June 14, 2016 - Page 13 of 16

Ergonomics Investment Adds to Healthy Bottom Line

Every dollar invested in an ergonomics program results in a savings of $4. That’s the astounding finding of a recent study on the cost effectiveness of implementing ergonomics programs in U.S. manufacturing and business settings.

In the past, many companies didn’t initiate ergonomic programs until forced to do so in response to workers’ compensation claims. The expense associated with claims coupled with the responsibility to eliminate hazardous work conditions forced companies to implement solutions to address ergonomics issues. But acting after the fact only prolongs the agony, pointed out Mike Kind, writing for the New Hampshire Business Review. “As claims are filed, an organization’s workers’ compensation premium increases immediately upon renewal. It then takes a three-year history of reductions in claims for the rate to drop.”

Proactively implementing an ergonomics program may not eliminate every future workplace injury, but the use of ergonomically-designed equipment and the introduction of ergonomic practices has been shown time and again to significantly reduce workplace injuries and their associated costs. In most cases, the cost of ergonomics equipment is recouped within the first year.

As an example, Kind cited a highly computerized operation in which more than half of the employees reported musculoskeletal disorders during their first year on the job. Implementation of an aggressive ergonomics program, including new equipment, procedures and training, resulted in an overall 50% decrease in worker complaints.

Proactive implementation of ergonomics initiatives impacts your bottom line immediately and positively. “In one client research study, it was determined that for every dollar invested in an ergonomics program, $4 in cost savings were achieved,” Kind said. Reduction of worker injury results in significant savings in direct medical costs, insurance and workers’ compensation premiums. Lost work-hours due to doctors’ appointments, physical therapy sessions, sick days and absenteeism decrease. As employee safety and well-being improve, workplace morale increases, bringing with it a healthy work environment, increased productivity and improved customer service.

Creating a successful ergonomics program hinges on three important elements, Kind said:

Support of top management and inclusion in the corporate culture
Establish goals and measure results
Provide effective education, training and leadership

Next time: Tips for creating a successful ergonomics program

How to Increase Pick & Pack Efficiency

With costs up and profits down, everyone is scrambling to improve efficiency. No matter what business you’re in, you’re trying to do the job faster and better — often with fewer people. Warehouses, fulfillment houses and distribution centers are particularly challenged, says Bill Hubacek of FKI Logistex North America in a recent article in Manufacturing & Technology eJournal. “Customers demand nearly 100% order accuracy; smaller and more frequent orders cover a greater number of SKUs; and senior management calls for lower costs and increased productivity.”

High volumes from more frequent orders and quick order-to-ship turn-arounds can place a significant strain on your system and your workers. As Hubacek points out, “picking and packing functions remain two of the most labor-intensive and costly jobs in the operation. When performed manually, picking and packing can be a major source of errors, expense and decreased efficiency.”

And a reputation for errors is definitely something you want to avoid. Errors erode consumer confidence and create a negative drain on customer loyalty. When the economy is tight, competition becomes even more fierce than usual. A reputation for order accuracy can ensure a high rate of customer satisfaction and garner valued customer loyalty. Anything you do to improve your workers’ ability to perform accurately while picking, packing and shipping orders is essential.

Hubacek makes a good argument for automating pick and pack operations, but most businesses are putting off that type of major retooling and restructuring effort until the economy improves. However, you don’t have to make a massive investment in automation to significantly improve productivity. Augmenting your workforce with a few ergonomically-designed powered carts or movers can improve the overall efficiency of your pick-pack-ship operation, increasing both speed and accuracy — and, ultimately, customer satisfaction.

DJ Products makes a full line of extremely versatile, highly maneuverable electric battery-powered movers designed to perform pushing, pulling and lifting tasks. Ergonomically designed to eliminate musculoskeletal injuries, DJ Products’ carts, tugs and movers take the physical burden of many pick-pack-ship tasks off your workers, allowing them to perform more efficiently. When not physically stressed, workers are able to perform tasks more quickly, concentrating on accuracy rather than the physical discomfort of the task. DJ Products’ powered movers allow you to add “mini-automation zones” to your warehousing, distribution or fulfillment process. And due to their versatility, DJ Products’ ergonomically-designed carts and movers can move with workers from one task to another or can be tasked to different key areas as needed.

Talk to one of our industry specialists to find out how DJ Products’ movers can improve your company’s efficiency — at a price you can afford.

Recession Leads to Survival of the Fittest

It’s Darwin’s principle of natural selection in action. In a poor economy, only the strong survive. A recession “always hits manufacturing first and hardest,” Hank Cox of the National Association of Manufacturers recently told the Minneapolis Star Tribune. According to the Associated Press, in December, “manufacturing activity sank to its lowest point in 28 years,” with indexes falling farther than expected. Some index components, including new orders, fell to historic lows not seen since the 1948-49 recession. Overall, the manufacturing index, which has been steadily declining over the past six months, reached its lowest reading since June 1980, the tail-end of the last major recession.

