How Can You Reduce Physical Strain at a Packaging Station?

Introduction

Repetitive movements, exposure to allergenic or hazardous products and manual handling of heavy loads can expose end-of-line employees to health risks such as musculoskeletal disorders (MSDs). Reducing these risks is now a major issue for many companies. What solutions can reduce physical strain at packaging stations? What steps can be taken to improve workstations and minimise risks to employees?

Analyse packaging workstations

Improving working conditions at packaging stations starts with analysing the current process and carrying out a detailed assessment to identify where changes are needed.

Reviewing company data is the first step in assessing physical strain. Relevant information may be found in occupational risk assessments, occupational health reports and any other documents that record workplace risks. Statistics on absence, workplace accidents, occupational illnesses and absenteeism can also help confirm initial findings.

This first review should be supplemented by speaking directly with the employees concerned. Their feedback can confirm existing issues and reveal new ones. Observation under real production conditions then provides the final part of the assessment.

Assess the potential for robotic automation

When integrating a robot into a complete end-of-line packaging system, preparing a detailed specification is essential. The company’s needs, objectives and improvement priorities must be clearly defined, together with the available budget and the environment in which the equipment will be installed.

A robot installed at a workstation must address the manufacturer’s new production requirements. The machine designer and integrator can then propose the most suitable solution based on the specification. The programming parameters required for the robot to perform its task and support the target performance are defined during the project. Case packing and palletising are among the most common applications. The growing use of collaborative robots across industry also makes it possible to automate simple repetitive tasks with lower investment levels than many traditional robotic cells.

All of these variables can be discussed throughout the installation project. Ongoing dialogue is important to ensure that the final solution genuinely meets the company’s requirements.

Optimise flows between machines

A production line must remain coherent from infeed to outfeed. When a new machine is introduced, both its immediate environment — the complete end-of-line packaging system — and the wider production line must be considered.

A robot installed at the end of the line should form part of a broader line-improvement approach. Product dimensions, weight and orientation as they arrive at the packaging station must all be assessed. Taking these characteristics and the surrounding equipment into account makes it possible to adjust robot programming and achieve the best possible performance.

Train the teams

Operators remain central to the smooth running of the production line. The robot supports them by taking over physically demanding movements. Team training is therefore essential to ensure that robotic automation is properly integrated into the complete packaging line.

Employees working at the relevant stations must be trained on safety requirements to reduce handling risks. The installed robot should also be straightforward for line operators to use and, where appropriate, programme. The integrator should provide training on correct operating practices and the working methods to adopt.

The integrator selected for a complete packaging line should provide strong technical guidance. Maintaining close communication at every stage — from the initial study through installation and final operation of the robot — is essential.