Pre-Task Plan: Material Handling

Date: [DATE] Work Area: [WORK AREA] Task Supervisor: [SUPERVISOR NAME]

1. Task Description

[Moving materials from storage to work area using manual and mechanical methods.]

2. Task Duration

Estimated Start: [START TIME] Estimated Completion: [END TIME]

3. Personnel Involved

• [ROLE 1: Material Handler]
• [ROLE 2: Spotter/Signaller]
• [ROLE 3: Equipment Operator]

4. Task-Specific Hazards and Controls

Hazard	Risk	Control Measures
Manual lifting of heavy objects [1]	Musculoskeletal injuries (strains, sprains) [1]	Use mechanical aids where possible [2]. Ensure proper lifting techniques are followed [1]. Team lifting for loads exceeding weight limits.
Motorized equipment operation (forklifts, etc.) [1]	Collisions, struck-by incidents [1]	Ensure operators are trained and certified. Use spotters in congested areas. Maintain safe operating distances. [3] Adhere to speed limits.
Improper storage of materials [4]	Falling materials, tripping hazards 8, 19	Stack materials securely, ensuring they are blocked and interlocked [5]. Keep aisles and passageways clear 11, 14, 19. Do not exceed floor load limits [4].
Use of rigging equipment (slings, chains) [3]	Load dropping due to rigging failure [6]	Inspect rigging equipment before each use 8, 18. Ensure rigging has legible identification markings indicating safe working load 8, 18. Do not exceed safe working loads 6, 8. Remove defective equipment from service 8, 18.
Slips, trips, and falls	Injuries due to loss of balance	Maintain good housekeeping practices 8, 18. Clean up spills immediately. Use appropriate footwear. Ensure adequate lighting.
Pinch points and sheer points on machinery [2]	Lacerations, crushing injuries [2]	Ensure machine guarding is in place and functioning correctly [2]. Use lockout/tagout procedures when servicing equipment. Be aware of pinch points.

5. Required PPE for Today's Task

• [PPE item 1: Safety glasses]
• [PPE item 2: Steel-toed boots]
• [PPE item 3: Gloves]
• [PPE item 4: High-visibility vest]

6. Tools and Equipment Needed

• [Tool/Equipment 1: Forklift]
• [Tool/Equipment 2: Pallet jack]
• [Tool/Equipment 3: Slings/Chains]
• [Tool/Equipment 4: Hand truck/Dolly]

7. Pre-Start Checklist

Area Preparation

• [Ensure adequate lighting in the work area]
• [Clear pathways of obstructions]
• [Check floor load limits are posted and not exceeded]

Equipment Checks

• [Inspect forklift for defects (tires, brakes, lights)]
• [Verify slings and chains are in good condition and rated for the load]
• [Ensure pallet jack wheels are functioning properly]

Communication

• [Review hand signals for forklift operation]
• [Confirm emergency shutdown procedures are understood]
• [Establish clear communication between equipment operator and spotter]

8. Task Steps Overview

1. [Inspect materials for damage before handling]
2. [Use appropriate lifting techniques or equipment to move materials]
3. [Secure materials properly during transport]
4. [Place materials in designated storage areas]
5. [Maintain clear pathways and avoid obstructing exits]

9. Emergency Response for This Task

• [Material spill] → [Contain the spill, report to supervisor, follow SDS guidelines]
• [Equipment malfunction] → [Stop operation, engage emergency brake/shutdown, report to supervisor]
• [Injury during lifting] → [Administer first aid, call for medical assistance if needed, report the incident]

10. Task-Specific Precautions

• [Precaution 1: No jewelry to be worn during manual handling [7]]
• [Precaution 2: Never walk under suspended loads]
• [Precaution 3: Report any unsafe conditions immediately]

Pre-Task Briefing Confirmation

All workers understand the task, associated hazards, and required controls.

Team Lead Initials: [___] Date: [DATE] Time: [TIME]

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