Pallet Jack & Material Mover

The SOP for Pallet Jack & Material Mover (SOP-MHE-001) is a comprehensive guide addressing key hazards associated with operating pallet jacks, including crush injuries, manual handling strain, and battery hazards. This document is essential for all personnel involved in material handling operations, ensuring compliance with Australian workplace safety legislation. By following this SOP, organizations can enhance worker safety, reduce injury risks, and promote effective handling practices.

• Run-over of feet by pallet jack wheels or load → crush injury, broken bones
• Crush injury between the load, jack, and a fixed structure → serious injury
• Manual handling strain from pushing or pulling overloaded pallet jacks → back, shoulder strain
• Loss of control on ramps, slopes, or inclines → struck-by or run-over
• Tip-over of unstable or overloaded pallet → struck-by
• Pinch injuries between the handle, tow yoke, and operator's body
• Battery hazards on electric units — acid spills, hydrogen off-gassing during charging
• Collision with pedestrians, racking, or other plant

• Work Health and Safety Act 2011 (Cth) and applicable state/territory WHS legislation
• Work Health and Safety Regulation 2011 (Cth) — Schedule 3 High Risk Work Licences; Part 3.1 Plant; Part 4.2 Hazardous Manual Tasks
• AS 2359.2 — Powered industrial trucks — Operations
• AS 2359.6 — Powered industrial trucks — Safety code
• AS/NZS 4024.1 series — Safety of machinery
• Safe Work Australia — Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia — Code of Practice: Hazardous Manual Tasks
• Safe Work Australia — General Guide for Industrial Lift Trucks
• Pallet Jack Pre-Use Checklist (associated document)