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Pick and Pack Order Fulfillment and Manual Handling Risk Assessment

Pick and Pack Order Fulfillment and Manual Handling Risk Assessment

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Pick and Pack Order Fulfillment and Manual Handling Risk Assessment

Product Overview

Identify and control organisational risks associated with Pick and Pack Order Fulfillment and Manual Handling through a structured, management-level WHS Risk Management framework. This Risk Assessment supports compliance with the WHS Act, demonstrates Due Diligence, and helps protect your business from operational and legal liability exposures.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Roles and Legal Compliance: Assessment of leadership responsibilities, allocation of WHS duties, consultation arrangements and evidence of due diligence in line with legislative requirements.
  • Warehouse Layout and Traffic Management: Management of pedestrian and mobile plant interaction, traffic flow design, segregation controls, signage and safe access/egress in pick and pack areas.
  • Manual Handling and Ergonomic Risk Management System: Evaluation of lifting, carrying, pushing, pulling and repetitive tasks, including engineering controls, task rotation and ergonomic design of workstations.
  • Plant, Tools and Equipment Management: Controls for forklifts, pallet jacks, trolleys and cutting tools, including selection, inspection, maintenance, pre-start checks and isolation procedures.
  • Storage, Racking and Large Metal Product Handling: Assessment of racking design and certification, load ratings, product stacking, stability controls and safe systems for handling bulky or heavy metal products.
  • Order Management, Workload Planning and Fatigue Control: Systems for balancing order volumes, shift patterns, KPIs, overtime and breaks to minimise fatigue, rushing and error-related incidents.
  • Training, Competency and Induction Systems: Protocols for verifying competency in manual handling, equipment use, traffic management and site-specific procedures, including refresher training and record keeping.
  • Packaging, Shrink Wrap Removal and Pallet Dismantlement: Management of cutting and unpacking tasks, pallet breakdown, banding and wrap removal to control laceration, puncture, trip and collapse risks.
  • Contractor and Labour Hire Management: Systems for prequalification, onboarding, supervision and performance monitoring of third-party workers involved in pick and pack and warehouse operations.
  • Incident Reporting, Investigation and Corrective Action: Processes for capturing near misses and incidents, conducting root cause analysis, implementing corrective actions and tracking close-out.
  • Emergency Preparedness, First Aid and Incident Response: Planning for fire, chemical, crush and medical emergencies, including evacuation procedures, first aid resources and drills.
  • Housekeeping, Waste Management and Environmental Conditions: Controls for floor cleanliness, debris, packaging waste, lighting, ventilation, noise and temperature in storage and packing zones.
  • Psychosocial Hazards, Consultation and Safety Culture: Assessment of workload pressures, conflict, bullying, communication channels and participation mechanisms that influence safety culture.
  • Change Management and Continuous Improvement: Governance of process changes, new products, new equipment and layout modifications, including risk review, consultation and monitoring of outcomes.

Who is this for?

