Concept to Reality: Safety in Design through to Safety in Operations for new Automated Distribution Centre

A major national retailer listed on the ASX has recently brought to life one of the most advanced distribution centres in the country — a 65,000‑square‑metre facility, roughly the size of nine football fields, designed to accelerate fulfilment, reduce reliance on external storage, and uplift both efficiency and safety outcomes.

Across a 24-month period, FEFO Consulting has been embedded in this journey from day one. What sets this project apart is the continuity of health and safety expertise applied across the entire asset lifecycle — from early concept and Safety in Design through construction, commissioning, and now into operations and maintenance.

This integrated approach ensured risks were eliminated early, controls were engineered into the asset, and safety became a seamless part of how the facility operates.

Safety in Design: Engineering Out Risk Before It Begins

From the earliest planning stages, FEFO Consulting partnered with designers, engineers, and operational leaders to shape a facility that is inherently safer and optimised for high‑throughput automation.

Key contributions included:

• Early hazard identification – mapping foreseeable risks across automated systems, high‑bay storage, pedestrian interactions, and vehicle movements.
• Design optimisation – influencing layout, equipment selection, and traffic flows to remove or minimise risks at the source.
• Integrated engineering controls – embedding robust safeguards that reduce reliance on procedural controls later in the lifecycle.

By addressing risk at the design table, the project avoided costly redesigns and created a safer foundation for construction and future operations.

Construction Phase: Translating Safe Design Into Safe Delivery

As the project moved from drawings to reality, fefo Consulting ensured that the safety intent established in design was carried through the build.

Our involvement included:

• Contractor safety assurance – verifying alignment with Safety in Design requirements and ensuring critical controls were implemented correctly.
• Critical risk management – focusing on high‑energy hazards such as automated equipment installation, working at height, and mobile plant interactions.
• Interface coordination – supporting smooth collaboration between trades, designers, and client teams to prevent emerging risks.

This continuity protected the integrity of the design and ensured the facility was built safely and efficiently.

Operations & Maintenance: A Living, Adaptive Safety System

Now fully operational, the highly automated distribution centre is a core enabler of the retailer’s national supply chain. fefo Consulting continues to support the transition into steady‑state operations, ensuring safety systems evolve alongside the facility’s technology and throughput.

Our ongoing role includes:

• Operational readiness – preparing teams, processes, and systems for safe commissioning and go‑live.
• Maintenance risk controls – embedding safe systems of work for complex automated equipment and facility upkeep.
• Continuous improvement – reviewing performance, strengthening controls, and supporting the facility’s long‑term resilience.

The result is a safety system that is not static, but dynamic – aligned with the pace and complexity of a modern automated distribution environment.

A Seamless, Asset Lifecycle Approach to Safety

This project demonstrates the value of involving health and safety expertise early — and keeping it engaged throughout the asset lifecycle.

FEFO Consulting’s integrated approach delivered:

• Risk elimination at the source, long before operations began
• Engineering‑led controls that support automation and reduce human exposure
• Consistency and continuity from concept to construction to operations
• A safer, more efficient, future‑ready asset for a major national retailer

This is what modern safety leadership looks like: proactive, embedded, and lifecycle‑driven.