Packing and inspecting product

Use solutions with the least risk

Most industries require packing of product from a conveyor line. Frequently this work involves repetitive reaching, twisting and lifting to pack individual items into tins, racks, boxes, packets or other containers. The task often also involves a quality inspection where employees have to remove any product that does not match quality requirements.

If employees are standing, anti-fatigue matting or comparable shoe insoles should be provided. If they are seated, an appropriate seat should be provided with a footrest so that the feet are supported with sufficient leg space beneath conveyors or benches.

The following solutions can help employers control risks to employees packing and inspecting product. These solutions may help eliminate or reduce the risk of employees developing a musculoskeletal disorder (MSD).

Solutions are listed in order, from those considered most effective to those considered less effective.

Employers should make sure employees use the handling solutions with the least risk, so far as reasonably practicable.

Solutions with reduced risks are an alternative only if least-risk methods are not reasonably practicable.

Employers should start implementing risk controls for the heaviest or highest-volume products first.

The following guidance also describes high-risk actions that can cause an MSD. Employers have a duty to eliminate or reduce the risk of MSDs so far as is reasonably practicable, and should make sure employees do not perform high-risk actions, where practicable.

Consultation

So far as reasonably practicable, employers must consult with employees and any health and safety representatives (HSRs) when identifying hazards and providing risk control measures. Consultation should include discussions about how employees will pack and inspect product, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Conveyor is too wide

High-risk actions that can cause an MSD

• Bending the back more than 20 degrees and reaching more than 30 cm from the body:
  • more than twice per minute or
  • for more than 30 seconds at a time

  for more than 30 minutes continuously or more than 2 hours over the whole shift. These actions may occur in the situations listed or in combination with other work activities.

Potential source of risk

• Wide conveyor.

Handling solutions

Preferred solution with the least risk

• Automate the task.

Solutions with a reduced risk

• Bring the product closer to the employee to reduce reach distances.
• Use 2 operators, one on either side of the conveyor, to reduce reach distances.
• Introduce appropriately designed job rotation, in combination with other risk controls.

  Note: Job rotation does not eliminate manual handling hazards. WorkSafe has guidance to help eliminate or reduce the health and safety risks associated with job rotation.

Conveyor or container is too low

High-risk actions that can cause an MSD

• Bending the back more than 20 degrees and reaching more than 30 cm from the body:
  • more than twice per minute or
  • more than 30 seconds at a time

  for more than 30 minutes continuously or more than 2 hours over the whole shift. These actions may occur in the situations listed or in combination with other work activities.

Potential source of risk

• Conveyor or container being packed is too low for employees.

Handling solutions

Preferred solution with the least risk

• Automate the task.

Solution with a reduced risk

• Raise the height of the conveyor and/or container into which the employee is packing.

Double handling of reject products

High-risk actions that can cause an MSD

• Bending the back more than 20 degrees and reaching more than 30 cm from the body:
  • more than twice per minute or
  • more than 30 seconds at a time

  for more than 30 minutes continuously or more than 2 hours over the whole shift. These actions may occur in the situations listed or in combination with other work activities.

Potential source of risk

• Rejected products require double handling by employees.

Handling solutions

Preferred solutions with the least risk

• Improve mechanics of machinery to prevent quality issues.
• Use robotics or electronic inspection.

Solutions with a reduced risk

• Introduce appropriately designed job rotation, in combination with other risk controls.

  Note: Job rotation does not eliminate manual handling hazards. WorkSafe has guidance to help eliminate or reduce the health and safety risks associated with job rotation.

Position of seated or standing workstations

High-risk actions that can cause an MSD

Twisting the back more than 20 degrees more than twice per minute, for more than 30 minutes continuously or for more than 2 hours over the whole shift. These actions may occur in the situations listed or in combination with other work activities

Potential source of risk

• Position of seated or standing workstation in relation to conveyor and boxes.

Handling solutions

Preferred solution with the least risk

• Automate the task.

