Ergonomic solutions take weight off workers' shoulders: designing an ergonomically sound packaging line doesn't have to be a pain in the back - Ergono

Certain sections along a packaging line can be a real pain in the back.

Areas along the line requiring awkward bending and heavy lifting or repetitive joint motion can result in debilitating injuries. According to the Bureau of Labor Statistics, 34% of lost workday injuries and illnesses are caused by work-related injuries. These injuries can include:

* Musculoskeletal disorders (MSDs), such as low back injury related to manual lifting;

* Cumulative trauma disorder to tendons, such as tendinitis and bursitis;

* Nerve disorder conditions, such as neuritis and carpal tunnel syndrome.

By the time the Bush Administration revoked the government regulated Occupational Safety & Health Administration (OSHA) Standard on Ergonomics in March, 2001, the standard had been in force for only two months. Critics argued that it was too focused on time-consuming paperwork and that it barely provided guidance for eliminating hazards in specific work situations. While the revocation could have been perceived as a blow to worker safety in packaging plants, the standard's withdrawal has led progressive companies toward more proactive ergonomics solutions.

OSHA states that almost one third of all recordable worker injuries each year result from ergonomic hazards while the cost of work-related injuries amounts to over $15 billion per year. OSHA estimates that lost time from job-related injuries is more than 105 million workdays yearly. OSHA also reports that worker's compensation, medical expenses, lost wages and lower productivity The Material Handling Industry of America (MHIA) has concluded that designing your packaging line to include equipment that specifically addresses ergonomics will help to reduce or eliminate packaging line worker injuries. Many leading packaging equipment manufacturers have taken or are taking an aggressive approach to either redesign traditional equipment or develop new ergonomically sound products. Here are some types of packaging equipment that can spare workers from MSDs and other types of packaging line injuries.

* Conveyors. Conveyors can provide an ergonomic advantage to workers by providing a mechanized way of moving work to the worker. Expandable conveyors are ideal for assisting workers with tasks such as loading products into containers or loading cartons onto pallets and trucks. Conveyors can be adjusted to proper positions and heights to reduce stooping and reaching.

* Industrial scissors lifts. Industrial scissors lifts can be used to position material or cartons so operators don't have to lift excessive loads, lift repetitively or bend to do their jobs. Tilting devices can be added so loads can be positioned both vertically and angularly. Lifts can be portable and powered with electric or air-powered hydraulic pumps, pneumatic lift systems or full mechanical lift systems.

* Manipulators. A manipulator has a mechanical arm, which can move a load horizontally as well as vertically. Manipulators combine mechanical arms, cylinders/motors and application-specific load handling devices or end effectors. Manipulators are operator controlled at or near the load control devices and operators can manually manipulate the load in the pick, move and place functions. Consequently, the load becomes near weightless and can be used to reach and orient heavy cartons onto or off of conveyors and/or pallets.

* Robots. Robots on a packaging line can lift heavy cartons and place them on pallets but they can also help automate highly repetitive tasks such as picking small products like baked goods, bottles and test tubes by placing them into containers at high speeds. Therefore, pick-and-place robots can spare workers from wrist and arm injuries.