Health surveillance for factories and warehouses
The risks on the factory floor.
Most come down to what people breathe, hear and lift, and when they work.
Noise
Presses, production lines and packaging machinery can expose staff above the levels where hearing checks are required.
Dust and fumes
Flour and grain dust, isocyanates, stainless-steel welding fume, rosin-based solder flux and some resins are known causes of occupational asthma.
Lifting and repetitive work
Manual handling and repetitive tasks are a major cause of musculoskeletal disorders in production and warehouse roles.
Lift trucks and night shifts
Forklift operators need to be fit to drive safely, and night workers must be offered a free health assessment.
The checks we recommend.
Matched to the exposures in your risk assessment. Hearing, lung function and HAVS checks form part of a health surveillance programme, with results tracked over time.
Hearing tests (audiometry)
For staff in noisy areas such as production lines, presses and packaging.
When it applies
- GB and NI: required above 85 dB(A), or where there's another risk
- Ireland: preventive audiometry offered above 80 dB(A)
- HSE suggests a baseline, then yearly for two years, then every three years
- Results recorded so changes can be spotted early
Lung function tests (spirometry)
For bakers, millers, food ingredient handlers, welders, spray painters and anyone working with substances that can cause occupational asthma.
When it applies
- Baseline before exposure, or soon after starting
- Usually repeated every year, more often for new starters
- Part of the health surveillance your COSHH assessment calls for
Hand-arm vibration (HAVS) assessments
For grinding, fabrication and power-tool users in engineering and maintenance.
When it applies
- Where exposure is likely to reach 2.5 m/s² A(8), the action value
- Check when someone joins the role
- Then reviewed regularly
Lift-truck operator medicals
HSE's L117 guidance says operators should be free from conditions that could affect safe driving, and suggests employers may screen before placement.
When it applies
- Pre-employment medical with a clear fitness outcome
- Vision screening, blood pressure and glucose
- Drug and alcohol testing where your policy requires it
- Reassessment after a long absence or a change in health
Musculoskeletal assessment
For manual handling roles, so your assessment can take account of each person's capability.
When it applies
- Musculoskeletal assessment
- Grip strength test
- At recruitment and after injury
Checks for shift and night workers
Fatigue and wellbeing checks for staff on rotating shifts and nights. These aren't the formal night-worker health assessment.
When it applies
- Stress and fatigue risk review
- Blood pressure and heart rate
- Mental health screening questionnaire
Your duties as an employer.
The main regulations behind health surveillance in manufacturing and warehousing. This is a summary to help you plan, not legal advice.
Great Britain
- Control of Noise at Work Regulations 2005(opens in a new tab)
Health surveillance, including hearing tests, where the risk assessment shows a risk to health.
- COSHH Regulations 2002, regulation 11(opens in a new tab)
Health surveillance where exposure is linked to a disease that is reasonably likely and detectable. Records kept for at least 40 years.
- Control of Vibration at Work Regulations 2005(opens in a new tab)
Health surveillance where there's a risk to health from hand-arm vibration.
- Working Time Regulations 1998, regulation 7(opens in a new tab)
Night workers must be offered a free health assessment before night work starts and at regular intervals.
Northern Ireland
- Control of Noise at Work Regulations (NI) 2006(opens in a new tab)
Hearing checks where the risk assessment shows a risk, as in GB.
- COSHH Regulations (NI) 2003(opens in a new tab)
The same tests for when health surveillance is needed as in GB.
- Control of Vibration at Work Regulations (NI) 2005(opens in a new tab)
Health surveillance for workers at risk from hand-arm vibration.
- Working Time Regulations (NI) 2016, regulation 9(opens in a new tab)
A free health assessment for night workers before and during night work.
Republic of Ireland
- General Application Regulations 2007, regulation 131(opens in a new tab)
Hearing checks above 85 dB(A), and preventive audiometry offered above 80 dB(A).
- General Application Regulations 2007, regulation 141(opens in a new tab)
Health surveillance for employees at risk, including anyone above the 2.5 m/s² action value.
- HSA Code of Practice: industrial trucks(opens in a new tab)
Medical fitness should be considered for every lift-truck operator.
- General Application Regulations 2007, regulation 157(opens in a new tab)
A free night-work assessment by, or supervised by, a registered medical practitioner.
Straightforward to arrange, from one starter to every site.
- Step 1
Tell us what you need
Share your workforce size, locations and screening requirements. We'll recommend the right checks.
- Step 2
We organise the checks
We arrange appointments at your workplace or in clinic and carry out the assessments.
- Step 3
Access your results
View fitness outcomes and download your documents from the employer portal.
Roles we commonly screen
- Production line operatives
- Press and machine operators
- Bakers and food ingredient handlers
- Welders and fabricators
- Spray painters
- Forklift and lift-truck operators
- Warehouse pickers and packers
- Night-shift staff
Common questions
Questions employers in manufacturing and warehousing often ask us.
Still have a question?
Our team can help with anything specific to your workforce.
Let’s plan your health surveillance.
Tell us about the roles and sites in your team and we'll recommend the right checks with a clear price.