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Retail Stocking Merchandising and Shelf Management Risk Assessment

Retail Stocking Merchandising and Shelf Management Risk Assessment

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Retail Stocking Merchandising and Shelf Management Risk Assessment

Product Overview

Identify and control organisational risks associated with Retail Stocking, Merchandising and Shelf Management at a management and systems level, before they impact workers or customers. This Risk Assessment supports WHS due diligence, strengthens WHS Risk Management practices, and helps protect your business from regulatory non‑compliance and operational liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Duties and Contractor Management: Assessment of officer due diligence, PCBU obligations, contractor onboarding, and integration of merchandising contractors into store WHS systems.
  • Store Layout, Traffic Management and Customer Interface: Management of customer and worker interaction zones, aisle widths, congestion, trip hazards, and segregation of stocking activities from public access areas.
  • Racking, Shelving and Display Unit Design, Procurement and Integrity: Controls for specification, procurement, load rating, inspection, maintenance and decommissioning of shelving, gondolas and display fixtures.
  • Stock Handling, Manual Tasks and Ergonomic Risk Management: Systematic assessment of hazardous manual tasks, repetitive movements, forceful exertions and implementation of engineering and administrative controls.
  • Working at Height and Use of Ladders for High Shelves and Displays: Protocols for ladder selection, inspection, storage and use, as well as alternatives to ladder work and controls for falls from low height.
  • Stock Storage Systems, Back‑of‑House and Product Flow: Management of stockroom layout, pallet and cage storage, product rotation, and safe movement of goods between receiving, storage and sales floor.
  • Use of Reorder Technology and Inventory Management Systems: Assessment of handheld scanners, tablets and POS‑linked inventory tools, including distraction risks, data accuracy, training and cybersecurity considerations.
  • Promotional Display and Display Unit Setup Management: Governance of temporary and seasonal displays, structural stability, location selection, traffic flow impacts and decommissioning processes.
  • Vending Machine Installation, Relocation and Restocking Management: Controls for siting, anchoring, power supply, manual handling, contractor interfaces and customer access to vending equipment.
  • Training, Competence and Supervision for Merchandising Activities: Development of competency requirements, induction content, refresher training and supervisory oversight for in‑house and contractor staff.
  • Fatigue, Workload and Scheduling for Replenishment and Merchandising: Assessment of night fill, early starts, extended trading hours, peak trading periods and staffing levels to minimise fatigue‑related risks.
  • Plant, Equipment and Tools Used for Stocking and Merchandising: Management of trolleys, pallet jacks, stock pickers, box cutters and other tools, including procurement, inspection, maintenance and safe operation.
  • Hazard Communication, Labelling and Chemical/Product Risks: Systems for product labelling, SDS access, handling of hazardous chemicals, spill risks, allergen and product‑specific hazards.
  • Emergency Preparedness, Incident Response and Recovery: Planning for fire, medical events, slips and trips, structural failures, product recalls and post‑incident investigation and corrective actions.

Who is this for?

