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Packout - General

Task 5: Stack Off

Stack Off
The stack off employee is responsible for removing boxes, which may weigh 40-80 pounds, from the conveyer and stacking them on pallets. Palletized loads are then stored or loaded onto trucks.

Hazards of this task may include:
Stack Off

Bending and twisting while lifting heavy loads
Hazardous Situation:
Stacking full boxes forces employees to bend the torso forward to place the box on the pallet, or to lift the box up to or above head height to place it on the top of the stack. This can result in back injuries since boxes can weigh up to 80 pounds.
Possible Solutions:
  • Limit the weight of boxes and arrange the workstation so loads lifted are safe according to the NIOSH Guidelines.
  • Reduce the size of the box or decrease the amount of weight to be lifted.
  • Provide lift assists, so boxes may be lifted from the conveyor with the assist and placed on the pallet.
  • Provide palletizers or scissor lifts for employees so they do not need to bend over to place boxes on pallets lying on floors.
  • Develop a whole new workstation where elevated, as well as low, lifts have been eliminated.
  • Rotate employees to tasks that do not require heavy lifting.
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Slips, trips, and falls
Hazardous Situation:
Employees must often move pallets of product with a hand jack while stepping on wet slippery surfaces, resulting in possible slips and falls.
Possible Solutions:
  • Whenever possible, replace manual operations with automated operations.
  • Provide a plan to keep water off walkways.
  • Use non-slip floor surfaces.
  • Provide employees with non-slip shoes.
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