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Stock Picking and Shelving Access Risk Assessment

Stock Picking and Shelving Access Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
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Stock Picking and Shelving Access Risk Assessment

Product Overview

Identify and control organisational risks associated with Stock Picking and Shelving Access through a structured, management-level WHS Risk Management approach that focuses on systems, planning and governance rather than task-by-task instructions. This Risk Assessment supports compliance with the Work Health and Safety Act and Regulations, helping to demonstrate Due Diligence and reduce operational liability for your business.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance & WHS Duties: Assessment of officer due diligence, PCBU obligations, risk management framework and integration of stock picking and shelving access into the organisation’s WHS management system.
  • Storage Design & Engineering Controls: Management of racking layout, load ratings, shelf configuration, separation distances and engineered controls to minimise fall, collapse and impact risks.
  • Working at Height Access Systems: Evaluation of ladders, step platforms, mobile platforms, EWPs and pulley systems, including selection criteria, hierarchy of control and safe access/egress planning.
  • Stock Storage Strategy & Material Handling at Height: Assessment of how stock is organised, stacked and retrieved at height, including load stability, product zoning and controls for overreaching and dropped objects.
  • Procurement & Maintenance of Access and Lifting Equipment: Protocols for equipment selection, supplier verification, inspection schedules, preventative maintenance and removal from service criteria.
  • Training, Competency & Supervision: Requirements for induction, task-specific training, EWP licensing, verification of competency and supervision arrangements for height-related stock picking.
  • Safe Systems of Work, Procedures & Permits: Development and control of documented procedures, permits-to-work for higher-risk activities, isolation requirements and interface with SWMS where applicable.
  • Consultation, Communication & Worker Engagement: Systems for consulting workers and HSRs, communicating changes to racking or access systems, and capturing worker feedback on height-related risks.
  • Contractor & Third-Party Management: Controls for visiting drivers, labour-hire workers, maintenance contractors and other third parties operating in storage and shelving areas.
  • Ergonomics, Manual Handling & Dropped Object Controls: Management of reach distances, force requirements, repetitive movements, use of mechanical aids and exclusion zones to prevent injuries and falling object incidents.
  • Emergency Preparedness, Rescue & Incident Response: Planning for falls from height, equipment failure, medical emergencies and entrapment, including rescue procedures, equipment and training.
  • Environment, Housekeeping & Traffic Management: Controls for floor conditions, lighting, congestion in aisles, interaction with forklifts and pedestrian traffic within storage and picking zones.
  • Fatigue, Workload & Scheduling: Assessment of shift patterns, peak periods, overtime and task rotation to reduce fatigue-related errors during height access and stock retrieval.
  • Monitoring, Audit & Continuous Improvement: Systems for inspections, audits, KPI monitoring, incident trend analysis and review of controls for ongoing improvement of stock picking and shelving access safety.

Who is this for?

