Safe Work Method Statement

Flat Pack Delivery - Assembly

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Overview

What this SWMS covers

Flat pack delivery and assembly work involves transporting knock-down furniture, cabinetry, and modular equipment to residential, commercial, and construction sites, then assembling these items according to manufacturer specifications. This work encompasses diverse activities from delivering individual furniture pieces to households through to assembling complete office fit-outs and commercial installations. Workers face significant manual handling risks when lifting and carrying packaged items, repetitive strain from extended assembly work using hand and power tools, and potential injuries from sharp packaging materials and hardware components. Assembly work often occurs in congested spaces with limited maneuvering room, on various floor surfaces, and around existing furniture or incomplete building structures. Flat pack delivery and assembly services have become essential to modern residential and commercial furnishing, with workers delivering and assembling everything from basic home furniture to complex modular office systems, retail fit-outs, and educational facility equipment. The work typically begins with loading packaged items at warehouses or suppliers, transporting them to installation sites, unloading and positioning packages, unpacking components whilst managing packaging waste, and systematically assembling items using hand tools, power tools, and specialised fasteners according to detailed manufacturer instructions. Assembly complexity ranges from simple two-piece items requiring basic tool use to intricate systems involving hundreds of components, precise alignment requirements, and structural integrity considerations. Workers operate across diverse environments including residential delivery in occupied homes, commercial installations in office buildings and retail spaces, and construction site installations within active building projects. The delivery component presents distinct hazards including vehicle loading and unloading with packages weighing up to 60kg or more, securing loads during transport, navigating delivery vehicles through urban areas, and managing delivery timing to coordinate with customer availability. Assembly work requires systematic processes including component inspection, hardware organisation, following manufacturer instructions, using appropriate tools, ensuring square and level installation, and verifying structural stability.

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Why this SWMS matters

Reinforce licensing, insurance, and regulator expectations for Flat Pack Delivery - Assembly crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Manual Handling of Heavy Flat Pack Packages During Loading, Transport, and Delivery

high

Flat pack furniture packages vary significantly in weight, size, and awkwardness, with items like wardrobes, desks, and bed frames commonly weighing 40-60kg and having dimensions that make them difficult to grip and control. Workers repeatedly lift these items from warehouse storage, load them into delivery vehicles, secure them during transport, unload at customer premises, and carry them to assembly locations that may involve stairs, narrow corridors, or multi-level buildings. The repetitive nature of this work means workers may handle dozens of packages daily, with cumulative loading on the spine, shoulders, and knees creating injury risks even when individual lifts are within worker capacity. Awkward package dimensions prevent proper lifting posture, with workers unable to maintain loads close to the body or adopt stable footing. Slippery packaging materials reduce grip security, particularly in wet conditions. Rushed delivery schedules create pressure to work quickly without proper manual handling procedures. Without mechanical lifting aids, team lifting for heavy items, proper lifting technique training, ergonomic work practices, and task rotation to prevent cumulative strain, workers commonly develop chronic back injuries, disc damage requiring surgery, shoulder and rotator cuff injuries, knee joint damage, and hand and wrist strains from gripping awkward loads.

Consequence: Acute back injuries from single heavy lifts, chronic musculoskeletal disorders from cumulative strain, shoulder injuries requiring extended recovery periods, knee damage from repeated lifting, potential career-ending injuries.

Trips, Slips, and Falls During Package Transport and Assembly Work

high

Delivery and assembly environments contain numerous trip and fall hazards that workers must navigate while carrying or handling items that obstruct their view and limit their ability to react to hazards. Residential properties have steps, uneven floor surfaces, loose carpets, pet toys, and cluttered pathways that create trip hazards. Construction sites present incomplete flooring, exposed services, building materials scattered across work areas, and varying floor levels without clearly marked transitions. Commercial installations occur in occupied buildings where workers encounter electrical cables, furniture, and building occupants moving through work areas. Assembly work involves sitting or kneeling on floors with tools, hardware, and packaging materials surrounding workers creating trip hazards when they stand or reposition. Packaging materials including cardboard sheets, plastic wrap, and packing foam are particularly hazardous as they create slip surfaces, especially on smooth flooring like tiles or polished concrete. Workers carrying large packages have limited visibility of ground conditions ahead. Stairs are especially hazardous when transporting furniture, with workers unable to see steps clearly or grip handrails whilst carrying loads. Wet conditions from rain, spills, or cleaning operations increase slip risks. Without clear pathways, removal of trip hazards before work, slip-resistant footwear, adequate lighting, and careful navigation when vision is obstructed, workers risk falls that can cause head injuries, fractures, lacerations, sprains, and injuries exacerbated by falling onto or being struck by the packages they are carrying.

Consequence: Serious injuries from falls including fractures and head trauma, injuries from falling packages striking workers, sprains and strains from awkward falls, increased injury severity in cluttered environments.

Cuts and Lacerations from Packaging Materials, Tools, and Sharp Furniture Components

medium

Flat pack work involves extensive contact with materials and items that can cause cuts and lacerations. Cardboard packaging has sharp edges that easily slice skin during handling, particularly when removing strapping and opening boxes. Metal banding straps used to secure packages are under tension and can whip violently when cut, causing deep lacerations and eye injuries. Staples securing packaging pierce skin if contacted during removal. Sharp-edged components including metal brackets, glass shelves, and cut edges of manufactured boards present laceration hazards during unpacking and assembly. Power tool bits and blades are extremely sharp, with broken bits creating particularly dangerous fragments. Hand tools including utility knives used for opening packages, screwdrivers with sharp tips, and allen keys present cut risks if they slip during use. Assembly hardware including screws with sharp threads and metal corners on components cause puncture wounds if workers contact them while handling furniture. Poorly maintained tools with damaged handles can cause hand injuries. Workers focused on assembly tasks may not notice minor cuts until blood loss becomes significant. Without cut-resistant gloves for unpacking, safe knife use procedures, proper tool maintenance, careful handling of components, adequate lighting to see sharp edges, and accessible first aid supplies including wound dressings, workers suffer frequent minor cuts that can become infected, deep lacerations requiring stitches, eye injuries from flying debris or whipping straps, and puncture wounds from screws and sharp components.

Consequence: Lacerations requiring medical treatment and work time loss, infected cuts from contaminated packaging, eye injuries from flying metal straps, tetanus risks from puncture wounds, cumulative impact of repeated minor injuries.

