Logistics operations are the backbone of supply chains, but they also present significant safety challenges. Jo Verheijen, a Health, Safety, and Environment Manager at Avery Dennison and a valued Rombit customer, recently shared his expertise on improving safety and efficiency in warehouse environments. His insights are a roadmap for companies striving to create safer and more efficient logistical operations, even in hybrid environments where human labor and automation coexist.
Addressing Safety Challenges in Warehouses
Despite advancements in automation, warehouses remain dependent on human labor, posing ongoing safety risks. Jo emphasized that creating a safe environment isn’t just a regulatory necessity but a strategic priority. From managing internal traffic flow to leveraging modern technology, every step taken to mitigate risks translates into fewer accidents, reduced damage, and improved efficiency.
The Challenges of Logistics Safety
Logistics operations often involve a mix of automated systems and manual labor in bustling warehouses. Despite advancements, human operators remain integral to these environments, necessitating a dual focus on safety and operational efficiency. Key risks include:
- Collisions: Between vehicles and pedestrians.
- Operational hazards: Slippery surfaces, uneven levels, and improperly loaded materials.
- Equipment failure: Malfunctions in forklifts, pallet stackers, or other vehicles can escalate into costly repairs or accidents.
A Five-Step Plan for Safer Logistics
Jo outlined a structured approach to enhance safety in logistics operations:
1 - Establish a Safety Policy
A clear policy is the foundation for internal traffic management. It should include goals for reducing interactions between mobile utilities and people, ensuring compliance with legal and corporate safety standards, and setting minimal safety requirements.
2 - Design Traffic Systems
Effective design starts with risk assessment. By mapping facility layouts and identifying points of interaction between pedestrians and vehicles, companies can proactively implement safety measures such as signage, barriers, and optimized traffic flows.
3 - Align Assets with Facility Needs
Matching mobile equipment, such as forklifts and automated guided vehicles (AGVs), to the facility’s design ensures smooth operations while minimizing risks.
4 - Train Personnel
Safety is everyone’s responsibility. Training programs should be tailored to operators, pedestrians, and coordinators, emphasizing situational awareness and proper use of equipment. Digital tools like pre-start checklists enhance compliance and provide traceability for audits.
5 - Evaluate and Evolve
Regular reviews ensure that safety measures adapt to evolving supply chain demands. Data-driven evaluations and audits help identify gaps and optimize processes.
Leveraging Technology for Safety
Jo highlighted how digital solutions are transforming warehouse safety. Innovations like presence detection systems, cameras mounted on forklifts, and automated safety features reduce risks in complex environments. For example, sensors can stop vehicles when people are detected nearby, while cameras improve visibility during operations at height.
Digital pre-start checklists were another standout innovation. These tools prevent complacency among operators by randomizing questions and ensuring thorough checks of equipment. By identifying and addressing issues early, companies avoid costly repairs and potential accidents.
Why Safety is a Strategic Investment
Investing in safety measures not only protects workers but also drives tangible business outcomes. Jo underscored the return on investment in safety through reduced equipment damage, lower maintenance costs, and improved productivity. Rombit’s approach to calculating the expected monetary value of safety further highlights how proactive measures save money in the long term.
One of the most significant challenges is demonstrating the return on investment (ROI) of safety measures. Jo highlighted several approaches:
- Preventative Maintenance Savings: Early detection of equipment damage reduces repair costs.
- Reduced Incident Costs: Avoiding accidents saves on potential medical expenses, legal fees, and downtime.
- Improved Product and Facility Safety: Preventing damage to goods and infrastructure contributes to operational efficiency.
The Future of Logistics Safety
As logistics operations evolve, hybrid environments combining human labor with automation will become more common. While technology like AGVs enhances efficiency, Jo reminded us that workers must remain vigilant and avoid over-reliance on automated systems. Training and awareness will continue to play a critical role in ensuring safety.
Conclusion
Jo’s insights provide a clear blueprint for improving safety in logistics operations. By combining robust policies, innovative technologies, and continuous evaluation, companies can create safer, more efficient warehouses. As Jo emphasized, safety isn’t just a requirement—it’s a strategic advantage that protects workers, assets, and the bottom line.
For companies looking to enhance their safety protocols, the lessons shared by Jo serve as a valuable guide to navigating the complexities of modern logistics.
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