Order Picker (Stock Picker) SWMS
High-level order-picker operations in warehouse and distribution centres — harness and fall-restraint anchoring, platform interlock, aisle navigation, product-dropping prevention and rescue-from-height planning.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
High-level order picker (stock picker) operations involve elevating an operator on a powered mobile platform to retrieve stock from racking above 2 metres in warehouses and distribution centres. This SWMS addresses WHS Regulation 2025 Chapter 4 Part 4.5 (Plant), Part 4.4 (Falls), and Schedule 3 high-risk work licensing (LO – Order Picking Forklift Truck). It covers harness anchoring to AS/NZS 1891, platform interlocks, aisle traffic management, dropped-object prevention and rescue-from-height planning required under sections 19 and 20 of the WHS Act.
Hazards identified
12 hazards covered, sorted by priority.
Operator falls from height causing serious injury or fatality if harness or guardrails fail.
Operating order picker without LO high-risk work licence breaches WHS Reg Schedule 3.
Non-compliant or unrated anchor point fails under arrest load causing fatal fall.
Defeated interlock allows travel at height risking ejection or tip-over.
Limited visibility in narrow aisles causes pedestrian struck-by injuries.
Stock falling from elevated platform strikes pedestrians or workers below causing serious injury.
Mast or platform impact destabilises racking triggering progressive collapse and crush injuries.
Order picker tips when traversing damaged floors or exceeding rated capacity at height.
Hydrogen gas, acid splash and arc flash during lead-acid battery charging cause burns or explosion.
Worker suspended in harness develops orthostatic shock without prompt rescue from height.
Reaching and lifting cartons on elevated platform causes musculoskeletal strain and loss of balance.
Poor illumination obscures hazards and labels increasing collision and mis-pick incidents.
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Verify operator holds current LO high-risk work licence and site-specific familiarisation before use.
- 2Wear full body harness with shock-absorbing lanyard anchored to manufacturer-rated platform anchor per AS/NZS 1891.
- 3Conduct documented pre-start inspection covering interlocks, brakes, harness, anchor, tyres and emergency lowering.
- 4Implement traffic management plan separating pedestrians via barriers, mirrors, blue spot lights and audible alarms.
- 5Prohibit travel at height above creep speed and never override platform or gate interlocks.
- 6Establish written rescue-from-height plan with trained rescuers and equipment available within 10 minutes.
- 7Charge batteries in ventilated bunded area with PPE, eyewash and no ignition sources nearby.
Applicable Codes of Practice
Approved code prescribing safe operation, inspection and maintenance of order picking forklift trucks.
Specifies harness, lanyard and anchor selection, inspection and use for elevated picker operations.
Mandates fall-prevention hierarchy and rescue planning for work above 2 metres on platforms.
High-Risk Construction Work triggered
Order picker is powered mobile plant operating in workplace requiring competent licensed operator and SWMS under Reg 291.
Picking operations elevate worker well above 2 metres on a platform exposing them to fall risk.
HRCW work without documented SWMS breaches WHS Reg 291; PCBU faces Category 2 penalties up to $1.5M and stop-work notices.
Who this is for
- →Warehouse and distribution centre PCBUs operating order picking forklifts
- →3PL logistics supervisors managing high-bay picking operations
- →Retail and e-commerce fulfilment centres with elevated stock picking
What you receive
- ✓Editable DOCX SWMS pre-filled for order picker operations
- ✓State-specific WHS legislation schedule (NSW, VIC, QLD, WA, SA, TAS, ACT, NT)
- ✓Hazard register with risk matrix and residual ratings
- ✓Worker sign-on register for SWMS consultation evidence
Worked example
A Sydney 3PL fulfilment centre uses order pickers to a 9-metre pick face. Implementing this SWMS, they verified LO licences, fitted rated anchor points, deployed blue-spot lights and pedestrian exclusion zones, and trained two rescuers per shift on descender-based retrieval. A SafeWork NSW spot audit confirmed compliance with WHS Reg 291 and the Falls Code, avoiding an improvement notice. Suspension-trauma rescue drills are now logged quarterly, reducing insurer premiums and eliminating near-miss pedestrian incidents.
Related legislation
- WHS Act 2011 (model) sections 19, 20, 28
- WHS Regulations 2025 Chapter 4 Part 4.5 – Plant
- WHS Regulations 2025 Part 4.4 – Falls
- WHS Regulations 2025 Schedule 3 – High Risk Work Licences (LO)
- WHS Regulations 2025 Reg 291 – SWMS for high-risk construction work