Pick and Pack Order Fulfillment and Manual Handling Risk Assessment

Product Overview

This risk assessment covers pick and pack order fulfilment, manual handling, packing, staging and dispatch activities. It supports planning work areas, identifying handling and interaction hazards, and managing risks throughout the task.

Activities & Risks Covered

This assessment addresses activities and risks including:

• Plan pick priorities, work areas and communication before work starts
• Pick items from shelves and racking
• Lift, lower and carry orders manually
• Use trolleys, pallet jacks and handling aids
• Manage pedestrian interaction with mobile plant
• Pack, label and complete bench work
• Stack, stage and palletise orders
• Manage slips, trips, lighting, ventilation and fatigue conditions
• Load, dispatch and hand over packed orders
• Respond to incidents, provide first aid and review controls

Who is this for?

For contractors, workers, supervisors and businesses involved in pick and pack order fulfilment and manual handling.

Activities & Hazards Covered

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

• Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
• Model guidance: Model Code of Practice: Managing the risk of fatigue at work — Provide sufficient breaks while at work; p. 30.
• Model guidance: Model Code of Practice: How to manage work health and safety risks — 5. Step 4 — How to review controls; p. 27.
• Model guidance: Model Code of Practice: Managing the work environment and facilities — 2. The work environment; p. 13.
• Model guidance: Model Code of Practice: Managing risks of plant in the workplace — Plant hazard identification — Traffic movements in the workplace; p. 17.
• Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
• Model guidance: Model Code of Practice: Work health and safety consultation, cooperation and coordination — 3. What is effective consultation?; p. 13.

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Standard Risk Assessment Features (Click to Expand)

• Activity-specific hazard identification and control measures
• Initial and residual risk ratings
• Assigned responsible persons for each activity
• Risk matrix and assessment classification
• Review, monitoring and sign-off fields
• Site-specific customisation before use