Replacement of wooden pallets by incorporating a recessed component into the product - The Netherlands

The issue under discussion

The company manufactures ribbed floor components. It uses a wooden pallet system to transport these products, in which workers have to handle awkwardly shaped pallet blocks weighing around 25kg when dry.

Action taken

The risk of MSDs arising out of the manual handling of these heavy pallet blocks was recognised during an assessment based on the “NIOSH method” (http://www.cdc.gov/niosh/topics/ergonomics/). A traffic light system was used to indicate risk levels: red for a major risk requiring action, amber for a risk where action is desirable and green for a situation where no action is required.

Potential solutions included changing the design or materials of the pallets and using mechanical lifting aids. However, the company concluded that the best solution was to get rid of the pallets altogether.

A brainstorming session with the employees identified the solution: incorporating a recessed element into the ribbed floor components themselves, rendering the wooden pallets redundant. The feasibility of this solution was tested, in particular, whether the redesigned components maintained the required quality and construction standards. The result is that neither Dycore employees nor other workers, such as sub-contracted drivers, have to expend physical effort handling pallets and risk injury.

Results achieved

At an annual cost of €137,000, the redesign saved €91,000 a year in other component use and €22,000 in the purchase of pallets. Improved handling capabilities also meant that three fewer workers were required in this process, saving €120,000. In total, there is a net benefit of €96,000 a year.

It is more difficult to attribute directly the fall in absence due to ill-health over the past three years to the redesign, but there must be a link. Other benefits include a cut in noise as nail guns are no longer needed to repair pallets and quicker deliveries on site because there is no need to load pallets onto trucks.