TLID107C - Shift Materials Safely Using Manual Handling Methods - Learner GUide

TLID107C Shift
materials safely using

manual handling
methods
Learner Guide
Contents
What this Learner’s Guide is about ........................................ 1
Planning your learning ........................................................... 2
How you will be assessed ...................................................... 4
Section 1............................................................................................. 5
Assess risks arising from the relocation of a load .................. 5
Section 2........................................................................................... 21
How do you plan a load relocation and relocate loads?....... 21
Additional resources ....................................................................... 31
Feedback on activities .................................................................... 33

TLID107C Shift materials safely using manual handling methods
Page 0 © Australian National Training Authority 2003

ADELG1003 Customised and Developed by Armstrong’s Driver Education P/L March
2008
What this Learner’s Guide is about
This Learner’s Guide is about the skills and knowledge required to shift
loads using manual handling methods, including assessing the risks
associated with relocating the load, planning the relocation process
and carrying out the relocation in accordance with the plan.
Persons achieving competence in this unit will need to fulfil all of the
relevant state/territory OHS regulatory requirements concerning the
safe lifting and handling of a load using manual handling techniques.
The Elements of Competency from the unit TLID107C Shift materials
safely using manual handling methods covered in this Learner’s Guide
are listed below.
Assess risks arising from the relocation of the load
Plan load relocation
Relocate load
This unit of competency is from the Transport and Logistics Training
Package (TLI07).
© Australian National Training Authority 2003 Page 1

Customised and Developed by Armstrong’s Driver Education P/L March 2008 ADELG1003
Planning your learning
It is important to plan your learning before you start because you may
already have some of the knowledge and skills that are covered in this
Learner’s Guide. This might be because:
• you have been working in the industry for some time,
and/or
• you have already completed training in this area.
Together with your supervisor or trainer use the checklists on the
following pages to help you plan your study program. Your answers to
the questions in the checklist will help you work out which sections of
this Learner’s Guide you need to complete.
This Learner’s Guide is written with the idea that learning is made more
relevant when you, the learner, are actually working in the industry.
This means that you will have people within the enterprise who can
show you things, discuss how things are done and answer any
questions you have. Also you can practise what you learn and see how
what you learn is applied in the enterprise.
If you are working through this Learner’s Guide and have not yet found
a job in the industry, you will need to talk to your trainer about doing
work experience or working and learning in some sort of simulated
workplace.

2008
Section 1: Assess risks arising from the

relocation of a load
Are you able to: Yes No

1. define manual handling and explain its
importance to the worker in a warehouse
situation?
2. understand the importance of Regulations
and Codes of Practice applicable to shifting
materials safely?
3. assess risks arising from relocation of
various loads (size up a load)?
4. demonstrate the six steps to manually
shifting materials safely?
Section 2: How do you plan a load relocation

and relocate loads?
Are you able to: Yes No

1. plan a load relocation?
2. check your plan for compliance with
workplace practise and procedures?
3. follow the relocation plan?
4. coordinate team lifting tasks?
5. set down and check load?

How you will be assessed
Assessment of this Unit of Competency will include observation of real
or simulated work processes using workplace procedures and
questioning on underpinning knowledge and skills. It must be
demonstrated in an actual or simulated work situation under
supervision.
You will be required to:

• describe manual handling operations undertaken in the
warehouse
• demonstrate correct techniques for shifting materials
safely
• demonstrate planning load relocation and load relocation.

2008
Section 1
Assess risks arising from the

relocation of a load

Section outline
Areas covered in this section
The need to assess (judge) risks arising from shifting materials
Common materials shifting hazards and how to minimise them
Identifying and demonstrating the safe and correct methods for

shifting materials safely
The importance of correct manual handling to the worker in the
warehouse

2008
How do you assess risks arising from relocation

of a load?
What is manual materials handling?
Shifting materials safely may make up the majority of the work the
storepeople do in a warehouse.
A large proportion of materials shifting may be done manually,

depending on how your warehouse operates.
Manual material handling is defined as:
‘any activity requiring the use of force exerted by a person to lift, push,
pull, carry or otherwise move, hold or restrain any person, animal or
thing’.
The main methods used are:

• pushing, such as pushing a drum
• carrying, such as carrying a carton of stock
• lifting, such as lifting a box up onto a shelf
• reaching or holding, such as placing or passing stock onto
higher shelving
• small, frequent tasks (repetitious) such a keyboard entries
or loading small stock items from a shelf onto a pallet from
one position.