Repetitive Strain Injuries from Prolonged Assembly Work in Awkward Postures

medium

Assembly work requires extended periods in awkward postures that create cumulative strain on joints, muscles, and connective tissues. Workers kneel on hard floors for long periods when assembling low furniture like beds and coffee tables, creating knee joint compression, damage to meniscus, and bursitis. Prolonged squatting during assembly of items requiring ground-level work causes knee and ankle strain, with workers often maintaining these positions for 30-60 minutes continuously. Reaching into deep furniture pieces like wardrobes and bookcases to install internal components requires extended reaching that strains shoulders and upper back. Overhead work when installing high components or adjusting tall furniture causes neck strain and shoulder fatigue. Repetitive tool use, particularly screwdrivers and Allen keys, creates hand and wrist strain through repeated gripping and twisting motions. Workers completing multiple similar assemblies daily perform thousands of identical movements, with cumulative loading exceeding tissue recovery capacity. Fine motor control required for aligning small components and handling tiny screws creates hand fatigue. Working on unpadded concrete or tile floors increases fatigue and joint stress. Time pressure to complete assemblies quickly discourages workers from taking breaks or changing positions. Without knee pads, cushioned mats for kneeling, task variety to reduce repetitive movements, micro-breaks to allow tissue recovery, proper tool ergonomics, and posture variation throughout work, workers develop chronic conditions including carpal tunnel syndrome requiring surgery, tendonitis in wrists and elbows, chronic knee pain and damage, shoulder impingement, and chronic back pain from extended awkward positioning.

Consequence: Chronic musculoskeletal disorders requiring ongoing treatment, carpal tunnel syndrome affecting hand function, knee damage potentially requiring surgery, reduced work capacity over career duration, permanent disability from cumulative injuries.

Power Tool Hazards Including Drill Bits, Impact Drivers, and Fastening Equipment

medium

Power tools used in flat pack assembly create multiple injury mechanisms that can cause serious harm. Cordless drills and impact drivers operate at high rotational speeds, with bits or sockets that can catch on workpieces causing sudden tool rotation that twists wrists and hands, drops tools onto users, or throws small components at high velocity. Drill bits penetrating through materials unexpectedly can drill into workers' hands or legs if furniture shifts during drilling. Broken drill bits become projectiles that can cause eye injuries or embed in skin. Over-tightening fasteners with impact drivers strips threads and cracks materials, creating structural failures in completed furniture. Battery failures in poorly maintained cordless tools cause unexpected tool stoppages that can result in stripped fasteners or tool dropping. Using incorrect bits or drivers damages fasteners making them impossible to tighten properly or remove if errors occur. Power tool noise in residential settings without hearing protection causes cumulative hearing damage. Triggers accidentally activated when passing tools or placing them down can cause unexpected tool operation. Loose components like chuck keys or extension bits can fly off during operation. Working in dimly lit areas reduces visibility of work point making bit alignment difficult. Without regular tool maintenance including battery testing, proper bit selection for each fastener type, eye protection when drilling, hearing protection during extended power tool use, secure workpiece stabilisation, appropriate tool speed settings, and training in power tool safe operation, workers suffer hand and wrist injuries from tool kickback, eye injuries from flying debris or broken bits, hearing damage from noise exposure, lacerations from sharp tool components, and injuries from incorrectly assembled furniture that fails structurally.

Consequence: Hand and wrist injuries from tool kickback, eye injuries requiring medical treatment, hearing damage from power tool noise, injuries from structurally compromised furniture due to incorrect fastening.

Working Alone in Residential or Remote Commercial Locations Without Immediate Assistance

medium

Flat pack delivery and assembly workers frequently work alone in residential homes or remote commercial premises where immediate assistance is unavailable if injuries or emergencies occur. Many delivery and assembly jobs are single-person operations where workers transport and assemble items without colleagues present, creating isolation hazards if injuries occur. Medical emergencies including heart attacks, severe allergic reactions, or injuries causing unconsciousness can become fatal if no one is present to call emergency services or provide first aid. Manual handling injuries may leave workers unable to move or call for help. Customer premises may have poor mobile phone reception limiting workers' ability to summon assistance. Some customers leave premises during assembly work, leaving workers completely isolated. Aggressive or threatening customer behaviour creates personal safety risks without colleague support or escape assistance. Customers' dogs or other animals may pose attack risks. Working in vacant properties or after-hours in commercial buildings creates vulnerability to assault or theft. Workers may feel compelled to continue working despite illness or injury to avoid disappointing customers or losing income. Without effective lone worker monitoring systems including regular check-ins, personal duress alarms, reliable communication methods, emergency contact procedures, authority to cease work if feeling unwell or threatened, and clear protocols for managing customer aggression, workers face delayed emergency response that increases injury severity, inability to summon help when seriously injured, risks of assault without witness support, continuation of work while injured due to isolation, and psychological stress from working without colleague support in unfamiliar environments.

Consequence: Delayed emergency response increasing injury severity, inability to call for help when injured, vulnerability to assault or aggressive behaviour, psychological stress from isolation, reluctance to report unsafe conditions.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Mechanical Lifting Aids and Manual Handling Equipment for Package Transport

Engineering

Implementing mechanical aids removes or significantly reduces the physical demands of manual handling, protecting workers from acute injuries and cumulative musculoskeletal damage. Engineering controls for flat pack delivery include hand trolleys and furniture dollies for moving packages over flat surfaces, stair climbing trolleys with rotating wheels designed for safe package transport up and down stairs, appliance straps and harnesses that distribute weight across workers' bodies rather than requiring lifting strength alone, loading ramps for delivery vehicles that eliminate the need to lift packages to vehicle height, and proper vehicle fit-outs with securing points and load distribution systems. These controls are most effective when matched to specific tasks and workers are trained in their proper use. Well-maintained equipment with appropriate weight ratings ensures reliability and safety.

Implementation

1. Assess package dimensions, weights, and delivery locations to determine appropriate mechanical aids needed for each job, documenting these requirements on delivery schedules before workers commence tasks. 2. Provide hand trolleys rated to 150kg minimum with pneumatic tyres for rough surfaces, ensuring trolleys are available in delivery vehicles and at warehouse loading areas. 3. Supply stair climbing trolleys for properties with stairs, training workers in proper load securing and stair negotiation techniques that maintain control throughout stair transit. 4. Issue appliance straps and lifting harnesses to all workers, demonstrating proper strap positioning, load sharing between partners, and communication methods for coordinated lifting. 5. Install loading ramps on all delivery vehicles rated for maximum package weights, with non-slip surfaces and secure attachment to vehicles that prevents movement during loading operations. 6. Conduct monthly equipment inspections checking for damaged wheels, worn straps, bent trolley frames, and loose fastenings, removing damaged equipment from service immediately and arranging repairs. 7. Provide refresher training quarterly on mechanical aid use, covering common errors, maintenance checks workers should perform before each use, and reporting procedures for equipment issues.

