Product Overview

Summary: This Maintenance and Repair Safe Operating Procedure sets out clear, safe and consistent methods for inspecting, servicing and repairing plant, equipment and facilities in Australian workplaces. It helps you control maintenance-related hazards, minimise downtime and demonstrate compliance with WHS duties for safe systems of work.

Unplanned breakdowns, ad‑hoc repairs and inconsistent maintenance practices can quickly lead to unsafe equipment, production delays and avoidable incidents. This Maintenance and Repair Safe Operating Procedure provides a structured framework for how maintenance work is requested, prioritised, planned, carried out and signed off, with a strong focus on WHS risk management. It supports organisations to move away from reactive, informal approaches and towards a documented, defensible system that is easy for workers and contractors to follow.

Tailored for Australian workplaces, the SOP integrates WHS obligations into everyday maintenance tasks, including isolation and lockout, verification of competency, use of permits, and post‑maintenance safety checks. It helps you control the risks associated with working on energised plant, working at heights, confined spaces, manual handling and use of tools and equipment. By implementing this procedure, businesses can reduce equipment‑related incidents, extend asset life, improve reliability and demonstrate due diligence in the event of audits, inspections or incidents.

Key Benefits

• Ensure maintenance and repair activities are carried out safely, consistently and in line with Australian WHS requirements.
• Reduce the likelihood of equipment‑related incidents, injuries and unplanned downtime.
• Standardise how maintenance requests, approvals, isolations and sign‑offs are managed across sites and teams.
• Demonstrate due diligence and compliance during regulator inspections, client audits and insurance reviews.
• Improve asset reliability and lifespan through structured inspections, preventive maintenance and documented repairs.

Who is this for?

• Maintenance Supervisors
• Facilities Managers
• WHS Managers
• Operations Managers
• Plant and Workshop Supervisors
• Mechanical and Electrical Technicians
• Property and Asset Managers
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Contact with moving or rotating plant during maintenance
• Electric shock or arc flash when working on or near energised electrical equipment
• Stored energy release (hydraulic, pneumatic, gravitational, spring‑loaded components)
• Falls from height during maintenance on roofs, platforms or elevated plant
• Slips, trips and falls in workshops, plant rooms and maintenance areas
• Exposure to hazardous chemicals, oils, greases and cleaning agents
• Noise and vibration from powered tools and machinery
• Manual handling injuries from lifting, pushing or carrying parts and equipment
• Use of hand and power tools (cuts, punctures, eye injuries, flying particles)
• Fire and explosion risks from hot work, flammable vapours or combustible dust
• Confined space hazards during inspection, cleaning or repair activities
• Inadequate guarding or safety devices following maintenance or modification

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Planning and Scheduling of Maintenance Activities
• 5.0 Maintenance Request, Assessment and Approval Process
• 6.0 Pre‑Work Risk Assessment (JSA / SWMS) and Permits
• 7.0 Isolation, Lockout/Tagout and Verification of De‑energisation
• 8.0 Tools, Equipment and Personal Protective Equipment (PPE) Requirements
• 9.0 Step‑by‑Step Procedure for Routine Maintenance
• 10.0 Step‑by‑Step Procedure for Breakdown and Emergency Repairs
• 11.0 Working with Contractors and Site Induction Requirements
• 12.0 Hazard Identification, Risk Controls and Hierarchy of Control
• 13.0 Hot Work, Confined Space and Working at Heights Considerations
• 14.0 Post‑Maintenance Inspection, Testing and Commissioning
• 15.0 Handover, Sign‑off and Return to Service
• 16.0 Documentation, Recordkeeping and Asset History
• 17.0 Housekeeping, Waste Management and Environmental Considerations
• 18.0 Incident, Near Miss and Defect Reporting During Maintenance
• 19.0 Training, Communication and Review of the Procedure
• 20.0 Continuous Improvement and Audit Checklist

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• AS/NZS 4024 series: Safety of machinery
• AS/NZS 3000: Electrical installations (Australian/New Zealand Wiring Rules)
• AS/NZS 3760: In‑service safety inspection and testing of electrical equipment
• AS/NZS ISO 31000: Risk management – Guidelines
• AS 1657: Fixed platforms, walkways, stairways and ladders – Design, construction and installation