Free Pre-Start Checklist (Order Picker) Template

Purpose of the Free Pre-Start Checklist (Order Picker) Template

A consistent pre-start inspection is a fundamental safety procedure for any workplace using powered mobile plant like order pickers. Our Free Pre-Start Checklist (Order Picker) Template provides a structured framework to formalise these crucial daily checks.

Using this checklist helps operators systematically inspect the machine for mechanical, structural, and electrical faults before operation begins. This proactive approach is vital for preventing incidents, protecting workers from harm, and minimising costly equipment downtime.

Implementing documented pre-start checks demonstrates a commitment to workplace safety and serves as an important record of due diligence. These records are a key component of a comprehensive WHS management system, showing that the organisation is actively managing risks associated with high-risk plant.

By identifying and addressing potential hazards early, you create a safer environment for everyone in the warehouse or facility.

How to use the Free Pre-Start Checklist (Order Picker) Template

This template is designed to be a user-friendly starting point. After downloading the DOCX or PDF file, you can integrate it into your operational procedures.

The process typically involves training operators on its use, establishing a system for submission and review, and defining clear actions for when faults are reported. This structured approach ensures consistency across all shifts and operators.

Important: This document must be customised to your specific operational needs. We have provided a solid foundation, but you are responsible for adapting it to the make, model, and configuration of the order pickers used in your workplace, as well as any unique environmental or operational risks. This process is similar for all plant-specific checklists, such as a free pre-start checklist for bin lifters.

The process involves several key steps:

• Download: Choose between the DOCX format for easy editing or the PDF for straightforward printing.
• Customise: Add your company branding. Most importantly, review and modify the checklist items to match the specific features and safety components of your order picker models. Consider adding items related to the specific environment, such as aisle width or flooring conditions.
• Train: Ensure all licensed operators are trained on how to properly complete the new checklist, what each item means, and the procedure for reporting faults.
• Implement: Integrate the checklist into your daily routine. Determine where completed checklists will be stored and who is responsible for reviewing them.
• Review: Periodically review the checklist's effectiveness and update it as needed, especially after an incident or when new equipment is introduced.

When to use a Pre-Start Checklist

The order picker pre-start checklist should be completed by a competent operator before the start of every shift or before the machine's first use on any given day. If an operator changes during a shift, the incoming operator should also perform a check to verify the machine's condition before they begin work.

Furthermore, a thorough inspection should be conducted if the machine has been involved in any incident, no matter how minor.

Regular completion and review of these checklists provide valuable data over time, which can be assessed during internal or external WHS compliance audits. This data can highlight recurring faults, indicate a need for further operator training, or inform preventative maintenance schedules, helping you move from a reactive to a proactive safety culture.

Who should use it

This Pre-Start Checklist should only be used by operators who hold the appropriate high risk work licence (LO class) and have been deemed competent on the specific make and model of order picker they are inspecting. Competency involves not just the ability to operate the machine, but also a thorough understanding of its safety features and potential failure points.

This ensures the person completing the check can accurately identify and assess any faults or damage.

Supervisors and managers also have a critical role. They are responsible for ensuring the pre-start checks are completed correctly and on schedule.

They must review the completed checklists, sign off on them where required, and take immediate action when a fault is reported. This includes removing the faulty equipment from service until it can be repaired by a qualified person.

If your organisation needs assistance developing competency frameworks, consider engaging specialist WHS consulting services.

By ensuring all site assets are properly maintained, from fixed plant like that covered in a pre-start checklist for a bench grinder to mobile plant, you create a safer workplace. You can explore our complete free WHS resources library for more templates and guides to support your safety management system.