Product Overview

Summary: This Order Picking Safe Operating Procedure sets out a clear, safe and efficient method for picking stock in warehouses, distribution centres and storerooms. It helps Australian businesses control manual handling, mobile plant and racking risks while lifting accuracy, productivity and WHS compliance.

Order picking is often the most labour-intensive and risk‑prone activity in a warehouse, where staff are exposed to manual handling, moving equipment, working at height and time pressure. This Order Picking Safe Operating Procedure provides a structured, step‑by‑step method for planning, performing and completing picking tasks safely and accurately. It covers everything from pre‑start checks and understanding pick slips through to safe use of trolleys, pallet jacks and forklifts, working around other traffic, and final verification of orders before dispatch.

Developed for Australian conditions, this SOP helps businesses meet their WHS obligations while improving fulfilment performance. It reduces variability in how different workers pick stock, embeds safe manual handling and traffic management practices, and builds in quality controls to minimise mis‑picks, damaged goods and rework. Whether you operate a small storeroom or a high‑volume distribution centre, this procedure provides a defensible, auditable framework that supports training, onboarding, contractor management and continuous improvement in your warehouse operations.

Key Benefits

• Reduce manual handling injuries by standardising safe lifting, carrying and use of handling aids during order picking.
• Improve order accuracy by embedding clear verification, labelling and documentation steps into the picking workflow.
• Streamline onboarding and training by providing a simple, consistent procedure for all new and existing pickers.
• Minimise collisions and near misses by clarifying pedestrian and mobile plant interaction rules in picking areas.
• Support WHS compliance and audits by documenting a defensible, risk‑based approach to order picking activities.

Who is this for?

• Warehouse Managers
• Distribution Centre Managers
• Storepersons and Pickers
• Inventory Controllers
• Logistics and Supply Chain Managers
• WHS Managers and Advisors
• Operations Managers
• Team Leaders and Supervisors
• Online Fulfilment Coordinators
• Small Business Owners with Warehouse Operations

Hazards Addressed

• Musculoskeletal disorders from repetitive lifting, bending, twisting and overreaching
• Slips, trips and falls due to cluttered aisles, uneven surfaces and poor housekeeping
• Struck‑by incidents involving forklifts, pallet jacks and other mobile plant in shared aisles
• Falls from low‑level platforms, step ladders or accessing higher racking levels
• Crush and pinch injuries from handling pallets, cages and heavy cartons
• Falling objects from poorly stacked pallets or incorrect item retrieval from racking
• Fatigue and time‑pressure related errors leading to unsafe shortcuts and mis‑picks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Pickers, Supervisors, Forklift Operators, WHS Representatives)
• 4.0 Required Competencies and Training
• 5.0 Required PPE and Equipment for Order Picking
• 6.0 Pre‑Start Checks and Work Area Preparation
• 7.0 Order Documentation: Pick Slips, RF Scanners and System Use
• 8.0 Safe Manual Handling Techniques for Picking
• 9.0 Use of Trolleys, Pallet Jacks and Other Handling Aids
• 10.0 Working Around Forklifts and Mobile Plant in Aisles
• 11.0 Safe Access to Racking and Higher Storage Levels
• 12.0 Step‑by‑Step Order Picking Procedure
• 13.0 Quality Control: Item Verification, Labelling and Damage Checks
• 14.0 Housekeeping, Aisle Management and Storage Practices
• 15.0 Hazard Identification, Risk Controls and WHS Considerations
• 16.0 Incident, Near Miss and Damage Reporting
• 17.0 Fatigue Management and Work Pace Expectations
• 18.0 Environmental Considerations (Waste, Packaging and Recycling)
• 19.0 Recordkeeping and Documentation Requirements
• 20.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Model Work Health and Safety Act and Regulations (as implemented in relevant Australian jurisdictions)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Work Health and Safety Consultation, Cooperation and Coordination
• AS 4084: Steel storage racking
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001: Occupational health and safety management systems (for organisations using ISO frameworks)