Product Overview

Summary: This PreStart Equipment Checks Safe Operating Procedure sets out a clear, repeatable process for inspecting plant and equipment before use, helping you identify faults before they become incidents. It supports compliance with Australian WHS laws by embedding practical, front-line checks that protect workers, reduce downtime, and keep your fleet safe and reliable.

Pre-start equipment checks are one of the simplest and most effective controls for preventing serious incidents, yet they are often rushed or overlooked on busy Australian worksites. This Safe Operating Procedure provides a structured, step-by-step approach for inspecting mobile plant, vehicles, and fixed equipment before each shift or task. It defines exactly what must be checked, how to record defects, and what to do when equipment is found to be unsafe, ensuring that your team moves beyond a tick-and-flick mindset to a genuinely risk-based pre-start process.

Developed with Australian WHS requirements in mind, this SOP helps businesses demonstrate due diligence under the model WHS Regulations and relevant plant and high-risk work provisions. It tackles common pain points such as inconsistent inspections across crews, undocumented defects, and equipment being used while unserviceable. By implementing this procedure, you create a defensible system for managing plant safety, improving reliability, and reducing unplanned breakdowns, while also providing a practical training tool for new operators and supervisors.

Key Benefits

• Ensure plant and equipment are inspected consistently before use, reducing the likelihood of mechanical failures and incidents.
• Reduce unplanned downtime and costly repairs by identifying and addressing defects early.
• Demonstrate compliance with WHS obligations for plant management and due diligence in the event of an audit or incident investigation.
• Standardise operator behaviour across sites with a clear, easy-to-follow pre-start inspection process.
• Improve communication between operators, supervisors, and maintenance teams through defined defect reporting and tagging procedures.

Who is this for?

• Site Supervisors
• Plant Operators
• Maintenance Coordinators
• Workshop Managers
• Fleet Managers
• Construction Project Managers
• WHS Advisors and HSE Officers
• Operations Managers
• Civil and Mining Supervisors
• Logistics and Transport Managers

Hazards Addressed

• Mechanical failure of plant or equipment during operation
• Uncontrolled movement of vehicles or mobile plant
• Hydraulic, pneumatic, or pressure system failures
• Brake and steering system failures on vehicles and mobile plant
• Falling objects due to damaged lifting points, guards, or attachments
• Electrical faults, damaged leads, and unsafe isolation on powered equipment
• Exposure to noise, fumes, and vibration from poorly maintained equipment
• Crush and entanglement hazards from missing or damaged guards
• Fire risk from fuel leaks, oil leaks, or faulty electrical components
• Slips, trips, and falls due to damaged access steps, handrails, or work platforms

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Applicable Equipment Types
• 3.0 Roles and Responsibilities (Operators, Supervisors, Maintenance, WHS)
• 4.0 Competency and Training Requirements for PreStart Checks
• 5.0 Required Tools, Checklists and Documentation
• 6.0 General PreStart Inspection Principles
• 7.0 Step-by-Step PreStart Procedure for Mobile Plant and Vehicles
• 8.0 Step-by-Step PreStart Procedure for Fixed Plant and Powered Equipment
• 9.0 Defect Identification, Tagging Out and Reporting Process
• 10.0 Criteria for Removing Equipment from Service
• 11.0 Communication and Escalation Requirements
• 12.0 Recordkeeping, PreStart Checklists and Audit Trail
• 13.0 Integration with Preventive Maintenance and Service Schedules
• 14.0 Hazard Controls and Risk Management Considerations
• 15.0 Emergency Response if Critical Defects Are Identified
• 16.0 Review, Continuous Improvement and Consultation Process

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 – Part 4.2: Duties of persons conducting businesses or undertakings involving management or control of plant
• Safe Work Australia – Managing the risks of plant in the workplace: Code of Practice
• Safe Work Australia – General guide for workplace traffic management
• AS/NZS 4024.1: Safety of machinery – Series
• AS 2550 series: Cranes, hoists and winches – Safe use (where applicable)
• AS 1418 series: Cranes, hoists and winches – Design and construction (where applicable)
• AS/NZS 3012: Electrical installations – Construction and demolition sites (for portable and site equipment)
• Manufacturer’s operating and maintenance manuals for specific plant and equipment