• Risks of upper limb disorders and back pain from a packing line with less than optimal layout
• Involving the workforce produced a redesign that lowered the risks and improved productivity.

A pharmaceutical plant packed small orders for tablets into vials by hand.  The vials moved along a line where stages such as fillling, capping, packing and security tagging were carried out by different operators.  It was recognised there were some inefficiencies in the process, additional staff often having to be brought in to clear backlogs. Problems included inadequate storage, cramped working conditions and poor communications between operators. 

Job rotation was used, but had not overcome the ergonomic problems such as excessive twisting by operators to collect or move vials or to speak to each other. Work was done seated and required repetitive hand and arm movements. The employer decided to act to reduce the risks of upper limb disorders and back pain and to improve morale and productivity.

The whole production team was given training in a method of work flow analysis.  This enabled them to take part in the investigation and suggest improvements.

The outcome was a new layout for the packing line that enabled workers to communicate easily and pass on vials by hand without uncomfortable reaching or twisting.  Better tables, chairs and storage units were also brought in.

After the changes

It cost £12,000 to investigate, decide on the changes and put them into effect.  Musculoskeletal risks were reduced and the morale of the team was improved.  There was a 25% increase in productive hours which brought about a saving of nearly £55,000 a year in overtime payments.  The payback period was under 3 months.

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