This Risk Assessment is designed for Business Owners, Retail Managers, Safety Managers and WHS Advisors responsible for planning, governing and auditing retail stocking, merchandising and shelf management activities across single or multi‑site operations.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Duties and Contractor Management
  • • Unclear allocation of WHS responsibilities between PCBUs, store management, merchandisers and labour-hire workers
  • • Inadequate consultation, cooperation and coordination between retailers, suppliers and contractors under WHS Act 2011
  • • Absence of a documented WHS management plan specific to retail merchandising and shelf management
  • • Failure to verify contractor WHS competence, licences and insurances (including for vending machine installers)
  • • Poor incident reporting and investigation systems leading to repeat events
  • • Lack of review of WHS performance indicators (e.g. manual handling injuries, near misses from falling stock, display collapses)
2. Store Layout, Traffic Management and Customer Interface
  • • Congested aisles limiting safe use of ladders, stock trolleys and roll cages
  • • No defined pedestrian and stock movement paths leading to collisions between staff, contractors and customers
  • • Poorly planned locations for promotional displays and dump bins causing trip hazards or blocking emergency exits
  • • Inadequate separation of merchandising activities from customers during busy trading times
  • • Uncontrolled access of customers into areas where display units or vending machines are being installed or moved
  • • Insufficient signage and exclusion zones during restocking and display setup work
3. Racking, Shelving and Display Unit Design, Procurement and Integrity
  • • Inadequate engineering design or rating of shelving, display units and gondolas for product weight and height
  • • Use of unstable or non‑compliant freestanding promotional displays and dump bins
  • • Poorly designed or unanchored display units for heavy or bulky goods (e.g. beverages, bulk packs) leading to tip‑over
  • • Failure to follow manufacturer installation specifications for shelving and display units
  • • Lack of system for periodic inspection and maintenance of shelves, pegs, brackets and fixtures
  • • Display units interfering with sprinkler systems, emergency lighting or fire equipment
4. Stock Handling, Manual Tasks and Ergonomic Risk Management
  • • Systemic reliance on manual lifting, carrying and reaching for stock replenishment and merchandising
  • • Inadequate manual tasks risk assessments for repetitive stocking, carton breakdown and high‑shelf placement
  • • Lack of engineered aids for moving heavy or awkward cartons and for restocking products on high shelves
  • • Inappropriate shelf heights forcing frequent bending, twisting, over‑reaching or work above shoulder height
  • • High workload during peak seasons leading to rushed, unsafe lifting techniques
  • • Failure to accommodate workers with pre‑existing musculoskeletal conditions or limited capacity
5. Working at Height and Use of Ladders for High Shelves and Displays
  • • Inappropriate selection and use of ladders or step stools for restocking products on high shelves and setting up overhead displays
  • • Lack of a system for ladder inspection, maintenance and replacement
  • • Overreaching from ladders, carrying heavy or bulky stock while climbing, and standing on top steps
  • • Use of makeshift access (e.g. stock cages, pallets, shelves) instead of approved access equipment
  • • Insufficient controls to manage work at height during trading hours around customers
  • • No documented competency requirements for workers using ladders or small platforms
6. Stock Storage Systems, Back‑of‑House and Product Flow
  • • Poorly controlled stock levels in back‑of‑house leading to over‑stacking, unstable pallets and blocked access ways
  • • Inadequate segregation of heavy, bulky and fragile items increasing risk of collapse or breakage
  • • Lack of systematic product rotation procedures (FIFO) contributing to rushed handling and poor housekeeping
  • • Unclear demarcation between staff‑only storage areas and customer accessible spaces
  • • Inadequate lighting and signage in storage areas impacting safe access and stacking
  • • Inefficient stock flow process from receiving to shelf, increasing handling steps and manual task exposures
7. Use of Operating Reorder Technology and Inventory Management Systems
  • • Over‑reliance on automated reorder systems causing overstocking and congested storage or display areas
  • • Inaccurate data entry or system parameters leading to urgent, last‑minute restocking and rushed work
  • • Lack of integration between inventory systems and WHS considerations such as weight, handling frequency and storage limitations
  • • Insufficient training in handheld scanning devices or stock management software leading to distraction and poor situational awareness in aisles
  • • Device charging and cabling creating trip or electrical hazards in merchandising areas
8. Promotional Display and Display Unit Setup Management
  • • Short lead times and commercial pressure for promotional launches resulting in inadequate WHS planning
