environment

Unless you have a fully automated business, you need people. They are the backbone of your operations and the ‘resource’ to meet your customers’ needs. A safe working environment goes beyond just meeting regulations. It’s about making sure employees feel valued, respected, and secure in their safety. Improving safety enables shared responsibility and leads to:

• Increased productivity resulting from better focus.
• Reduced absenteeism with fewer incidents and less time off work.
• Improved morale by creating a positive and supportive work environment where people are committed to keeping each other safe.
• Reduced operational downtime due to fewer incidents.

A workplace riddled with hazards can cause more stress and anxiety. It also lowers focus and productivity. This can lead to more absences resulting from injuries or illness. Plus, it creates a culture of fear and distrust among workers.

The Impact of Incidents on Productivity and Morale

Unhappy people are not productive people. Workplace incidents have a ripple effect far beyond the injured person.  They disrupt operations, impact productivity, and significantly lower morale.  Rather than efficient output, you will have this on your hands instead:

• Lost work hours dealing with the incident and its aftermath.
• Potential resignations and difficulty recruiting workers.
• Medical expenses and costs to treat injuries.
• Insurance claims and paperwork.
• Legal fees
• Reputational damage resulting from a poor safety record can negatively impact your brand image and ability to attract employees.

A safety culture leads to efficient operations. By creating consistent warehouse operations people know what to do, when to do it, how to operate equipment and also, where the no-go zones are.

Physical Controls: Designing Safe, Efficient Sites

We’ve talked a lot about behaviour, culture and consequences. Now let’s consider another part of the equation – physical controls that can help manage risks to enhance safety and efficiency.

Installing physical barriers is often the best way to keep people away from machines, vehicles and moving objects. This should align with your risk assessment and safety plans. To reduce risk if something goes wrong, like stock falling from a pallet stack onto a steel pedestrian tunnel (like in this picture), people walking below will be safe. You’ve prevented an accident. Now, that person can keep working and go home to their family at the end of the day.

Using physical controls can also improve your warehouse floor layout. This leads to more consistent operations and can boost your profit margin.

Image: Steel pedestrian tunnels protect people and increase operational efficiency.

I’m ready to invest in safety

You don’t need a massive warehouse to invest in safety. It’s a strategic decision that enhances efficiency and profitability for every business.  Keeping in mind that a safe workplace is a productive workplace, safety and efficiency are key to boosting your operations and creating a happier, healthier workforce.

Vanguard has over 30 years of experience. We help people like you to improve safety, manage risk and improve operational efficiency. Contact us today for a free consultation. Let us show you how our expertise can make your warehouse safer and more efficient.