Product Overview

Summary: This Equipment Maintenance and Calibration SOP sets out a clear, repeatable system for keeping plant, tools and instruments safe, reliable and compliant. It helps Australian businesses manage inspection, servicing and calibration in line with WHS and quality requirements, reducing the risk of equipment-related incidents, downtime and regulatory non‑conformance.

Poorly maintained or out-of-calibration equipment can lead to serious safety incidents, product defects, environmental releases and costly unplanned downtime. This Equipment Maintenance and Calibration Safe Operating Procedure provides a structured, defensible approach to planning, performing and recording maintenance and calibration activities across plant, machinery, tools and measuring instruments. It guides your team through risk-based maintenance scheduling, pre-use inspections, isolation and lockout requirements, and the correct handling of non-conforming or out-of-tolerance equipment.

Developed with Australian WHS obligations in mind, this SOP helps you demonstrate that plant and equipment are maintained in a safe condition and that critical measurements are accurate and traceable. It supports both safety and quality systems by defining clear responsibilities, documentation requirements, and escalation pathways when faults or calibration failures are detected. Whether you operate in manufacturing, construction, laboratories, utilities or service industries, this procedure helps standardise maintenance and calibration practices across sites, improve audit readiness, and protect workers, customers and your brand.

Key Benefits

• Ensure plant and equipment are maintained in a safe, compliant condition in line with Australian WHS legislation.
• Reduce the likelihood of equipment failures, injuries and unplanned downtime through structured, preventive maintenance.
• Improve product and service quality by maintaining accurate, traceable calibration of instruments and measurement devices.
• Streamline maintenance and calibration planning, scheduling and record-keeping for easier audits and inspections.
• Strengthen accountability by clearly defining responsibilities, escalation processes and documentation requirements.

Who is this for?

• WHS Managers
• Maintenance Managers
• Operations Managers
• Production Supervisors
• Laboratory Managers
• Quality Assurance Managers
• Engineering Managers
• Electrical Supervisors
• Workshop Supervisors
• Calibration Technicians

Hazards Addressed

• Mechanical failure of poorly maintained plant and machinery
• Unexpected start-up or movement of equipment during servicing
• Electrical faults, short circuits and shock from degraded equipment
• Inaccurate measurements leading to unsafe product or process conditions
• Exposure to hazardous substances due to failed containment or control equipment
• Noise, vibration and ergonomic issues from worn or damaged tools
• Fire and ignition risks from faulty electrical or rotating equipment

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Equipment Register and Criticality Assessment
• 5.0 Preventive Maintenance Planning and Scheduling
• 6.0 Calibration Planning, Frequency and Acceptance Criteria
• 7.0 Pre-use Inspections and Operator Checks
• 8.0 Lockout, Tagout and Isolation Requirements for Maintenance
• 9.0 Detailed Maintenance Procedures (Routine and Corrective)
• 10.0 Calibration Procedures and Use of External Providers
• 11.0 Handling of Faults, Out-of-Tolerance and Non-conforming Equipment
• 12.0 Documentation, Records and Traceability Requirements
• 13.0 Risk Management and WHS Considerations
• 14.0 Tools, Test Equipment and Spare Parts Management
• 15.0 Training, Competency and Authorisation of Personnel
• 16.0 Audit, Review and Continuous Improvement
• 17.0 References, Applicable Standards and Legislation

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Part 4.1 Use of plant and Part 5.1 General duties of PCBUs
• Safe Work Australia – Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• AS/NZS ISO 9001: Quality management systems – Requirements (maintenance and calibration control)
• AS ISO/IEC 17025: General requirements for the competence of testing and calibration laboratories
• AS/NZS 3760: In-service safety inspection and testing of electrical equipment (where applicable)
• AS/NZS 4024 series: Safety of machinery (relevant parts for maintenance and inspection)