Loading Web Film into Machines
This manufacturer makes plastic products used in the pharmaceutical and medical industries. Workers teamed up to load rolls of web plastic packaging material weighing 150 to 250 lbs. into machines 4 to 5 times each day.

Concerns with Manual Lifting:
Too Many Back Injuries Heavy lifting on the production floor always invites back injuries, but when the rate of such maladies nears 30%, there are serious implications for worker morale in addition to lost productivity and higher insurance rates.

The rolls of material were packed vertically on their shipping pallet. The operators then had to lift these large, heavy rolls and flip them so they could be loaded horizontally onto the machine. The rolls were awkward to lift and maneuver. In just 12 months, 6 of the 25 workers on this production line had experienced back problems or injuries.