Two-Person Lift Procedures and Team Handling Protocols for Heavy Packages

Administrative

Administrative controls establish systematic procedures ensuring heavy or awkward packages are handled by teams rather than individual workers, reducing force requirements on any single person. Two-person lift protocols define weight thresholds triggering team handling requirements, establish communication methods for coordinated lifting, specify roles and responsibilities during team lifts, and provide decision frameworks for determining when packages cannot be safely handled even with teams. These procedures are particularly important for items exceeding 25kg, packages with awkward dimensions preventing proper grip, and items requiring transport up stairs or through difficult access points. Effective implementation requires management commitment to staffing levels supporting team handling, scheduling that allows time for proper procedures, and worker empowerment to refuse solo handling of items exceeding safe limits.

Implementation

1. Establish written policy requiring two-person handling for all packages exceeding 25kg, items with dimensions exceeding 1200mm in any direction, and any package individual workers identify as awkward or difficult to control safely. 2. Schedule deliveries and assemblies ensuring adequate staffing for team handling, with fallback procedures if staffing shortages occur including postponing deliveries rather than attempting solo handling of heavy items. 3. Train all workers in standard lifting commands and counting methods (three-count lift coordination), proper positioning for team lifts maintaining balanced load distribution, and communication if either person experiences difficulty during lifting. 4. Designate a lead person for each team lift responsible for assessing lift path, identifying hazards, communicating lift plan to partner, and making final decision on whether lift is safe to proceed. 5. Implement route planning before lifting requiring teams to walk the intended path, remove trip hazards, identify rest points for heavy items, and confirm doors are open and destination is prepared. 6. Provide guidance on refusing unsafe lifts including authority to decline customer requests for rapid delivery if safety requires team handling, procedures for explaining delays to customers, and management support for safety decisions. 7. Document team handling requirements on delivery manifests showing which items require two-person handling, ensuring warehouse staff and delivery personnel both understand requirements before loading commences.

Site Preparation and Hazard Clearance Before Package Transport and Assembly

Administrative

Systematic site preparation before commencing delivery and assembly work removes or controls trip, slip, and fall hazards, establishes clear pathways for package transport, and creates safe work zones for assembly tasks. This administrative control requires workers to inspect routes and work areas, remove or mitigate identified hazards, and confirm safe conditions before handling packages or beginning assembly. In residential settings, this involves negotiating with customers to clear pathways, remove loose floor coverings, secure pets, and provide adequate space for assembly work. In commercial and construction environments, it requires coordination with site management to establish safe access routes, ensure adequate lighting, and confirm floor surfaces are clean and dry. Effective site preparation prevents the majority of trip and fall incidents whilst creating professional work environments that improve efficiency and customer satisfaction.

Implementation

1. Conduct initial site inspection immediately upon arrival before unloading any packages, walking delivery route from vehicle to assembly location, photographing any hazards or difficult access points, and discussing pathway clearance requirements with customers or site management. 2. Request customers remove items from delivery pathways including toys, floor mats, electrical cords, furniture, and any items creating trip hazards, explaining this is standard safety procedure required before work can commence. 3. Inspect floor surfaces for slip hazards including spills, wet areas, loose carpets, polished surfaces, and debris, cleaning or marking hazards and selecting routes avoiding known slip hazards where possible. 4. Arrange adequate lighting for delivery routes and assembly areas, requesting customers switch on lights, opening curtains for natural light, or using portable work lights from delivery vehicles if site lighting is inadequate. 5. Establish assembly work zone with minimum 2m clearance around assembly area, moving existing furniture if necessary, laying drop sheets to protect floors and catch small components, and ensuring workers have clear space to kneel, position components, and move around furniture during assembly. 6. Identify safe package storage area near assembly location where multiple packages can be staged without creating trip hazards, positioned to allow easy access but not blocking exits or creating customer inconvenience. 7. Confirm emergency egress routes remain clear throughout work, positioning packages and packaging waste to maintain clear pathways to exits at all times.

Proper Tool Selection, Maintenance, and Safe Operation Procedures

Administrative

Systematic tool management ensures workers have appropriate tools in good working condition, understand safe operation procedures, and maintain equipment to prevent failures that cause injuries. Administrative controls for tool safety include tool specification sheets matching correct tools to assembly tasks, pre-work tool inspection checklists identifying damaged or worn equipment, maintenance schedules ensuring regular servicing of power tools, battery management procedures maintaining cordless tool reliability, and safe operating procedures for each tool type covering correct use, common errors, and emergency procedures. These controls prevent injuries from tool failures, incorrect tool use, and poor maintenance whilst ensuring consistent quality in assembly work.

Implementation

1. Develop comprehensive tool kit specifications listing all hand tools and power tools required for flat pack assembly work including screwdrivers (multiple sizes and types), Allen keys (metric and imperial sets), hammer, tape measure, level, cordless drill with clutch adjustment, impact driver, utility knife, pliers, and any specialised tools for specific furniture ranges. 2. Implement daily tool inspection checklist requiring workers to check each tool before commencing work, inspecting power tools for damaged cords or housings, checking drill chucks for secure bit holding, confirming screwdriver tips are not worn or damaged, ensuring knife blades are sharp (dull blades require excessive force and slip more easily), and testing power tool operation before arriving at job sites. 3. Establish battery management system maintaining two charged batteries for each cordless tool, charging batteries overnight, rotating battery use to maximise life, and replacing batteries showing reduced capacity or charging failures before they cause operational issues. 4. Provide manufacturer-specific operation guidance for power tools including recommended torque settings for different fastener types and materials, proper bit selection matching fastener heads, speed settings appropriate to task, and correct grip positions preventing wrist strain. 5. Supply appropriate Personal Protective Equipment for tool use including safety glasses meeting AS/NZS 1337 for all power tool operation, hearing protection for extended cordless drill use, and work gloves for handling tools (though not while operating power tools where gloves create entanglement risks). 6. Schedule quarterly tool maintenance including professional servicing of cordless tools checking motor brushes, gearbox condition, and electrical safety, sharpening or replacing blunt or damaged drill bits, and replacing any tools with cracked housings or missing safety guards. 7. Train workers in recognising tool failure signs including unusual noise, reduced power, smoking or odours from power tools, and procedures for immediately ceasing use and removing failed tools from service until repaired.