Activity 1: Injuries arising from manual handling
What percentage of workplace injuries does manual handling

cause?
Place a tick in the space that you think is the correct answer to this
question.
Percentage 
5% ?
10% ?
20% ?
33% ?
50% ?
There is feedback on this activity at the back of this Learner’s

Guide.

2008
Using safe and correct methods to shift materials will:

• save time
• reduce or remove stresses and strains on your body
• prevent injury.
How do you identify the correct goods?
There are many small steps making up the process of risk assessment
of a load relocation job.
Firstly, you need to make sure you have identified the correct goods or
materials to be shifted. Always make sure you are looking at the right
load. Check your product or stock numbers carefully.

Activity 2: What is the most common way of identifying stock

items in your warehouse?
Please write or draw eight different stock identification codes/labels

and describe the stock they refer to. Check your answers with your
trainer.
Stock code or Description of stock item

label

2008
What makes up load relocation risk assessment

and why is it important?
What is a hazard?
A hazard is ‘a source of potential loss or danger’. In other words, it is
an accident waiting to happen. It is up to everyone involved in the
workplace to recognise hazards and fix them before the accident can
happen. In particular, this is the employer’s responsibility. This rule is
the basis of a safe and healthy workplace.
This is done is by following these steps:

• risk identification
• risk assessment
• risk control.
What is a risk?
A risk is ‘the possibility of suffering harm or loss’. This means doing
something that is likely to cause some sort of damage or injury (harm
or loss).
However, harm or loss might not happen at that particular time or the
injury might not be immediately obvious. This is quite often the case,
especially with back injuries, which tend to develop over time and with
repetition of activity; for example, frequent twisting and turning.

Activity 3: List common warehouse hazards
Can you think of some examples of manual handling hazards and

risks in a warehouse? You should think about the many activities in
a warehouse as well as the types of material (goods or stock) being
handled.
List your ideas of hazards and risks:
Hazards Risks
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________
_______________________ ________________________

Guide.

2008
The hazards and risks you face will change from place to place. As you
are moving around from section to section (or business to business), it
is important to be constantly on the lookout for hazards.
If you are entering a new situation with products and/or equipment

that are new to you, it is absolutely essential that you get training on
these items.
The risk of injury can be reduced or removed by:
• doing tasks in new ways that remove the need for lifting
and carrying
• ensuring that tasks beyond your ability are only attempted
with help. Use teamwork and/or mechanical aids.
What safe methods can be used for manual

materials handling?
The key to safe manual materials handling is in the way you carry out
the tasks. Tasks can be made safer by:
• reducing lifting and lowering forces
• avoiding bending, twisting and reaching
• reducing pushing, pulling, carrying and holding.
Parts of these problems can be overcome by job redesign. This is
largely a matter for management. You can help by suggesting ideas to
your OHS Committee or supervisor.
Job redesign can reduce the risk to you by:
• modifying (changing) the object; for example, making
smaller packages
• modifying the workplace layout (the area you actually
work in)

• rearranging materials flow; for example, reducing

distances travelled
• performing different (and less risky) actions, movements
and forces
• using mechanical assistance (this is covered in a later
section)
• use of team lifting; for example, working together to share
(and reduce) the burden.
Adjustable work heights. Store heavier and frequently A simple lever and wheels avoids
used items at waist level. stooping and reduces effort.

2008
Activity 4: Improving manual handling
What do you think are some of the ways to improve your manual
handling methods and reduce risks to yourself and others?
List your ideas here:
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Discuss your thoughts with your trainer, in a group session if

possible.

You must be able to accurately assess all the risks involved with a
particular load relocation task. This includes risks to yourself, the load
and any other materials on your relocation route. You will only become
good at assessing risks with practice. If you are in any doubt, ask for
help! Always adopt a careful attitude.
How do you size up the load?
Estimate the weight of the load before lifting by:

• asking your trainer
• checking for a weight tag
• pushing or lifting one corner of the load.
Always test the weight of the load before attempting to lift it. Many
injuries are caused by trying to lift a load that is much heavier than
expected.
When you know the weight you will also have a good idea of the
centre of gravity.
If the load seems too heavy or difficult to balance, don’t lift it.
You also need to consider the effect that relocating part of the load
will have on the original load base.
We have all seen a cartoon character remove a can from the bottom of
a pyramid display in a grocery store. Sometimes the pile stays up,
defying gravity, but more often the cans go everywhere. That is a very
obvious example; you will deal with load relocations that are far more
subtle.
You must also think about the contents of the load.
Different load contents have different behaviour and must be treated
accordingly. For example, liquids behave very differently to solids
when being moved.
Dangerous or hazardous materials require special handling that is the
subject of regulations and workplace codes of practice.

