Tag: Equipment to Prevent Warehouse Injuries

Where there are forklifts, there are forklift accidents. A person who is tired or distracted while operating one of these powerful machines can cause extensive property damage and serious personal injury. One of the best ways to prevent workplace accidents is by using the right material handling equipment for the job.

A large, bulky forklift is not always the best option for moving materials in tight areas where people are working. The following are the most common types of forklift accidents.

Forklift vs pedestrian

The pressure to achieve quotas and accomplish as much work as possible in a short amount of time can result in forklift operators driving too fast. Warehouses and production facilities have lots of obstacles and areas that pedestrians may walk from behind into the path of a fast-moving forklift.

Ongoing safety training is a must. Also, part of the routine maintenance of each forklift should include checking their maximum attainable speed. Speed governors can prevent the heavy machines from reaching high and potentially deadly speeds.

Forklift overturns

Approximately 22 percent of the people killed in forklift accidents are crushed by an overturning forklift. Overturns can happen when drivers make sharp turns at high speed. These fatal accidents can also happen easily when operating forklifts on uneven surfaces.

Proper forklift safety must be enforced. It is better to penalize an unsafe driver or revoke their forklift certification than have someone killed by their unsafe forklift operation. Loads should never be raised while the forklift is in motion. Forklifts should be driven straight up or straight down ramps at safe speeds.

At DJ Products, we specialize in providing you with the most efficient material handling equipment available to safely maximize manpower. Contact us today for a free demo.

In order to stay competitive and counteract flat sales, supply chain executives are being tasked with reducing labor costs while customers are ordering more frequently in smaller quantities. State-of-the-art material handling equipment is a start, but what’s the rest of the solution?

How to Maximize Order Picking Productivity

A majority of your workforce is involved in order picking, so that’s a logical place to look for areas of improvement. Here are some valuable tips for improving order picking efficiency.

One SKU per Pick Location

Each SKU should have its own individual pick location. The importance of this principle can’t be overstated. Studies show that multiple SKUs at one location can add 15 seconds per transaction.

Some warehouses slot as many as 10 SKUs in one bin location. Not only does this practice add time to the order picking process, it increases the chances of mispicks.

Implement Batch and Cluster Processes

At least half the time of an order picking job is spent in travel. With the average order coming in smaller quantities, this is a perfect opportunity to combine multiple orders that can be completed in a single pick cycle.

Pick Horizontally, Not Vertically

It’s a time-tested fact that it costs more to pick vertically than horizontally. Ideally, all pick facings should be at ground level.

Are you constrained by the dimensions of your warehouse? Wherever possible, slot the highest-velocity items at ground level and proceed vertically from lowest to highest.

Optimize Labor with Material Handling Equipment from DJ Products

Inferior material handling equipment in the warehouse can reduce both productivity and employee morale. Our best-selling CartCaddyLite and other electric tugs, pushers and movers are like adding another worker to the team.

Call 800.686.2651 for more information.

When it comes to warehouses, lean and mean is the order of the day. Faced with flat or negative growth, supply chain executives are turning to updated material handling equipment and other strategies to reduce labor costs while maintaining high levels of customer service.

Here is the conclusion of our two-part look at effective tips to improve order picking efficiency.

How to Maximize Order Picking Productivity

Set Up “Hot Zones”

In an earlier tip, we talked about the importance of reducing the amount of time it takes order pickers to travel through the warehouse. One way to do that is to set up “hot zones” where higher-velocity items are concentrated.

Some companies find it useful to implement an ABC analysis that assigns items to one of three categories based on velocity. Another option is to widen the aisles where the higher-velocity items are located to prevent congestion from multiple order pickers.

Use Appropriate Storage Media

Warehouse efficiency can be measured by the number of times an item is handled from the time it arrives until the time it leaves. That rate goes up when product is stored in the wrong media, such as when slow-moving SKUs are slotted in pallet racks.

Cube movement velocity is calculated by movement in units times cubic dimensions. Use this metric to determine the optimum storage medium for each SKU.

Quality Material Handling Equipment for All Applications

Our battery-powered material handling equipment lets a single worker safely and quickly move loads weighing thousands of pounds. We have a full line of tugs, pushers and movers, including models that can accommodate awkward loads such as drums and carpet rolls.

Visit our website to learn more from a helpful member of our sales engineer team.

