Manual handling injuries are the most common injury type in Australian manufacturing, accounting for the largest share of workers compensation claims across the sector. Workers lift, carry, push, and position raw materials, components, sub-assemblies, and finished products throughout production, packing, and dispatch operations. Repetitive tasks on production lines cause cumulative musculoskeletal damage even when individual loads are manageable. This template maps controls to the binding Hazardous Manual Tasks Code of Practice effective 1 July 2026 under Section 26A.
WHS Regulation 2025 Part 4.2 — Hazardous Manual Tasks
Hazardous manual tasks
Hazardous Manual Tasks (binding 1 July 2026 under Section 26A)
Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.
| Hazard | Consequence | Likelihood |
|---|---|---|
| Lifting heavy raw materials and finished products | Back injuries, disc prolapse, shoulder injuries | Almost Certain |
| Repetitive assembly and packing movements | Cumulative musculoskeletal disorders, tendinitis | Likely |
| Pushing and pulling heavy trolleys and containers | Back strains, shoulder injuries | Likely |
| Awkward postures during machine loading and unloading | Back strain, knee injuries | Likely |
| Sustained static postures during inspection and assembly | Neck pain, upper back pain | Likely |
| Vibration from hand-held power tools | Hand-arm vibration syndrome | Possible |
Worker death during manufacturing operations with inadequate safety procedures and equipment.
2024 — SafeWork SA Manufacturing Prosecution [2024]
Multiple safety failures in manufacturing operations including inadequate controls.
2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]
Our ergonomics consultants build task-specific SWMS that reduce musculoskeletal injuries in your manufacturing operations.
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