Case Study: How Monthly Racking Inspections Helped Build a Safer Warehouse at Makita Manufacturing

In March 2025, UK Rack Inspection Ltd were invited to support operations at Makita Manufacturing in Telford.

Makita had previously been undertaking racking inspections, but were looking for a more structured, consistent, and proactive approach to managing racking safety across their large and complex facility.

Following initial discussions, UK Rack Inspection Ltd were appointed to carry out monthly inspections as part of a planned and proactive safety strategy. The aim was not simply to identify damage, but to introduce a consistent system that would support long-term improvement across the whole warehouse operation.

A Structured Approach to Monthly Racking Inspections

Because of the size and complexity of the site, the facility was divided into three key areas. This allowed inspections to be carried out on a rolling three-month cycle, ensuring that the entire site was reviewed regularly while keeping the process manageable for the Makita team.

This approach created a clear and consistent inspection regime. It also made it easier to plan remedial works, prioritise actions, and keep improvements moving forward without overwhelming day-to-day operations.

For a busy warehouse environment, that level of structure is often the key to making warehouse racking inspections both practical and effective.

Inspections Carried Out to SEMA Standards

Each monthly inspection was carried out to full Storage Equipment Manufacturers Association standards, with all findings classified using the recognised Red, Amber, Green (RAG) system. This provided clear visibility of risk, enabled the Makita team to prioritise actions, and supported more effective ongoing management of the racking system.

Using a recognised inspection standard gave the site a more consistent framework for decision-making. Rather than relying on ad hoc observations or reactive fixes, Makita were able to work from a clear picture of the condition of their racking and the level of action required in each area.

What We Found Across the Warehouse

From the outset, standards across the site varied. The VNA areas were operating to a very high standard, with minimal damage recorded, something that remains consistent today. This reflected a strong level of control and good operational discipline within those parts of the facility.

However, within the larger warehouse areas, a number of issues were identified. These included incorrectly installed frames, damaged structural components, and load notices that did not reflect the current configuration of the racking. While some areas showed only minor damage, others required more significant attention and intervention.

This is often the reality in large and established warehouse environments. Different areas can evolve over time, layouts can change, and damage can build up gradually if there is not a structured inspection programme in place to monitor it properly.

From Racking Inspections to Meaningful Improvement

Over the course of the year, we worked closely with the Makita team to address these issues, supporting them not only through inspections but also through practical maintenance training. This enabled their team to take greater ownership of their racking systems, building both confidence and competence in identifying and rectifying damage in-house.

This is an important part of long-term racking safety. Inspections are essential, but the best outcomes are achieved when site teams also understand what they are looking at, what damage matters, and how to respond appropriately. That is where racking awareness training and practical maintenance support can make a real difference.

Over 900 Corrective Actions Completed

As a result of this collaboration, Makita carried out extensive remedial works across the site, completing over 900 corrective actions in the past year alone. These ranged from replacing damaged bracing and securing loose floor fixings, through to changing uprights, replacing beams, and correcting frame orientation.

This volume of corrective work shows what can be achieved when findings are not just recorded, but acted upon in a structured and consistent way. It also highlights the value of regular inspections in helping businesses work through issues progressively, rather than waiting until damage becomes a larger operational or safety problem.

Building In-House Ownership of Racking Safety

What has been particularly impressive is the level of diligence shown by the Makita team. In many cases, during remedial works, they identified underlying issues that were not immediately visible during inspection, demonstrating a genuine understanding of their systems and a commitment to doing the job properly.

That level of engagement is what turns a basic inspection programme into a genuine safety improvement process. Instead of relying entirely on external input, Makita developed stronger internal awareness and ownership of their warehouse racking safety standards.

This is exactly what many businesses aim for. A professional inspection programme provides the structure, but real improvement happens when warehouse teams become actively involved in maintaining standards on site.

A Working Partnership Built on Shared Standards

As a reflection of this strong working relationship, and as a proud partner, UK Rack Inspection Ltd have aligned our own maintenance training with Makita by upgrading our training equipment to a full suite of Makita tools. This ensures that both our team and our candidates are working with high-quality, industry-leading equipment, further strengthening the connection between our businesses.

While this detail sits outside the inspection process itself, it reflects the wider nature of the partnership. This has not been a one-off inspection contract or a purely transactional arrangement. It has been an ongoing collaboration built around consistency, trust, and a shared commitment to improving standards.

Why This Racking Inspection Case Study Matters

A year on, this partnership stands as a clear example of what can be achieved when inspections, training, and on-site engagement come together. Makita have demonstrated outstanding commitment to improving their racking safety standards, and we are proud to support them on that journey.

For other businesses, this case study shows that the most effective pallet racking inspection programmes do more than produce reports. They create a framework for action, help prioritise maintenance, support internal development, and drive measurable improvement over time.

Conclusion

This is more than just an inspection contract. It is a working partnership built on trust, consistency, and shared standards.

At UK Rack Inspection Ltd, we believe the best results are achieved when inspection is not just a report, but the start of meaningful improvement. Makita have embraced that approach, and the results speak for themselves.

If your business is looking for a more structured and proactive approach to managing warehouse racking safety, our racking inspection services can help you build a clearer, more consistent path to compliance and long-term improvement.