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11Rochester Institute of TechnologyRochester Institute of Technology
Material Handling and StorageMaterial Handling and Storage
22Rochester Institute of TechnologyRochester Institute of Technology
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.
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Material Handling and StorageMaterial Handling and Storage
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ObjectivesObjectives
Discuss the basics of ergonomics and functions of the Discuss the basics of ergonomics and functions of the spinespine
Describe the various types of order picking systemsDescribe the various types of order picking systems Describe proper lifting techniquesDescribe proper lifting techniques Identify material handling hazards associated with Identify material handling hazards associated with
various warehouse operationsvarious warehouse operations– Transport techniquesTransport techniques– StorageStorage– PackagingPackaging– Work practicesWork practices
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Basic Functions of the SpineBasic Functions of the Spine
Supports the body’s weightSupports the body’s weight
Structure for bodyStructure for body
Flexibility to bend and rotateFlexibility to bend and rotate
Maintains natural Maintains natural SS curve for curve for maximum strengthmaximum strength
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Proper Lifting TechniquesProper Lifting Techniques
No tripping or slipping No tripping or slipping hazardshazards
Plan rest stopsPlan rest stops
Easiest routeEasiest route
Avoid stairsAvoid stairs
If it is too heavy - GET If it is too heavy - GET HELP!HELP!
XPlan the JobPlan the Job
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Proper Lifting Techniques Proper Lifting Techniques (cont’d)(cont’d)
A ddress the itemA ddress the item B end at the kneeB end at the knee
G et a good gripG et a good grip R aise with the legsR aise with the legs
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Keep the Load CloseKeep the Load Close
Closer to your spineCloser to your spine
Less force on backLess force on back
10 pound load at arms’ 10 pound load at arms’ length is 100 pounds on length is 100 pounds on the backthe back
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Lifting TechniquesLifting Techniques
Diagonal liftDiagonal lift
Power liftPower lift
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Pivot…Don’t TwistPivot…Don’t Twist
Pivot your feetPivot your feet
Turn entire bodyTurn entire body
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Materials Handling Hazards in Materials Handling Hazards in WarehousesWarehouses
Consist of job features which have a Consist of job features which have a potentially harmful effect on the bodypotentially harmful effect on the body
– Work station layout/environmentWork station layout/environment
– Improper work methodsImproper work methods
– Improper toolsImproper tools
– Job design problemsJob design problems
– Poor housekeepingPoor housekeeping
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Transport TechniquesTransport Techniques
Placing boxes on Placing boxes on palletspallets
MaintenanceMaintenance
See: http://www.osha.gov/SLTC/etools/grocerywarehousing/transport_techniques_animation.html
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Placing Boxes on PalletsPlacing Boxes on Pallets
Repeated bending at the waist to Repeated bending at the waist to place boxes on the lowest level of place boxes on the lowest level of palletspallets
Heaviest units are placed on the Heaviest units are placed on the bottom layer for stabilitybottom layer for stability
Requires employees to lift the Requires employees to lift the heaviest loads using their worst heaviest loads using their worst body posturesbody postures
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SolutionsSolutions Raise height of the bottom level Raise height of the bottom level Provide height-adjustable picking Provide height-adjustable picking
equipmentequipment Educate employees about the hazards of Educate employees about the hazards of
bending while moving heavy loadsbending while moving heavy loads Stack empty pallets on the pallet jack to Stack empty pallets on the pallet jack to
elevate bottom of loadelevate bottom of load Place palletizer on forks of pallet jack to Place palletizer on forks of pallet jack to
keep product at waist heightkeep product at waist height Utilize power equipmentUtilize power equipmentSee: http://www.osha.gov/SLTC/etools/grocerywarehousing/transport_techniques_animation2.html
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StorageStorage
Low locationsLow locations High locationsHigh locations Double or triple slotsDouble or triple slots Reaching Reaching Aisle widthAisle width
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Low LocationsLow Locations
Pallets are stored in pick bins Pallets are stored in pick bins a few inches from the floora few inches from the floor
Low racking requires Low racking requires employees to bend at waist employees to bend at waist
Is a significant problem since Is a significant problem since the heaviest load is in the heaviest load is in shortest stackshortest stack
Storing pallets in taller slots Storing pallets in taller slots still requires employees to still requires employees to bend at waist bend at waist
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SolutionsSolutions
Elevate pallets within slot bin Elevate pallets within slot bin Place empty pallets under Place empty pallets under
load load Raise bottom level of racking Raise bottom level of racking
so loads are at heights where so loads are at heights where bending is not necessary bending is not necessary
Provide a forklift with built-Provide a forklift with built-in vacuum hoistin vacuum hoist
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Solutions Solutions (cont’d)(cont’d)
Empty pallets stacked to raise product to waist height
Raised shelving
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Solutions Solutions (cont’d)(cont’d)
Vacuum hoist
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High LocationsHigh Locations
Reaching above shoulder to Reaching above shoulder to access products on upper access products on upper shelvesshelves
Results in stress to back and Results in stress to back and shoulders shoulders
Requires awkward hand and Requires awkward hand and wrist postureswrist postures
Reaching above Reaching above shoulder heightshoulder height
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SolutionsSolutions
Use elevated rack locationsUse elevated rack locations
Provide "Pick Sticks" or Provide "Pick Sticks" or "Bow Peep" hooks "Bow Peep" hooks
“Bow Peep” hook
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Multi-slot HazardsMulti-slot HazardsMaximizes shelving space Maximizes shelving space Increases ergonomic Increases ergonomic
stressors stressors Forces workers to bend to Forces workers to bend to
access productaccess productWorkers must reach above Workers must reach above
shoulders to access shoulders to access materials materials
Double slotting
Triple slotting requires elevated reaches to access product
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SolutionsSolutions
Provide full slottingProvide full slotting