2008
Activity 5: Manual handling regulations and codes of practice
What regulations apply to the handling of dangerous or hazardous

goods?
Please list them:
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Do you know where to locate copies of these regulations in your

workplace?
Yes  No 
If not, ask your trainer.

In most instances of safely shifting materials that you will undertake,
you are the person who will make the assessment of the risks arising
from relocating that load.
You are also the person most likely to suffer from a miscalculation.
The six steps in lifting materials safely are as follows.
1. Size up the load (described in detail above).
2. Position your feet by:

− making sure they are close to the load
− making sure your feet will not slip
− not lifting, if you feel unsteady.
3. Take a secure grip by:

− positioning hands diagonally
− using your whole hand
− keeping your arms bent.
4. Keep your back straight.
5. Position head and arms and:

− keep your head and chin tucked in
− keep the arms close to the body.
6. Use the muscles in your legs to lift, not the muscles in your back.
The correct method of lowering a load is very similar to the above rules
for lifting, except done in reverse!

2008
Activity 6: Use shifting materials safely methods
This activity is divided into two parts. It is important that you work
through these in order and review your progress on completion of
each part. Refer to the feedback section at the end of this guide.
Part one
Go to a work area with your supervisor or trainer who will identify

three loads that you will be required to shift safely in Part Three.
Assess all the risks arising from lifting those three loads. Explain to
your supervisor or trainer, in your own words, the thought
processes that you are going through while you make your risk
analysis.
Part two
Under supervision, apply manual handling techniques to the three

situations described below which are to be set up by your trainer.
1. Lift a box not exceeding 60 cm on any side and weighing

between 9 & 12 kg. The box is to be raised from floor level to
bench height.
2. Move a 20 litre drum of liquid over a distance of 15 metres.
3. Remove a container (bag, box, bin or tin) of weight in the range

of 4 to 6 kg. The container is to be removed from a shelf at
about head height and moved to a nearby bench.

Guide.


2008
Section 2
How do you plan a load relocation

and relocate loads?

Section outline
Areas covered in this section
Planning a load relocation task
Carrying out the task and checking that the task has been completed
to the relevant workplace standards

2008
Planning a load relocation
You will need to plan the relocation of the stock to the correct site. Go
to the new site and check exactly where and how the relocated load is
to be placed. Check all documentation to ensure that you have correct
stock and have the correct place for the new location.
You will need to consider all aspects of shifting materials safely,
including planning the route for your relocation. You must also assess
all the risks associated with the route you are planning to use.
Wherever possible, use a mechanical aid.
Ask yourself these questions when you are planning to relocate a load:
• Where are you relocating the stock to?
• Which route is the quickest?
• Is this route the safest (taking account of protrusions,
width, height, packages or pallets in aisles, fragile goods
along the way)?
• How will you place the load in the new location?
• Are you adding the load to an existing load?
• How will the existing load be affected?
• Have you checked the points of balance and total resulting
load weight?
• Can you do the job alone or do you need help?
For each task you will need to make your assessment by close
observation and identification of the stock or materials to be moved,
the actual relocation site, the route to that site and the manual
handling procedures most suitable to the task. When you have
observed and considered all these elements you need to plan your
relocation.

Activity 7: Planning load relocation
Use this planning checklist to make sure that you have all the
information you need and have considered all risks associated with
shifting materials and relocating loads. You may like to photocopy
these sheets and use them for several load relocation tasks. If you
are shifting materials with a team, you can complete the checklist
together.
Load relocation Answer

checklist
How will you identify

the stock you are
relocating?
What quantities are

you relocating?
Are there any hazards

and safety regulations
covering the handling
of this stock?
Where are you taking

the load?
Have you observed the

exact location?
Which route is the

quickest?

