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Packout - General

Task 1: Box Maker



The box maker is responsible for building boxes out of flat box stock and providing them to the stations where they will be filled with product. This task may be automated. Hazards of this task may include:
 
Congested work area
Hazardous Situation:
Problems can occur at this task because it is often an unplanned workstation, originally intended to be temporary. Placing such a workstation in a process line without adequate planning and space allocation can result in a highly congested work area, creating the potential for injury from working in awkward postures and coming in contact with other moving machinery.
Possible Solutions:
  • Redesign task station to provide adequate room for the worker and performance of the task.
  • Whenever possible, replace manual operations with automated operations.
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Hot glue burns, splashes
Hazardous Situation:
Problems can occur at this task station from exposure to hot glue as boxes are made. There is potential for employee burns and splashing hot glue when adding glue sticks to the pot, or when cleaning the machine.
Possible Solutions:
  • Wear protective gloves
  • Whenever possible, replace manual operations with automated operations.
  • Provide first aid for burns to prevent infection.
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Poor access to emergency exits
Hazardous Situation:
Box making operations are often placed in remote and hard-to-get-to locations, which makes access to emergency exits difficult. Quick and easy access to emergency exits from any room or workstation is very important to the safety of the employee. Without it, employees could be trapped or killed if unable to reach emergency exits during an emergency.
Possible Solutions:
  • Designate emergency exits and platforms/walkway with stairs to move to lower levels.
  • Post emergency escape routes in all areas of the plant.
  • Keep emergency exits clear.
  • Educate employees on what to do in the case of an emergency evacuation.
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Bending and reaching
Hazardous Situation:

Employees are required to repeat the same motion over and over, (i.e., reaching and or bending to obtain box stock and placing finished boxes on conveyor), which can result in work-related musculoskeletal disorders.
Possible Solutions:
  • Use a palletizer to maintain the position of box materials so the employee can stand up-right and keep arms in close to the body during tasks.
  • Whenever possible, replace manual operations with automated operations.
  • Rotate tasks.
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