Material Handling and Storage

1. Material Handling and Storage

2. This material was produced under grant number 46B4-HT15 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

3. Material Handling and Storage

4. Objectives • Discuss the basics of ergonomics and functions of the spine • Describe the various types of order picking systems • Describe proper lifting techniques • Identify material handling hazards associated with various warehouse operations • Transport techniques • Storage • Packaging • Work practices

5. Basic Functions of the Spine • Supports the body’s weight • Structure for body • Flexibility to bend and rotate • Maintains natural S curve for maximum strength

6. Proper Lifting Techniques • No tripping or slipping hazards • Plan rest stops • Easiest route • Avoid stairs • If it is too heavy - GET HELP! Plan the Job

7. Proper Lifting Techniques (cont’d) • A ddress the item • B end at the knee • G et a good grip • R aise with the legs

8. Keep the Load Close • Closer to your spine • Less force on back • 10 pound load at arms’ length is 100 pounds on the back

9. Lifting Techniques • Diagonal lift • Power lift

10. Pivot…Don’t Twist • Pivot your feet • Turn entire body

11. Materials Handling Hazards in Warehouses • Consist of job features which have a potentially harmful effect on the body • Work station layout/environment • Improper work methods • Improper tools • Job design problems • Poor housekeeping

12. Transport Techniques • Placing boxes on pallets • Maintenance See: http://www.osha.gov/SLTC/etools/grocerywarehousing/transport_techniques_animation.html

13. Placing Boxes on Pallets • Repeated bending at the waist to place boxes on the lowest level of pallets • Heaviest units are placed on the bottom layer for stability • Requires employees to lift the heaviest loads using their worst body postures

14. Solutions • Raise height of the bottom level • Provide height-adjustable picking equipment • Educate employees about the hazards of bending while moving heavy loads • Stack empty pallets on the pallet jack to elevate bottom of load • Place palletizer on forks of pallet jack to keep product at waist height • Utilize power equipment See: http://www.osha.gov/SLTC/etools/grocerywarehousing/transport_techniques_animation2.html

15. Storage • Low locations • High locations • Double or triple slots • Reaching • Aisle width

16. Low Locations • Pallets are stored in pick bins a few inches from the floor • Low racking requires employees to bend at waist • Is a significant problem since the heaviest load is in shortest stack • Storing pallets in taller slots still requires employees to bend at waist

17. Solutions • Elevate pallets within slot bin • Place empty pallets under load • Raise bottom level of racking so loads are at heights where bending is not necessary • Provide a forklift with built-in vacuum hoist

18. Solutions (cont’d) Empty pallets stacked to raise product to waist height Raised shelving

19. Solutions (cont’d) Vacuum hoist

20. High Locations • Reaching above shoulder to access products on upper shelves • Results in stress to back and shoulders • Requires awkward hand and wrist postures

21. Solutions • Use elevated rack locations • Provide "Pick Sticks" or "Bow Peep" hooks “Bow Peep” hook

22. Multi-slot Hazards • Maximizes shelving space • Increases ergonomic stressors • Forces workers to bend to access product • Workers must reach above shoulders to access materials Double slotting Triple slotting requires elevated reaches to access product

23. Solutions • Provide full slotting • Use gravity feed flow rack for slow moving product Full slotting Gravity fed flow racks

24. Reaching • Product is often removed from the front of pallets first • Leaves remaining product in the back of pallets • Creates additional stress on the shoulders and back Reaching to the back of the pallet

25. Solutions • Develop product rotation process • Place pallets on turntables • Use roller and channel devices • Provide wider slots for heavier products • Train stockers to allow sufficient space to move pallet during selection For optimal access, place product on turntable

26. Aisle Width • Insufficient access to faster-moving product • Creates congestion • Forces selectors to stop farther from pick slot and carry product longer distances to pallet jack • To save trips, selectors may be tempted to carry multiple parcels at the same time Congested aisle

27. Solutions • Increase aisle width of aisles where fast-moving product is located • Will allow pallet jacks to get closer and reduce distance loads must be carried • Stagger the start times at beginning of day • Results in fewer selectors hitting the same slots at the same time

28. Packaging • Heavy containers • Inadequate handholds • Plastic wrapping • Wooden pallets • Wrapping pallets • Opening boxes 5-Gallon (40 lbs)

29. Heavy Containers • Boxes are extremely heavy in cold or freezer warehouses • Weigh as much as 100 lbs. • Manually lifting places stress on employee’s muscles • Repeated lifting can result in back injuries, muscle strains and disc injury

30. Solutions • Work with suppliers to provide product in smaller, lighter containers • Improve access to heaviest items • Provide handhold cutouts or handles on all heavy products • Work with suppliers to ensure container integrity is adequate • Load pallets with lighter product in center and heavier on outer edges Some suppliers are willing to modify weight of packages

31. Solutions (cont’d) Heavier packages on the outside

32. Inadequate Handholds • Many packages do not have handles or handle cut-outs • Makes heavy cases difficult to grasp • Forces employees to use awkward posture Boxes without handles are difficult to grasp

33. Solutions • Encourage suppliers to provide product in stable boxes with hand hold cut-outs or handles • Is especially important for product that is extremely heavy Examples of handhold devices

34. Wooden Pallets • Weigh between 40 and 70 pounds • Lifted several times during work shift • Repeated lifting causes stress to lower back • Splinters from handling wood is also a hazard to worker Workers bend to lift pallets several times during a shift

35. Solutions • Request lighter, plastic pallets • Easily nest together to reduce space of stacking • Eliminates splinters and uneven surfaces • Provide a pallet dispenser to reduce handling of pallets Pallets weigh 20 to 30 lbs. Pallet dispenser

36. Training New Employees • New employees may not recognize ergonomic hazards or understand effective techniques used to minimize these hazards

37. Solutions • Provide general ergonomics and work-task specific training at time of orientation • Explain risk factors and proper work techniques to minimize hazards • Provide video tapes of proper work practice for employee review • Retrain injured employees regarding ergonomic risks pertinent to their injuries • Mentor new employees with experienced workers • Explain the medical management system

38. Summary • Discussed the science of ergonomics and functions of the spine • Described the various types of order picking systems • Described proper lifting techniques • Identified various material handling hazards associated with warehouse operations • Transport techniques • Storage • Packaging • Work practices