  • • Complex or oversized promotional displays that are unstable or obstruct sight lines, aisles or emergency exits
  • • Display unit setup occurring during busy trading periods without effective exclusion or supervision
  • • Use of non‑standard fasteners, adhesives or temporary supports not rated for the loads applied
  • • Lack of clear responsibility for inspecting and maintaining temporary promotional displays across the promotion period
9. Vending Machine Installation, Relocation and Restocking Management
  • • Inadequate planning and risk assessment for delivery, positioning and anchoring of heavy vending machines
  • • Uncontrolled movement of machines on uneven floors or ramps leading to crush or impact risks
  • • Electrical hazards from incorrect connection, damaged cords or lack of isolation points
  • • Insufficient clearance around machines for maintenance, restocking and emergency access
  • • Inadequate training and procedures for safe restocking, including manual handling of heavy products and access to internal components
  • • Lack of clear ownership of WHS responsibilities between the retailer and vending service provider
10. Training, Competence and Supervision for Merchandising Activities
  • • Workers and contractors performing merchandising, display setup and restocking tasks without adequate induction or role‑specific training
  • • Inconsistent understanding of safe systems of work between directly employed staff and external merchandisers
  • • No formal verification of competence for high‑risk tasks such as ladder use, heavy stock handling or vending machine work
  • • Insufficient supervision, particularly for new or young workers, during peak trading and high‑pressure promotional periods
  • • Lack of refresher training leading to drift from procedures over time
11. Fatigue, Workload and Scheduling for Replenishment and Merchandising
  • • Extended or irregular shifts for overnight or early‑morning replenishing stock and display setup
  • • High workloads during promotional changes and seasonal peaks leading to rushed work and reduced adherence to procedures
  • • Insufficient staffing levels for large product resets or complex display installations
  • • Lack of consideration of rest breaks during physically demanding stocking and merchandising tasks
  • • Pressure to complete merchandising tasks during short windows, increasing risk of shortcutting controls
12. Plant, Equipment and Tools Used for Stocking and Merchandising
  • • Inadequate maintenance and inspection of trolleys, roll cages, pallet jacks and other handling equipment
  • • Poor design or selection of equipment leading to instability, excessive push/pull forces or pinch points
  • • Uncontrolled use of powered equipment (e.g. ride‑on or walk‑behind equipment, compact order pickers) around customers
  • • Lack of standard operating procedures for safe use, parking and storage of merchandising equipment
  • • Improvised tools or modifications made to equipment without assessment
13. Hazard Communication, Labelling and Chemical/Product Risks
  • • Insufficient information provided to staff and merchandisers about hazardous products (e.g. cleaning chemicals, aerosols, pressurised containers)
  • • Inadequate management of damaged or leaking products leading to slip, trip or exposure risks
  • • Poorly controlled disposal of waste packaging, shrink wrap and strapping creating trip and entanglement hazards during restocking
  • • Lack of clear labelling and signage for heavy or awkward products on shelves and in stockrooms
14. Emergency Preparedness, Incident Response and Recovery
  • • Unclear procedures for responding to shelf collapses, falling objects, or display unit failures in customer areas
  • • Inadequate first aid coverage during early morning, late night or promotional changeovers
  • • Poor communication paths for escalating serious incidents involving contractors or visitors
  • • Emergency exits and equipment obscured by stock, display units or vending machines
  • • Lack of drills or training specific to merchandising‑related emergencies (e.g. product spillage, glass breakage, electrical fault in vending unit)

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Guidance on risk management principles and processes.
  • Model Code of Practice – Hazardous Manual Tasks: Guidance on identifying and controlling risks from manual handling in retail environments.
  • Model Code of Practice – Managing the Work Environment and Facilities: Requirements for safe layout, amenities and work environment in retail premises.
  • Model Code of Practice – Managing Risks of Falls at Workplaces: Controls for ladder use and work at height for shelving and displays.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines.
  • AS 4084 (series) Steel Storage Racking: Requirements for design, installation, use and inspection of storage racking systems.
  • AS 3745-2010 (Incorporating Amendments) Planning for Emergencies in Facilities: Framework for emergency response planning in retail stores.
  • AS/NZS 4801 / ISO 45001 (where adopted): 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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