Systematic Assembly Procedures and Component Verification

Administrative

Structured assembly procedures ensure workers follow logical sequences, verify component presence and condition before commencing assembly, and implement quality checks throughout assembly preventing structural failures in completed furniture. These procedures reduce risks of rework requiring disassembly (creating additional manual handling), structural instability from incorrect assembly sequences or missing components, and component damage from forcing misaligned parts. Systematic approaches improve work quality, reduce completion times through elimination of errors requiring correction, and ensure furniture safety for end users. Clear manufacturer instruction interpretation and systematic hardware organisation prevent common assembly errors.

Implementation

1. Unpack all packages for each assembly item before commencing construction work, laying out all panels, hardware, and components in an organised manner that allows visual confirmation of all parts against manufacturer packing list. 2. Separate hardware into types using compartmented organisers or labelled containers, grouping screws by size and type, keeping washers with their corresponding fasteners, and ensuring small components are contained to prevent loss on customer floors. 3. Review complete manufacturer instructions before beginning assembly, identifying any unclear steps or potential difficulties, determining tool requirements for each assembly stage, and confirming logical component assembly sequence. 4. Follow manufacturer assembly sequence precisely unless experience clearly indicates a superior method, recognising that manufacturers design sequences to prevent common errors and ensure structural integrity. 5. Verify correct component alignment before fastening, checking that panel edges align flush, pilot holes line up with fastener positions, and components are square using a level or carpenter's square before tightening fasteners. 6. Apply fasteners in two stages, initially tightening to approximately 75% firmness allowing adjustment of component positions, then performing final tightening only after confirming all components are correctly positioned and square. 7. Perform stability check on completed furniture including rocking test to confirm level installation, drawer operation check ensuring smooth movement without binding, door alignment verification confirming even gaps and proper closure, and testing any moving components meet manufacturer operation specifications. 8. Clean furniture surfaces after assembly removing dust, fingerprints, and any marking from handling, positioning completed furniture in customer's preferred location, and disposing of all packaging materials unless customer requests retention.

Lone Worker Safety Protocols and Emergency Communication Systems

Administrative

Administrative procedures for lone worker safety ensure workers have reliable means of summoning assistance, regular monitoring confirms worker welfare, and emergency response protocols are activated if workers fail to report as required. These controls are essential for flat pack work where workers operate alone in residential properties or isolated commercial premises without colleague oversight. Systems include scheduled check-in requirements, duress alarm provision, emergency contact procedures, and authority to postpone or cease work if workers feel unsafe. Effective implementation requires management commitment to monitoring systems, worker training in proper use, and clear escalation procedures if workers cannot be contacted.

Implementation

1. Implement scheduled check-in system requiring workers to contact dispatch or management at specified intervals (typically every 2 hours during normal work and at job completion), using mobile phones, SMS, or dedicated lone worker applications providing location data. 2. Issue personal duress alarms or smartphone applications with emergency alert functions to all workers, training them in activation methods, testing devices weekly to confirm functionality, and establishing clear procedures for emergency response when alarms are activated. 3. Provide all workers with company mobile phones if their personal phones lack reliable coverage, ensuring phones are charged before each work day and workers carry portable battery packs for extended work days. 4. Establish emergency contact protocols including backup telephone numbers if primary contacts are unavailable, procedures for workers to report feeling unwell or unsafe before conditions become critical, and authority to leave job sites if workers identify serious risks or threatening behaviour. 5. Conduct site risk assessment before dispatching workers to residential jobs, obtaining customer contact details, address verification, and any relevant safety information (aggressive dogs, difficult access, remote locations) that affects worker safety. 6. Require workers to provide expected completion times before commencing each job, with automatic escalation procedures if workers have not checked in within 30 minutes of expected completion time. 7. Train workers in managing difficult customer interactions including recognising early warning signs of aggression, de-escalation techniques, authority to cease work and leave if feeling threatened, and immediate reporting of concerning incidents to management.

Download complete control procedures

Personal protective equipment

Safety Footwear with Slip-Resistant Soles

Requirement: Steel-capped boots or shoes meeting AS/NZS 2210.3 for construction sites. Slip-resistant soled footwear for residential and commercial premises.

When: Required for all delivery and assembly work. Steel caps mandatory on construction sites. Slip-resistant soles essential when working on smooth floors, wet surfaces, or areas with packaging materials.

High-Visibility Clothing

Requirement: Day/night high-visibility vest meeting AS/NZS 1906.4 for roadside deliveries and construction sites.

When: Required when loading/unloading vehicles on public roads, working on construction sites with mobile plant, or in any area where visibility to other workers or drivers is required.

Work Gloves with Grip Enhancement

Requirement: Cut-resistant gloves meeting AS/NZS 2161.2 for unpacking. General work gloves with enhanced grip for package handling.

When: Cut-resistant gloves mandatory when opening packages and handling metal strapping. General work gloves for package transport and handling. Remove gloves when operating power tools to prevent entanglement.

Safety Glasses with Side Shields

Requirement: Impact-resistant safety glasses meeting AS/NZS 1337 with side shields for particle protection.

When: Mandatory when operating power tools including drills and impact drivers. Required when cutting packaging strapping due to whipping hazards. Recommended during unpacking when dealing with metal banding.

Knee Pads for Extended Kneeling Work

Requirement: Foam or gel knee pads meeting AS/NZS 4501 for floor work. Strap-on type preferred for mobility.

When: Required for any assembly work requiring kneeling for periods exceeding 10 minutes. Mandatory for low furniture assembly including beds, coffee tables, and low cabinets.

Hearing Protection for Power Tool Use

Requirement: Ear plugs or ear muffs meeting AS/NZS 1270 with appropriate noise reduction rating (minimum 20dB).

When: Required when using power tools continuously for periods exceeding 15 minutes. Mandatory in enclosed spaces or residential environments where tool noise is amplified. Optional but recommended for short-duration power tool use.

Inspections & checks

Before work starts

✓Inspect delivery vehicle condition including tyre pressure, secure load area, functioning ramps or tail-lifts, and adequate load restraints before loading packages
✓Check all packages against manifest confirming correct items loaded, identify any damaged packaging requiring special handling or customer notification, and verify all components present before departing warehouse
✓Test mechanical handling equipment including trolleys, dollies, and straps confirming proper operation, secure wheels, and no damage affecting safe use
✓Verify tool kit completeness checking all required hand tools present, power tools charged and operating correctly, spare batteries charged, and safety equipment including glasses and gloves available
✓Inspect PPE condition ensuring safety footwear has intact soles and toecaps, work gloves are not torn or worn through, and high-visibility clothing is clean and reflective elements functional
✓Review job details including delivery address, customer contact information, access considerations, assembly requirements, and any special instructions or safety concerns documented during booking
✓Check mobile phone charge and reception, confirm emergency contact numbers are stored, and verify lone worker monitoring system is operational and understood

