Workplace health, safety and wellbeing for Corrugated Box Manufacturers: safe handling of reels and stacks
Reels weigh a lot and stacks fall. Handling injuries and forklift near-misses are common unless the plant has set routines and trained crews.
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Helpers lift bundles by hand, climb on stacks and walk through forklift lanes. Reel handling depends on whoever is on shift, and gloves and cut protection are worn when convenient. A rush order means shortcuts, and a minor injury becomes a few days of absence and a new helper's early exit.
A plan sets handling methods for each task: reel loading, stack building, bundle lifting and loading. Forklift routes and walking paths are marked. Protective gear is issued and worn. Training is short and repeated at the line. Near misses are reported without blame, and fixes are made to the layout, not only to people.
How to set it up
1. Walk the floor with the crew
Observe reel loading, die cutting, stitching and dispatch. Note lifting, stacking and walking paths, and ask helpers what hurts.
2. Set handling methods
Write a simple method with pictures for each task. Use mechanical aids where possible, and limit manual lifts.
3. Mark routes and zones
Paint forklift lanes and pedestrian paths and keep stacks within safe height. Our workplace health, safety and wellbeing work would help set the routines.
4. Issue and check gear
Provide gloves, cut protection and footwear that fit. Check that they are worn at the start of each shift.
5. Report near misses
Make it easy for helpers to say what almost happened. Review the reports each month and fix layout or routine before blaming people.
Check these first
Before changing anything, find out what is true today. These take an afternoon and use your own records.
- Injuries and near misses recorded in the last quarter by task
- Helpers who have had short handling training on their line
- Forklift routes with no marked pedestrian path
- Gear issued but not worn on the last shift check
GullyHR can do this with you. Read how we approach workplace health, safety and wellbeing in general, or share your requirements and we will tell you where to start.
Questions owners ask
That depends on size and the law, so ask your adviser. In any case, name one person to own floor safety routines and report to the owner.
Make it comfortable, supply it free and check at the start of each shift. Supervisors must wear it too. Explain what happens without it.
Use trolleys, lift tables and smaller bundles where you can. Teach the method with pictures and check by watching, not asking.