This Risk Assessment is designed for Business Owners, Warehouse and Operations Managers, and Safety Professionals responsible for planning, controlling and reviewing stock picking and shelving access activities across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Risk Management Framework
  • • Lack of a documented WHS risk management procedure for stock picking and shelving access at height
  • • Officers not exercising due diligence to ensure compliance with WHS Act 2011 and WHS Regulations
  • • Inadequate consultation with workers and HSRs on height‑related storage and access risks
  • • Failure to integrate working at height risks into the organisation’s overall WHS management system
  • • No clear allocation of responsibilities for managing storage height, equipment selection and inspection
  • • Inadequate monitoring, review and continuous improvement of controls related to shelving access
2. Storage Design, Racking Layout and Engineering Controls
  • • Inappropriate racking and shelving design leading to unstable loads or collapse
  • • High‑use or heavy items stored at excessive height requiring unsafe reaching or climbing
  • • Inadequate design of pulley systems or hoists for accessing high stock, creating crush or struck‑by risks
  • • Insufficient clearance around aisles, high shelves and overhead compartments increasing collision risks with forklifts or pedestrians
  • • Uncertified or non‑compliant racking for working at heights (rack storage access platforms, mezzanines)
  • • No formal engineering assessment of load ratings for high storage areas and overhead cupboards
3. Working at Height Access Systems (Ladders, Platforms, EWP, Pulleys)
  • • Reliance on unsuitable or domestic‑grade ladders for industrial stock picking
  • • No formal system for selection, inspection and withdrawal from service of ladders, step platforms, mobile scaffolds and EWPs used for shelving access
  • • Inappropriate use of forklifts or pallets as work platforms to reach high storage
  • • Uncontrolled use of pulley systems or makeshift lifting devices for fetching items from high places
  • • Inadequate controls for working at height while fitting cupboards or working on rack storage
  • • Failure to control environmental factors (uneven floors, wet surfaces, congestion) when using access equipment
4. Stock Storage Strategy and Material Handling at Height
  • • Poorly planned stock placement leading to frequent climbing or overreaching into overhead compartments and high storage
  • • Heavy or bulky items stored above shoulder height creating manual handling and drop object risks
  • • Ad‑hoc storage of materials and tools at height during cupboard fitting or rack installation
  • • No system for securing items on high shelves or in overhead cupboards against movement or dislodgement
  • • Inadequate labelling of load limits on shelves and high storage areas
  • • Uncontrolled stacking of cartons or materials above racking height or on top of cupboards
5. Procurement, Suitability and Maintenance of Access and Lifting Equipment
  • • Procurement of low‑quality, unsuitable or non‑compliant ladders, pulleys, hoists and access platforms
  • • Lack of a preventative maintenance program for order pickers, EWPs, hoists and pulley systems
  • • Failure to maintain safety features such as brakes, guardrails, interlocks and fall‑prevention devices
  • • Inadequate verification of equipment against Australian Standards for working at height and mechanical lifting
  • • Spare keys, tools or critical items stored at height without consideration of safe access equipment required to retrieve them
6. Training, Competency and Supervision for Work at Height
  • • Workers not trained in safe stock picking practices or correct use of height access equipment
  • • Inadequate competency assessment for persons operating order pickers, EWPs or using pulley systems at height
  • • Supervisors unaware of their responsibilities regarding enforcement of working at height procedures
  • • No training in hazard identification for overreaching, unstable loads and inappropriate storage at height
  • • Lack of refresher training leading to unsafe shortcuts or normalisation of deviance over time
7. Safe Systems of Work, Procedures and Permits
  • • Absence of documented procedures for accessing high storage areas, using pulleys or working on rack storage
  • • Procedures that focus only on manual tasks rather than system and management controls
  • • No permit‑to‑work or authorisation process for higher‑risk work at height (e.g. fitting cupboards, altering racking, using EWPs)
  • • Inconsistent practices between shifts, contractors and sites when accessing high shelves
  • • Failure to incorporate lessons learned from incidents into procedures and systems
8. Consultation, Communication and Worker Engagement
  • • Workers’ practical knowledge of storage and access risks not captured in system design
  • • Lack of clear communication on rules for using ladders, platforms and equipment when accessing high areas
  • • Poor reporting culture for hazards and near misses involving working at height or dropped objects
  • • Multi‑lingual workforce not fully understanding instructions relating to safe access to high shelving
  • • Insufficient involvement of workers in decisions about storage redesign, equipment procurement and process changes
9. Contractor and Third‑Party Management
  • • External installers or contractors fitting cupboards or racking at height without following site WHS procedures
  • • Contractor equipment (ladders, scaffolds, pulleys, EWPs) not meeting site standards or Australian requirements
  • • Lack of coordination between contractors and employees working in the same storage areas, leading to overlapping height risks
  • • Inadequate verification of contractor competence in working at heights and racking installation
  • • Poor induction of contractors regarding site‑specific hazards, emergency procedures and exclusion zones
10. Ergonomics, Manual Handling and Dropped Object Controls
  • • Excessive reaching, twisting or force when retrieving stock from high shelves or overhead compartments
  • • Inadequate controls to prevent tools and materials falling from height during cupboard fitting or rack work
  • • Lack of consideration of human factors when designing pulley systems and high storage workflows
  • • No system for segregating people from areas where items may be dropped from height
  • • Cumulative strain injuries from repeated overhead lifting and reaching to high storage
11. Emergency Preparedness, Rescue and Incident Response
  • • No rescue plan for persons incapacitated while working at height on shelving, platforms or EWPs
  • • Delayed emergency response due to poor access to high storage areas or lack of communication systems
  • • Inadequate first aid capability for injuries resulting from falls or struck‑by incidents involving falling objects
  • • Workers unaware of emergency procedures for incidents occurring in high‑bay racking or mezzanine areas
  • • Lack of post‑incident investigation and learning focused on systemic and management failures
12. Environment, Housekeeping and Traffic Management in Storage Areas
  • • Poor housekeeping resulting in trip hazards around ladders, platforms and access equipment
  • • Inadequate lighting in high‑bay storage areas affecting depth perception and safe placement of access equipment
  • • Slippery or uneven flooring contributing to falls from ladders and platforms used to reach high stock
  • • Uncontrolled interaction between pedestrians, stock pickers and mobile plant near racking and high shelves
  • • Unsecured access to mezzanines, high storage platforms and restricted overhead areas
13. Fatigue, Workload and Scheduling Controls for Height‑Related Tasks
  • • Workers accessing high storage areas or pulleys when fatigued, increasing likelihood of mis‑steps or poor judgement
  • • High workload and time pressure encouraging shortcuts such as climbing racking or overloading platforms
  • • Inadequate breaks during intensive stock picking periods leading to reduced concentration at height
  • • Rosters that do not account for physically demanding tasks like repeated climbing or overhead reaching
  • • Lack of supervision during early morning, night or weekend shifts when height‑related tasks may still occur
14. Monitoring, Audit and Continuous Improvement of Height Controls
  • • Controls for stock picking and shelving access at height not regularly reviewed for effectiveness
  • • Lack of structured inspections for racking integrity, access equipment condition and storage compliance
  • • Data on incidents, near misses and observations not analysed to identify trends in height‑related risks
  • • Non‑compliances with procedures (e.g. unsafe ladder use, storing heavy items at height) going uncorrected
  • • Changes in stock types, volumes or layouts implemented without reassessment of height risks

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 – Managing the Risk of Falls at Workplaces: Requirements and guidance for controlling work at height risks.
  • Model Code of Practice – Managing Risks of Plant in the Workplace: Controls for access equipment, lifting devices and associated plant.
  • Model Code of Practice – Hazardous Manual Tasks: Risk management for manual handling during stock picking and shelving activities.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines.
  • AS 4084 (Series) – Steel Storage Racking: Design, installation, use and maintenance of steel storage racking systems.
  • AS/NZS 1891 (Series) – Industrial Fall-Arrest Systems and Devices: Selection, use and maintenance of fall protection systems where applicable.
  • AS 1657:2018 – Fixed Platforms, Walkways, Stairways and Ladders: Design and construction requirements for fixed access systems.
  • AS 2550 (Series) – Cranes, Hoists and Winches – Safe Use: Safe use and inspection requirements for relevant lifting and hoisting equipment.
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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