Manufacturing and warehousing remain among the highest-risk workplace sectors. Machinery, vehicle movements, manual handling, and hazardous substances create an environment where serious injuries occur regularly. Effective health and safety management is essential for protecting workers and maintaining operations.
This guide covers the key health and safety requirements for UK manufacturing and warehouse operations.
The Legal Framework
Manufacturing and warehousing is governed by extensive health and safety legislation:
Provision and Use of Work Equipment Regulations 1998 (PUWER) - Requirements for safe machinery, guarding, maintenance, and operator training.
Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) - Covers cranes, hoists, fork lift trucks, and lifting accessories.
Control of Substances Hazardous to Health Regulations 2002 (COSHH) - Assessment and control of hazardous substances.
Control of Noise at Work Regulations 2005 - Protection from noise-induced hearing loss.
Workplace (Health, Safety and Welfare) Regulations 1992 - Standards for the working environment.
Machinery Safety
Machinery causes some of the most severe workplace injuries - amputations, crushing, and fatalities.
PUWER Requirements
The Provision and Use of Work Equipment Regulations require:
- Equipment suitable for intended use
- Maintained in safe condition
- Inspected where significant risk exists
- Dangerous parts guarded
- Controls clearly marked and safe
- Emergency stops provided
- Operators trained and competent
Guarding Principles
All dangerous parts must be guarded. The hierarchy of guarding:
- Fixed guards - permanently attached, require tools to remove
- Interlocked guards - machine stops when guard opens
- Adjustable guards - can be positioned for different operations
- Self-adjusting guards - automatically adjust to workpiece
Guards must prevent access to dangerous parts during normal operation and not be easily defeated.
Common Machinery Hazards
| Hazard | Examples | Controls |
|---|---|---|
| Entanglement | Rotating shafts, spindles, drills | Guards, emergency stops, no loose clothing |
| Cutting | Saws, shears, guillotines | Fixed guards, interlocked guards |
| Crushing | Presses, moulding machines | Two-hand controls, light curtains, interlocks |
| Impact | Hammers, presses | Guards, hold-to-run controls |
| Ejection | Swarf, broken parts | Guards, screens, PPE |
| Drawing in | Nip points, rollers | Fixed guards, emergency stops |
Maintenance Safety
Many machinery injuries occur during maintenance:
- Lock out/tag out procedures essential
- Isolation of all energy sources
- Verification that machine is safe before work
- Controlled restart procedures
- Never defeat guards for maintenance convenience
Fork Lift Truck (FLT) Safety
Fork lift trucks cause numerous deaths and serious injuries annually - both to operators and pedestrians.
LOLER Requirements
Fork lift trucks are lifting equipment, requiring:
- Thorough examination before first use
- Thorough examination at least every 12 months
- Daily pre-use checks by operators
- Competent, trained operators
- Records of examinations
Operator Training
FLT operators must be trained and competent:
- Formal training (typically accredited courses)
- Specific training for vehicle types used
- Familiarisation with the workplace
- Assessment of competence
- Refresher training as needed
Only authorised persons should operate FLTs.
Traffic Management
Separating pedestrians and vehicles is critical:
- Designated pedestrian walkways
- Physical barriers where practicable
- One-way systems
- Speed limits (typically 5-10 mph indoors)
- Mirrors at blind corners
- Warning signs and floor markings
- Audible reversing alarms
Safe Operation
- Never exceed rated capacity
- Travel with forks low
- Sound horn at junctions and blind spots
- No passengers on forks or counterweight
- Secure loads properly
- Park safely with forks down, handbrake on, key removed
Fatal Pedestrian Strike
A warehouse worker was struck by a reversing fork lift truck while walking through a loading area. The FLT had a working reversing alarm, but the pedestrian was wearing ear defenders to protect against noise from nearby operations and didn't hear it.
The worker died from crush injuries. Investigation found no physical separation between FLT routes and pedestrian access, and workers routinely walked through the loading area as a shortcut.
- •Physical separation of pedestrians and vehicles is essential
- •Audible warnings alone aren't sufficient protection
- •Traffic routes should be clearly defined and enforced
- •Convenience shortcuts create fatal risks
Manual Handling
Manual handling injuries are the most common cause of absence in manufacturing and warehousing.
High-Risk Tasks
- Lifting and carrying stock
- Loading and unloading
- Repetitive assembly operations
- Awkward handling in confined spaces
- Handling heavy or bulky items
Assessment
Assess manual handling tasks considering:
- Task - distances, heights, frequency, duration
- Individual - capability, training, health
- Load - weight, size, grip, stability
- Environment - space, floor conditions, temperature
Controls
Eliminate or reduce:
- Mechanical handling equipment (FLTs, conveyors, hoists)
- Delivery to point of use
- Smaller pack sizes
- Team lifting for heavy items
Improve:
- Adjustable work surfaces
- Rotate tasks to reduce repetition
- Training on handling technique
- Adequate rest breaks
Racking and Storage
Racking collapse can cause multiple fatalities. Proper installation, use, and inspection are essential.
