Product Overview

Summary: This Wheel Alignment Safe Operating Procedure sets out a clear, step‑by‑step method for carrying out wheel alignment safely, accurately and in compliance with Australian WHS requirements. It protects technicians from common workshop hazards while ensuring consistent, high‑quality alignment results that reduce rework, warranty claims and customer complaints.

Wheel alignment work combines precision measurement with the use of heavy vehicles, lifting equipment and specialised alignment machinery. Without a structured procedure, technicians can be exposed to crush injuries, slips, trips and falls, eye injuries from debris, and musculoskeletal strain from poor manual handling. This Wheel Alignment Safe Operating Procedure provides a comprehensive, WHS‑aligned framework that covers the entire task, from pre‑job planning and vehicle reception through to post‑alignment verification, documentation and customer handover.

Designed specifically for Australian automotive workshops, dealerships and fleet maintenance operations, this SOP helps you integrate safety controls directly into your everyday workflow. It details how to assess and control hazards around hoists, alignment racks and moving vehicles, how to correctly use and maintain alignment equipment, and how to set up the work area to minimise trip hazards and manual handling risks. At the same time, it standardises the technical process for performing wheel alignment across different vehicle types, improving consistency, protecting your reputation, and supporting compliance with your WHS obligations and quality standards.

Key Benefits

• Ensure technicians carry out wheel alignment tasks in line with Australian WHS legislation and recognised industry best practice.
• Reduce the risk of crush injuries, falls, and manual handling incidents associated with hoists, jacks and vehicle movement.
• Improve alignment accuracy and consistency, reducing comebacks, warranty claims and customer complaints.
• Streamline technician training and onboarding with a clear, step‑by‑step procedure for all stages of the alignment process.
• Demonstrate due diligence to regulators, insurers and clients through documented, repeatable safety and quality controls.

Who is this for?

• Automotive Technicians
• Tyre Fitters
• Workshop Supervisors
• Service Managers
• Automotive Dealership Managers
• Fleet Maintenance Managers
• WHS Advisors in Automotive Workshops
• Mechanical Apprentices

Hazards Addressed

• Crush injuries from vehicle movement on and off hoists or alignment racks
• Falls from height or slips and trips around hoists, pits and alignment bays
• Manual handling injuries from handling wheels, tyres and alignment equipment
• Eye injuries from dust, rust, metal fragments and other debris during inspection and adjustment
• Electrical hazards from powered alignment equipment and accessories
• Ergonomic strain from repetitive bending, awkward postures and overreaching
• Noise exposure from workshop tools and traffic in busy service areas
• Fire hazards from flammable liquids and ignition sources in the workshop environment

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Competencies and Training
• 6.0 Tools, Equipment and Alignment Systems
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre‑Job Planning and Vehicle Reception
• 9.0 Work Area Preparation and Traffic Management
• 10.0 Pre‑Use Inspection of Hoists and Alignment Equipment
• 11.0 Safe Vehicle Positioning, Lifting and Securing
• 12.0 Wheel and Suspension Inspection Procedures
• 13.0 Step‑by‑Step Wheel Alignment Procedure
• 14.0 Quality Checks, Test Drive and Verification
• 15.0 Post‑Job Housekeeping and Equipment Shutdown
• 16.0 Hazard Identification and Risk Control Measures
• 17.0 Manual Handling and Ergonomic Guidelines
• 18.0 Emergency Procedures and Incident Response
• 19.0 Recordkeeping, Calibration Logs and Documentation
• 20.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and corresponding state and territory WHS regulations
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• AS/NZS 4024.1: Safety of machinery (series)
• AS 2550.9: Cranes, hoists and winches – Vehicle hoists
• AS/NZS 4801: Occupational health and safety management systems (superseded but still referenced in many systems)
• ISO 45001: Occupational health and safety management systems – Requirements with guidance for use