Whether you need a larger space, a more convenient location or a more affordable warehouse, relocating is a major move that requires careful planning. You need to ensure that all of your products, material handling equipment and other supplies are brought to the new place in good condition. Also, take care of practical matters such as adjusting your budget for the move. Keep the following tips in mind for planning your warehouse relocation:

Find the Right Location

This means weighing your options with your business needs and budget in mind. Look for locations that provide you with the space you need at a price that fits comfortably within your budget. Consider whether or not your move will require hiring new management and staff, such as if you go to a different part of the state or to another state entirely.

Keep Track of the Timeline

The amount of time it will take you to relocate depends on different factors, such as how large your business is. Plan out the steps you need to take in order to prepare for it, and keep track of the overall timeline. Work out a schedule that allows you and your staff to get everything ready for the move without having to rush.

Adjust Your Budget

Factor in expenses that you will be dealing with before, during and after the move, such as a recruitment budget for new staff. You might also need to budget for productivity loss as you move from one warehouse to another.

If you need to invest in new material handling equipment after your warehouse relocation, please contact DJ Products. We offer high-quality equipment that can help you run your warehouse as efficiently as possible.

The explosion of e-commerce has brought with it a greater need for speedy last-mile delivery. Accommodating these increase requires far more than adding material handling equipment. A recent report shows that warehouse inventory is “aging,” with supply lagging well behind demand.

The New Realities of the Warehouse Industry

In March 2018 CBRE, the world’s largest commercial real estate services and investment firm, published a report about warehouse modernization in the U.S. According to their findings, 1 billion square feet of new warehouse capacity has been added over the last 10 years, yet it makes up only 11 percent of total warehouse inventory.

In addition, these modern warehouses account for just four percent of total buildings. This is due to new warehouse structures being built approximately three times the size of existing facilities.

In the push to fulfill the needs of today’s business environment, developers are facing a dilemma. Focusing on streamlined last-mile delivery systems requires warehouses located in proximity to large urban centers and densely populated areas. Unfortunately, such land is so limited that it carries a premium price, making it difficult for developers to be profitable.

Finding Solutions

Warehouses may start growing up instead of out. Developers could take their cues from vertical and stack warehousing models used in cosmopolitan cities such as Tokyo and Hong Kong, where population sizes and real estate prices effectively prohibit conventional warehouse buildings.

Material Handling Equipment for Today’s Modern Warehouses

DJ Products offers a full line of battery-powered tugs, movers and pushers for all warehouse applications. Visit our website to learn more about state-of-the-art material handling equipment such as our popular CartCaddyLite. Sales engineers are ready to help you via our convenient online chat feature.

Have you provided your employees with top-of-the-line material handling equipment such as our CartCaddyLite? That’s a crucial step in maximizing productivity, but it’s only part of the answer. All workers should be trained to spot safety hazards and how to avoid them.

We recently listed the top three forklift dangers along with corresponding safety tips. In this post we’re concluding with a look at the last two of the top five dangers.

Falls from Forklifts

Not all forklift injuries and fatalities are caused directly by the vehicle. A fall from a forklift can have serious results, ranging from cuts and contusions to broken bones to death.

– Institute a zero-tolerance policy for lifting workers who are standing directly on the fork.

– Always use an approved lifting cage and make sure the platform is securely attached to the fork or carriage.

– Use rails, chains, body belts or other restraining devices for the worker on the platform.

– Always lower the platform before traveling.

Shoddy or Inconsistent Maintenance

Forklifts require maintenance just as any other motorized vehicle does. Accidents due to poor maintenance are doubly tragic because they could have been prevented. In addition, your company could be liable for negligence.

– At a minimum, follow the manufacturer’s recommended maintenance schedule. You may want to have more frequent inspections based on heavy usage.

– Pull a forklift out of operation immediately if any problems are found.

Turn to DJ Products for Safe and Efficient Material Handling Equipment

Our battery-powered tugs, movers and pushers are designed to let a single employee transport loads of up to 10,000 pounds, including irregular shapes and sizes. Visit our website and use the convenient online chat feature to learn more from our friendly and knowledgeable sales engineers.

With an estimated 1 million in use in workplaces around the United States, forklifts are an essential part of material handling equipment. These vehicles also carry an inherent risk of injury that calls for special safety measures during operation.

There are 20,000 serious injuries and 100 fatalities associated with forklift use each year. Make sure your employees are aware of the top forklift dangers and how to avoid them.

Forklift Turnovers

Nearly 25 percent of forklift-related fatalities are caused by turnovers. These types of accidents are primarily due to excess or unbalanced loads, but they can also result from traveling with the forks raised too high.