Requirements
Installation:
- Designed and installed by competent persons
- Suitable for loads to be stored
- Secured to floor where required
- Load notices displayed
Safe use:
- Never exceed stated capacities
- Load correctly (heavier items lower)
- Don't climb on racking
- Report damage immediately
- Use proper access equipment for high levels
Inspection:
- Regular inspection for damage
- Formal inspection by competent person (SEMA recommends annually)
- Immediate action on significant damage
- Records of inspections and repairs
Common Damage
- Impact damage from FLTs
- Overloading
- Incorrect assembly after modification
- Corrosion in damp environments
Damaged racking should be unloaded and repaired or replaced.
COSHH - Hazardous Substances
Manufacturing often involves hazardous substances - chemicals, dusts, fumes, and biological agents.
Common Hazards
- Cutting fluids and coolants
- Solvents and degreasers
- Welding fumes
- Metal dusts
- Adhesives and resins
- Paint and coatings
Assessment
For each hazardous substance:
- Identify the substance and its hazards
- Assess who might be exposed and how
- Evaluate the level of risk
- Identify control measures needed
- Implement controls
- Monitor and review
Control Hierarchy
- Eliminate - can the substance be removed from the process?
- Substitute - use a less hazardous alternative
- Engineering controls - LEV, enclosure, automation
- Administrative controls - reduce exposure time, procedures
- PPE - last resort, not first choice
Health Surveillance
Required where workers are exposed to substances causing identifiable diseases:
- Skin checks for dermatitis-causing substances
- Lung function for respiratory sensitisers
- Specific surveillance for substances like lead, isocyanates
Noise at Work
Manufacturing environments are often noisy. Uncontrolled exposure causes permanent hearing damage.
Legal Limits
| Level | Action Required |
|---|---|
| 80 dB(A) Lower Action | Information, hearing protection on request |
| 85 dB(A) Upper Action | Hearing protection mandatory, hearing protection zones |
| 87 dB(A) Limit | Must not be exceeded (at ear with protection) |
Controls
- Engineering controls first (quieter machines, enclosures, damping)
- Reduce exposure time
- Hearing protection zones clearly marked
- Suitable hearing protection provided and worn
- Health surveillance (audiometry)
Fire and Explosion
Manufacturing premises often have significant fire risks.
Common Hazards
- Flammable materials storage
- Dust explosions (wood, metal, food dusts)
- Hot works
- Electrical faults
- Waste accumulation
Controls
- Fire risk assessment
- Control of ignition sources
- Safe storage of flammables
- Good housekeeping (dust management)
- Hot works permits
- Appropriate detection and suppression
- Emergency procedures and training
DSEAR
The Dangerous Substances and Explosive Atmospheres Regulations apply where explosive atmospheres may occur. This requires:
- Risk assessment for explosive atmospheres
- Classification of hazardous areas
- Appropriate equipment in classified zones
- Written explosion protection document
Working at Height
Falls from height occur in warehouses and manufacturing from:
- Racking access
- Mezzanine floors
- Loading bays
- Maintenance on elevated equipment
Controls
- Proper access equipment (platforms, towers)
- Edge protection on mezzanines and loading bays
- Training on equipment use
- Fall protection where needed
Welfare Facilities
Adequate facilities must be provided:
- Toilets and washing facilities
- Drinking water
- Rest areas
- Changing facilities where needed
- First aid facilities
Common Questions
Frequently Asked Questions
Thorough examination is required at least every 12 months under LOLER. However, insurance schemes often require 6-monthly examination. Daily pre-use checks by operators are also required, checking brakes, steering, warning devices, and visible damage.
No. PUWER requires that anyone using work equipment has received adequate training including methods of use, risks, and precautions. Operators should be trained and assessed as competent before using machinery independently.
Keep records of: risk assessments, maintenance and inspections, thorough examinations (for lifting equipment), training records for operators, any incidents or near misses. Examination records must be kept until the next examination.
Share information about site hazards, coordinate activities, check contractor competence, monitor their work, ensure they follow site rules. For significant work, use permit systems. Remember you have duties to contractors working on your site.
Identify hazardous substances, assess exposure risks, decide on and implement controls, record the assessment, train workers, review regularly. You need Safety Data Sheets for all substances. Health surveillance may be required for some exposures.
Summary
Manufacturing and warehouse safety requires systematic management of multiple hazards:
- Machinery safety - proper guarding, maintenance, and trained operators
- Fork lift safety - trained operators, traffic management, thorough examination
- Manual handling - assessment, mechanical aids, training
- COSHH - assessment and control of hazardous substances
- Noise - assessment, engineering controls, hearing protection
The complexity of these environments demands robust safety management systems and genuine commitment to protecting workers.
Related content
Topics:
- Machinery Safety - Equipment safety requirements
- Manual Handling - Safe lifting and carrying
- COSHH - Hazardous substances control
Articles:
Related sectors:
- Construction - CDM and site safety
- Retail - Warehousing and distribution
Tools:
- Responsibility Checker - Find out what applies to you
*This guidance covers key health and safety requirements for UK manufacturing and warehouse operations. It is not exhaustive and does not constitute legal advice.