2008

checklist
Are there any safety

hazards along the
way?
How will you avoid or

minimise hazards?
Does the load fit along

the route?
How will you lift the

load?
How will you carry the

load?
How will you place the

load in the new
location?
Can you do the job

alone or do you need
help?
Who will help you?
Do you need any

equipment?


checklist
Are you adding the

load to an existing
load?
How will the existing

load be affected?
How will you minimise

the effect of relocation
on the existing load
and ensure the safety
of the combined load?
Does this plan comply

with workplace
practices and
procedures?

2008
Ask your trainer to check the plan and give you feedback and
suggestions before you perform the task.
Write your trainer’s suggestions here:
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Incorporate your trainer’s suggestions into the relocation plan.

Relocating the load
Put your plan into action and follow the steps you have outlined. You
should not need to make any adjustments to your relocation plan if
you have considered everything carefully beforehand.
Since you are taking responsibility for the task you should make sure
that all activities are performed with due care whether you are
working alone or with a team. In particular, make sure that your
manual handling techniques are followed correctly.
If you are working with a team, make sure that each team member
understands the plan and the correct procedures for lifting, carrying,
pulling, pushing and setting down. Make sure you have a set of agreed
instructions for each of the movements you are making. Talk the team
through the plan and the instructions you will be calling to them.
Follow the exact route that you have selected. Make sure you have
clearance beforehand, especially if other people are performing similar
tasks in the same area.
When you have set the goods down in their new location, check the
stability from all angles and consider pressures or incidents that may
affect the stability of the load. Do the relocated goods comply with
workplace regulations?
Make sure that you report any changes to the plan or to the condition
of the goods.

2008
Activity 8: Performance checklist for load relocation
When you have shifted the load and set it down, check through the
following items:
Did you: 
• use the correct lifting, lowering, carrying, pulling or

pushing techniques?
• apply and coordinate team lifting tasks if

appropriate?
• follow the planned route?
• set down the goods without damage to goods,

personnel or equipment?
• check the stability of the relocated goods?
• check the relocated goods for compliance with

workplace procedures?
• report any damage to goods or variance from

expected outcome?


2008
Additional
resources

Publications:
• Ackerman K.B. Practical Handbook of Warehousing, Van
Nostrand Reinhold, New York
• Lindkvist R.G.T Handbook of Materials Handling, Ellis
Horwood Ltd, Chichester, UK 1985
• Tomkins & Smith The Warehouse Management Handbook,
Megraw Hill Book Company, USA
• Occupational Health, Safety & Welfare Regulations, 1995
• Occupational Health, Safety and Welfare Act, 1986.
Regulations and Approved Code of Practice. Manual
Handling No2 1990
• Workplace Health & Safety Handbook, Occupational Health
& Safety Commission, 1992
• Understanding Manual Handling, Occupational Health &
Safety Commission
• Young Workers and Manual Handling -‐ Issues for Employers,
Occupational Health & Safety Commission
• Manual Handling -‐ Health and Safety Issues for Women
Workers, Occupational Health and Safety Commission
Videos:
• Manual Handling -‐ Safetycare Series
• Recognition, Evaluation & Control of Hazards -‐ Safetycare
Series
• Slips, Trips and Falls -‐ Safetycare Series
• An easy guide to manual handling -‐ Avoiding back strains
& pains -‐ Workplace Video Productions

2008
Feedback on
activities
The responses provided in this section are suggested responses.
Because every workplace is different, your responses may vary
according to your specific workplace procedures, the equipment
available and the nature of the business.

Activity 1: Injuries arising from manual handling
What percentage of workplace injuries does manual handling

cause?
Percentage 
5% ?
10% ?
20% ?
33% ? 
50% ?
The actual statistic is one in every three, or 33%.
This is a significant amount when you think of it in relation to the

large number of manufacturing jobs where workers are constantly
involved with machinery. The main object is to get you to think
more about that statistic: one out of every three workplace injuries.