During work

✓Assess site conditions upon arrival including delivery route hazards, floor surfaces, lighting adequacy, and any obstacles requiring removal before commencing package transport
✓Monitor worker fatigue levels throughout delivery and assembly work, recognising signs of overexertion, taking breaks when needed, and using two-person handling if fatigue affects safe solo handling
✓Verify correct package handling techniques during transport observing proper lifting posture, use of mechanical aids, clear vision over packages, and safe navigation around obstacles
✓Inspect work area organisation during assembly ensuring components are systematically arranged, hardware containers prevent spillage, tool placement prevents trip hazards, and packaging waste is contained
✓Check assembly quality throughout construction process verifying component alignment, secure fastening, structural stability at each stage, and proper operation of moving parts before proceeding to next assembly steps
✓Observe power tool operation for any signs of malfunction including unusual noises, reduced power, overheating, or bit wobble requiring immediate cessation and tool inspection
✓Monitor customer premises security ensuring tools and components are not left unattended in accessible areas, valuable items are not moved without customer present, and customer property is protected from damage during work
✓Maintain communication with dispatch or management according to lone worker protocols, reporting any issues or safety concerns immediately, and updating on progress and expected completion times

After work

✓Inspect completed furniture assembly for structural stability performing wobble test, checking all fasteners are secure, confirming drawers and doors operate correctly, and verifying furniture is level
✓Collect all packaging materials, off-cuts, and waste ensuring customer premises are left clean and tidy with all debris removed to vehicle for proper disposal
✓Verify all tools, equipment, and unused hardware are collected preventing any items left at customer premises that create hazard or require return visits
✓Clean and inspect tools after use removing any debris, checking for damage that occurred during work, charging depleted batteries, and reporting any tool failures or maintenance requirements
✓Review job completion with customer confirming satisfaction with assembly, operation of all components, answering any questions about furniture use or care, and providing manufacturer instructions
✓Document any issues encountered during delivery or assembly including access difficulties, missing components, assembly challenges, or customer concerns requiring follow-up
✓Report any incidents, near misses, or safety concerns to management immediately including manual handling difficulties, tool failures, customer interactions raising concerns, or site conditions affecting safety

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Job Preparation and Vehicle Loading at Warehouse

Begin work day by checking job schedule and reviewing all deliveries and assembly assignments for the day. Verify customer addresses, contact phone numbers, estimated assembly times, and any special instructions or access requirements documented during booking. Check mobile phone is charged and emergency contact details are accessible. Inspect delivery vehicle condition including tyres, lights, load area cleanliness, and ramp operation. Collect mechanical handling equipment including hand trolley, stair climber if required, appliance straps, and any specialised equipment needed for today's jobs. Verify tool kit is complete with all required hand and power tools, spare batteries are charged, and safety equipment is present. Locate packages for first delivery in warehouse, checking package labels match manifest. Inspect packaging condition noting any damage that may indicate contents are compromised. Use mechanical aids to transport packages from storage to vehicle. Load packages methodically positioning heaviest items at bottom, securing all items with straps or load bars, and ensuring packages cannot shift during transport. Load hand trolley and handling equipment last ensuring they are accessible when reaching delivery locations.

Safety considerations

Use mechanical aids for all packages exceeding 15kg to prevent manual handling strain. Wear safety footwear and high-visibility vest throughout loading operations. Ensure adequate lighting in warehouse areas when loading early morning or after hours. Avoid reaching or leaning into vehicle load areas creating fall risks. Secure all packages preventing movement during transit. Check weather forecast and adjust planned route if adverse conditions affect safe driving.

Site Arrival and Initial Safety Assessment

Upon arriving at delivery location, park vehicle legally and safely minimising obstruction to traffic while allowing safe unloading access. Activate hazard lights if unloading on roadside. Don high-visibility vest before exiting vehicle if working near traffic. Before unloading any packages, approach property entrance and conduct initial site assessment. Identify delivery route from vehicle to final assembly location noting any steps, narrow doorways, tight corners, or obstacles requiring navigation during package transport. Assess floor surfaces for trip and slip hazards including mats, tiles, carpets, and any wet areas. Check lighting adequacy throughout delivery route. Photograph any concerning access issues with phone camera for documentation. Make contact with customer or site representative explaining work scope, estimated timeframe, and requesting pathway clearance if trip hazards are present. Obtain any site access requirements including visitor registration, safety induction, or site-specific rules at commercial or construction locations. Discuss assembly location and confirm customer expectations regarding furniture placement. Request customer secure pets that may interfere with work or create safety risks.

Safety considerations

Never commence unloading until delivery route has been assessed and hazards identified. Ensure customer is present or arrangements for site access are confirmed before unloading packages. Verify mobile phone has adequate reception to summon assistance if needed. Check weather conditions and postpone delivery if rain or ice create unsafe unloading or transport conditions. Note locations of exits and emergency egress routes at commercial properties.

Package Unloading and Transport to Assembly Area

Return to vehicle and prepare mechanical handling equipment positioning hand trolley near vehicle load area. Unload packages one at a time, checking each package label confirms correct delivery before transporting into premises. Use vehicle ramp or tailgate for safe package removal avoiding lifting packages from vehicle height. Position each package on hand trolley using proper manual handling technique with bent knees and straight back. Secure packages to trolley with strapping if available preventing packages shifting during transport. Transport packages along predetermined route moving slowly and carefully around any obstacles. For stairs, switch to stair climbing trolley using proper technique maintaining control on both ascent and descent. For packages too large for trolley, employ two-person lift technique with clear communication between handlers. Make multiple trips rather than overloading trolleys or attempting heavy solo carries. Stack packages in designated assembly area ensuring stable positioning and no trip hazards in customer's living space. Remove and collect all delivery documentation for customer signature. Return trolley to vehicle securing it for departure.

Safety considerations

Use mechanical aids for all package transport preventing manual handling injuries. Get assistance for packages exceeding 25kg or awkward dimensions. Watch for ground surface changes including steps or floor level differences during transport. Maintain clear sight over packages ensuring vision is not obstructed. Take breaks between packages if experiencing fatigue. Keep delivery route clear removing any obstacles encountered during first package transport. Avoid rushing to complete unloading creating injury risks from improper handling.