Solutions with a reduced risk

• Place the tins or boxes in front of the operator to minimise any twisting and tilt the outer to reduce awkward wrist postures.
• Introduce appropriately designed job rotation, in combination with other risk controls.

  Note: Job rotation does not eliminate manual handling hazards. WorkSafe has guidance to help eliminate or reduce the health and safety risks associated with job rotation.

Box or container is too high

High-risk actions that can cause an MSD

• Ecessive bending of the wrist and lifting and lowering:
  • more than twice per minute for more than 30 minutes continuously or
  • more than 2 hours over the whole shift

  These actions may occur in the situations listed or in combination with other work activities

Potential source of risk

• The position of boxes or containers is too high for employees.

Handling solutions

Preferred solutions with the least risk

• Automate the task.
• Improve mechanics of machinery to prevent quality issues.
• Use robotics or electronic inspection.

Solutions with a reduced risk

• Reduce the height of the box or container or reduce the height of the stand/table/bench it is sitting on.
• Have adjustable height stand/table/ benches to cater for all sizes of containers.
• Change the system of work.
• Tilt the tin or box towards the operator to improve wrist postures during packing.

Box flaps stand up

High-risk actions that can cause an MSD

• Excessive bending of the wrist and lifting and lowering:
  • more than twice per minute for more than 30 minutes continuously or
  • more than 2 hours over the whole shift

  These actions may occur in the situations listed or in combination with other work activities.

Potential source of risk

• Box flaps stand up.

Handling solutions

Preferred solutions with the least risk

• Automate the task.
• Improve mechanics of machinery to prevent quality issues.
• Use robotics or electronic inspection.

Solutions with a reduced risk

• Create a wedge or fixture to hold the box in place, holding the flap down.

Employees unable to keep up with production line speed

High-risk actions that can cause an MSD

• Repetitive and very fast movement for more than 30 minutes continuously or for more than 2 hours over the whole shift.

Potential source of risk

• Production line speed is too fast for employees.

Handling solutions

Preferred solutions with the least risk

• Automate the task.
• Improve mechanics of machinery to prevent quality issues.
• Use robotics or electronic inspection.

Solutions with a reduced risk

• Ensure there are enough employees to perform the task, including enough employees to cover absenteeism.
• Set the production line speed to a comfortable level that is sustainable. Consult with employees regularly about line speeds and adjust speed as required.
• Implement rest breaks.
• Use appropriately designed job rotation in combination with other risk controls.

  Note: Job rotation does not eliminate manual handling hazards. WorkSafe has guidance to help eliminate or reduce the health and safety risks associated with job rotation.

• Introduce buffers to allow a safe area for product to rest whilst employees catch up.

Your legal duties

Employers

The Occupational Health and Safety Act 2004 (OHS Act) requires employers to provide and maintain a working environment that is safe and without risks to health, so far as reasonably practicable. An employer contravenes this duty if they fail to:

• provide or maintain plant or systems of work that are, so far as reasonably practicable, safe and without risks to health
• make arrangements for ensuring, so far as reasonably practicable, safety and the absence of risks to health in connection with the use, handling, storage or transport of plant or substances
• maintain, so far as is reasonably practicable, each workplace under the employer's management and control in a condition that is safe and without risks to health
• provide, so far as is reasonably practicable, adequate facilities for the welfare of employees at any workplace under the management and control of the employer
• provide information, instruction, training or supervision to employees of the employer as is necessary to enable those employees to perform their work in a way that is safe and without risks to health

Employers also have an obligation to consult, so far as is reasonably practicable, with employees and any HSRs on matters related to health and safety that directly affect them, or that are likely to directly affect them. This duty to consult also extends to independent contractors, including employees of the independent contractor, engaged by the employer in relation to matters over which the employer has control.

Employees

While at work, employees also have duties under the OHS Act to take reasonable care for their own health and safety and the health and safety of others who may be affected by their acts or omissions in the workplace. Employees must also co-operate with their employer's actions to make the workplace safe and comply with the OHS Act and Regulations.

The WorkSafe website has guidance about the occupational health and safety (OHS) responsibilities of employers and employees.