How to Train Warehouse Staff for Employee PPE compliance in warehouses

Personal Protective Equipment (PPE) is a frontline defense in warehouse safety, especially in industries like building materials where heavy, sharp, and hazardous items are handled daily. But issuing PPE isn’t enough—warehouse staff must be properly trained to understand when, how, and why to use it.

If your facility is aiming to improve safety and reduce violations, here’s how to structure an effective PPE compliance training program that sticks.

• Start With a PPE Hazard Assessment

Before you train employees, you need to identify exactly what types of PPE are required in your warehouse. Conduct a hazard assessment that looks at:

Material handling tasks (e.g., lifting lumber, metal, or stone)

Equipment operation (e.g., forklifts, saws, packaging machines)

Chemical exposure (e.g., adhesives, treated wood)

Noise levels, air quality, and foot traffic zones

Based on your findings, determine the required PPE: gloves, steel-toe boots, high-visibility vests, hard hats, hearing protection, safety glasses, respirators, etc.

• Develop a Clear PPE Policy

Create a written PPE policy that outlines:

Required PPE for each role or task

Where and when PPE must be worn

How PPE should be inspected, maintained, and replaced

Disciplinary procedures for non-compliance

This policy should be included in employee handbooks and posted visibly in break rooms, locker areas, and work zones.

• Conduct Hands-On PPE Training

Effective training is more than a slideshow. Make it interactive and task-specific:

Demonstrate proper use: Show how to wear and adjust PPE correctly

Practice sessions: Let employees handle and wear gear in simulated work conditions

Inspection techniques: Teach staff to check for damage or wear (e.g., frayed straps, cracked helmets)

Donning and doffing: Train on how to put on and remove PPE safely to avoid contamination (especially with respirators or gloves)

Employees should walk away confident in both the purpose and the correct usage of their assigned gear.

• Reinforce With Visual Cues and Reminders

In busy warehouses, quick visual cues make a big difference. Use:

Signage at PPE-required entry points

Wall-mounted mirrors for self-checks

Posters or banners with proper PPE images

Color-coded zones where different PPE levels are required

These constant reminders help make PPE use second nature.

• Train Supervisors to Monitor and Correct Behavior

Supervisors are your first line of enforcement. Train them to:

Monitor PPE use on the floor

Address non-compliance in the moment—constructively, not punitively

Keep track of PPE inventory and reorder supplies as needed

Lead by example by wearing their own required PPE consistently

When supervisors reinforce standards daily, employees are more likely to follow suit.

• Keep Records of All Training

Document every training session with:

Sign-in sheets

Training materials used

Topics covered

Quiz or hands-on assessment results

This documentation is critical for regulatory compliance and will help during OSHA inspections or incident investigations.

• Offer Refresher Training and Updates

Don’t assume that one-time training is enough. Schedule periodic refreshers:

Annually for all employees

After any safety incident

When new PPE types or procedures are introduced

For new hires or temp workers

Keep training materials updated with the latest OSHA guidelines and industry-specific best practices.

Final Thoughts

PPE compliance isn’t about gear—it’s about behavior. Training warehouse staff to understand the why behind the rules builds a culture of safety that lasts. With the right combination of clear policies, hands-on instruction, and daily reinforcement, you can significantly reduce injuries, boost morale, and stay on the right side of regulatory inspections.

Make PPE training part of your safety foundation—not just a checkbox.