Work Zone Setup and Package Unpacking

Before commencing assembly, establish proper work zone in designated assembly area. Request customer remove any valuable or fragile items from immediate vicinity. Lay drop sheets or protective covering over floor protecting customer flooring from tools, dropped components, and potential scratches during assembly. Arrange adequate lighting requesting additional lights if room lighting is insufficient or opening curtains for natural light. Set up component staging area adjacent to assembly location where all panels and parts can be organised. Begin unpacking process using utility knife carefully cutting strapping and tape without damaging contents or creating whipping hazards from metal bands. Remove all packaging systematically collecting cardboard, plastic wrapping, foam, and other materials in designated pile away from assembly area preventing trip hazards. As each component is removed, verify it against manufacturer packing list checking off items and identifying any damage or missing parts before commencing assembly. Lay out all panels in sequence helpful for assembly identifying each piece and confirming orientation. Separate and organise all hardware using compartmented container or arranging on drop sheet in groups by type and size. Identify all required tools for this specific assembly based on manufacturer instructions and hardware types present.

Safety considerations

Wear cut-resistant gloves during unpacking to prevent lacerations from packaging. Cut away from body when using utility knife. Be cautious when cutting metal banding as it may whip under tension. Collect all loose staples and fasteners from packaging immediately. Ensure sharp cardboard edges are folded or contained. Position packaging waste securely preventing it spreading across floor creating slip hazards. Verify adequate workspace preventing workers from being cramped into awkward positions during assembly.

Systematic Furniture Assembly Following Manufacturer Instructions

Review complete manufacturer assembly instructions before beginning construction, familiarising with all steps, identifying any unclear sections, and determining optimal assembly sequence. Position base components or panels that form foundation of furniture in approximately correct location recognising that fully assembled furniture may be too heavy to move easily. Commence assembly following manufacturer steps precisely using correct fasteners for each connection point. Insert fasteners hand-tight initially allowing component adjustment before final tightening. Use power drill with torque setting appropriate to fastener type preventing over-tightening that strips threads or cracks panels. Verify component alignment frequently using level or square checking that furniture remains square and true throughout assembly. If components do not align easily, stop and recheck assembly instructions rather than forcing misaligned parts creating damage or weak joints. Progress through assembly steps systematically completing each stage fully before moving to next. For tall furniture, temporarily secure partially assembled items preventing tipping during construction. Install drawer runners, hinges, and mechanical components according to manufacturer specifications ensuring proper operation before proceeding. Perform mid-assembly stability check confirming structure is developing correctly. Complete final tightening of all fasteners only after confirming all components are correctly positioned and furniture is square.

Safety considerations

Wear safety glasses during all power tool operation. Use knee pads during extended kneeling work. Take short breaks every 30 minutes to prevent muscle fatigue and repetitive strain. Maintain good posture avoiding extreme bending or twisting. Ensure power tool batteries have adequate charge to prevent incomplete fastening from battery depletion. Do not force misaligned components as this creates weak joints and potential furniture failure. Keep work area tidy with tools positioned to prevent trip hazards when standing from kneeling position. Stop work immediately if experiencing pain or discomfort in hands, wrists, back, or knees.

Quality Verification and Stability Testing of Completed Assembly

Upon completing final fastener tightening, conduct comprehensive quality verification of assembled furniture. Perform stability test by applying gentle sideways force at top of furniture checking for wobbling or movement indicating loose fasteners or improper assembly. If any movement is detected, identify and rectify cause before considering assembly complete. Test all moving components including drawer operation verifying smooth movement without binding or misalignment, door swing checking for even gaps and proper closure with no rubbing, and any adjustable elements confirming they operate as designed. Verify furniture is level using spirit level making minor adjustments with adjustable feet if fitted or using thin shims if necessary. Check that all visible fasteners are properly seated and tightened with no protruding screw tips or loose fittings. Inspect surfaces for any damage that occurred during assembly identifying any issues requiring customer notification. For furniture with back panels or anti-tip devices, verify these are installed correctly per manufacturer safety requirements. For tall furniture including wardrobes and bookcases, install any provided anti-tip straps according to instructions discussing wall mounting with customer. Position completed furniture in customer's desired location, checking fit and clearances. Clean furniture surfaces with appropriate cleaner removing dust, fingerprints, and handling marks.

Safety considerations

Use caution during stability testing applying only moderate force to prevent furniture toppling. Do not allow children or pets near furniture during testing. If furniture shows any instability, disassemble and inspect for errors rather than accepting marginally stable assembly. Ensure anti-tip devices are installed on all tall furniture preventing tip-over hazards particularly in homes with children. When moving completed furniture into final position, use proper manual handling technique or obtain assistance for heavy items. Be aware of finger pinch points when positioning furniture near walls.

Site Cleanup and Waste Removal

After completing assembly and customer accepts furniture, systematically clean work area collecting all packaging materials and waste. Fold cardboard boxes flat for easier handling and transport to vehicle. Collect all plastic wrapping, foam protectors, and loose packaging ensuring no small pieces remain on customer floors where they create slip hazards or affect vacuuming. Gather all off-cuts, broken packaging pieces, and any damaged components being returned. Search assembly area for any dropped fasteners, small components, or tool accessories preventing sharp items being left where they pose injury risks. Lift drop sheets carefully from edges collecting any debris trapped on them without spreading it across floor. Sweep or vacuum if appropriate and customer supplies equipment, leaving assembly area cleaner than found condition. Remove all tools, equipment, and unused hardware to vehicle preventing any items being left behind. Make final walk-through of delivery route checking no equipment, packaging, or debris remains in halls, stairs, or entry areas. Load all waste into vehicle for proper disposal at approved facility.

Safety considerations

Wear work gloves when handling packaging waste to prevent cuts from sharp cardboard edges or staples. Use proper manual handling technique when carrying loads of packaging material preventing back strain. Watch for unstable piles of packaging that may shift during carrying. Keep pathways clear during waste removal maintaining trip-free route to vehicle. If packaging volume is large, make multiple trips rather than overloading preventing vision obstruction or loss of balance. Properly secure waste in vehicle preventing it blowing from vehicle during transport.

Customer Handover and Post-Job Documentation

Conduct final handover meeting with customer at completed furniture location. Demonstrate any adjustable features, drawer removal for cleaning, proper operation of sliding doors or extending tables, and any maintenance requirements. Provide customer with manufacturer assembly instructions, warranty information, and care guidelines. Review customer satisfaction asking if they have any concerns or questions about furniture assembly or operation. Request customer signature on completion documentation confirming work acceptance. Discuss any damaged items noted during unpacking or issues encountered during assembly that may affect warranty or require follow-up. Take photos of completed installation for company records documenting quality of completed work. Provide customer with company contact details for any post-installation issues or questions. Thank customer for their business and confirm any follow-up arrangements if additional items scheduled for later installation. Return to vehicle and complete job documentation including actual time spent, any issues encountered, customer feedback, and notations of excellent or concerning site conditions for future reference. Update lone worker monitoring system confirming job completion and departure from site. Review upcoming jobs and proceed to next delivery location or return to warehouse if work day is complete.

