• Removal of bungs using hand tools was causing back and shoulder problems
• Changes to the production line and tools used made the task quicker and easier.

Returned empty beer casks were prepared on a conveyor line before washing and re-use.  The bung and top cap of each barrel was removed using a chisel.  This work required repetitive forceful movements and some of it was done at awkward heights as the bungs were on the sides of the barrels.  Both the staff doing the job had taken sick leave for back and shoulder injuries.
The company decided to take action to reduce the injury rate and to enable the speed of the production line to be increased.  Workplace meetings were used to bring engineers and operators together to devise a solution, and an ergonomist was used to get specialist advice.

There was insufficient space to use an gradually sloping conveyor to present the barrels at a varying height to make the task comfortable for both tall and short workers.  However it was possible to alter the conveyor to present the caps and bungs to the workers at a more suitable compromise height.  The manual force required for bung removal was also reduced by providing better tools.

The changes cost just under £9,000.  Benefits were substantial;  sickness absence was reduced, with no lost time due to musculoskeletal disorders or injuries in the year after the intervention.  There was less need for overtime working.  There was a reduction in conveyor belt breakdowns, which were previously frequent due to wooden fragments of bungs falling into the conveyor.  The payback period was under 3 months.

For a detailed economic analysis of this case study, see HSE Research Report RR 491