Major players from Dow Chemical to Ford Motor Co. to Anheuser Busch are chopping jobs and shutting down factories in an attempt to stop the financial hemorrhaging, but it may not be enough. With the global economy in a tailspin, manufacturers can’t rely on exports to save them from disaster. And when the big guys are flailing, you can bet small businesses are being hammered. From manufacturing to retail and everywhere in between, the economy is taking a toll on American businesses. No sector of the economy is proving to be recession proof. No one reported growth in December and most sectors of the economy reported declines in everything from new orders to production, employment and prices. Weak companies are going to fail. It’s survival of the fittest, but those companies that do survive the recession are predicted to emerge far stronger than before and in an arena with less competition. To make the cut, you’ll need to roll with the punches and be proactive about the changes that are coming.

The floundering economy and growing jobs crisis has given the incoming Obama administration a popular mandate to change America (see our previous two posts). Industry experts tell us to expect increased government oversight and regulation. Public backlash from the highhanded attitude of financial institutions that refused to disclose how they spent bailout money has assured that future government help will come with lots of strings attached. Add to that President-elect Obama’s campaign pledge to American workers to improve workplace safety and his pledge to the public to increase environmental protection, and American businesses should be girding for a new era of more invasive government regulation.

There are always two ways to handle change. You can rail and fight against it, or you can embrace it and use it to position yourself ahead of the competition. Time and again, history proves that those who look to the future and embrace change survive. As competition increases, the companies that are proactive about incorporating new technology, new equipment and new processes into their operations are the ones that will rise above their competition and live to see a better tomorrow.

Next time: How DJ Products can help you be a survivor.

Pushmi-Pullyu Mentality Increases Workplace Injury

Remember the Pushmi-pullyu (push-me-pull-you) from Hugh Lofting’s Dr. Dolittle stories for children? It was an antelope with two heads, one on each end of its body. (In the popular Eddie Murphy movies, they used a llama.) Whenever the creature wanted to move, both heads would take off at once, pushing and pulling back and forth and going nowhere. Since pushing and pulling exert two of the greatest stresses on the body, the poor critter must have been in constant need of the good doctor’s chiropractic skills! That same Pushmi-pullyu mentality toward workplace task and equipment design can put your employees at serious risk of sustaining disabling musculoskeletal injuries.

Pushing, pulling, lifting and carrying tasks place a greater strain on the human body’s soft tissues — muscles and tendons — than any other tasks. These tasks are also universal to nearly all work environments. Wheeled carts, platforms or equipment must be loaded and unloaded and pushed and pulled through manufacturing plants, distribution centers, hospital corridors, grocery store aisles, hotel hallways, office buildings and retail establishments. Most jobs require at least occasional pushing, pulling, lifting or carrying; and many jobs require workers to spend their entire workday engaged in these activities, performing the same, repetitive movements hour after hour. The cumulative wear and tear on the body can lead to serious injury of soft tissues and eventual disability.

Too often tasks, work spaces and equipment aren’t designed to accommodate the natural differences in the size and physical capabilities of workers. A task performed first shift by a six-foot, 180-pound, 25-year-old male may be performed second shift by a five-foot three-inch, 130-pound, 45-year-old female and third shift by a five-foot seven-inch, 260-pound, 60-year-old male. Because work tasks and equipment are usually designed around a “standard” worker type — which, unfortunately, few workers match — most workers are forced to assume awkward postures while exerting force to complete work tasks. Serious, debilitating strains and sprains can result, particularly when these actions are repeated over time.

When soft tissues in the arms, shoulders, back and legs are injured, the tissues recover, though it may take some time. But repeated injury, particularly when it occurs before tissues have had time to fully recover, interferes with the body’s natural healing process, overwhelming the body’s ability to recover and leading to permanent, disabling injury. Such cumulative traumas are called musculoskeletal disorders. Also referred to as repetitive stress injuries and repetitive motion injuries, these serious, disabling strains and sprains cost U.S. businesses tens of billions of dollars each year.

Next time: Ergonomics; just what the doctor ordered.

Ergonomics: Just What the Doctor Ordered

Pushing, pulling, lifting and carrying tasks place a greater strain on the human body’s soft tissues — muscles and tendons — than any other workplace tasks. Universal to nearly every work environment, these tasks are the source of musculoskeletal injuries that annually cost U.S. businesses tens of billions of dollars. Fortunately, most of these injuries are preventable. The debilitating and disabling strains and sprains that annually plague millions of U.S. workers can be largely prevented with the adoption of ergonomic practices and the use of ergonomically-designed equipment.

