Purpose

Poor manual handling is one of the most common causes of absence from work. These injuries can affect areas including the back, shoulders, arms, legs, and other joints. Many of these injuries can have long-lasting effects, which can negatively affect a person’s quality of life. These recommendations will promote good practice in lifting, handling, and carrying items and it will help prevent back and other musculoskeletal strain injuries.

Scope

This SOP applies to all employees lifting or carrying a load in the workplace.

Definitions

• Manual Handling: the transporting or supporting of a load including the lifting, putting down, pushing, pulling, holding, carrying, and moving by hand or bodily force.
• Load: A moveable object. This includes packages, boxes, tools and in rare instances people.

Responsibilities

• Supervisors/Managers:
  • Avoid the staff from manual handling which involves risk of injury wherever it is possible.
  • Provide adequate information, instructions, and training to employees.
  • Provide equipment to eliminate or reduce any risks.
• Staff
  • Ensure you apply the correct manual handling procedure.
  • Immediately report any incident to First Aiders, Health and Safety Reps and Human Resources.
• Safety Officer:
  • Conduct assessments for all manual handling operations.
  • Record and review assessment as required.

Pre-Start Checks

1. Ensure that the equipment supplied by the company is suitable for the task and meets the requirements.
2. Check the load and size it up (weight, size, and shape). Consider your ability to manage the load, if in doubt, get assistance.
3. Prior to lifting/moving the item, confirm where the object will be delivered or stored to verify sufficient space and if the area can manage the weight of the object.
4. Wear appropriate PPE: foot protection, and gloves, if necessary.
5. Ensure the path is clear of obstructions and personnel.

Safe Operating Procedure

1. Position yourself as close to the centre of the load as possible.
2. Adopt a balanced position, place your feet apart to make sure your body posture is evenly balanced. If the load is below waist height, straddle it if possible before lifting.
3. Bend knees to comfortable degree and get a good handhold.
4. Maintain normal spinal curves, always bend your knees not your back.
5. Tighten stomach muscles, commence to lift the load keeping it close to the body.
6. Lift the load using leg muscles and allow the load to rest in fully extended arms.
7. With the load comfortably supported by the hands and arms, move off in the direction of travel.
8. Setting the load down is just as important as picking it up. Using leg muscles, lower the load by bending your knees. When safe to release the load release your grip.
9. If using a trolley, never overload – always adhere to the weight capacity.
10. When loading and unloading the trolley follow the principles of the standard lifting technique, make sure the load is as close as possible before lifting.
11. Never walk with items stacked so high that your vision is obstructed.
12. Do not stack items so that they are unstable.

Overhead Loads

1. When overloading a load from shelving always use a step stool or ladder to avoid overreaching.
2. Evaluate weight of item before removing from shelving.
3. Slide the object towards you.
4. Hold load close to your body when stepping off ladder or step stool.
5. Store heavy item and the most frequently used items at waist level.
6. If item is awkward or heavy to manage, ask for help.

Emergency Responses

• Stop work immediately.
• Call for medical assistance e.g. first aider or emergency services.
• Do not move the injured person, unless in immediate danger.
• Notify a supervisor or manager immediately and complete incident report.

While Waiting for Help:

• Keep the injured person stable and elevated if possible.
• Apply ice (if appropriate) to reduce swelling.
• Reassure the injured person and monitor for shock.

Incident Reporting & Investigation

• Report all manual handling incident or near misses and complete an Incident Report Form within 24 hours by reporting it to your Health and Safety Reps, Human Resources, and your manager.
• Supervisor to conduct a preliminary investigation.
• Safety officer to perform a root cause analysis.
• Document all findings and update any relevant risk assessments or SOPs.
• Ensure corrective actions from investigations are implemented and reviewed for effectiveness.

Post-Operation Procedure

• After completing any manual handling task, return all equipment (trolleys, lifting aids) to designated storage areas.
• Check equipment for any signs of damage or wear.
• Report any faults or maintenance needs.
• Access yourself for any signs of strains, discomfort, or injury.
• Report any symptoms to your supervisor immediately.
• Note any difficulties or hazards encountered during the task.

Training & Review

• All staff must receive manual handling training annually.
• Review this SOP every 12 months or following any incident.
• Refresher training provided after incidents or procedural changes.
• Keep training records and attendance logs for auditing and compliance.