Use gravity feed flow rack Use gravity feed flow rack for slow moving productfor slow moving product
Full slotting
Gravity fed flow racks
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ReachingReaching
Product is often removed Product is often removed from the front of pallets firstfrom the front of pallets first
Leaves remaining product Leaves remaining product in the back of palletsin the back of pallets
Creates additional stress on Creates additional stress on the shoulders and backthe shoulders and back
Reaching to the back of the pallet
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SolutionsSolutions
Develop product rotation processDevelop product rotation process Place pallets on turntables Place pallets on turntables Use roller and channel devicesUse roller and channel devices Provide wider slots for heavier Provide wider slots for heavier
productsproducts Train stockers to allow sufficient Train stockers to allow sufficient
space to move pallet during space to move pallet during selectionselection
For optimal access, place product on turntable
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Aisle WidthAisle Width
Insufficient access to faster-Insufficient access to faster-moving productmoving product
Creates congestion Creates congestion Forces selectors to stop farther Forces selectors to stop farther
from pick slot and carry from pick slot and carry product longer distances to product longer distances to pallet jackpallet jack
To save trips, selectors may be To save trips, selectors may be tempted to carry multiple tempted to carry multiple parcels at the same time parcels at the same time
Congested aisle
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SolutionsSolutions
Increase aisle width of aisles where fast-Increase aisle width of aisles where fast-moving product is locatedmoving product is located
Will allow pallet jacks to get closer and reduce Will allow pallet jacks to get closer and reduce distance loads must be carrieddistance loads must be carried
Stagger the start times at beginning of dayStagger the start times at beginning of dayResults in fewer selectors hitting the same Results in fewer selectors hitting the same
slots at the same timeslots at the same time
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Packaging Packaging
Heavy containersHeavy containersInadequate handholdsInadequate handholdsPlastic wrappingPlastic wrappingWooden palletsWooden palletsWrapping palletsWrapping palletsOpening boxesOpening boxes
5-Gallon (40 lbs)
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Heavy ContainersHeavy Containers
Boxes are extremely heavy in Boxes are extremely heavy in cold or freezer warehouses cold or freezer warehouses
Weigh as much as 100 lbs.Weigh as much as 100 lbs. Manually lifting places stress on Manually lifting places stress on
employee’s musclesemployee’s muscles Repeated lifting can result in Repeated lifting can result in
back injuries, muscle strains and back injuries, muscle strains and disc injurydisc injury
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SolutionsSolutions
Work with suppliers to provide Work with suppliers to provide product in smaller, lighter product in smaller, lighter containerscontainers
Improve access to heaviest itemsImprove access to heaviest items Provide handhold cutouts or Provide handhold cutouts or
handles on all heavy productshandles on all heavy products Work with suppliers to ensure Work with suppliers to ensure
container integrity is adequate container integrity is adequate Load pallets with lighter product Load pallets with lighter product
in center and heavier on outer in center and heavier on outer edges edges
Some suppliers are willing to modify weight of packages
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Solutions Solutions (cont’d)(cont’d)
Heavier packages on the outside
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Inadequate HandholdsInadequate Handholds
Many packages do not Many packages do not have handles or handle have handles or handle cut-outs cut-outs
Makes heavy cases Makes heavy cases difficult to graspdifficult to grasp
Forces employees to use Forces employees to use awkward postureawkward posture
Boxes without handles are difficult to grasp
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SolutionsSolutions
Encourage suppliers to Encourage suppliers to provide product in stable provide product in stable boxes with hand hold cut-boxes with hand hold cut-outs or handles outs or handles
Is especially important for Is especially important for product that is extremely product that is extremely heavyheavy
Examples of handhold devices
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Wooden PalletsWooden Pallets
Weigh between 40 and Weigh between 40 and 70 pounds 70 pounds
Lifted several times Lifted several times during work shift during work shift
Repeated lifting causes Repeated lifting causes stress to lower backstress to lower back
Splinters from handling Splinters from handling wood is also a hazard to wood is also a hazard to workerworker
Workers bend to lift pallets several times during a shift
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SolutionsSolutions Request lighter, plastic Request lighter, plastic
pallets pallets Easily nest together to reduce Easily nest together to reduce
space of stackingspace of stacking Eliminates splinters and Eliminates splinters and
uneven surfaces uneven surfaces Provide a pallet dispenser to Provide a pallet dispenser to
reduce handling of palletsreduce handling of pallets
Pallets weigh 20 to 30 lbs.
Pallet dispenser
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Training New EmployeesTraining New Employees
New employees may not New employees may not recognize ergonomic recognize ergonomic hazards or understand hazards or understand effective techniques used to effective techniques used to minimize these hazardsminimize these hazards
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SolutionsSolutions
Provide general ergonomics and work-task specific Provide general ergonomics and work-task specific training at time of orientationtraining at time of orientation
Explain risk factors and proper work techniques to Explain risk factors and proper work techniques to minimize hazardsminimize hazards
Provide video tapes of proper work practice for Provide video tapes of proper work practice for employee reviewemployee review
Retrain injured employees regarding ergonomic risks Retrain injured employees regarding ergonomic risks pertinent to their injuriespertinent to their injuries
Mentor new employees with experienced workers Mentor new employees with experienced workers Explain the medical management systemExplain the medical management system
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Summary Summary
Discussed the science of ergonomics and functions of Discussed the science of ergonomics and functions of the spinethe spine
Described the various types of order picking systemsDescribed the various types of order picking systems Described proper lifting techniquesDescribed proper lifting techniques Identified various material handling hazards Identified various material handling hazards
associated with warehouse operationsassociated with warehouse operations– Transport techniquesTransport techniques– StorageStorage– PackagingPackaging– Work practicesWork practices