Safety considerations

Do not feel pressured to rush completion or skip safety checks due to customer time pressures. If customer identifies concerns about stability or quality, address them before leaving rather than accepting unsatisfactory work. Report any customer behaviour that was concerning or aggressive to management immediately. Ensure adequate break between jobs preventing fatigue accumulation across work day. If final job runs late, inform management and consider whether safe to continue or whether job should be rescheduled to avoid working while fatigued. Maintain professional boundaries with customers declining requests for additional work not included in original job scope without proper authority.

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Frequently asked questions

What is the maximum weight a single worker should attempt to lift alone when delivering flat pack furniture?

While regulatory maximum manual handling limits vary by jurisdiction, Safe Work Australia guidelines recommend implementing controls when individual lifts exceed 15-20kg, with teamwork mandatory for loads exceeding 25kg. For flat pack work specifically, the decision should consider not just weight but also package dimensions, grip availability, worker height and strength, distance to be carried, and environmental factors. A 25kg box with good handholds carried 5 metres on level ground differs significantly from a 25kg wardrobe panel with no grip points being carried up stairs. Best practice requires two-person handling for any package exceeding 25kg, awkwardly shaped items regardless of weight, items requiring stair navigation, or any package a worker identifies as beyond their comfortable capacity. Workers should never feel pressured to attempt solo handling creating injury risk simply to meet delivery schedules.

What should a flat pack assembly worker do if manufacturer instructions are unclear or appear to contain errors?

If assembly instructions are unclear or appear incorrect, stop assembly work before creating errors requiring disassembly. First, review instructions completely ensuring you have not missed supplementary diagrams or notes explaining the confusing step. Check if multiple language versions exist with one possibly clearer. Examine the actual components comparing them to instruction diagrams, as three-dimensional viewing sometimes clarifies two-dimensional drawings. Search online for assembly videos or guides specific to the furniture model, as many manufacturers and users post detailed assembly guidance. Contact your supervisor or company technical support describing the issue and obtaining guidance before proceeding. If uncertainty remains and attempting assembly risks creating unsafe furniture, explain the situation to the customer offering to halt work until manufacturer clarification is obtained rather than guessing. Document the instruction quality issue in job notes supporting any complaints or warranty claims that may arise. Never proceed with assembly you believe is incorrect simply to avoid customer disappointment, as structurally inadequate furniture creates serious safety hazards to end users.

How should flat pack workers manage customer requests to rush work or take shortcuts during assembly?

Flat pack assembly workers regularly face customer pressure to work faster, skip unpacking stages, or take shortcuts to complete work quickly. Workers have the right and responsibility to follow proper procedures ensuring safe and quality outcomes regardless of customer preferences. If customers request rushed work, politely explain that systematic assembly procedures are necessary to ensure structural integrity, prevent damage requiring rework, and maintain your personal safety. Outline that proper assembly includes component verification preventing missing parts being discovered only after partial assembly, systematic hardware organisation preventing lost fasteners and assembly delays, and quality checks ensuring stable furniture. Most customers accept these explanations once safety and quality implications are clarified. If customers become insistent or aggressive, workers should contact their supervisor explaining the situation and obtaining management support for maintaining proper procedures. In extreme cases where customer behaviour becomes threatening, workers have authority to cease work and leave the premises, prioritising personal safety over job completion. All such incidents require immediate reporting to management for appropriate customer relationship handling and to protect workers from unfair criticism for refusing unsafe practices.

What are the specific risks of assembling flat pack furniture on carpeted versus hard floor surfaces?

Floor surface type significantly affects assembly work safety and ergonomics. Carpeted floors provide cushioning making kneeling more comfortable and reducing knee joint compression, but create instability when furniture is positioned for assembly with items sometimes sinking unevenly into pile affecting alignment and making it difficult to verify level installation. Thick carpet makes rolling furniture difficult after assembly potentially requiring disassembly to reposition items. Dropped fasteners disappear into carpet pile making component retrieval time-consuming and creating risks of lost fasteners leaving incomplete assembly. Hard floors including tiles, polished concrete, and timber provide stable work surfaces allowing accurate levelling and easier furniture repositioning, but create significant knee discomfort during extended kneeling requiring knee pads or cushioned mats. Hard floors allow dropped components to roll away creating retrieval challenges. Tiled floors are often slippery when contaminated with packaging materials. Workers should carry both knee pads for hard floors and a firm board for use on carpet providing stable surface for component organisation and making fastener retrieval easier. Adjust assembly techniques to floor type, using shims on carpet to achieve level installation and taking extra care with component organisation on hard floors where items roll away easily.

What training and qualifications are required for workers performing flat pack delivery and assembly work?

Flat pack delivery and assembly work requires comprehensive manual handling training covering lifting techniques, use of mechanical aids, two-person lift procedures, and recognition of manual handling risks specific to package transport and furniture assembly. Workers need training in power tool safe operation including cordless drill use, bit selection, torque settings, and maintenance procedures. First aid training is valuable for workers operating alone in residential premises, providing capability to respond to minor injuries or assess whether injuries require immediate medical attention. Driver licencing appropriate to vehicle type is mandatory for delivery drivers, with light rigid licence required for vehicles exceeding 4.5 tonnes. Specific furniture assembly training covering interpretation of manufacturer instructions, systematic assembly procedures, quality verification methods, and common assembly errors should be provided before workers are deployed unsupervised. Workers operating on construction sites require general construction site induction and any site-specific safety training mandated by principal contractors. Confined space or working at heights licences are not typically required for basic flat pack work, though workers accessing basements, roofs, or elevated mezzanines may require additional certification. All training should be documented with records maintained demonstrating worker competency and supporting due diligence in contractor management.

How should flat pack workers handle situations where they discover damaged components or missing parts during unpacking?

Discovery of damaged or missing components requires immediate documentation and customer communication before commencing assembly. Photograph all damage using phone camera capturing multiple angles showing extent and nature of damage. Check component damage is shipping related versus manufacturing defect, as this affects warranty and replacement procedures. Count all components against manufacturer packing list confirming exactly which items are missing rather than assuming parts are present. Contact your supervisor or dispatch immediately reporting the situation and obtaining guidance on whether replacement parts can be expedited, whether partial assembly should proceed, or whether job should be rescheduled. Communicate situation to customer explaining that assembly cannot proceed safely without all components or with damaged parts, as this would create structurally inadequate furniture posing safety risks. Most customers accept explanations when safety implications are clarified. Discuss options including rescheduling when replacement parts arrive, or proceeding with partial assembly if missing components are non-structural and can be installed later. Document everything on job completion report including what was unpacked, what was damaged or missing, customer discussions, and agreed action plan. Repack damaged components carefully for return and replacement, keeping all packaging for warranty claims. Never attempt assembly with missing structural components or damaged panels creating unstable furniture, as this creates liability if furniture fails causing injuries.

