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• JSA template · pick-face and pallets

Warehouse JSA template Australia

Order picking and pallet wrapping can be a JSA — manual handling, wrap machines, a yellow line. The moment you are working in an area with powered mobile plant movements, that is high-risk construction work and a JSA is not enough. Be honest about whether forklifts actually stay out of the pick module.

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Forklifts can make this HRCW

HRCW includes work in an area where there are powered mobile plant movements. Construction work in a warehouse still counts. If pickers and forklifts share the aisle, do not use this JSA as the legal document — you need a SWMS that names that category. See the HRCW checklist.

This example is a segregated pick module at a 3PL in Truganina: forklifts are locked out of the module during pick hours. If that rule is fiction on your site, this is the wrong page.

Filled example: pick module, Truganina VIC

Night shift pick-face. Cartons off low racking, pallet wrap at the marshalling slot, yellow line at the module gate. Reach trucks work the next aisle only after a documented handover.

Job / task
Pick cartons and wrap pallets in a forklift-excluded module
Site
3PL warehouse, Truganina VIC 3029
Document
JSA · not HRCW only if plant stays out · example only
PPE
Hi-vis, steel-caps, gloves when wrapping, high-vis vest on the yellow line

Example layout. If a forklift enters the module while people pick, this JSA is the wrong document — powered mobile plant is HRCW. Victoria: OHS Act 2004 / OHS Regulations 2017.

StepHazardsControls5×5 risk
1. Pre-start: confirm the forklift exclusion is actually locked for this shift
Responsible: Shift supervisor
  • Reach truck still in the module from the previous shift
  • New labour-hire pickers who don’t know the yellow line
  • Battery charger leads across the gate
  • Walk the module; chain or gate shut; radio the forklift supervisor before pick starts
  • Induct labour-hire on the exclusion; no pick until they sign on
  • Coil charger leads; keep the gate clear
InitialL3×C4 = 12 High
ResidualL2×C4 = 8 Medium
2. Pick cartons from low racking onto the pallet jack
Responsible: Picker
  • Manual handling of 15–20 kg cartons above shoulder height
  • Falling cartons from a messy bay
  • Jack run-over on a foot
  • Two-person for anything awkward or overhead; use the step-stool only if it is stable and under 2 m
  • Don’t pull from a leaning stack; restack first
  • Jack behind you, not riding; steel-caps
InitialL4×C3 = 12 High
ResidualL2×C3 = 6 Medium
3. Wrap pallets at the marshalling slot
Responsible: Picker
  • Turntable wrap machine pinch points
  • Trips on wrap tails and dunnage
  • Unstable pallet collapsing mid-wrap
  • Guards on; no reaching in while it turns; emergency stop known
  • Bin tails as you go; keep the slot clear
  • Rebuild a leaning pallet before wrapping; don’t “wrap it tight to hold it”
InitialL3×C3 = 9 Medium
ResidualL2×C2 = 4 Low
4. Handover at the yellow line when a forklift must take the pallet
Responsible: Shift supervisor
  • Forklift entering while pickers are still in the bay
  • Blind corner at the gate
  • People walking behind the forklift
  • Pickers out, radio clear, then the gate opens — not the other way around
  • Horn and spotter at the gate; no pedestrians behind the truck
  • If this handover becomes constant mixed traffic, stop using a JSA and write a SWMS for mobile plant
InitialL4×C4 = 16 Critical
ResidualL2×C5 = 10 High

Frequently asked questions

Do I need a warehouse JSA template?

For segregated pick-face work without powered mobile plant in the same area, a JSA is the usual written assessment. If forklifts, reach trucks or a tug run the aisle while people pick, that is HRCW — you need a SWMS, not a relabelled JSA.

Is the warehouse JSA free?

Trial generate and PDF, no card. This Truganina pick module assumes a documented forklift exclusion. If your site doesn’t have that, don’t use this layout.

SWMS or JSA around forklifts?

Powered mobile plant movements in the work area = HRCW under Schedule 3. JSA is not a substitute. A yellow line that nobody polices is not a control.

NSW, VIC, QLD, WA?

Victoria (this example) uses the OHS Act 2004 and OHS Regulations 2017. NSW, QLD and WA use WHS. The mobile-plant HRCW trigger is treated the same way on a 3PL floor.

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