Follow-up Checklists >> Packout

Use this checklist as a tool to help you in your efforts to identify hazards in your facility and keep track of follow-up measures.

  1. Print out the checklist for all of the tasks in this area of your plant to take with you as you evaluate this area of your plant. To use this option, select "Print Blank Checklist" below and a new window/tab will appear with the checklist. Then, using your browser's print option, print the checklist.

  2. Use the online checklist below and make selections and comments before printing. To do this, first check the box next to each hazardous situation that you have identified. Then for each suggested solution, indicate whether the solution is currently in use, something you want to consider, or not applicable. Include comments about the solutions or applicable follow-up procedures. Note that you may wish to identify other solutions that would prevent or control the hazardous situation in your plant. At the end of each task, there is also a field for identifying other hazards related to the task or comments about the task.

    Select "Print Completed Checklist" and a new window/tab will appear with the checklist filled out. Using your browser's print option, print the checklist. The checklist printed with this option will include only the hazardous situations for which you have made entries. YOUR ENTRIES WILL NOT BE SAVED ON YOUR COMPUTER.

Box Maker
Congested Work Area

Redesign task station to provide adequate room for the worker and performance of the task.

Whenever possible, replace manual operations with automated operations.

Hot Glue Burns, Splashes

Wear protective gloves.

Whenever possible, replace manual operations with automated operations.

Provide first aid for burns to prevent infection.

Poor Access to Emergency Exits

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.

Bending and Reaching

Use a palletizer to maintain the position of box material 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.

Other Hazards

 

Box Packer
Repetitive Reaching and Lifting

Use diverter bars to push the product closer to the employee.

Reduce width of conveyor so the product is presented closer to the employee.

Position packing fixtures and product so all activities of the task can be performed with the elbows in close to the torso.

Tilt work surface so product slides to the employee.

Develop both left- and right-hand stations so employees can rotate through different stations and provide periods of working rest for employees.

Provide adjustable work tables or stands so task can be performed without torso bending or reaching.

Standing For a Long Time

Install sit/stand stools, which allow employees to lean and have their weight supported while still remaining in an upright posture.

Rotate workers to tasks that do not require prolonged standing.

Provide shoe insoles that cushion the feet and spread foot pressure over a larger surface.

Provide a foot rest in front of employees so they can shift their posture.

Other Hazards

 

Scale Operator
Lifting Heavy Loads

Whenever possible, replace manual operations with automated operations, for example, installing conveyors to transport boxes to scales.

Reduce the amount of weight to be lifted. If containers must be lifted by employees, reduce the amount each container weighs.

Establish a workplace ergonomic program that teaches employees to avoid using awkward postures such as twisting and bending while lifting.

Provide mechanical lifting devices if boxes must be lifted from the conveyor to a scale.

Incorporate scales into the conveyor so boxes do not need to be lifted.

Standing For a Long Time

Install sit/stand stools, which allow employees to lean and have their weight supported while still remaining in an upright posture.

Rotate workers to tasks that do not require prolonged standing.

Provide shoe insoles that cushion the feet and spread foot pressure over a larger surface.

Provide a foot rest in front of employees so they can shift their posture.

Other Hazards

 

Box Sealer
Standing For a Long Time

Install sit/stand stools, which allow employees to lean and have their weight supported while still remaining in an upright posture.

Rotate workers to tasks that do not require prolonged standing.

Provide shoe insoles that cushion the feet and spread foot pressure over a larger surface.

Provide a foot rest in front of employees so they can shift their posture.

Other Hazards

 

Stack Off
Bending and Twisting While Lifting

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.

Slips, Trips, and Falls

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.

Other Hazards

 

Box Liner
Congested Work Area

Redesign task station to provide adequate room for worker and performance of task.

Whenever possible, replace manual operations with automated operations.

Bending and Reaching

Use palletizer to maintain position of box materials so employee can stand up-right and keep arms in close to body during tasks.

Whenever possible, replace manual operations with automated operations.

Rotate tasks.

Provide an adjustable work table or stand so task can be performed without torso bending or reaching.

Other Hazards

 

Unloader / Box Filler
Bending at the Waist to Put Birds Into Packing Boxes

Use a diverter to push birds off the conveyor directly into the box so employees do not need to manually lift product.

Provide a height adjustable packing stand so boxes can be loaded without bending at the waist.

Use a tub dumper at the workstation to empty contents on the conveyor.

Forceful Gripping of Slick Product

Use a diverter to push birds off the conveyor directly into the box so employees do not need to manually lift product.

Provide a height adjustable packing stand so boxes can be loaded without bending at the waist.

Use a tub dumper at the workstation to empty contents on the conveyor.

Reaching to Elevated Work Areas

Use a diverter to push birds off the conveyor directly into the box so employees do not need to manually lift product.

Provide a height adjustable packing stand so boxes can be loaded without bending at the waist.

Provide a height adjustable work platform so employees can adjust their height in relation to the conveyor.

Other Hazards

 

Giblet Packer
Repetitive Reaching and Lifting

Position packing fixtures, bags, scales, and product so all activities of the task can be performed with the elbows in close to the torso.

Tilt work surface so product slides to the employee.