This Risk Assessment is designed for Business Owners, Warehouse Managers, Operations Leaders and Safety Officers responsible for planning and overseeing pick and pack order fulfillment and manual handling activities across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Roles and Legal Compliance
  • • Lack of clearly defined WHS responsibilities for directors, managers, supervisors and workers under WHS Act 2011 and WHS Regulations
  • • Inadequate consultation mechanisms with workers and Health and Safety Representatives (HSRs)
  • • Absence of documented WHS policy specific to online order fulfilment, pick/pack and large metal product handling
  • • Failure to monitor changes in legislation, Australian Standards and industry guidance (e.g. Safe Work Australia model codes) relevant to manual handling and freight
  • • Poor integration of WHS obligations into contracts with labour hire providers, transport companies and suppliers
  • • Insufficient due diligence by officers (e.g. lack of WHS performance reporting and resourcing decisions)
2. Warehouse Layout, Traffic Management and Segregation
  • • Poor warehouse layout causing interaction between forklifts, pallet jacks and pedestrians in pick/pack areas
  • • Inadequate physical separation between heavy metal product storage, pallet dismantling areas and general picking aisles
  • • Congestion in loading docks and dispatch zones leading to collision and crush risks
  • • Insufficient design of racking and storage systems for large-scale metal items (e.g. overloading, unstable storage)
  • • Obstructed emergency exits and access routes due to staging of large orders and pallets
  • • Lack of formal traffic management plan for internal vehicles, visiting trucks and mobile plant
3. Manual Handling and Ergonomic Risk Management System
  • • Lack of formal hazardous manual task risk assessment for pick and pack, moving large metal products and pallet dismantlement
  • • Reliance on manual lifting and carrying of oversized, heavy or awkward metal items due to inadequate mechanical aids
  • • Inadequate system for job rotation and task variation, leading to repetitive strain and musculoskeletal disorders
  • • Poor design of pick faces, bench heights and packing stations causing awkward postures and overreach
  • • Absence of documented criteria for maximum manual lift weights and team lifting for bulky freight
  • • Insufficient assessment and control of manual forces involved in shrink wrap removal and prying apart timber pallets
4. Plant, Tools and Equipment Management (Forklifts, Pallet Jacks, Cutting Tools)
  • • Inadequate procurement controls for forklifts, reach trucks, overhead lifting devices and pallet jacks used with heavy metal freight
  • • Lack of preventative maintenance program for material handling equipment, resulting in failures under heavy loads
  • • Poor management of hand tools used for shrink wrap and pallet dismantlement (knives, utility blades, crowbars, nail pullers, saws)
  • • Insufficient guarding or safety features on cutting or sawing equipment used to dismantle timber pallets
  • • No formal system for pre-start inspections, fault tagging and removal from service of defective equipment
  • • Use of improvised lifting attachments or unverified lifting points for large metal products
5. Warehouse Systems for Storage, Racking and Large Metal Product Handling
  • • Inappropriate racking configuration for size, shape and weight of large metal products (beams, plates, bundles, long stock)
  • • Uncontrolled stacking of heavy or irregular metal items, increasing collapse or toppling risk
  • • Lack of system for verifying load ratings on racks, stillages and pallets used for heavy metal freight
  • • Inadequate procedures for segregating damaged racks, pallets or timber components from service
  • • Poorly controlled handling of long loads with forklifts or overhead devices, leading to instability and swing hazards
6. Order Management, Workload Planning and Fatigue Control
  • • Uncontrolled spikes in online orders leading to excessive workloads, rushing and cutting of safety corners in pick and pack activities
  • • Inadequate staffing levels and shift design for handling heavy, awkward metal products and high pick volumes
  • • Poor systems for managing overtime, extended shifts and consecutive workdays in warehouse and dispatch roles
  • • Lack of formal fatigue management procedures, particularly for early starts, night shifts or long commutes
  • • Insufficient communication between sales, planning and operations regarding lead times and realistic fulfilment capacity
7. Training, Competency and Induction Systems
  • • Workers and labour hire staff performing pick and pack or pallet dismantling tasks without demonstrated competency
  • • Induction programs failing to address specific hazards of large metal product handling, shrink wrap removal and timber pallet work
  • • No structured refresher training for manual handling, forklift operation and use of cutting tools
  • • Inadequate verification of high-risk licences, VOCs and previous experience for plant operators and leading hands
  • • Training materials not maintained or updated when plant, processes or layouts change
8. Safe Systems for Packaging, Shrink Wrap Removal and Pallet Dismantlement
  • • Uncontrolled cutting of shrink wrap and banding leading to lacerations and sudden release of tensioned loads
