WorkSafe Victoria\u2019s free programs are helping manufacturers tackle hazardous manual handling with practical tools, guidance and participatory approaches.<\/p>\n
Hazardous manual handling remains the most common cause of injury in Victorian workplaces, and for manufacturers, the implications are both human and operational. Musculoskeletal disorders (MSDs) such as sprains and strains, back injuries, soft-tissue damage, hernias and chronic pain continue to drive absenteeism, reduce productivity and place pressure on already stretched workforces.<\/p>\n
Building safer foundations in manual handling<\/p>\n
WorkSafe Victoria\u2019s Manual handling basics program is designed to address this challenge head-on. Delivered as a free online workshop, the initiative is tailored for employers, managers and supervisors in small to medium-sized businesses, particularly those with direct occupational health and safety (OHS) responsibilities.<\/p>\n
The program is about capability building. Participants are guided by an independent expert in ergonomics and safety, who provides practical advice on managing the risks associated with hazardous manual handling. The workshop moves beyond theory, equipping attendees with tools they can immediately apply in their workplaces.<\/p>\n
The program covers key areas such as understanding MSDs, recognising early warning signs of injury, and conducting effective risk assessments. Importantly, it also outlines a straightforward risk management approach, enabling businesses to implement preventative measures without unnecessary complexity.<\/p>\n
Outcomes are both tangible and strategic, with businesses who complete the Manual handling basics program better positioned to identify hazards early, reduce injury rates and foster a safer working environment. This, in turn, supports improved productivity and lower absenteeism \u2013 outcomes that are particularly critical in manufacturing settings where workflow disruptions can have cascading effects.<\/p>\n
Beyond compliance, there is also a workforce dimension. Demonstrating a commitment to safety helps manufacturers retain skilled employees and attract new talent in a competitive labour market. For many, the added peace of mind that comes with a structured approach to safety is equally valuable.<\/p>\n
OHS Essentials: tailored support for small businesses<\/p>\n
While Manual handling basics focuses on foundational knowledge, WorkSafe Victoria\u2019s OHS Essentials program takes a more hands-on, tailored approach to workplace safety.<\/p>\n
The WorkSafe Victoria program connects small businesses with an independent safety expert who works alongside them to identify risks and implement practical safety measures. The emphasis is on simplicity and relevance \u2013 ensuring that safety improvements are suited to the specific needs of each business.<\/p>\n
\u201cThe benefits have been immense. Knowing that we now have solid support for workplace safety gives us peace of mind,\u201d said Ross McCullogh, builder, RM Building and Design Group.<\/p>\n
Eligibility for the program reflects its focus on smaller operators. It is available to Victorian small businesses with 60 workers or fewer that hold a WorkCover insurance policy, as well as sole traders using contractors. Notably, for 2026, manufacturers located in postcode 3175 with fewer than 200 employees are also eligible to register.<\/p>\n
The program unfolds over three structured visits. The first, conducted within the initial month, involves a comprehensive site review by a health and safety expert and the development of a simple safety plan. A follow-up visit three to six months later assesses progress and provides further guidance, while a final visit between nine and 12 months ensures that all actions have been completed and that safety measures are embedded.<\/p>\n
For growing manufacturers, this structured support can be transformative. Sunset Sleepers, a Melbourne-based producer of concrete sleepers for retaining walls, offers a case in point. Since its establishment in 2014, the company has expanded to three sites and approximately 30 employees. A change in ownership in 2021 brought renewed focus on workplace safety, prompting site manager Wendy Archer to engage with the OHS Essentials program.<\/p>\n
Working with safety expert Frank Rizzo, Sunset Sleepers undertook a series of targeted improvements. Across three visits, Rizzo provided hands-on support and tailored recommendations, helping the business strengthen its safety practices while accommodating ongoing growth.<\/p>\n
The result is a safer, more efficient operation, where employees are better supported and the business is equipped to scale sustainably. For manufacturers navigating similar growth trajectories, the program highlights the value of embedding safety into operational planning rather than treating it as an afterthought. Wendy shared one key takeaway: \u201cThe program re-emphasized the critical importance of OHS and workplace safety.\u201d Thanks to the OHS Essentials Program, Sunset Sleepers is not only ensuring its operations are safe and efficient but also creating a workplace where employees can thrive as the company continues to grow.<\/p>\n
A participatory approach to risk management<\/p>\n
For medium to large manufacturers, WorkSafe Victoria\u2019s participative hazard identification and risk management (APHIRM) toolkit introduces a more advanced, collaborative approach to workplace safety.<\/p>\n
Developed in partnership with La Trobe University, the APHIRM toolkit is a free online resource designed to address MSDs. What sets APHIRM apart is its participatory framework, which actively involves employees in identifying hazards and shaping solutions.<\/p>\n
The toolkit enables organisations to systematically identify both physical and psychosocial hazards that contribute to injury risk. Physical hazards can include environmental factors such as vibration, extreme temperatures, poor lighting, slippery or uneven surfaces and workplace obstructions. Psychosocial hazards, meanwhile, encompass elements such as high job demands, low job control and insufficient support from supervisors or colleagues.<\/p>\n
When these factors intersect, the risk of MSDs increases \u2013 a reality that many manufacturing environments must contend with daily.<\/p>\n
The APHIRM toolkit provides a structured pathway to address these risks. It supports businesses in designing targeted interventions, monitoring progress and reviewing outcomes over time. The result is an approach to risk management that evolves alongside the workplace.<\/p>\n
Crucially, the toolkit also strengthens engagement. By involving employees directly in the process, organisations can improve staff morale, increase buy-in for safety initiatives and create a more proactive safety culture.<\/p>\n
WorkSafe Victoria is planning two introductory workshops in 2026-2027 that provide an overview of the toolkit\u2019s functionality and practical application. Here, participants learn how to use the toolkit in conjunction with other resources, ensuring a cohesive approach to risk management. The workshops also highlight the broader organisational benefits, from reduced absenteeism to improved workforce engagement. Subscribe to Manual Handling updates to be the first to hear when the new workshops are available.<\/p>\n
A cohesive approach to workplace safety<\/p>\n
Together, WorkSafe Victoria\u2019s Manual handling basics, OHS Essentials and APHIRM programs provide a structured support pathway for manufacturers at every stage of development.<\/p>\n
For smaller operators, the focus is on building core knowledge and establishing practical safety processes. As businesses grow, the priority shifts to embedding those systems and aligning them with expansion. For larger organisations, attention turns to continuous improvement, workforce engagement and data-led decision-making.<\/p>\n
In a sector defined by tight margins and constant pressure, this accessibility matters. It allows manufacturers to strengthen safety without sacrificing competitiveness \u2013 often improving both. As the industry evolves, effective manual handling will only become more critical, but with the right tools and guidance, manufacturers are well placed to reduce injuries and build more resilient operations.<\/p>\n","protected":false},"excerpt":{"rendered":"WorkSafe Victoria\u2019s free programs are helping manufacturers tackle hazardous manual handling with practical tools, guidance and participatory approaches.…\n","protected":false},"author":2,"featured_media":773720,"comment_status":"","ping_status":"","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[6],"tags":[64,63,105],"class_list":["post-773719","post","type-post","status-publish","format-standard","has-post-thumbnail","category-technology","tag-au","tag-australia","tag-technology"],"_links":{"self":[{"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/posts\/773719","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/comments?post=773719"}],"version-history":[{"count":0,"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/posts\/773719\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/media\/773720"}],"wp:attachment":[{"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/media?parent=773719"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/categories?post=773719"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.newsbeep.com\/au\/wp-json\/wp\/v2\/tags?post=773719"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}