A warehouse audit is a detailed assessment of a warehouse’s operations, inventory and processes. Audits are commonly performed once a month and are crucial processes for improving the overall operations of a warehouse and avoiding potentially costly mistakes. The main components of a warehouse audit include:
- Equipment checking and maintenance
- Physical inventory count
- Warehouse layout inspection
- Employee training and performance
- Warehouse safety inspection
Read on to see these components discussed in further detail and gain a broad understanding of what to look out for when performing a warehouse audit.
Equipment Maintenance
Warehouses contain an extensive amount of machinery and equipment that undergoes constant use and bears heavy loads, meaning overtime they are susceptible to wear and tear. It is crucial that this equipment and machinery is consistently monitored and maintained to ensure the safety of staff and the quality of inventory. The following checks should be completed when reviewing equipment and machinery:
- Forklifts must be inspected and maintained regularly and have the correct documentation.
- All machinery and electrical equipment must be functioning correctly and fully secured.
- Storage racking systems must be sturdy, contain no rust and free from any damage.
- Loading bays must be clear and free from all obstructions.
- Safety equipment, like CCTV and locks, must be working effectively and free from damage.
Once these steps have been taken it is essential that warehouses remove any damaged equipment or machinery instantly and they are either fixed or completely replaced before returning to the warehouse.
Physical Inventory Count
A physical inventory count involves taking an accurate count of all inventory using inventory forms. This should be cross-analysed with your existing inventory records to ensure that all warehouse inventory is accounted for. This is a timely and comprehensive process but it is extremely important for ensuring that orders can be fulfilled and businesses aren’t financially impacted.
Warehouse Layout Inspection
In order for your warehouse operations to run effectively it is key that there is an efficient layout that allows processes to run smoothly. Inspecting the warehouse layout is ideal for identifying areas of improvements and it can be performed by conducting walk-throughs of the space to identify hazards. When performing a layout inspection, it is important to ensure the following:
- Walkways are clean, clearly marked and free from any obstructions.
- Walkways comply with regulatory standards and are a sufficient width for equipment and vehicles.
- Storage racking systems are used to make the most of vertical space and storage is well organised.
- Light fixtures are fitted correctly and placed in appropriate locations.
- Emergency exits are clearly signposted and are clear at all times.
- Ladders are damage free and stored correctly.
- Loading and unloading bays are positioned to allow for minimal handling.
Employee Training and Performance
Employee training and the monitoring of performance is a crucial step in navigating workplace challenges, especially within a warehouse setting where work is fast paced and there is a magnitude of hazards. Audits must assess whether employees are taking the correct safety measures, working well with their colleagues and are meeting expectations. This helps to identify areas for improvement in order to allocate targeted training sessions.
Warehouse Safety Inspection
A variety of different activities are performed on a daily basis within a warehouse setting, making them busy and hazardous environments. It is therefore extremely important to comply with the necessary safety regulations in order to safeguard the wellbeing of staff. This is when a safety audit comes into play as it ensures that the correct safety procedures are being fully adhered to. Warehouse safety checklists are extensive so we have created a list covering the some of the main points that should be considered when performing a safety audit:
- Staff are wearing the appropriate Personal Protective Equipment (PPE).
- Walkways and exits are clear of any obstructions and free from debris.
- Warehouses are well lit and emergency lighting is fully operational.
- The correct stocking and handling procedures are followed.
- Regular employee training sessions are performed.
- All workplace incidents are reported and documented appropriately.
- Fire safety procedures are followed.
Summary
Regular warehouse audits are extremely important as they ensure the safety and efficiency of all warehouse operations and identify areas of improvement to help prevent major accidents or failings. This guide offers a concise and straightforward checklist for warehouses undertaking audits and ensures a sufficient starting point for understanding the importance of such a process.