Overview

Flat pack delivery and assembly services have become essential to modern residential and commercial furnishing, with workers delivering and assembling everything from basic home furniture to complex modular office systems, retail fit-outs, and educational facility equipment. The work typically begins with loading packaged items at warehouses or suppliers, transporting them to installation sites, unloading and positioning packages, unpacking components whilst managing packaging waste, and systematically assembling items using hand tools, power tools, and specialised fasteners according to detailed manufacturer instructions. Assembly complexity ranges from simple two-piece items requiring basic tool use to intricate systems involving hundreds of components, precise alignment requirements, and structural integrity considerations. Workers in this field operate across diverse environments. Residential delivery and assembly occurs in occupied homes where workers navigate around existing furniture, work in various room configurations from compact apartments to large homes, and coordinate with homeowners who may be present during installation. Commercial installations take place in office buildings, retail spaces, educational facilities, and healthcare environments, often requiring work outside business hours to minimise disruption, coordination with building management and security personnel, and compliance with site-specific safety requirements. Construction site installations involve working within active building projects where flat pack items form part of the overall construction scope, requiring integration with other trades, adherence to site safety management plans, and completion within construction schedules. The delivery component presents distinct hazards including vehicle loading and unloading with manual handling of packages ranging from small boxes to large wardrobe components weighing 60kg or more, securing loads during transport to prevent shifting that could affect vehicle stability, navigating delivery vehicles through urban areas and accessing sites with restricted entry points or difficult parking, and managing delivery timing to coordinate with customer availability and site access restrictions. Urban deliveries often involve parking in busy streets, carrying items up stairs or through narrow corridors, and working under time pressure to complete multiple deliveries within scheduled timeframes. Assembly work requires systematic processes including inspecting all components against packing lists to identify any missing or damaged parts before commencing assembly, organising hardware and fittings to prevent loss or confusion during assembly, following manufacturer instructions that may vary significantly in clarity and detail, using appropriate hand tools including Allen keys, screwdrivers, hammers, and spanners, operating power tools including cordless drills and impact drivers for efficient fastener installation, ensuring square and level installation through careful measurement and adjustment, and verifying structural stability before leaving completed assemblies. Workers must possess strong spatial awareness to interpret assembly diagrams, manual dexterity for handling small components and fasteners, physical endurance for extended periods of kneeling, bending, and reaching, and problem-solving skills to address assembly challenges or instruction ambiguities. Quality and safety considerations directly impact both worker welfare and customer satisfaction. Incorrect assembly can result in unstable furniture that poses collapse hazards to end users, particularly with items like wardrobes, shelving units, and beds where structural failure could cause serious injuries. Workers rushing to meet productivity targets may take shortcuts that compromise safety, skip verification steps, or force misaligned components causing damage and reducing structural integrity. The repetitive nature of assembly work, particularly for workers completing multiple similar items daily, creates risks of complacency where critical steps may be overlooked or safety considerations diminished.

Why This SWMS Matters

Safe Work Method Statements for flat pack delivery and assembly are essential under Australian WHS legislation as this work involves significant manual handling that represents one of the leading causes of workplace injuries across all industries. WorkSafe data consistently identifies manual handling injuries including back strains, shoulder injuries, and musculoskeletal disorders as the most common and costly workplace injuries, with furniture delivery and assembly workers particularly vulnerable due to the nature of their work. A single back injury can end a worker's career in this physically demanding field, whilst accumulated minor strains from poor lifting technique or inadequate manual handling practices can lead to chronic conditions requiring ongoing medical treatment and reducing quality of life. The Work Health and Safety Act 2011 Section 19 requires PCBUs to eliminate risks to health and safety so far as reasonably practicable, or if elimination is not possible, to minimise those risks through the hierarchy of controls. For flat pack operations, this means systematically addressing manual handling through engineering controls like mechanical lifting aids and trolleys, administrative controls including two-person lifting procedures and task rotation, and ensuring workers have appropriate training in manual handling techniques specific to furniture delivery and assembly. The high frequency of manual handling tasks in this work—with some workers lifting dozens of packages daily and spending entire shifts in physically demanding positions—means that small improvements in technique and work practices can significantly reduce injury rates. Power tool use during assembly presents electrical and mechanical hazards requiring specific controls. Cordless power tools must be maintained in good condition with appropriate battery management to prevent failures that could cause injuries. Workers using impact drivers, drills, and other power equipment need training in safe operation, understanding of tool limitations, and awareness of hazards including bit breakage, unexpected tool reaction when fasteners bind, and risks of over-tightening that can strip threads or crack components. Construction sites and some commercial installations may require residual current devices (RCDs) on all electrical equipment, with documented testing of portable tools meeting Australian standards. Packaging waste management creates underestimated hazards in flat pack work. Cardboard boxes with sharp edges, metal banding straps that can whip when cut under tension, staples and fasteners in packaging, and plastic wrap that creates slip hazards all contribute to cut and laceration injuries. Workers often work in customer homes or completed buildings where packaging must be collected and removed, creating additional manual handling and trip hazards if not managed systematically. Appropriate procedures for unpacking, waste containment, and disposal protect both workers and site occupants whilst maintaining professional presentation. Customer interaction and working in occupied spaces introduces psychological hazards and unique safety considerations. Workers may feel pressure from customers to rush completion, work in uncomfortable conditions without requesting reasonable accommodations, or continue working despite fatigue or minor injuries to avoid disappointing clients. Some workers experience verbal abuse from dissatisfied customers, work in isolation without colleague support, and face unrealistic expectations regarding completion times for complex assemblies. A comprehensive SWMS provides workers with documented procedures supporting them in maintaining safe work practices even when facing customer pressure, including protocols for refusing unsafe work, procedures for addressing workplace violence or aggression, and clear completion time estimates based on realistic work rates. The casual or subcontract nature of much flat pack work means workers may have limited safety training, inadequate supervision, and pressure to maximise productivity at the expense of safety. PCBUs engaging flat pack services must verify that workers have received appropriate manual handling training, understand safe work practices, possess necessary tools and equipment, and have access to documented SWMS that addresses the specific hazards they will encounter. This documentation demonstrates due diligence, supports systematic safety management, and provides evidence of proper contractor management in the event of incidents requiring investigation by safety regulators or during workers compensation claims that may arise from accumulated injuries in this physically demanding work.

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