Free Pre-Start Checklist (Stock Picker) Template

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

A stock picker, also known as an order picker or stock-picking truck, is essential for efficient warehouse operations but introduces significant safety risks if not properly maintained. This free Pre-Start Checklist (Stock Picker) Template provides a structured framework for operators to conduct thorough pre-operational inspections.

Regular use helps identify potential faults, mechanical issues, or damage before the equipment is used, preventing incidents, minimising downtime, and demonstrating a commitment to workplace health and safety. Formalising these daily checks is a fundamental part of managing plant safety in any organisation.

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

This document serves as a robust starting point for developing a site-specific checklist. To implement it effectively, download the template in your preferred format (DOCX for easy editing or PDF).

The next step is crucial: you must customise the checklist to reflect the specific make and model of the stock pickers used in your workplace, as well as the unique environmental and operational risks present. Effective implementation of such safety tools is a core component of well-designed WHS management systems.

• Review the default items and add or remove checks relevant to your equipment (e.g., specific controls, battery type, safety harness anchor points).
• Incorporate your company’s branding and safe operating procedures.
• Train all operators and supervisors on how to complete the checklist correctly and the procedures for reporting faults.
• Implement a system for filing and reviewing completed checklists regularly.

Important: We have created this template as a guide based on common WHS practice. It is not a complete, out-of-the-box solution.

You must adapt it to the specific plant, personnel, and risks in your workplace to ensure it is effective.

Key Components of a Stock Picker Check

A comprehensive pre-start inspection covers several critical areas to ensure the stock picker is safe to operate. While your customised checklist will be more detailed, it should generally assess:

• Controls and Instruments: Check that all operating controls (lift, lower, travel, steering) function smoothly. Verify that gauges, lights, and the horn are working correctly.
• Safety and Emergency Equipment: Inspect the harness, lanyard, and anchor points for wear or damage. Test the emergency stop button and emergency lowering device. Ensure safety gates and guardrails are secure.
• Structure and Chassis: Look for any cracks, dents, or other signs of damage to the mast, platform, chassis, and overhead guard.
• Power System: For electric models, check battery charge, fluid levels, and look for any damage to cables or connectors. For internal combustion models, check fuel and oil levels.
• Wheels, Tyres, and Brakes: Inspect wheels and tyres for excessive wear or damage. Test the parking and service brakes to ensure they hold the machine securely.

Periodic reviews of completed checklists can provide valuable data for your safety program, often forming a key part of WHS compliance auditing.

When to use it

The pre-start checklist should be completed by the operator before the first use of the stock picker on every shift. It should also be completed if the operator changes during a shift.

A new check is also recommended after the equipment has undergone significant repairs or maintenance to verify its safe return to service. Integrating these checks into daily routines can be reinforced by discussing their importance, which is an ideal topic for our Pre-Start Checks and Plant Maintenance Toolbox Talk Template.

Who should use it

The checklist must be completed by a person who is competent to operate the stock picker. This means they have received the necessary training, instruction, and information on the specific model in use.

Supervisors or managers should also be familiar with the checklist process to verify that checks are being completed correctly and to action any reported faults. Assessing and verifying operator skill is a critical WHS duty, and our Verification of Competency (Cherry Picker (Truck-Mounted)) Template provides a structured example for a related piece of plant.

Integrating Pre-Start Checks into Daily Operations

To make pre-start checks an effective and consistent habit, they should be integrated into the start-of-shift workflow. Many organisations find it helpful to discuss safety matters, including any faults found on plant, during brief daily team meetings.

Using a formal document like our Free Pre-Start Meeting Template can help structure these discussions and ensure important safety information is communicated to all relevant workers before work commences.

This stock picker checklist is just one of many tools available to help you build a safer workplace. Explore our complete free WHS resources library for more templates, toolbox talks, and guides to support your safety management system.