– Ensure that all loads are balanced and secure.

– Use caution on inclines and wet or slippery surfaces.

– Keep forks stationary when traveling.

Striking Pedestrians

Even when forklifts are traveling at slow speeds, pedestrians will almost always be on the losing end of a collision.

– Keep forklift and pedestrian traffic separated as much as possible.

– Restrict forklift use around time clocks, lunchrooms, exits and other areas of high foot traffic.

– Install workstations at a safe distance from aisles and protect them with physical barriers.

– Enforce safe driving guidelines such as stop signs, speed limits and use of horns.

Worker Pinned or Crushed by Forklift

The average forklift weights several thousand pounds. Approximately 16 percent of fatalities occur when a forklift pins or crushes a worker.

– Forklift drivers and passengers must be in a seat with seatbelts engaged.

– Riding on the forks should be absolutely prohibited.

– Drivers should always be on the lookout for hazards.

Protect Employees with Material Handling Equipment from DJ Products

Our best-selling CartCaddyLite and other battery-powered movers include safety features to minimize workplace accidents and repetitive-motion injuries. Contact us for more information.

Today’s most successful warehouse and distribution ventures know the key to maximizing profits and boosting efficiency lies in the right material handling equipment and operational tactics. What are the best supply chain engineers in the business doing to drive down costs?

Tried and True Ways to Boost Warehouse & Production Efficiency Include:

Vendor Compliance Reward Programs
Rewards, not punishments for non-compliance, offer incentive for all involved parties to contribute toward a more efficient supply chain. Developing a team mentality between your business, vendors, and 3PL providers is key. Small efficiency boosts can have a big impact on your bottom line over time, with success boosting profits for all parties. Where should you optimize?

– Reduced handling.

– Clear/specific labeling.

– Standard case quantities.

– Common product ID and tracking, upstream to domestic/offshore vendors.

– Speedier transportation.

– Resultant customer satisfaction ratings.

Shipping Notifications
Still relying on a ‘regular’ shipping/receiving schedule? You’re likely paying in staffing issues and delays. Advanced electronic shipping notifications through purchasing/inventory management functions can help you plan labor more precisely, optimizing fulfillment and transport activities to keep costs contained.

Automatic Data Collection
RF barcode and RFID systems remove the human error element of tracking. Each automated step is one less to manage, with the added advantage of data collection helping you make smart supply chain decisions.

Hands-Free Order Picking
The latest wrist-mounted RF units and voice pick/put-to-light fulfillment technologies accelerate picking.

Picking Waves
Preplanned picking waves with Tier1 WMS tech can boost route efficiency.

Material Handling Equipment
Motorized material handling equipment, such as cart pullers/movers, trailer and heavy equipment tuggers, boost efficiency and protect workers from costly injuries.

Looking for new ways to save? Boost efficiency and manpower with the latest in material handling equipment technology from DJ Products today.

An ever-increasing number of retailers are relying on warehouse personnel to receive, store, and distribute products directly to end users. This results in an increased demand for warehouse workers. You can minimize the risks of warehouse injuries by incorporating efficient material handling equipment and being mindful of these four common warehouse injuries.

Falling objects and collapsing pallet racks

Forklifts can be useful when moving and lifting heavy loads. One person has an immense amount of power literally right at their fingertips. A slight distraction can result in someone being struck by falling objects or an entire rack of products. Consider having assigned safety personnel who regularly inspect racks and other areas where forklifts are used for potential dangers.

Forklift accidents

The Bureau of Labor Statistics estimates that 100 U.S. workers are killed by forklift accidents each year and another 20,000 sustain serious injuries. Reducing the number of forklift accidents requires worker training, ongoing safe work practices, and warehouse traffic management. The National Institute for Occupational Safety and Health has tips to prevent injuries and deaths to people operating and working near forklifts.

Slips, trips, and falls

Approximately 15 percent of all accidental deaths are due to slips, trips, and falls. These accidents are common in all work industries. They are also among the easiest to prevent. All employees should be vigilant about reporting spills, damaged flooring, and other safety hazards. Managers must promptly correct any unsafe condition.

Overexertion injuries

Warehouse work involves pulling, lifting, and carrying products. Overexertion injuries are common and very expensive for companies. Provide your workers with energy-efficient material handling equipment specifically designed for busy warehouses. Contact DJ Products to consult with one of our sales engineers and schedule a free demo.