Product Overview

This Safe Work Method Statement (SWMS) sets out the high-level hazards, risks, and step-by-step controls for Pick and Pack Order Fulfillment and Manual Handling activities in warehouse and logistics environments. It is a comprehensive, integrated document that covers multiple aspects of order picking, packing, pallet work and manual handling to support strong WHS compliance and safer operations.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Online order fulfilment workflows, including receiving, locating, picking and staging customer orders
• Safe pick, pack and organisation of large-scale metal products, including handling of awkward, sharp or heavy items
• Picking freight from racking, floor stacks and staging areas while managing traffic and pedestrian interaction risks
• Removing shrink wrap from pallets using knives or cutters with controls for cuts, punctures and rebound injuries
• Manual dismantlement of timber and wood pallets, including nail and splinter hazards, and use of appropriate tools
• Selection and use of mechanical aids (trolleys, pallet jacks, conveyors) to reduce manual handling and overexertion
• Safe lifting, carrying and team lifting techniques for cartons, metal products and bulky or irregular loads
• Stacking, wrapping and securing pallets and freight to prevent collapse, movement and crush injuries
• Housekeeping and layout controls to maintain clear aisles, emergency exits and safe access to storage locations
• Segregation of pedestrian and mobile plant (forklifts, pallet jacks, delivery vehicles) in pick and pack zones
• Use, inspection and maintenance of personal protective equipment (PPE) such as gloves, safety footwear and eye protection
• Incident response, first aid and reporting procedures for strains, sprains, cuts and impact injuries
• Induction, training and supervision requirements for warehouse staff, casuals and contractors involved in order fulfilment

Who is this for?

This SWMS is designed for warehouse and logistics operators, online retailers, freight and distribution centres, metal product suppliers, and site supervisors managing pick and pack and manual handling activities.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Model Code of Practice: How to Manage Work Health and Safety Risks – Guidance on identifying hazards, assessing and controlling risks in warehouse and logistics environments
• Model Code of Practice: Hazardous Manual Tasks – Requirements and controls for manual handling, lifting, carrying and repetitive tasks
• Model Code of Practice: Managing the Work Environment and Facilities – Guidance on safe layout, amenities, lighting and access in warehouses
• Model Code of Practice: Managing Risks of Plant in the Workplace – Controls for pallet jacks, conveyors and other mechanical aids used in pick and pack operations
• AS 4084 Steel Storage Racking – Requirements for design, use and inspection of racking systems used in picking and freight storage
• AS/NZS 2161 Occupational Protective Gloves – Selection and use of gloves for handling metal products, pallets and shrink wrap
• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017