Manual Handling and Lifting SOP Template

1.Purpose

To reduce manual handling injuries by requiring a load assessment, use of mechanical aids where available, and correct lifting technique for any manual lift.

2.Scope

Applies to any employee lifting, carrying, pushing or pulling a load as part of their work, in offices, warehouses, production areas or client sites.

Definitions

Manual handling

Any activity requiring a person to lift, lower, push, pull, carry or move a load using bodily force.

Mechanical aid

Equipment such as a trolley, hoist, forklift or hand truck used to move a load instead of, or in support of, manual lifting.

3.Responsibilities

Employee

Assesses the load before lifting, uses mechanical aids where available, applies safe lifting technique and reports strain injuries.

Supervisor

Makes sure mechanical aids are available and maintained, and enforces team lifting for loads beyond a safe individual limit.

Safety Officer

Provides manual handling training, reviews injury trends and recommends changes to tasks or equipment.

RACI matrix

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

4.Materials and PPE

Materials, tools and systems

• →Hand trucks, trolleys or dollies
• →Hoists or lifting equipment where provided
• →Manual handling risk assessment for known heavy or awkward tasks
• →Clear, marked walkways free of obstacles
• →Manual handling training materials

Personal protective equipment

• →Gloves for grip and hand protection
• →Safety footwear with slip resistance

5.Procedure

1. 5.1

   Assess the load

   Employee

   Before lifting, check the load's weight, size, shape and stability, and look for sharp edges or shifting contents that could change how you handle it.

2. 5.2

   Plan the route

   Employee

   Look at the path you will carry the load along and clear obstacles, confirm doors can be opened in advance, and identify where you will set the load down.

3. 5.3

   Use a mechanical aid where available

   Employee

   Use a trolley, hand truck, hoist or other mechanical aid instead of a manual lift whenever one is available and suitable for the load.

   Checkpoint: A mechanical aid is used for the task whenever one is available and appropriate for the load.

4. 5.4

   Position your feet and body

   Employee

   Stand close to the load with feet shoulder-width apart, one foot slightly forward, to give a stable base before lifting.

5. 5.5

   Bend your knees, not your back

   Employee

   Bend at the knees and hips while keeping your back straight, lowering yourself to the load rather than bending forward from the waist.

   Warning: Bending and twisting your back while lifting is one of the most common causes of manual handling injury.

6. 5.6

   Get a firm grip and lift smoothly

   Employee

   Get a secure grip on the load using handles if provided, then lift smoothly using your leg muscles, avoiding jerky or sudden movements.

7. 5.7

   Keep the load close to your body

   Employee

   Carry the load as close to your body as possible, at waist height where practical, since holding it away from your body increases the strain on your back.

8. 5.8

   Turn your feet instead of twisting

   Employee

   If you need to change direction while carrying a load, move your feet to turn your whole body rather than twisting at the waist.

9. 5.9

   Team-lift loads beyond a safe individual limit

   Supervisor

   For loads too heavy, bulky or awkward for one person, arrange a team lift or mechanical aid, coordinating the lift together rather than each person lifting independently or as required by your local regulations.

10. 5.10

    Set the load down with control

    Employee

    Lower the load with a controlled movement, bending your knees again rather than bending forward, and check your fingers are clear before releasing it.

11. 5.11

    Report strain or discomfort

    Employee

    Report any strain, pain or discomfort from a lift to your supervisor right away, rather than continuing to work through it, so it can be assessed and treated early.

12. 5.12

    Request reassessment for repetitive tasks

    Supervisor

    For tasks involving frequent or repetitive lifting, request a manual handling reassessment or refresher training to check whether the task can be improved.

6.Quality checks

• →Mechanical aids are available and in working order for known heavy or awkward tasks.
• →Employees can demonstrate correct lifting technique during observation.
• →Team lifts are used for loads identified as too heavy or awkward for one person.
• →Reported strains and discomfort are logged and followed up promptly.

7.Records

• →Manual handling training records
• →Strain and discomfort incident reports
• →Manual handling risk assessments for repetitive tasks

8.KPIs

• →Number of manual handling injuries or strains reported per quarter
• →Percentage of employees trained in manual handling technique
• →Number of tasks converted from manual lifting to mechanical aids

9.Common mistakes

• →Bending forward from the waist instead of bending the knees.
• →Twisting the back while carrying a load instead of turning the feet.
• →Attempting to lift a heavy or awkward load alone instead of getting help.
• →Ignoring early discomfort instead of reporting it before it becomes an injury.

10.Revision history