Develop both left- and right-hand stations so employees can rotate through different stations and experience periods of working rest.

Provide height-adjustable work tables, packing stands or work platforms so task can be performed without torso bending or reaching.

Standing For a Long Time

Install sit/stand stools, which allow employees to lean and have their weight supported while still remaining in an upright posture.

Rotate workers between tasks that do not require prolonged standing.

Provide shoe insoles that cushion the feet and spread foot pressure over a larger surface.

Provide a foot rest in front of employees so they can shift their posture.

Other Hazards

 

Bagger
Repetitive Reaching

Use diverter bars to push the product closer to the employee.

Reduce width of conveyor so the product is presented closer to the employee.

Position packing fixtures and product so all activities of the task can be performed with the elbows in close to the torso.

Tilt work surface so product slides to the employee.

Develop both left- and right-hand stations so employees can rotate through different stations and experience periods of working rest.

Provide height-adjustable work tables or stands so tasks can be performed without torso bending or reaching.

Standing For a Long Time

Install sit/stand stools, which allow employees to lean and have their weight supported while still remaining in an upright posture.

Rotate workers between tasks that do not require prolonged standing.

Provide shoe insoles that cushion the feet and spread foot pressure over a larger surface.

Provide a foot rest in front of employees so they can shift their posture.

Highly Repetitive Activities

Rotate workers to tasks that do not use such rapid motions of the shoulder.

Use two employees to complete bagging task and ease the strain on one employee. One employee opens the bag while the other pushes the bird into the bag.

Use an automated bagging system. This type of system uses a powered ram to push the bird into the bag. Once the bird is bagged and removed from the system a stream of air automatically blows open a new bag and the cycle begins again. Employees place birds into the run and monitor for problems.

Other Hazards

 

Bag Sealer
Repetitive Reaching

Use diverter bars to push the product closer to the employee.

Reduce width of conveyor so product is presented closer to the employee.

Position bag sealing machines so all activities of the task can be performed with the elbows in close to the torso.

Tilt work surface so product slides to the employee.

Develop both left- and right-hand stations so employees can rotate through different stations and experience periods of working rest.

Provide adjustable work tables or stands so task can be performed without torso bending or reaching.

Repetitive Pinch Grips

Rotate workers to tasks that do not require the use of repetitive forceful pinch grips.

Use automatic bag sealers.

Arrange the workstation so bags can slide while being moved from conveyors to sealing machines. This will limit lifting of bag and reduce necessary finger force.

Other Hazards

 

Tray Packer
Repetitive Reaching

Use diverter bars to push the product closer to the employee.

Reduce width of conveyor so product is presented closer to employee.

Position packing fixtures, trays, conveyors, and product so all activities of the task can be performed with the elbows in close to the torso.

Tilt work surface so product slides to the employee.

Develop both left- and right-hand stations so employees can rotate through different stations and experience periods of working rest.

Provide adjustable work tables or stands so task can be performed without torso bending or reaching.

Standing For a Long Time

Install sit/stand stools, which allow employees to lean and have their weight supported while still remaining in an upright posture.

Rotate workers to tasks that do not require prolonged standing.

Provide shoe insoles that cushion the feet and spread foot pressure over a larger surface.

Provide a foot rest in front of employees so they can shift their posture.

Other Hazards

 

Quick Freeze Line Loader
Repetitive Reaching

Use diverter bars to push the product closer to the employee.

Reduce width of conveyor so product is presented closer to employee.

Position supplies and product so all activities of the task can be performed with the elbows in close to the torso.

Develop both left- and right-hand stations so employees can rotate through different stations and experience periods of working rest.

Provide adjustable work tables or stands so task can be performed without torso bending or reaching.

Standing For a Long Time

Install sit/stand stools, which allow employees to lean and have their weight supported while still remaining in an upright posture.

Rotate workers to tasks that do not require prolonged standing.

Provide shoe insoles that cushion the feet and spread foot pressure over a larger surface.

Provide a foot rest in front of employees so they can shift their posture.

Other Hazards

 

Quick Freeze Bagger
Repetitive Reaching to Elevated and Distant Location

Use diverter bars to push the product closer to the employee.

Reduce width of conveyor so product is presented closer to employee.

Position bagging fixtures and product so all activities of the task can be performed with the elbows in close to the torso.

Tilt work surface so product slides to the employee.

Develop both left- and right-hand stations so employees can rotate through different stations and experience periods of working rest.

Provide adjustable work tables or stands so task can be performed without torso bending or reaching.

Standing For a Long Time

Install sit/stand stools, which allow employees to lean and have their weight supported while still remaining in an upright posture.

Rotate workers between tasks that do not require prolonged standing.

Provide shoe insoles that cushion the feet and spread foot pressure over a larger surface.

Provide a foot rest in front of employees so they can shift their posture.

Repetitive Pinch Grips

Rotate employees to tasks that do not require using repetitive forceful pinch grips.

Use automatic bag sealers.

Arrange the workstation so bags can slide while being moved from conveyors to sealing machines. This will limit lifting bags and reduce necessary finger force.

Handling Cold Product

Provide employees with properly fitting gloves.

Develop an automated bagging machine so employees do not touch the product.

Other Hazards

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