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Plant and Machinery Maintenance Repair and Overhaul SWMS

Plant and Machinery Maintenance Repair and Overhaul SWMS

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Plant and Machinery Maintenance Repair and Overhaul SWMS

Product Overview

This Safe Work Method Statement (SWMS) provides a structured, step-by-step approach to safely conducting plant and machinery maintenance, repair and overhaul activities, helping your business maintain strong WHS compliance. It is a comprehensive document covering multiple aspects of Plant and Machinery Maintenance Repair and Overhaul, from routine servicing through to complex onsite repair works and retrofits.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

  • Planning and scheduling of plant and machinery maintenance, repair and overhaul activities
  • Safe isolation, lockout and tagout of energy sources prior to machinery repairs
  • Machinery repairs on fixed and mobile plant, including troubleshooting and fault-finding
  • Maintaining plant and equipment to manufacturer specifications and site requirements
  • Major plant or equipment maintenance, including strip-down, inspection and reassembly
  • Onsite repair works in operational areas, including coordination with other trades and site personnel
  • Performing temporary repairs to keep equipment safe and serviceable until permanent rectification
  • Reinstalling mishandled units and verifying correct alignment, mounting and securing
  • Removing broken or damaged components using appropriate tools, lifting aids and techniques
  • Repair and maintenance of extraction and ventilation equipment, including filters and ducting
  • Repairing minor damages, scratches or surface defects while controlling dust, fumes and noise
  • Repairing worn-out components and assessing suitability for continued service
  • Repairs on faulty machinery, including testing, commissioning and verification of safe operation
  • Replacing defective parts and worn-out seals, gaskets and consumables
  • Retrofitting obsolete parts or components with updated alternatives in line with engineering guidance
  • Use of hand tools, power tools and portable equipment for maintenance and repair tasks
  • Manual handling and use of lifting equipment (jacks, hoists, cranes) for components and assemblies
  • Managing slip, trip, crush, entanglement and pinch-point hazards around plant and machinery

Who is this for?

This SWMS is designed for maintenance technicians, mechanical fitters, plant operators, service contractors, and site supervisors responsible for plant and machinery maintenance, repair and overhaul on Australian worksites.

Specific Job Steps & Hazards Covered

Job Step / Activity Potential Hazards
Pre-start planning and documentation
  • • Unclear work scope
  • • Incorrect isolation boundaries
  • • Unfamiliar plant operating parameters
  • • Inadequate resourcing
  • • Unqualified personnel
  • • Conflicting work activities
Site access and work area setup
  • • Vehicle and mobile plant interaction
  • • Restricted access and egress
  • • Poor housekeeping
  • • Inadequate lighting
  • • Slips trips and falls on uneven surfaces
  • • Unauthorised entry to work area
Plant shutdown and isolation
  • • Unexpected plant start-up
  • • Stored hydraulic pressure
  • • Stored pneumatic pressure
  • • Residual electrical energy
  • • Rotating components run-down
  • • Gravity and suspended loads
Accessing and securing plant
  • • Falls from plant
  • • Falls from ladders
  • • Crushing between components
  • • Unstable plant movement
  • • Contact with hot surfaces
  • • Sharp edges and pinch points
Inspection and fault diagnosis
  • • Contact with moving parts during testing
  • • Exposure to fumes and dust
  • • Eye injury from debris
  • • Noise from running machinery
  • • Contact with live electrical circuits
  • • Incorrect lockout removal for testing
Dismantling and removing components
  • • Manual handling strain
  • • Crushing by heavy parts
  • • Stored spring or tension energy
  • • Use of incorrect lifting points
  • • Flying particles from tools
  • • Oil and coolant spills
Repairing and replacing components
  • • Incorrect part installation
  • • Use of incompatible retrofit parts
  • • Failure of temporary repairs
  • • Exposure to solvents and adhesives
  • • Contact with sharp or worn parts
  • • Tool-related injuries
Major overhauls and heavy machinery servicing
  • • Collapse of supported plant
  • • Failure of jacks or stands
  • • High-force assembly and disassembly
  • • Complex multi-person tasks
  • • Incorrect reassembly of critical systems
  • • Extended exposure to noise and vibration
Servicing extraction and motorised equipment
  • • Exposure to hazardous dusts
  • • Inhalation of fumes and vapours
  • • Contact with rotating fans and impellers
  • • Electrical shock from motors
  • • Confined or restricted spaces around ducting
  • • Fire from combustible dust buildup
Onsite temporary repairs and minor damage
  • • Uncontrolled plant movement during repair
  • • Failure of temporary fix in operation
  • • Misjudged structural integrity
  • • Use of unsuitable repair materials
  • • Burns from hot work
  • • Poor surface preparation
Reinstallation and alignment of units
  • • Crushing during positioning
  • • Misaligned couplings and belts
  • • Trapped fingers in mounting points
  • • Overstressed fasteners
  • • Incorrect fluid and hose connection
  • • Uncontrolled lowering of loads
Testing, commissioning and verification
  • • Unexpected movement during start-up
  • • Failure of repaired components
  • • Noise and vibration exposure
  • • Leaks of fluids or gases
  • • Ejection of loose tools or parts
  • • Inadequate guarding during test
Post-work cleanup and handover
  • • Residual trip hazards
  • • Left-over tools in plant
  • • Exposure to waste fluids
  • • Incorrect status communication
  • • Environmental contamination
  • • Delayed discovery of defects

Need to add specific site requirements?

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

Legislation & References

This document was researched and developed to align with:

  • Managing Risks of Plant in the Workplace Code of Practice: Guidance on the safe use, maintenance and repair of plant and machinery
  • How to Manage Work Health and Safety Risks Code of Practice: Framework for identifying, assessing and controlling WHS risks
  • Work Health and Safety Consultation, Cooperation and Coordination Code of Practice: Requirements for consulting with workers and other duty holders
  • Managing Noise and Preventing Hearing Loss at Work Code of Practice: Controls for noise exposure during machinery maintenance and repair
  • Hazardous Manual Tasks Code of Practice: Risk controls for lifting, carrying and handling components and equipment
  • Safe Work Australia – Guide to Inspecting and Maintaining Elevating Work Platforms: Where access equipment is used during maintenance activities
  • AS/NZS 4024 Safety of Machinery (series): Principles for the safe design and guarding of machinery
  • AS/NZS 3000 Electrical Installations (Wiring Rules): Where electrical isolation and work near electrical plant is involved
  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
Standard SWMS Features (Click to Expand)
  • Operational guidelines, with a step-by-step approach to safe work
  • Possible hazards that may be encountered
  • Step-by-step safety procedures to follow
  • Before work starts – Guidelines and Checks
  • Safety measures and guides
  • Operational Safety Checks
  • Before and After Risk Ratings
  • Risk Assessment Matrix
  • High Risk Work Involved
  • Emergency Evacuation Procedure
  • Plant and Equipment
  • Qualifications and Permits
  • Specific Personal Protective Equipment (PPE)
  • Company Personnel Sign-off form

$96.8

Safe Work Australia Aligned