We spend much of our time in this space discussing the benefits of both mechanized and automated material handling alternatives for various types of logistics operations. While much of the focus of these technologies is on improving efficiency and throughput, they also substantially reduce the amount of manual handling tasks, thereby reducing the amount of time lost because of work related injuries – particularly important in today’s difficult economy.

However, we know that many DCs have little or no material handling equipment other than the prerequisite fork lift trucks. Therefore, they are at higher risk for manual material handling injuries, which are reported to be the single largest claims component of workers’ compensation insurance.

Regardless of how mechanized or automated the DC may be, there will still be a considerable amount of manual handling of containers. It’s the nature of the business. Unfortunately, this reality may expose workers to physical conditions (e.g., force, awkward postures, and repetitive motions) that can lead to injuries, reduced productivity, and increased operating cost.

The really good news is that most problems associated with manual handling can be avoided by adopting a strategy that will “improve the fit” between the demands of the work tasks and the capabilities of the workers. This means recognizing that workers’ abilities to perform work tasks vary due to differences in age, physical condition, strength, gender, dexterity, and other factors. Typical goals of a strategy that improves the fit in the DC are:

• Reducing or preventing injuries
• Reducing workers’ efforts by decreasing forces in lifting, handling, pushing, and pulling materials
• Reducing risk factors for MSD (musculoskeletal disorders) sometimes brought about by awkward postures from reaching into containers
• Increasing productivity, product and service quality, and worker morale
• Lowering costs by reducing or eliminating product jams and/or bottlenecks, errors, use of medical services, workers’ comp claims, excessive worker turnover and absenteeism

What to Look For

Various studies have shown that the main risk factors, or conditions, associated with the development of injuries in manual material handling tasks include:

• Awkward postures - bending, twisting
• Repetitive motions – frequent reaching, lifting, carrying
• Forceful exertions – carrying or lifting heavy loads
• Pressure points – grasping (or contact from) loads, leaning against parts or surfaces that are hard or have sharp edges
• Static postures – maintaining fixed positions for a long time

Repeated or continual exposure to one or more of these factors initially may lead to fatigue and discomfort. Over time, injury to the back, shoulders, hands, wrists, or other parts of the body may occur. MSD injuries include damage to muscles, tendons, ligaments, nerves and blood vessels. In addition, poor environmental conditions, such as extreme heat, cold, noise, and poor lighting, may increase workers’ chances of developing other types of problems.

Types of Ergonomic Improvements

In general, there are (2) types of ergonomic improvements or changes (Engineered and Administrative) made to “improve the fit” between the demands of work tasks and the workers’ capabilities. However, there are usually many options for improving a particular manual handling task. Therefore, it’s up to the company to make informed choices about which improvements will work best for a particular task.

Engineered Improvements – These include rearranging, modifying, redesigning, providing or replacing tools, equipment, workstations, packaging, parts, processes, or systems. The Materials Handling Industry of America www.mhia.ogr and the Material Handling Equipment Distributors Association www.mheda.org are comprised of many diverse and specialized manufacturers and engineering firms offering a large variety of solutions.

Administrative Improvements – Here the focus is on observing how different workers perform the same task to get ideas for improving work practices or organizing the work. Then consider the following improvements:

• Alternate heavy tasks with light tasks
• Provide variety in jobs to eliminate or reduce repetition (overuse of the same muscle groups)
• Adjust work schedules, work pace, or work practices
• Provide recovery time (multiple short rest breaks)
• Modify work practices so that workers perform work within their power zone (above the knees, below the shoulders, and close to the body) and provide training on these techniques.
• Rotate workers through jobs that use different muscles, body parts, or postures.

Administrative improvements, such as job rotation, can help reduce workers’ exposure to risk factors by limiting the amount of time workers spend on “problem jobs”. However, these measures may still expose workers to risk factors that can lead to injuries. For these reasons, the most effective way to eliminate “problem jobs” is to change them. This can be done by putting into place the appropriate engineering improvements (mechanized and/or automated solutions) and modifying work practices accordingly.

A Proactive Action Plan

Manual material handling tasks are dynamic. That is to say they require movement and physical activity. But, how do companies find answers to questions such as:

• Why workplace problems are occurring?
• Which tasks may be causing injuries or production bottlenecks or decreasing quality/productivity?
• What to do about problems once you find them?
• How to reduce workers’ compensation costs?

One of the best ways to answer these questions is to be proactive in your problem solving. This simply means finding the problem first by looking thoroughly around the DC rather than waiting for problems to occur. Then improve the fit between the work and the worker by putting the appropriate changes into place. And be sure to do at least the following:

• Talk to various employees. Brainstorming with engineers, maintenance personnel, floor managers and supervisors, and production workers is a great way to generate ideas.
• Contact others in your industry. Network at trade shows. Chances are good that your peers have already been down this path and have solutions that could also apply to your problems, saving you time, money, and effort.
• Look through trade publications (SCDigest) and equipment catalogs. Focus on solutions dealing with the types of problems/challenges you are trying to solve.
• Talk with MH industry experts and providers. They draw on experience from a variety of MH applications and will be able to share ideas that would never occur to you.
• Consult with an expert in ergonomics. An ergonomics specialist can “cut-to-the-chase” providing insights into available improvements, the cost, and the potential value.

Much of the above was summarized from a 2007 report “Ergonomic Guidelines for Manual Material Handling” which was prepared for publication by the Cal/OSHA Consultation Service, Research and Education Unit, Division of Occupational Safety and Health, California Department of Industrial Relations. It was distributed under the provisions of the Library Distribution Act and Government Code Section 11096.

The 68 page 3MB PDF file is available at no cost at the MHIA Bookstore at www.mhia.org/bookstore or by calling 800-345-1815/704-676-1190.

Final Thoughts

Even in the worst of economic times, eliminating high risk manual handling operations makes perfect sense. Unnecessary handling and duplication of material and product movement is expensive and a misuse of valuable resources. Making tasks less physically demanding and more efficient is the first step to higher productivity and lower operating cost.

Agree or disagree with Holste's perspective? What would you add? Let us know your thoughts for publication in the SCDigest newsletter Feedback section, and on the website. Upon request, comments will be posted with the respondent's name or company withheld.

You can also contact Holste directly to discuss your material handling or distribution challenges at the Feedback button below.