2008
Activity 3: List common warehouse hazards
Some of the hazards and risks that you might have thought of are:
Hazard Risk
Heavy objects Muscular sprains and strains
Items with sharp or rough Cuts, abrasions and punctures.

edges
Hazardous substances like Burns, poisoning, cancer.

acid, alkaline, radioactive
material
Animals Kicks, bites, scratches.
Small, frequent movements Swelling of ligaments or joints.
Unnatural movement, such as Fatigue, aches & pains, sprains

bending reaching, twisting & strains
Awkward posture with little or Sprains, strains, fatigue,

no freedom increased blood pressure
Vibration Feeling loss, reduced blood flow
Static loading and physical Fatigue, aches & pains,

exertion increased blood pressure
Activity 4: Improving manual handling
Many ideas to improve manual materials handling are presented in

the Manual Handling Approved Code of Practice. You can review
these when you read this reference.
Some of the ideas that you might have considered to improve your
manual handling methods are:
• plan the movement before you lift, carry, hold, push, etc.
• stand close to the load
• bend your legs, not your back - keep your back straight
• apply a firm grip, keep the load close to your body
• don’t jerk the load; move or lift it smoothly
• use your feet to turn, don’t twist your body

• avoid pulling a load - pushing allows you to apply your body

force
• arrange your workstation to ensure that frequently used items
are in easy reach
• avoid reaching down and behind if at all possible
• use any available support
• vary tasks to rest specific muscles
• use mechanical aids or get assistance (team lifting)
• prepare areas for receipt of goods beforehand.
Activity 6: Use manual materials handling techniques
Part one
As you consider all the risks associated with each of the three
loads you will find that a checklist would be very useful.
Create a checklist and discuss it with your trainer; ask for

suggestions.
Incorporate these suggestions in your final checklist.
Part two
Check list for carrying out manual handling tasks:
Did you: Yes No
1. Plan each task?
2. Check weights and size to assess if the object

was within your abilities?
3. Obtain personal assistance if beyond your

abilities?
4. Use mechanical assistance - trolley, cart, steps

(for high level object)?
5. When lifting, place your feet close to the

object, bend at the knees, (not your back) and
get a firm grip on the item?
6. Use appropriate protective equipment; i.e.

gloves?
7. Ensure that the distance to move the object

2008
was not excessive if you decided to carry the

object?
8. Prepare the space to receive the object prior to

moving it?


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TLID107C Shift

materials safely using

Additional resources ....................................................................... 31

Feedback on activities .................................................................... 33

Page 0 © Australian National Training Authority 2003

What this Learner’s Guide is about

© Australian National Training Authority 2003 Page 1

Planning your learning

Page 2 © Australian National Training Authority 2003

Section 1: Assess risks arising from the

Are you able to: Yes No

Section 2: How do you plan a load relocation

Are you able to: Yes No

© Australian National Training Authority 2003 Page 3

How you will be assessed

You will be required to:

Page 4 © Australian National Training Authority 2003

Assess risks arising from the

© Australian National Training Authority 2003 Page 5

Areas covered in this section

Common materials shifting hazards and how to minimise them

Identifying and demonstrating the safe and correct methods for

Page 6 © Australian National Training Authority 2003

How do you assess risks arising from relocation

What is manual materials handling?

A large proportion of materials shifting may be done manually,

Manual material handling is defined as:

The main methods used are:

© Australian National Training Authority 2003 Page 7

Activity 1: Injuries arising from manual handling

What percentage of workplace injuries does manual handling

There is feedback on this activity at the back of this Learner’s

Page 8 © Australian National Training Authority 2003

Using safe and correct methods to shift materials will:

How do you identify the correct goods?

© Australian National Training Authority 2003 Page 9

Activity 2: What is the most common way of identifying stock

Please write or draw eight different stock identification codes/labels

Stock code or Description of stock item

Page 10 © Australian National Training Authority 2003

What makes up load relocation risk assessment

What is a hazard?

This is done is by following these steps:

© Australian National Training Authority 2003 Page 11

Activity 3: List common warehouse hazards

Can you think of some examples of manual handling hazards and

List your ideas of hazards and risks:

There is feedback on this activity at the back of this Learner’s

Page 12 © Australian National Training Authority 2003

If you are entering a new situation with products and/or equipment

What safe methods can be used for manual

© Australian National Training Authority 2003 Page 13

• rearranging materials flow; for example, reducing

Page 14 © Australian National Training Authority 2003

Activity 4: Improving manual handling

List your ideas here:

Discuss your thoughts with your trainer, in a group session if

© Australian National Training Authority 2003 Page 15

How do you size up the load?

Estimate the weight of the load before lifting by:

Page 16 © Australian National Training Authority 2003

Activity 5: Manual handling regulations and codes of practice

What regulations apply to the handling of dangerous or hazardous

Please list them: