This Order Picking and Pick-Pack Operations Risk Assessment/JSA (Job Safety Analysis) is pre-filled for picking stock at ground level and at height, building and wrapping pallets, and packing orders in a warehouse or distribution centre. It covers 36 activities, from the pre-start and traffic management to battery charging and emergency response, with the hazards, control measures and risk ratings before and after controls for each. It's written by WHS specialists, aligned to Australian WHS legislation, and fully editable in Microsoft Word.
 
Who it's for
Warehouses and distribution centres
Third-party logistics (3PL) providers
Online retailers and fulfilment centres
Wholesalers and manufacturers with dispatch areas
Labour hire providers supplying pickers
A risk assessment, also called a JSA, JSEA or task risk assessment, records the hazards of a task and how you control them. If the task is part of high risk construction work, the law requires a SWMS for that work, so use our Order Picking and Pick-Pack Operations SWMS instead.
 
Use it to
Show clients, insurers and auditors how you manage the risks
Apply for tenders, contracts and supplier panels
Get through prequalification with Avetta, Cm3 and other contractor portals
Induct new workers and train them in the task
 
What this risk assessment covers
Pick rates, fatigue, operator authorisation and warehouse traffic management
Racking inspection and replenishment work above the pick face
Order picker pre-starts, mounting, harness use and rescue arrangements
Elevating and travelling in the order picker, including tip-over and overhead strikes
Falls when picking at height, from racking, mezzanines and pick modules
Manual handling, overhead picking and repetitive strain across the shift
Damaged or leaking stock, RF scanners and voice picking headsets
Pallet jacks, walkie stackers, roll cages and plant in narrow aisles
Building, wrapping and staging picked pallets, including stretch wrapping machines
Packing benches, safety knives, strapping and clearing conveyor blockages
Noise, warehouse heat, battery charging and working alone
Emergency response to falls, harness suspension, crush, plant impact, fire or chemical exposure
 
What's included
Hazards and control measures for 36 work activities
Risk ratings before and after controls, with a 5x5 risk matrix and the hierarchy of controls
PPE requirements checklist
Plant and equipment list, materials, maintenance checks and the training each worker needs
Relevant Australian Standards, including AS 4084.2 for racking and AS/NZS 1891.4 for harnesses
Licence guidance on when operators need an LO licence and when an LF licence applies
Site specific hazards section for anything unique to your job
Further controls action plan to track anything still to be done
Worker sign-off sheet and worker consultation record
 
Why use this template
Saves hours compared with writing a risk assessment from a blank page
Covers the most common hazards and control measures for this work, ready to use out of the box
Fully editable, so you can add, remove or change anything to suit your workplace and how your team works
Helps your business stay compliant, with risk ratings, an action plan, worker sign-off and consultation records already set up
Comes with a step-by-step implementation guide
 
How it works
Buy online and download straight away. You'll also get an email with your link.
Add your logo, ABN, area and site details.
Check it suits your workplace and task, edit anything you need to, and consult your workers before you finalise it.
Brief your team and collect signatures.
 
Common questions
Do I need a SWMS or a risk assessment for order picking?
No. Warehouse order picking isn't high risk construction work, so a SWMS isn't a legal requirement. You still have to manage the risks, including falls from order pickers and pickers struck by forklifts, and a risk assessment or JSA is a practical way to record how. Clients, insurers and prequalification portals often ask for one.
Which licence do order picker operators need?
The risk assessment sets out that order picking forklift operators, and operators of trucks where they rise with the load carriage, hold an LO licence. Reach truck and forklift operators who don't elevate hold an LF licence, and pedestrian pallet jacks and walkie stackers need no licence.
Can I change it?
Yes. It's a Microsoft Word file, so you can add, remove or change any hazard, control or rating, and add your own logo and details.
Does it suit my state?
Yes. It's written to the model WHS laws and suits all states and territories, including Victoria under the OHS Act and Regulations.
What if it doesn't suit my work?
You're covered by our 30-day money-back guarantee if it isn't fit for purpose.