Workers come in all shapes and sizes, but work tasks and equipment are usually “one size fits all.” Most workplace musculoskeletal injuries occur when workers are forced to adapt their bodies to fit the task or equipment, torquing their bodies into awkward postures that increase stress on muscles and tendons. For example, when pushing, pulling or maneuvering a heavy wheeled cart, a worker must exert significant force to overcome rolling resistance. While handholds designed to assist in force delivery may be at the correct level for an average-sized male, even an averaged-sized female worker will have to stretch and strain to move the cart, placing undue stress on back, leg, shoulder and arm muscles. The risk of musculoskeletal injury is great when worker and equipment are not a perfect fit.

Ergonomics is the science of fitting the equipment or task to the capabilities of the worker to prevent musculoskeletal injury. Ergonomically-designed equipment, like the powered carts and movers designed and manufactured by DJ Products, takes into account a host of variables that affect worker production and efficiency. The type of task, force required, worker gender and diversity, optimal handhold height, distance, and frequency of the task must all be considered in the design of ergonomic equipment.

DJ Products is a major innovator in the design and manufacture of ergonomic solutions to material handling situations. Our ergonomically-designed electric and motorized carts, tugs and movers eliminate the strains and pains associated with manually pushing and pulling heavy carts, equipment or materials in a wide variety of industrial and retail environments. Our products are less costly, smaller and more maneuverable than traditional electric equipment used to move carts and equipment on production floors and in warehouses. Our battery-powered walk-behind movers provide maximum operator control and safety while offering superior maneuverability, even in narrow or tight spaces like busy hospital corridors and crowded grocery aisles. As a leading manufacturer of ergonomic powered carts and movers, DJ Products has built a reputation for developing ergonomic solutions to unique and specialized customer material handling challenges. Contact our ergonomic sales engineers today for an evaluation of your ergonomic needs.

Ergonomic Material Handling Equipment Meets Needs of Multi-Generational Workforce

Finding, training and keeping qualified workers is slated for discussion at the Material Handling Industry of America (MHIA) annual conference NA 2010 scheduled for April 26-29 (see our January 4 post). The conference will devote two educational sessions to managing the supply chain workforce:

How Industry is Changing Material Handling Training and Education will focus on the demanding skill sets now necessary to perform even entry-level jobs in highly sophisticated, automated warehouses, distribution centers and fulfillment houses.
Building the Workforce of Tomorrow will focus on the challenge of integrating multi-generational workforces successfully as baby boomers and the knowledge they harbor leave the industry.

The move toward more automated supply chain operations and the increasing sophistication of the technology that drives them presents a considerable workforce challenge for supply chain managers. Technology is necessitating a more highly skilled supply chain worker making it difficult to find suitable workforce candidates among the industry’s traditional unskilled labor pool. Exacerbating the problem is the coming retirement of skilled baby boomers who have been the backbone of the supply chain industry for decades. Supply chain managers worry that there simply won’t be enough new workers coming into the system to replace those who are leaving it. The poor economic climate has actually alleviated that part of the problem somewhat. Lost savings and pinched budgets have forced many baby boomers to return to the workforce or push retirement back a few more years.

While their expertise is welcome, the distinct physical needs of an aging workforce have thrown another wrench into the supply chain machinery. Ergonomic material handling equipment that removes the physical burden from the worker could be the key to accommodating senior workers. Adjustability allows ergonomically designed carts and tugs to accommodate workers of every shape, size, sex and physical ability, providing supply chain managers with maximum use of their workforce.

Battery Powered Carts Reduce the risk of injury

Operating a forklift or battery powered cart without following the necessary safety guidelines is a huge risk that can result in serious injuries or even death, but not all material handling injuries stem from improper use on the part of the operator. If you allow any employee to operate material handling equipment that you know isn’t functioning properly, you are putting every employee in your business at serious risk.The older a piece of equipment is, the more likely it is to malfunction or breakdown, which can cause delays in the completion of work and potentially lead to injuries. Forklifts and powered carts require regularly scheduled preventative maintenance, but if there is ever a question of proper operation it needs to be tended to immediately to ensure your employees’ safety.Distribution of materials is often a fast paced environment with many activities going on at the same time. There may be dozens of employees scurrying around the warehouse filling orders and receiving shipments while a number of machines are working to load and unload trucks or put away stock – if even one of these pieces of equipment malfunctions it could lead to several serious injuries.In order to keep your fast paced environment as safe and productive as possible, you need to have the safest and most reliable equipment. Battery powered carts and lifts from DJ Products are engineered to be quieter, safer, more reliable and cheaper to operate than traditional forklifts and lift trucks. Each piece of DJ Products equipment is ergonomically designed to prevent many of the nagging injuries often associated with manually material handling and easy enough to use so a single employee can tackle heavy jobs quickly and safely.Truly efficient warehouse and distribution environments don’t rely on equipment that may or may not get them through a shift. In order to be as safe and successful as possible your equipment needs to be the safest around and completely reliable day in and day out – and that’s exactly what DJ Products strives for with every piece of equipment sold, including our battery powered carts.

