Paying attention to workplace ergonomics means understanding the capabilities and limitations of the human body and reducing situations that could put it under too much strain. Here are some simple ways to keep your warehouse workers safe and healthy throughout the workday.
Photo: Adrian Sulyok / Unsplash
Become More Aware of Item Placement
When tasks involve moving something by lifting, pushing or pulling it, change the initial placement of the item depending on its type. Most movement tasks should ideally occur at a position between a worker's knee and shoulder. However, if the items are heavy or awkwardly sized, the worker should be able to handle the movement when the product is between knuckle and elbow height.
Don't Overload Warehouse Trolleys
The wheeled bases and integrated handles of warehouse trolleys make them well-suited to help workers transport loads. However, if a person loads a trolley with more weight than it should hold, the equipment may cause wrist or arm strains.
Additionally, an overloaded trolley may have things piled on it so high that the user does not have a clear field of view and may run into obstacles. Plus, if an overloaded trolley becomes top-heavy, it may be challenging to steer, especially around corners. Always study the documentation for equipment regarding the maximum weight a model can bear.
Assess and Reduce Manual Handling Risks
Improving workplace ergonomics requires a willingness to make changes that reduce or eliminate risks. Concerning manual handling, a manager may investigate whether mechanical equipment could assist workers and cut down on the number of times they lift, bend and reach in a given workday. However, some material handling tasks are unavoidable.
In those cases, evaluate the overall injury risk, and which characteristics of the task or item make a person more likely to get hurt. For example, if a load is slippery or sharp, the risk of dropping it could rise. If a person's role requires frequent and prolonged heavy lifting, they're more likely to get tired compared to people who work in less-intensive positions.
Some ergonomic tools make particular tasks less strenuous and more feasible for the workers who perform them. For example, when moving drums, ergonomic drum transporters can reduce risks, whether you choose a foot pedal model or one that uses pneumatics to work. Statistics indicate that the right equipment and proper training can eliminate over 95% of drum handling injuries.
Reduce Weight Lifted As Frequency Increases
When a person's job requires them to do an above-average amount of lifting, reducing the weight of each load handled is an excellent ergonomic principle to follow. Ireland's Health and Safety Authority published a document that includes guideline weights for loads lifted with both hands and when the person is in a stable position. It suggests reducing the weight by 30% when a person hefts the item once or twice per minute and halving the weight when the frequency is 5 to 8 times per minute.
Finally, when the person's job necessitates lifting more than 12 times per minute, reduce the weight by 80%. Remember that factors such as a previous injury or a lower overall fitness level may cause a person to become tired more quickly. Regardless of the weight lifted or the frequency, look for signs of exertion such as sweating and grunting.
Coach Employees on Proper Lifting Techniques
When warehouse workers know the right steps to lift things safely, they'll avoid injuries. Watch the body mechanics of people as they lift things and provide them with actionable suggestions when necessary. For example, a person should keep the back as straight as possible while lifting. Putting a slight bend in the back at the start of the lift is preferable to squatting or stooping.
Also, people should not lean or twist the spine throughout the lift. Doing so can introduce abnormal biomechanical forces. Besides the positioning of the back and striving for the proper alignment, people should keep a firm base of support by standing with their feet apart and one leg slightly forward if the load is at ground level. They should also keep the knees bent and let them gradually straighten as the lifted item rises.
Use Solutions That Prevent Blind Overhead Reaching
If a warehouse employee engages in picking tasks, there's a good chance the company stores some of the products above eye level. In such instances, a person may need to reach into the container and feel around for the products they need, unable to rely on visual cues.
However, you can avoid that scenario by investing in containers that tilt toward the user and make it easier for them to see the contents. Alternatively, picking devices that look like sticks with gripping attachments on the ends allows a person to use that tool instead of reaching up and potentially straining their arm, shoulder or back.
Awareness Can Boost Productivity
The human body is robust and capable, but it's liable to injury, particularly when subjected to challenging conditions over an extended period. Working in a warehouse is often strenuous, but by following these tips, you can help employees increase output without damaging their bodies.
Megan R. Nichols is a technical writer and blogger who covers manufacturing and industrial automation topics. She regularly contributes to sites like IndustryWeek, MHL Network, and ReadWrite. Megan also publishes easy to understand manufacturing articles on her blog, Schooled By Science, to encourage others to learn about these industries. Keep up with Megan by following her on Twitter.
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