BlueSafe
Automation Safety SWMS

Automation Safety SWMS

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Automation Safety SWMS

Product Overview

This Automation Safety SWMS is a detailed Safe Work Method Statement designed to identify, control, and monitor risks associated with programming, testing, and maintaining automated machinery and control systems, supporting strong WHS compliance. It provides a comprehensive framework for managing hazards across multiple aspects of automation safety, including PLC programming, microprocessor controllers, testing automated systems, and upgrading industrial controls.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

  • Programming of PLC-controlled machinery, including safe access to control panels and isolation of plant during software changes
  • Reprogramming microprocessor-based controllers to ensure safe handling of live circuits, data connections, and firmware updates
  • Testing automated systems and sequences, including simulation, dry runs, and staged commissioning to minimise unexpected plant movement
  • Updating and retrofitting outdated industrial controls, including changeover planning, lockout/tagout, and verification of safety interlocks
  • Selection and configuration of safety-rated devices such as emergency stop circuits, light curtains, interlocks, and safety relays
  • Management of electrical hazards when working inside control cabinets, MCCs, and switchboards associated with automation systems
  • Control of stored energy hazards (pneumatic, hydraulic, mechanical) during programming and testing of automated plant
  • Use of laptops, programming tools, and test equipment in operational production areas, including trip, manual handling, and electrical risks
  • Coordination of automation works with production staff, including permit-to-work, communication protocols, and exclusion zones
  • Change management and version control of automation software, including backup, rollback procedures, and documentation updates
  • Emergency stop, isolation, and restart procedures following software changes or system faults
  • Working with third-party integrators, OEMs, and remote support while maintaining site safety and cybersecurity controls

Who is this for?

This SWMS is designed for automation engineers, industrial electricians, control systems technicians, OEM service technicians, and site supervisors responsible for automated plant and machinery.

Specific Job Steps & Hazards Covered

Job Step / Activity Potential Hazards
Pre-start planning and consultation
  • • Unclear scope of automation work
  • • Unidentified high-risk construction activities
  • • Conflicting work with other trades
  • • Inadequate emergency preparedness
  • • Inadequate change management
  • • Insufficient competence of personnel
Site isolation and lockout tagout
  • • Unintended energisation of machinery
  • • Unexpected movement of automated plant
  • • Release of stored pneumatic energy
  • • Release of stored hydraulic pressure
  • • Exposure to live electrical conductors
  • • Uncontrolled restart by other personnel
Physical inspection of plant and guards
  • • Missing or defeated interlocks
  • • Damaged fixed or interlocked guards
  • • Unprotected pinch and crush points
  • • Sharp edges and protrusions
  • • Inadequate emergency stop access
  • • Unlabelled or misleading controls
Electrical isolation and verification
  • • Contact with energised circuits
  • • Arc flash during testing
  • • Incorrect isolation of control circuits
  • • Backfeed from UPS or generators
  • • Static discharge to sensitive electronics
  • • Use of non-compliant test equipment
Programming PLC controlled machinery
  • • Unintended machine movement from logic changes
  • • Defeat of safety-related functions
  • • Incorrect sequencing causing collisions
  • • Loss of interlocks between machines
  • • Data corruption or loss of existing program
  • • Program changes without traceability
Reprogram microprocessor controllers
  • • Incorrect firmware or configuration loading
  • • Loss of critical protection settings
  • • Bricking of controllers during update
  • • Incompatible parameter sets
  • • Electrostatic discharge damage
  • • Uncontrolled restart after reboot
Updating outdated industrial controls
  • • Incompatibility between old and new hardware
  • • Unverified migration of safety functions
  • • Incorrect wiring of replacement IO
  • • Unexpected behaviour from legacy code
  • • Loss of historical data and diagnostics
  • • Extended downtime impacting operations
Testing and commissioning automated systems
  • • Unexpected start-up of machinery
  • • High-speed movement during tests
  • • Failure of new safety functions
  • • Collision between automated equipment
  • • Entrapment in robotic or conveyor cells
  • • Remote start from control room
Network, SCADA and cybersecurity changes
  • • Loss of control due to network failure
  • • Unauthorised access to control system
  • • Incorrect addressing causing mis-operation
  • • Time synchronisation errors
  • • Unsecured remote connections
  • • Malware introduction via portable media
Working around robots and conveyors
  • • Robotic arm striking personnel
  • • Crush and shear points on conveyors
  • • Inadequate safeguarding distances
  • • Unexpected restart after fault reset
  • • Obstruction of safety sensors
  • • Manual intervention inside guarded cells
Manual handling and access to panels
  • • Musculoskeletal strain from lifting gear
  • • Falls from ladders or steps
  • • Trip hazards from cables and tools
  • • Crush injuries from swinging panel doors
  • • Contact with hot components
  • • Poor lighting in switch rooms
Environmental and chemical hazards
  • • Inhalation of dusts in plant rooms
  • • Exposure to cleaning solvents
  • • Contact with coolant or lubricants
  • • Noise from automated machinery
  • • Heat stress near furnaces or kilns
  • • Poor ventilation in confined areas
Housekeeping, documentation and handover
  • • Residual trip hazards after work
  • • Incorrect or missing documentation
  • • Operators unaware of new risks
  • • Uncontrolled changes to live systems
  • • Loss of backup and recovery capability
  • • Confusion during future maintenance

Need to add specific site requirements?

Don't worry if a specific job step isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom job steps at no extra cost. We take care of the hard work—creating the hazards and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Safe Work Australia – Managing the Risks of Plant in the Workplace Code of Practice: Guidance on identifying and controlling risks associated with plant and automated machinery.
  • Safe Work Australia – Managing Electrical Risks in the Workplace Code of Practice: Requirements for electrical safety when working on control systems and powered equipment.
  • Safe Work Australia – How to Manage Work Health and Safety Risks Code of Practice: Framework for risk management applied to automation design, programming, and testing activities.
  • Safe Work Australia – Work Health and Safety Consultation, Cooperation and Coordination Code of Practice: Guidance for coordinating automation works with other trades and production personnel.
  • AS/NZS 3000 Electrical Installations (Wiring Rules): Fundamental electrical safety requirements relevant to control panels and associated wiring.
  • AS 4024 Safety of Machinery (series): Principles for the design and integration of safety-related parts of control systems and guarding of machinery.
  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
Standard SWMS Features (Click to Expand)
  • Operational guidelines, with a step-by-step approach to safe work
  • Possible hazards that may be encountered
  • Step-by-step safety procedures to follow
  • Before work starts – Guidelines and Checks
  • Safety measures and guides
  • Operational Safety Checks
  • Before and After Risk Ratings
  • Risk Assessment Matrix
  • High Risk Work Involved
  • Emergency Evacuation Procedure
  • Plant and Equipment
  • Qualifications and Permits
  • Specific Personal Protective Equipment (PPE)
  • Company Personnel Sign-off form

$96.8

Safe Work Australia Aligned