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Manual Inspection Scheme

manual inspection eye fatigue personnel sorting policy program

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#1 Ken Lim

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Posted 05 September 2014 - 01:11 AM

Hi there! I'm currently reviewing the effectiveness of our manual inspection process. These manual inspections are manned by trained personnels to identify rejects / defects all throught identified areas in during processing and packaging. This is for a multi category plant having snacks production line, bottled tea drink, chocolate bars line, noodle production line, bakery/biscuit line etc.. The identified areas for manual inspection are all for vissual defects on labelling/packaging, foreign contamination for in-process goods prior to packing, sorting activity prior to processing, etc. The concern is that assigned personnels at these manual inspection areas are working in one area for the entire 8 hours duty (or more). I know the potential problem with this set up is the eye fatigue that could greatly reduce the effectiveness of our manual inspection process and other human factors. I am currently generating a policy to address this concern, Im looking at an inspection rotation scheme, setting a limit of 30 mins or 1 hour maximum stay of each personnel manning the manual inspection areas then will be rotated to a non-inspection role (such as utility/cleaning activity) then will be rotated back to inspection role after an hour, thus to help relax their eyes and avoid eye fatigue. My question here is that, is there any reference study or document that i could refer to regarding the best maximum inspection time for a person to avoid eye fatigue. Is a 30 min inspection time or a 60 min inspection time better? What can you suggest? Thanks! Ken

#2 fcchoi


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Posted 05 September 2014 - 04:13 AM

Hi Ken,

A 30 mins inspection time is even too long for naked eyes, I usually do it at a 15 mins interval. TQ.

#3 Ken Lim

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Posted 06 September 2014 - 02:08 AM

Thank you, is there any reference study or document that can support the 15 mins inspection time? Thanks

#4 Charles.C


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Posted 06 September 2014 - 07:13 AM

Dear ken Lim,


Personally i have never seen/ employed anything remotely resembling 15 mins for a worker changeover period. Looks to have excellent opportunities for organizational chaos IMO. Unless perhaps only 1- 2 workers.?


But i suppose it might also relate to the specification /  typical foreign materials which are actually found in yr product. Are they microscopic or something ?


On the other hand, a continuous stint of 8 hours sounds equally unrealistic. And illegal ?


Rgds / Charles.C

Kind Regards,



#5 fgjuadi


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Posted 08 September 2014 - 09:12 PM

This article can help out with manual inspection, but it is intended for pharma -



It doesn't list a time, but suggests that each inspector has a "baseline" test

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