EASA Part 145 Stores Manual Lifting – Reducing Injury Risk and Ensuring Compliance

The Overlooked Risk in Aviation Stores – Are Your Teams Protected?

Aviation maintenance depends on precision, compliance, and efficiency. Yet, one often underestimated risk within EASA Part 145-approved organizations is manual handling injuries. Stores personnel routinely lift, push, and transport aircraft components, tools, and materials. Without structured ergonomic controls and procedural discipline, these routine tasks expose personnel to musculoskeletal disorders (MSDs), chronic back injuries, and operational downtime.

Industry data indicates that manual handling-related injuries account for up to 30 percent of lost workdays in maintenance and logistics operations. This underscores the necessity of proactive risk mitigation, regulatory compliance, and a safety-first culture in aviation logistics and stores management.

The Role of Manual Handling Safety in EASA Part 145 Compliance

EASA Part 145 organizations are required to integrate systematic risk assessments, structured handling procedures, and competency-based training into their Safety Management System (SMS). Key compliance obligations include:

• Ergonomic Risk Assessments – Evaluating workplace layout, load characteristics, and task frequency to determine exposure levels.
• Competency Development & Procedural Adherence – Ensuring all stores personnel receive recurrent training on lifting techniques and hazard identification.
• Use of Mechanical Handling Equipment – Prioritizing lifting aids such as pallet jacks, hoists, and forklifts to minimize reliance on manual handling.
• Storage Optimization & Workspace Configuration – Reducing overreaching, bending, and twisting through optimized shelving, workstations, and storage height.

Organizations that fail to implement these safeguards expose themselves to regulatory non-compliance, increased operational costs, and elevated injury rates—directly impacting both safety and efficiency.

Key Risk Factors in Aviation Stores Operations

The logistics and material handling environment in aviation maintenance presents specific risk challenges:

• Lifting and Transporting Aircraft Components – Unusual shapes, asymmetric loads, and awkward lifting angles create significant strain.
• High-Frequency Handling – Repetitive movements lead to cumulative trauma injuries over time.
• Uncontrolled Postural Adjustments – Twisting, overextending, and lifting in compromised positions increase the risk of musculoskeletal stress.
• Time-Sensitive Operations – Pressure to meet turnaround times may result in non-compliant lifting practices.

These risks must be mitigated through structured training, engineering controls, and adherence to EASA Part 145 safety policies.

Best Practices for Injury Prevention in Aviation Stores

To enhance safety and regulatory alignment, organizations should embed the following best practices into their logistics and maintenance procedures:

1. Conduct Load Risk Assessments
2. Reinforce Correct Handling Techniques
3. Implement Mechanical Handling Support
4. Optimize the Work Environment
5. Create a Safety-First Workplace Culture

Regulatory Framework & Compliance Obligations

EASA mandates compliance with Council Directive 90/269/EEC, which requires aviation maintenance organizations to:

• Minimize the necessity of manual handling wherever possible.
• Provide structured training and risk assessment programs.
• Ensure all handling tasks comply with ergonomic best practices.
• Monitor employee health and injury risk factors.

Non-compliance can lead to workplace safety violations, increased liability, and operational inefficiencies.

Building a Resilient & Compliant Logistics Operation

Effective aviation logistics is not just about inventory control and material movement—it is about ensuring that every component of the EASA Part 145 operational environment meets stringent safety and compliance standards.

A well-managed stores and logistics function:

• Reduces workplace injuries and lost productivity.
• Ensures compliance with regulatory directives.
• Enhances operational efficiency through structured handling policies.
• Creates a safer working environment for all personnel.

Final Thought: Is Your Aviation Stores Operation Managing Manual Lifting Risks Effectively?

How does your organization approach manual handling safety in EASA Part 145 logistics operations? Have you implemented best practices to reduce injury risks? Share your insights in the comments.

For structured training on EASA Part 145 Stores Manual Lifting & Handling Safety, contact Sofema Aviation Services (SAS) at [email protected].

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