Forklift Operation (Manufacturing) SWMS

Forklift operations in manufacturing facilities involve moving raw materials from receiving to production, transferring work-in-progress between production stages, and loading finished products for dispatch. Pedestrian interaction in shared production spaces is the primary fatality risk. The WHS Regulation 2025 requires High Risk Work Licences for all forklift operators and specific traffic management plans where forklifts and pedestrians share workspaces. This template maps controls to the binding Managing Risks of Plant Code of Practice effective 1 July 2026 under Section 26A.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.5 — High Risk Work Licences and Part 4.7 — Plant

hrcw category

Work involving powered mobile plant

code of practice

Managing Risks of Plant in the Workplace (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

hrwl required

LF class licence for forklift operation

Hazards

Hazard	Consequence	Likelihood
Pedestrian strike in shared production and warehouse areas	Crush injuries, fractures, death	Possible
Forklift tip-over during turning or on ramps	Operator crush, death	Unlikely
Racking collapse from forklift impact	Multiple injuries, product avalanche, entrapment	Unlikely
Load drop from unstable or oversized loads	Struck-by injuries, crush	Possible
Collision with structures, plant, and other vehicles	Structural damage, operator and bystander injuries	Possible
LPG or diesel exhaust in enclosed warehouse spaces	CO poisoning, respiratory irritation	Possible

Controls (Hierarchy of Controls)

Verify HRWL currency for all forklift operators before work commences

Establish designated pedestrian and forklift zones with physical barriers or floor markings

Install pedestrian detection systems, blue safety lights, and audible alarms on all forklifts

Conduct pre-start inspections covering brakes, steering, tyres, mast, and safety devices

Implement speed limits appropriate to each area of the facility

Use electric forklifts in enclosed production areas to eliminate exhaust emissions

Install racking protection bollards and conduct annual racking integrity inspections

Train all workers in pedestrian safety awareness around forklift operating areas

Recent Prosecutions

SafeWork SA prosecution$840,000

Worker death in manufacturing facility incident involving plant and equipment safety failures.

2024 — SafeWork SA Manufacturing Prosecution [2024]

Orica Australia Pty Ltd$1,200,000

Multiple safety failures in industrial operations including plant management deficiencies.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

What Your SWMS Must Include

✓HRWL verification records for all forklift operators

✓Traffic management plan showing pedestrian and forklift zones

✓Pre-start inspection checklist

✓Speed limits for each area of the facility

✓Racking inspection schedule and damage reporting procedure

Need a compliant Manufacturing Forklift SWMS?

Our WHS consultants build site-specific SWMS that address pedestrian safety, traffic management, and HRWL compliance for your manufacturing forklift operations.