Incident reporting and near miss systems

Why this matters

Incident reporting and near miss systems is part of a broader system of warehouse risk control. A good warehouse does not rely on memory alone. It uses layout, signs, training, supervision, maintenance records and security controls that can be checked.

Use this guide as a planning document before changing layout, introducing new plant, engaging contractors or upgrading security.

Step-by-step review

1. Define the area, task, people involved and equipment used.
2. Identify hazards from traffic, plant, height, manual handling, electricity, security, emergency access and environment.
3. Check existing controls and whether workers actually follow them.
4. List practical improvements, assign owners and set due dates.
5. Review records after incidents, near misses, layout changes or new shifts.

Controls to consider

• Physical separation: barriers, bollards, rails, cages, marked walkways and locked doors.
• Engineering controls: lighting, mirrors, cameras, alarms, interlocks, guards and speed controls.
• Administrative controls: procedures, inductions, toolbox talks, registers, permits and supervisor checks.
• Behavioural controls: clear site rules, reporting expectations and escalation paths.
• Verification: inspections, maintenance logs, CCTV checks, incident reviews and worker consultation.

Common mistakes

• Copying a template without making it site-specific.
• Leaving blind corners or shared zones unmanaged.
• Buying equipment before defining the risk or coverage objective.
• Failing to review controls after a near miss.
• Not keeping records that prove the control was checked.

Useful references

Start with Safe Work Australia traffic management guide for warehousing. Always check current state or territory regulator requirements.