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Stock Picking and Shelving Access Risk Assessment

This risk assessment covers stock picking and shelving access activities, including planning, accessing storage, handling stock and responding to incidents.

Activities covered include

  • Complete work area planning and pre-start checks
  • Use trolleys, pallet jacks and order-picking aids
  • Respond to falls, struck-by incidents, blocked aisles and other emergencies

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Stock Picking and Shelving Access Risk Assessment
  • 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

Product Overview

This risk assessment covers stock picking and shelving access activities, including planning, accessing storage, handling stock and responding to incidents. It supports planning and risk management by identifying hazards associated with access equipment, shelving, manual tasks, mobile plant, damaged stock and work pace.

Activities & Risks Covered

This assessment addresses activities and risks including:

  • Complete work area planning and pre-start checks
  • Access shelving and elevated storage using access equipment
  • Manually handle cartons, totes and loose stock
  • Pick stock from low, deep and awkward shelf positions
  • Load, unload and place stock on shelving
  • Use trolleys, pallet jacks and order-picking aids
  • Work around pedestrians and mobile plant
  • Handle damaged stock, spills and hazardous contents
  • Manage fatigue, work pace and communication while picking
  • Respond to falls, struck-by incidents, blocked aisles and other emergencies

Who is this for?

Suitable for contractors, workers, supervisors and businesses carrying out stock picking, shelving access and storage activities.

Activities & Hazards Covered

Activity Potential Hazards
Work area planning and pre-start checks
  • Unclear picking task, load destination or access route
  • Blocked aisles, poor housekeeping and trip hazards
  • Damaged shelving, racking or access equipment not identified before use
  • Workers starting in areas affected by other activities or mobile plant
Accessing shelving and elevated storage
  • Falls from steps, ladders or other access equipment
  • Overreaching from access equipment
  • Using unsuitable items such as pallets, boxes or racking as a work platform
  • Loss of balance while handling stock at height
Manual handling of cartons, totes and loose stock
  • Musculoskeletal strain from lifting, lowering, carrying or twisting
  • Awkward postures when handling stock from low or high shelves
  • Repetitive picking creating cumulative strain
  • Unstable, bulky or poorly packed loads
Picking from low, deep or awkward shelf positions
  • Strain from bending, kneeling, reaching into deep shelves or working in confined spaces
  • Hand injuries from sharp edges, strapping or damaged packaging
  • Stock shifting while being retrieved from congested shelves
Shelf loading, unloading and stock placement
  • Falling objects striking workers
  • Shelving overload or instability
  • Items placed where they can roll, slide or topple
  • Hands or feet caught while setting stock into place
Use of trolleys, pallet jacks and order-picking aids
  • Collision with people, shelving or doors
  • Runaway loads or loss of control on slopes or uneven floors
  • Pinch points to hands and feet
  • Equipment failure due to poor maintenance
Pedestrian and mobile plant interaction
  • Workers struck by forklifts or other mobile plant
  • Blind spots at aisle ends and intersections
  • Unexpected entry into active loading or replenishment areas
  • Distraction from scanning devices, paperwork or conversation
Handling damaged stock, spills and hazardous contents
  • Exposure to leaking chemicals, dusts or contaminated packaging
  • Slips from spills or broken containers
  • Manual handling of compromised or unstable loads
  • Incompatible storage creating additional risks
Fatigue, pace of work and communication during picking
  • Errors, poor judgement and unsafe shortcuts under time pressure
  • Fatigue during repetitive or sustained picking tasks
  • Breakdown in communication between pickers, spotters and plant operators
  • Inexperienced workers not recognising unsafe loads or unsafe access
Emergency response and incident management
  • Delayed response to falls, crush injuries or struck-by incidents
  • Workers trapped by collapsed stock or blocked aisles
  • Confusion during evacuation or emergency shutdown
  • Inadequate first aid access in storage areas

Need to tailor this risk assessment?

Use the BlueSafe Portal to add site-specific activities, hazards, controls, responsibilities and review details before the assessment is put into use.

Acceptance Guaranteed: If your client or principal requests changes during document review, BlueSafe will help revise the document at no extra cost and support resubmission until it is accepted.

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

  • Model guidance: Model Code of Practice: Managing the work environment and facilities — 2. The work environment; p. 13.
  • Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
  • Model guidance: Model Code of Practice: Managing risks of plant in the workplace — Plant hazard identification — Traffic movements in the workplace; p. 17.
  • Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
  • Model guidance: Model Code of Practice: Managing the risk of fatigue at work — Provide sufficient breaks while at work; p. 30.
  • Model guidance: Model Code of Practice: Managing risks of hazardous chemicals in the workplace — 2.1 How to identify which chemicals are hazardous; p. 15.
  • Model guidance: Model Code of Practice: Work health and safety consultation, cooperation and coordination — 3. What is effective consultation?; p. 13.
  • Model guidance: Model Code of Practice: How to manage work health and safety risks — 4. Step 3 — How to control risks; p. 20.
  • Model guidance: Model Code of Practice: Confined spaces — 3.4 Assessing the risks; p. 24.

Standard Risk Assessment Features (Click to Expand)
  • Activity-specific hazard identification and control measures
  • Initial and residual risk ratings
  • Assigned responsible persons for each activity
  • Risk matrix and assessment classification
  • Review, monitoring and sign-off fields
  • Site-specific customisation before use

Suitable for Industries

Transport and LogisticsWarehousing and DistributionRetail and Wholesale

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