Downsizing? Can Your Equipment Handle the Move?

Unfortunately many material handling companies and distribution centers are still having trouble making ends meet and this has led to a trend of companies moving into smaller builds to cut expenses. If your company has a lease coming up for renewal and you are considering the possibility of cutting overhead by moving into a smaller building, ask yourself this –is your equipment reliable enough to conquer the work involved in a move?

If you have issues with outdated material handling equipment that gives you fits because of regular maintenance issues, odds are that your move will be a disaster. Consider the fact that moving your entire operation will be a labor intensive affair unlike any other. Moving isn’t just high volume – it’s all volume, you need to get everything: racks, pallets, desks and every last piece of product moved as quickly as possible to the new operation to avoid missed sales and risk being labeled unreliable. Make no mistake about it – moving is not a job to perform with unreliable equipment.

That’s not all you have to consider either – is there adequate room in your new facility to merit the big, bulky equipment that you are currently running? If there isn’t than upgrading to smaller, safer and more efficient powered carts like those offered by DJ Products is a very simple decision – just be sure to implement it prior to moving.

You won’t be able to ship or receive product during your move, so it’s absolutely integral to your future success to get the move completed as quickly and efficiently as possible so you can open for business again. You don’t need any hitches thrown into the process by having a piece of equipment fail at the wrong time. Upgrading to the best and most reliable material handling equipment prior to the move will ensure that you get into your new facility with as few headaches as possible and that you can resume regular businesses soon as possible upon getting settled in your new building.

Material Handling and Distribution Heats Up in the Summer – Literally

Warehouses are generally poorly ventilated buildings with no good source of circulation, many with metal roofs that absorb the heat of the sun, and certainly no provisions for air conditioning. So as the temperatures of the Summer rises, so does the temperature of the workplace.

Open dock and receiving doors let in the Summer heat and the fast pace of the employees and the bustle of the machinery just forces the temperatures even higher throughout the course of the day. In this type of environment it’s critical to have safe and reliable material handling equipment, because the extreme heat will only add to the dangers of manual material handling.

Having the proper equipment to assist in the transport of heavy loads gives your employees the opportunity to complete their work according to (or even ahead of) schedule without having to over exert themselves inside of the scorching warehouse environment. Old, outdated propane forklifts can throw hot exhaust, which can also work to drive up the temperature in an already borderline dangerous environment making a very uncomfortable workplace practically unbearable.

Just because the temperature has risen outside, it doesn’t necessarily mean that you have to slow down your operation or that you have to compromise your employees’ safety. Reliable, battery operated carts and lifts help to ensure that your employees will have the assistance they need with heavy materials, minimizing the risks involved with manual material handling. Battery operated carts don’t tend to get as hot as propane operated lifts and they also don’t release hot exhaust into the already stifling air.

Your warehouse or distribution center is most likely going to be hot – even with ceiling and floor exhaust fans running it’s difficult to keep temperatures down. It’s up to you to do whatever you can to keep your employees safe and one of the best ways to do that is to operate with the most reliable battery powered lifts. Lifts and carts from DJ Products will help minimize unnecessary excess heat while ensuring that your employees can safely perform their regular duties without the fear of over exertion.

Repetitive Stress Injuries: High Cost to Employers and Employees

Manpower is the most significant asset of a company, so it stands to reason that it’s also one of the major expenses. When an employee is out of work for health reasons, the financial impact is twofold. There is the cost of replacing him along with the potential loss of efficiency if the replacement is less skilled or if the position simply goes unfilled. Repetitive stress injuries (RSI) account for 30 percent of missed time, making them one of the biggest workplace dangers.

Reports from the Occupational Safety and Health Administration state that roughly 1.8 million workers per year are affected by RSI, while government studies place the cost to businesses at between $17 billion and $20 billion. Employees themselves also suffer a personal financial toll. The chronic nature of RSI can lead to more serious or permanent injuries. An affected worker may be forced to take a job that pays less or pay for education and training in order to find alternate employment.

Repetitive stress injuries affect soft tissue such as muscles, tendons and joints. As the name implies, they occur from repeating the same motion or activity on a regular basis. Use of ergonomically designed equipment such as our CartCaddyShorty can greatly reduce the threat of RSI in your workplace by relieving stress and strain, making tasks easier to perform.

The CartCaddyShorty is just one of the full line of material handling tugs available from DJ Products. Contact us at 800.686.2651 to have one of our trained Sales Engineers help you find the right solution for your business.

Day: June 14, 2016