Product Overview

Summary: This Manual Handling and Ergonomics Safe Operating Procedure sets out clear, practical steps to prevent musculoskeletal injuries across your workplace. It guides workers and supervisors in identifying manual handling risks, applying ergonomic principles, and implementing safe work techniques that align with Australian WHS requirements.

Musculoskeletal disorders (MSDs) from poor manual handling and sub‑optimal ergonomics remain one of the most common and costly injury types across Australian workplaces. This Manual Handling and Ergonomics SOP provides a structured, step‑by‑step approach to identifying hazardous manual tasks, assessing the level of risk, and implementing practical controls such as task redesign, mechanical aids and safe lifting techniques. It supports organisations in meeting their primary duty of care under WHS legislation while giving workers clear, easy‑to‑follow instructions for everyday tasks.

The procedure is designed to be flexible enough to apply across a wide range of environments, from warehouses and manufacturing plants to healthcare, construction and office settings. It addresses both physical manual tasks—lifting, pushing, pulling, carrying, repetitive movements—as well as workstation ergonomics, including screen setup, seating, and task rotation. By implementing this SOP, businesses can reduce injury rates, improve productivity, and demonstrate due diligence to regulators, insurers and workers through a documented, defensible system for managing manual handling and ergonomic risks.

Key Benefits

• Reduce the incidence and severity of musculoskeletal injuries linked to manual handling and poor ergonomics.
• Ensure alignment with Australian WHS legislation and the Hazardous Manual Tasks Code of Practice.
• Standardise safe manual handling techniques and ergonomic practices across all sites and shifts.
• Improve worker comfort, productivity and job satisfaction through better task and workstation design.
• Support effective training, induction and refresher programs with clear, documented procedures.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• Site Supervisors
• Warehouse and Logistics Managers
• Production and Operations Managers
• Aged Care and Disability Support Supervisors
• Office and Facilities Managers
• Injury Management and Return to Work Coordinators
• Human Resources Managers
• Training and Induction Coordinators

Hazards Addressed

• Musculoskeletal disorders from lifting, carrying, pushing and pulling loads
• Back, neck and shoulder strain from awkward postures and overreaching
• Repetitive strain injuries from repetitive or sustained movements
• Fatigue and discomfort from poorly set up workstations and seating
• Crush and pinch injuries from unsafe load handling or use of trolleys and mechanical aids
• Slips, trips and falls associated with carrying loads and obstructed walkways

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Key Terms (Manual Handling, Hazardous Manual Task, Ergonomics, MSDs)
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Workers, HSRs)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification for Manual Handling and Ergonomic Risks
• 6.0 Risk Assessment Process for Hazardous Manual Tasks
• 7.0 Hierarchy of Control for Manual Handling and Ergonomics
• 8.0 Task and Workplace Design Principles (Elimination, Engineering and Administrative Controls)
• 9.0 Safe Manual Handling Techniques (Lifting, Lowering, Carrying, Pushing and Pulling)
• 10.0 Use of Mechanical Aids and Handling Equipment (Trolleys, Pallet Jacks, Hoists)
• 11.0 Office and Workstation Ergonomics (Desk, Chair, Monitor, Keyboard and Mouse Setup)
• 12.0 Job Design, Task Rotation and Break Management
• 13.0 Training, Induction and Competency Requirements
• 14.0 Pre‑existing Injuries, Fitness for Work and Early Reporting of Discomfort
• 15.0 Incident, Near Miss and Symptom Reporting Procedures
• 16.0 Monitoring, Review and Continuous Improvement of Manual Handling Controls
• 17.0 Recordkeeping and Documentation Requirements
• 18.0 Appendices – Sample Risk Assessment Checklist and Ergonomic Setup Guide

Legislation & References

• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• Model Work Health and Safety Act 2011 (as implemented in relevant states and territories)
• Model Work Health and Safety Regulations 2011 – Part 4.2 Hazardous Manual Tasks
• AS/NZS ISO 45001:2018 Occupational health and safety management systems
• Comcare and state-based regulator guidance material on Office Ergonomics and Musculoskeletal Disorders