A sweet manufacturer produced a sweet that came in different sizes and also was sold in bags of various weights. This gave the packing department a manual handling problem, as it required bags of different sizes. The bags were made by forming tubes and a different tube was needed for each size of bag. 

They varied in size from 25Kg to 33Kg and were changed manually by removing the tube in use and carrying it to a holding stand. The correct tube for the new line code was then lifted off the stand, carried to the machine and fitted into position. The fitting of the forming tube involved stretching while holding the tube to put it into position. Although the task was frequent the operation was high risk.

The manufacturer wanted a solution that addressed all aspects of the job:

• A storage solution that gave better access;
• A means of transporting the forming tubes what would include a lifting facility to set it to the right height;
• A system for inserting the forming tube into the machine which minimised manual handling while stretching; and
• a lighter version of the forming tubes. 

In the event a solution was found that satisfied all these requirements: 

• A revolving carousel, with a foot pedal to rotate it, was specially built to store the forming tubes (photo 1).
• A trolley was developed to carry the forming tubes between the machine and the carousel.  This included a hydraulic foot pump to allow the operator to lift and lower the forming tube to the desired height (photo 2).
• A swinging arm was developed so that when it was placed into the machine it swung open and the forming tube was lifted onto the arm and rotated into position (photo 3).
• The forming tubes themselves were redesigned using stronger but slimmer material. This reduced the weight of each forming tube by up to 10Kg (photos 4).

The benefits of the changes are:

• A dramatically lowered manual handling risk throughout the operation
• No accidents since the change was implemented
• A greater flexibility in personnel able to carry out the operation.

Photo 1 showing the new revolving carousel

Photo 2 showing the new transportation for the forming tubes including the ability to raise and lower the tubes to the correct height.

Photo 3 showing the swinging arm to fit the tube into position

Photo 4 showing the new, lighter, tubes, compared with the older ones.