  • • Inconsistent methods for dismantling timber pallets, increasing risk of flying timber, splinters and impact injuries
  • • No standardised system for managing nails, sharp metal banding and offcuts created during pallet dismantling
  • • Poorly managed waste streams for plastic wrap, timber and metal banding causing trip hazards and blocked walkways
  • • Failure to assess and control noise and vibration exposure from mechanical pallet dismantling equipment
9. Contractor and Labour Hire Management
  • • Contractors and labour hire workers unfamiliar with site-specific hazards of handling large metal products and dismantling pallets
  • • Inconsistent WHS standards between host employer and labour hire/contractor organisations
  • • Lack of clarity over WHS responsibilities and supervision for contracted freight handlers and truck drivers in loading areas
  • • Inadequate verification of training, licences and medical fitness for high-risk tasks
  • • Failure to involve contractors in consultation processes and change management related to warehouse operations
10. Incident Reporting, Investigation and Corrective Action
  • • Under-reporting of near misses, minor injuries and property damage involving manual handling and material handling equipment
  • • Superficial investigations that do not address root causes related to systems, training and layout
  • • Delayed or incomplete implementation of corrective actions following incidents or audit findings
  • • Lack of trend analysis for manual handling injuries, cuts, crush injuries and pallet-related incidents
  • • Failure to meet statutory notification requirements for notifiable incidents under WHS Act 2011
11. Emergency Preparedness, First Aid and Incident Response
  • • Inadequate emergency response planning for crush injuries, severe cuts, falls from height and structural failures in racking or stacking
  • • Poor accessibility of first aid equipment and trained first aiders within warehouse and pallet dismantling zones
  • • Emergency procedures not accounting for visitors, contractors and truck drivers in loading areas
  • • Insufficient drills for fire, chemical spill (where applicable), and evacuation under realistic warehouse operating conditions
  • • Lack of specific response plans for entrapment under heavy metal products or pallet collapse
12. Housekeeping, Waste Management and Environmental Conditions
  • • Poor housekeeping leading to trip hazards from plastic wrap, banding, broken timber and offcuts in pick and pack aisles
  • • Dust, noise and poor ventilation in pallet dismantling and metal handling areas
  • • Insufficient lighting in racking aisles, loading docks and dismantling zones affecting visibility and accuracy
  • • Wet or contaminated floors around docks and storage areas causing slips when moving heavy loads
  • • Inadequate pest and vermin control where timber waste accumulates
13. Psychosocial Hazards, Consultation and Safety Culture
  • • High work pace and performance pressures associated with online order fulfilment targets for heavy and awkward items
  • • Limited worker involvement in decision-making about layout changes, new equipment and work methods
  • • Inadequate systems to manage work-related stress, bullying or conflict between teams (e.g. warehouse vs. transport)
  • • Fear of reprisal for reporting hazards, injuries or speaking up about unsafe practices
  • • Insufficient mechanisms for workers to provide feedback on manual handling difficulties and system issues
14. Change Management and Continuous Improvement
  • • Uncontrolled introduction of new products, particularly larger or heavier metal items, without reassessing manual handling and storage risks
  • • Process changes to picking strategies, WMS rules or racking configuration implemented without WHS review
  • • Installation of new plant or technology (e.g. conveyors, automated storage) without adequate commissioning and training
  • • Failure to capture lessons learned from incidents, audits and worker feedback into system improvements
  • • Temporary workarounds becoming permanent practice without risk assessment

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Code of Practice: How to Manage Work Health and Safety Risks: Guidance on systematic identification, assessment and control of workplace hazards.
  • Code of Practice: Hazardous Manual Tasks: Requirements for managing risks associated with manual handling and repetitive tasks.
  • Code of Practice: Managing the Risk of Plant in the Workplace: Guidance for the safe use, inspection and maintenance of forklifts, pallet jacks and other plant.
  • Code of Practice: Managing the Work Environment and Facilities: Standards for layout, amenities, lighting, ventilation and general warehouse conditions.
  • Code of Practice: Work Health and Safety Consultation, Cooperation and Coordination: Requirements for worker engagement, contractor coordination and safety communication.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 4084 (Series): Steel storage racking — Design, installation, use and inspection requirements.
  • AS 2359 (Series): Powered industrial trucks — Safety requirements for forklifts and similar equipment.
  • AS ISO 45001:2018: Occupational health and safety management systems — Requirements with guidance for use.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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