Free Safe Operating Procedure (Manual Order Picking) Template

Purpose of the Free Safe Operating Procedure (Manual OrderPicking) Template

Manual order picking is a common task in warehouses, distribution centres, and retail environments, but it carries significant risks. This Free Safe Operating Procedure (Manual Order Picking) Template provides a structured framework to help your organisation document the safest way to perform these tasks.

By clearly outlining the steps, potential hazards, and required controls, you can systematically manage risks such as musculoskeletal disorders (MSDs) from repetitive lifting, bending, and reaching. A well-defined SOP is a critical component of your overall safety management system, demonstrating a commitment to worker health and safety.

Using this template helps formalise your approach to managing common warehouse hazards, including slips, trips, falls, and being struck by falling objects. It establishes a consistent, repeatable method for training new and existing staff, ensuring everyone understands the benchmark for safe performance.

Documented procedures also form a vital part of your risk management records and support investigations if an incident occurs. This SOP is intended for manual tasks; for mechanised equipment, you will require separate procedures, such as our FREE Telehandler SOP Template.

How to use the Free Safe Operating Procedure (Manual Order Picking) Template

This resource is provided as a fully editable DOCX file and a ready-to-use PDF. The DOCX version allows for complete customisation to align with your specific operational context.

It's designed to be a starting point, providing a logical structure based on Australian WHS principles and common industry practice.

IMPORTANT: This is a template only. We have provided a structured starting point, but you MUST customise this document to reflect the specific equipment (e.g., trolleys, pallet jacks), layout, products, and tasks at your workplace.

You must consult with your workers and other relevant stakeholders during this process to ensure the SOP is practical and effective.

To implement this SOP:

• Download the DOCX template.
• Conduct a risk assessment of your manual order picking activities to identify all relevant hazards.
• Customise the template by adding site-specific details, including the types of goods handled, required Personal Protective Equipment (PPE), and emergency procedures.
• Involve your workers in the review process to capture their valuable on-the-ground knowledge.
• Finalise and approve the SOP through your organisation's official channels.
• Train all relevant workers on the finalised SOP and ensure they can demonstrate competency.
• Schedule regular reviews to keep the procedure current. If you need assistance with customisation or implementing WHS management systems, professional support can be invaluable.

When to use it

A Safe Operating Procedure for manual order picking should be a living document, integrated into your daily operations. It should be formally used before any worker undertakes the task for the first time.

It serves as a primary training tool during induction and for any refresher training sessions, reinforcing correct technique and hazard awareness. This document is particularly important when using equipment as part of the picking process, such as ladders; for these specific tasks, consider using a dedicated procedure like our FREE Step Ladder SOP Template.

The SOP should also be reviewed and referenced after any incident or near miss related to order picking. This helps in identifying gaps in the procedure or training.

Furthermore, it must be updated whenever there is a change in the workplace, such as the introduction of new racking systems, different types of products, new handling equipment, or a change in the workflow. Regular reviews ensure it remains relevant and effective in preventing harm. If your warehouse or workshop environment includes other fixed plant, you may also need procedures for equipment like our Free Air Compressor SOP (Safe Operating Procedure) Template.

Who should use it

This SOP template is designed for a range of personnel within an organisation. WHS Managers and Advisors will use it as a foundational tool to build and formalise their safety processes.

Warehouse Managers, Supervisors, and Team Leaders are responsible for implementing the SOP on the floor, using it for training, and monitoring compliance. They play a key role in the customisation and review process, ensuring the procedure is practical for their teams.

Workers who perform manual order picking are the primary end-users. They should be trained on the SOP's contents and use it as a reference to perform their duties safely.

Finally, a Person Conducting a Business or Undertaking (PCBU) can use the finalised SOP to demonstrate how they are meeting their primary duty of care under WHS law to provide and maintain safe systems of work. You can explore our entire catalogue of procedural documents in our free WHS resources library to support your safety framework.