Standard Operating Procedure for Implementing Safety Training Programs for Warehouse Personnel

Department	Warehouse / Quality Assurance / Safety
SOP No.	SOP/RM/186/2025
Supersedes	SOP/RM/186/2022
Page No.	Page 1 of 15
Issue Date	21/04/2025
Effective Date	28/04/2025
Review Date	21/04/2026

1. Purpose

This Standard Operating Procedure (SOP) outlines the process for implementing safety training programs for warehouse personnel to ensure workplace safety, regulatory compliance, and adherence to Good Manufacturing Practices (GMP).

2. Scope

This SOP applies to all warehouse personnel, including permanent, temporary, and contract staff involved in raw material handling, storage, and warehouse operations.

3. Responsibilities

• Warehouse Manager: Ensure all staff receive appropriate safety training and maintain training records.
• Quality Assurance (QA) Team: Verify that training programs meet regulatory standards and conduct periodic audits of training records.
• Safety Officer: Design, deliver, and monitor safety training programs, and ensure compliance with safety protocols.

4. Accountability

The Safety Manager is accountable for the design and implementation of safety training programs, while the Warehouse Manager ensures participation and compliance. The QA Manager oversees the validation and documentation of training activities.

5. Procedure

5.1 Training Program Development

1. Identifying Training Needs:
   • Conduct a risk assessment to identify specific safety training needs based on job roles and warehouse activities.
   • Document the identified needs in the Training Needs Assessment Log (Annexure-1).
2. Training Program Design:
   • Develop training modules covering topics such as material handling, hazardous material safety, fire safety, and emergency response.
   • Record program details in the Training Program Design Log (Annexure-2).

5.2 Training Delivery

1. Scheduling Training Sessions:
   • Schedule training sessions regularly, ensuring all employees attend mandatory safety programs.
   • Document schedules in the Training Schedule Log (Annexure-3).
2. Conducting Training:
   • Deliver training through a combination of lectures, demonstrations, and hands-on practice.
   • Record attendance and training completion in the Training Attendance Log (Annexure-4).

5.3 Evaluation and Certification

1. Training Evaluation:
   • Evaluate participants’ understanding through quizzes, practical assessments, and feedback sessions.
   • Document evaluation results in the Training Evaluation Log (Annexure-5).
2. Issuing Certificates:
   • Issue safety training completion certificates to participants who pass the evaluation.
   • Maintain records in the Certification Log (Annexure-6).

5.4 Monitoring and Continuous Improvement

1. Post-Training Monitoring:
   • Monitor employee performance post-training to ensure application of safety practices in daily operations.
   • Document monitoring activities in the Post-Training Monitoring Log (Annexure-7).
2. Feedback and Updates:
   • Collect feedback from participants and update training content periodically to reflect current regulations and best practices.
   • Record feedback and updates in the Training Feedback and Update Log (Annexure-8).

5.5 Documentation and Review

1. Maintaining Training Records:
   • Ensure all training records are complete, accurate, and readily accessible for audits and inspections.
   • Document record-keeping activities in the Training Record Maintenance Log (Annexure-9).
2. Periodic Audits:
   • Conduct audits of training programs to ensure compliance with regulatory standards and internal policies.
   • Document audit results in the Training Audit Log (Annexure-9).

6. Abbreviations

• SOP: Standard Operating Procedure
• GMP: Good Manufacturing Practice
• QA: Quality Assurance
• PPE: Personal Protective Equipment

7. Documents

1. Training Needs Assessment Log (Annexure-1)
2. Training Program Design Log (Annexure-2)
3. Training Schedule Log (Annexure-3)
4. Training Attendance Log (Annexure-4)
5. Training Evaluation Log (Annexure-5)
6. Certification Log (Annexure-6)
7. Post-Training Monitoring Log (Annexure-7)
8. Training Feedback and Update Log (Annexure-8)
9. Training Record Maintenance Log (Annexure-9)

8. References

• OSHA Standards for Workplace Safety
• 21 CFR Part 211 – Current Good Manufacturing Practice for Finished Pharmaceuticals
• WHO Good Practices for Health and Safety in the Pharmaceutical Industry

9. SOP Version

Version: 2.0

10. Approval Section

	Prepared By	Checked By	Approved By
Signature
Date
Name
Designation
Department

Annexure-1: Training Needs Assessment Log

Date	Employee Name	Assessment Area	Identified Training Need	Assessed By
21/04/2025	Ravi Kumar	Hazardous Material Handling	Advanced PPE Use	Neha Verma

Annexure-2: Training Program Design Log

Date	Training Module	Content Summary	Designed By
21/04/2025	Fire Safety	Evacuation procedures and extinguisher use	Amit Joshi

Annexure-3: Training Schedule Log

Date	Training Topic	Scheduled Date	Trainer
21/04/2025	Fire Safety	25/04/2025	Kiran Patel

Annexure-4: Training Attendance Log

Date	Employee Name	Training Topic	Trainer
25/04/2025	Ravi Kumar	Fire Safety	Kiran Patel

Annexure-5: Training Evaluation Log

Date	Employee Name	Evaluation Score	Evaluator
25/04/2025	Ravi Kumar	85%	QA Supervisor

Annexure-6: Certification Log

Date	Employee Name	Certificate Issued	Issued By
26/04/2025	Ravi Kumar	Fire Safety Certification	QA Manager

Annexure-7: Post-Training Monitoring Log

Date	Employee Name	Observed Performance	Monitored By
27/04/2025	Ravi Kumar	Proper extinguisher handling observed	Safety Officer

Annexure-8: Training Feedback and Update Log

Date	Employee Name	Feedback Provided	Updated By
28/04/2025	Ravi Kumar	Suggested more hands-on practice	QA Manager

Annexure-9: Training Record Maintenance Log

Date	Document Name	Status	Updated By
29/04/2025	Training Attendance Log	Updated	Sanjay Mehta

Revision History:

Revision Date	Revision No.	Revision Details	Reason for Revision	Approved By
01/01/2024	1.0	Initial Version	New SOP Implementation	QA Head
21/04/2025	2.0	Expanded training procedures and feedback mechanisms.	Regulatory Update	QA Head