Warehouse Traffic Safety Audit: Risks and Recommendations After AGV Removal and FLT Reintroduction in UK Beverage Facility

Objectives

• Assess the current health and safety arrangements following the reintroduction of FLTs.
• Identify risks associated with pedestrian and vehicle interaction.
• Recommend improvements to enhance safety and operational efficiency.

Methodology

A team of Finch consultants conducted a site inspection and reviewed existing documentation, including risk assessments and Safe Operating Procedures (SOPs). The inspection focused on:

• Warehouse layout and environment
• FLT and pedestrian movement
• Safety procedures and controls

Key Findings

Warehouse Operations

• The warehouse spans approximately 2000m², with roller shutter doors on three sides and gravity roller racking for pallet dispatch.
• FLTs are diesel-powered, operating in confined areas with limited ventilation, raising concerns about air quality and hygiene due to open doors.
• Pedestrian access is managed via sign-in procedures and verbal communication, with limited physical segregation from FLT operating zones.

Safety Observations

• FLT drivers demonstrated vigilance, but simultaneous operation of multiple FLTs increases risk without defined traffic flow systems.
• Diesel fumes were noticeable, and open doors compromised hygiene and access control.
• Pedestrian access points lacked interlocking systems, and signage was ambiguous.
• Gravity roller racking was damaged, causing operational delays and increased pedestrian exposure to FLT zones.
• Contractors and maintenance personnel lacked formalised control measures during non-routine tasks.

Outcome

The client was provided with a comprehensive set of recommendations aimed at reducing risk, improving operational flow, and enhancing safety culture. Finch Consulting remains available to support the implementation and review of these measures.