Material Handling SOP Template

1.Purpose

To move material safely and accurately between storage, production and shipping areas, keeping inventory records correct and material moving in the right rotation to support the production schedule.

2.Scope

Applies to internal movement of raw material, work-in-process and finished goods using forklifts, pallet jacks or hand carts. Receiving inspection at the dock is covered by a separate SOP.

Definitions

WMS

Warehouse management system, used to track material location, quantity and movement transactions.

FIFO

First in, first out. A stock rotation method that uses the oldest available material first.

Pick list

The list of materials, quantities and locations to be retrieved for a production order or shipment.

Point of use

The location on the production floor where material is staged for consumption by a process or workstation.

3.Responsibilities

Material Handler

Picks and transports material per the pick list, verifies quantities, and updates WMS transactions.

Forklift Operator

Performs pre-operation equipment inspection and transports loads safely per site traffic rules.

Warehouse Supervisor

Maintains storage locations, reviews inventory accuracy, and enforces safe handling practices.

Production Supervisor

Confirms point-of-use staging supports the production schedule and reports material shortages.

RACI matrix

R = Responsible, A = Accountable, C = Consulted, I = Informed

4.Materials and PPE

Materials, tools and systems

• →Warehouse management system (WMS) with pick lists
• →Forklift and pallet jack pre-operation checklist
• →Barcode scanner
• →Site traffic route map
• →Material handling instructions for hazardous or fragile items
• →Damaged material report form

Personal protective equipment

• →High-visibility vest
• →Steel-toe boots
• →Gloves appropriate to the material
• →Hearing protection in high-noise areas

5.Procedure

1. 5.1

   Complete the forklift pre-operation inspection

   Forklift Operator

   Forklift operator completes the pre-operation checklist covering brakes, forks, horn, lights and fluid levels before using the equipment for the shift.

   Checkpoint: Pre-operation checklist is completed and signed before the forklift is used for any move.

2. 5.2

   Review the pick list in the WMS

   Material Handler

   Material handler reviews the pick list generated by the WMS for the production order or shipment, noting locations, quantities and any special handling instructions.

3. 5.3

   Retrieve material from the storage location

   Material Handler

   Handler retrieves the material from the location shown on the pick list, following FIFO or lot rotation rules for the material type.

4. 5.4

   Verify material against the pick list

   Material Handler

   Handler checks the part number, lot number and quantity of the retrieved material against the pick list before moving it.

   Checkpoint: Part number, lot and quantity match the pick list before the material leaves the storage location.

5. 5.5

   Inspect the load for stability

   Forklift Operator

   Forklift operator inspects the load for stability and confirms it is within the equipment's rated weight capacity before lifting or moving it.

   Warning: Never exceed the forklift's rated load capacity or transport an unstable or improperly stacked load.

6. 5.6

   Transport material on designated routes

   Forklift Operator

   Operator transports the load following the site's designated traffic routes and posted speed limits, sounding the horn at blind corners and intersections.

7. 5.7

   Stage material at point of use

   Material Handler

   Handler stages the material at the correct point-of-use location for the production line, following FIFO so older lots are consumed first.

8. 5.8

   Scan and update the WMS transaction

   Material Handler

   Handler scans the material and location to update the WMS inventory transaction, confirming the system location matches the physical location.

9. 5.9

   Handle empty containers and returns

   Material Handler

   Handler returns empty pallets, containers and racks to their designated staging area for reuse or pickup, keeping them out of active traffic lanes.

10. 5.10

    Report damaged material or packaging

    Warehouse Supervisor

    Handler reports any damaged material, packaging or containers found during handling to the warehouse supervisor and completes a damage report before the material is used or shipped.

11. 5.11

    Maintain clear aisles and staging areas

    Material Handler

    Handler keeps aisles, fire lanes and staging areas clear of material and debris, following the site's floor marking standards.

12. 5.12

    Secure hazardous or fragile materials

    Material Handler

    Handler follows the specific handling instructions for hazardous or fragile materials, including required secondary containment or protective packaging during transport.

6.Quality checks

• →Forklift pre-operation checklists are completed for every shift the equipment is used.
• →WMS system location matches the physical location during periodic spot checks.
• →Material staged at point of use follows FIFO rotation with no expired or aged lots skipped.
• →Damaged material is reported and documented before it reaches production or shipping.

7.Records

• →Forklift pre-operation checklists
• →WMS inventory transaction log
• →Damaged material reports
• →Pick list completion records

8.KPIs

• →Inventory location accuracy
• →On-time material delivery to point of use
• →Material handling incidents or near-misses
• →Damaged material rate

9.Common mistakes

• →Skipping the forklift pre-operation checklist on a shift that's already running late.
• →Moving material without scanning it, causing the WMS to show the wrong location.
• →Breaking FIFO rotation by grabbing the most convenient pallet instead of the oldest lot.
• →Overloading a forklift or stacking a load beyond a safe height.
• →Leaving empty pallets or containers blocking an aisle or fire lane.

10.Revision history