Product Overview

Summary: This Key Cutting Safe Operating Procedure provides a clear, step-by-step method for cutting and duplicating keys safely, accurately and securely in Australian workplaces. It helps control risks associated with cutting machinery, metal swarf, and access control, while standardising how staff verify authority, handle customer keys and protect sensitive security information.

Key cutting appears straightforward, but it involves rotating machinery, sharp tools, metal swarf, and significant security implications if not managed correctly. This Key Cutting Safe Operating Procedure sets out a consistent, WHS-aligned method for preparing, operating and maintaining key cutting equipment while ensuring only authorised keys are duplicated. It provides a practical, plain-English framework suitable for hardware stores, locksmiths, service kiosks, and facilities teams across Australia.

The SOP addresses both safety and security: from pre-use inspection of key cutting machines and selection of appropriate personal protective equipment, through to verification of customer identity and authorisation for restricted or master-key systems. It helps businesses reduce the likelihood of hand injuries, eye injuries and equipment damage, while also minimising the risk of unauthorised duplication of keys that could compromise premises, plant or asset security. By implementing this procedure, organisations can demonstrate due diligence under Australian WHS laws, improve staff training consistency, and give customers confidence that key cutting is carried out professionally and securely.

Key Benefits

• Ensure safe use of key cutting machinery, reducing the risk of cuts, eye injuries and entanglement.
• Standardise customer verification and authorisation checks for key duplication, protecting premises security.
• Reduce equipment damage and downtime through structured pre-use inspections and maintenance steps.
• Improve training quality and consistency for new and existing key cutting staff.
• Demonstrate compliance with Australian WHS obligations and internal security policies for access control.

Who is this for?

• Hardware Store Managers
• Locksmiths
• Retail Key Cutting Operators
• Facilities and Maintenance Managers
• Security Managers
• WHS Coordinators
• Shopping Centre Services Managers
• Apprentice Locksmiths

Hazards Addressed

• Contact with rotating cutting wheels and moving parts
• Eye injuries from flying metal swarf and debris
• Hand and finger lacerations from sharp keys and key blanks
• Noise exposure from key cutting machinery
• Electrical hazards from damaged cords, plugs or equipment
• Manual handling strains from handling bulk key blanks or key boards
• Unauthorised duplication of restricted, master or security keys
• Slips and trips from metal swarf or offcuts on floors and work surfaces

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Key Types (standard, restricted, master, security keys)
• 3.0 Roles and Responsibilities
• 4.0 Required Competencies and Training
• 5.0 Tools, Equipment and Safety Devices
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre-Use Inspection and Setup of Key Cutting Machine
• 8.0 Customer Verification and Authorisation for Key Cutting
• 9.0 Step-by-Step Key Cutting Procedure
• 10.0 Quality Checks, Finishing and Labelling of Keys
• 11.0 Housekeeping, Waste Management and Swarf Disposal
• 12.0 Security Controls for Restricted and Master Keys
• 13.0 Hazard Identification and Risk Control Measures
• 14.0 Emergency Procedures and Incident Reporting
• 15.0 Maintenance, Servicing and Isolation of Equipment
• 16.0 Training, Induction and Competency Records
• 17.0 Document Control and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: How to manage work health and safety risks
• AS/NZS 4024 series: Safety of machinery (as applicable to key cutting equipment)
• AS/NZS 1319: Safety signs for the occupational environment
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161 series: Occupational protective gloves