Product Overview

This Plant Maintenance Repair and Commissioning Safe Work Method Statement (SWMS) is designed to identify hazards, assess risks, and implement effective controls for plant and machinery work on Australian worksites. It is a comprehensive document that covers multiple aspects of plant maintenance, repair and commissioning to support robust WHS compliance and risk management.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Adjusting complex machinery settings, guards, and components to ensure safe and efficient operation
• Changing machine fittings, attachments, and tooling using correct isolation and lock-out procedures
• Cleaning machinery post-operation to remove product build-up, dust, and debris while controlling exposure to moving parts and chemicals
• Cleaning complex machinery internals and externals, including managing confined or restricted access areas
• Conducting regular maintenance, inspections, and servicing in line with manufacturer’s recommendations and site procedures
• Identifying and dealing with faults in the system, including fault-finding, testing, and safe rectification
• Managing and isolating faulty equipment to prevent inadvertent use and ensure safe repair or removal from service
• Designing and reviewing safety systems for plant, including interlocks, guarding, and emergency stop arrangements
• Disassembling plant and machinery components safely, including control of stored energy and heavy parts
• Dismantling, cleaning, and maintaining machinery with appropriate manual handling, lifting, and ergonomic controls
• Dismantling heavy machinery using cranes, hoists, jacks, and lifting equipment with exclusion zones and load control
• Equipment assembly and installation, including alignment, securing, and commissioning checks before operation
• Fitting and removing rollers, bearings, and rotating components while managing pinch points and crush hazards
• Accessing and greasing nipples, lubrication points, and moving parts without exposure to in-running nip points
• Establishing safe greasing sequences and maintenance routines to minimise downtime and prevent mechanical failure
• Lock-out/tag-out (LOTO) and isolation procedures for electrical, hydraulic, pneumatic, and mechanical energy sources
• Use of hand tools, power tools, and mobile plant during maintenance and repair activities

Who is this for?

This SWMS is designed for maintenance fitters, mechanical trades, plant operators, commissioning engineers, and site supervisors responsible for plant maintenance, repair, and commissioning activities.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Safe Work Australia – Managing Risks of Plant in the Workplace Code of Practice: Guidance on hazard identification, risk assessment, and control measures for plant
• Safe Work Australia – How to Manage Work Health and Safety Risks Code of Practice: Framework for systematic risk management
• Safe Work Australia – Managing the Work Environment and Facilities Code of Practice: Requirements for safe access, egress, amenities, and general work environment
• Safe Work Australia – Hazardous Manual Tasks Code of Practice: Controls for lifting, carrying, pushing, pulling, and awkward postures during maintenance
• Safe Work Australia – Confined Spaces Code of Practice: Applicable where maintenance or cleaning occurs in confined or restricted plant areas
• AS/NZS 4024 Safety of Machinery (series): Guidance on machinery guarding, interlocks, emergency stops, and safe design principles
• AS/NZS 3000 Electrical Installations (Wiring Rules): Electrical safety requirements relevant to isolation and maintenance of plant
• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017