Tag: ergonomics

Simple Measures Can Improve Warehouse Safety, Productivity

The bottom line advantage of improving worker safety was a recurrent theme this past week as businesses celebrated North American Occupational Safety and Health Week. The annual cost to American businesses of workplace injuries and illnesses is $171 billion. Safety improvement need not come at the expense of efficiency and productivity was the oft-promoted lesson.

“When it comes to improved productivity, safety is an overlooked area,” said Michael Davis of Sedlak Management Consultants. “A lot of times, you don’t realize how much a workmen’s compensation claim costs or the hit you take to morale and productivity if someone gets hurt on the job.” Davis suggested four easy fixes for creating a safer, more productive work environment in warehouses and distribution centers:

  • Create designated walkways for pedestrians and equipment. This is particularly important when forklifts or other equipment must share the same floor space with pedestrians. A low-cost solution can be as simple as outlining walkways in yellow paint and installing guardrails to protect pedestrians from equipment traffic.
  • Install an alert system to warn pickers of coming traffic. Mirrors can also be installed to help workers track the activity of others, particularly when picking areas are crowded or are shared by both pedestrian and vehicle traffic. Davis says an alert system can be installed for $1,500 to $4,500, a fraction of the cost of a workmen’s compensation claim.
  • Safety gates that protect mezzanines are required by OSHA. Unfortunately, most safety gates are manually operated and may occasionally be left open. Installing a safety gate that closes automatically better protects high traffic areas.
  • Sensors around automated equipment can protect workers from inadvertent injury. Robotic pickers and palletizers are often used alongside human workers to improve productivity in picking and shipping operations. Davis suggests, “the installation of a light curtain around automated equipment. That’s  a system of photoelectric eyes that create a barrier around the equipment. If the beam from the photoelectric eye is broken because someone is in that area, the equipment automatically shuts off.”

Ergonomic Scissors Lift Adjusts to Workers’ Heights

Bending, twisting and reaching all day long can have workers reaching for the Tylenol well before the day is over. These muscle-torquing activities lead to aches, strains and sprains that slow workers down and can eventually cause musculoskeletal injuries that entail multiple doctor’s visits, costly physical therapy and time off from work, placing an added burden on fellow workers who have to pick up the slack.

This was the problem being experienced by an Ohio manufacturer of aftermarket exhaust systems. Management noticed a high level of sprains and strains reported by workers. Investigation found the culprit to be the awkward positions workers assumed while performing production and packing tasks.

Workers come in different shapes and sizes but, as is true in most facilities, materials were delivered to work stations at a single, stationary height. Since few workers fit the “ideal” height around which equipment and tasks were designed, this meant that most workers, being either shorter or taller than the “ideal” height, were forced to bend, stretch, and strain to perform their work tasks. In the process, they overtaxed and injured muscles.

Company management sought a solution in ergonomics. Ergonomics is the science of fitting equipment and tasks to the capabilities of the worker to eliminate strain on the human body. Ergonomic design allows equipment that will be used by multiple workers to be adjusted to fit the size and capability of each individual. 

In the case of the Ohio exhaust manufacturer, the perfect solution proved to be an ergonomically-designed, portable scissor lift. The portable scissor lift allowed relatively heavy parts (120 lbs.) to be quickly moved from one station to the next. The power scissor feature permitted each worker to quickly and easily adjust the lift bed to the optimal height for his size. The result was virtual elimination of musculoskeletal injuries, an increase in productivity from 65% to 88%, and increased on-time delivery.

The problems experienced by this Ohio company are common to many industries, including manufacturing, fulfillment, packing, logistics, shipping and warehousing. DJ Products’ PWP2000 Cart Puller mobile electric lift table could be the perfect solution for your facility. Our ergonomically-designed, self-propelled electric scissor lift is available in a variety of shapes and sizes for various applications. Our lift tables deliver work items to the appropriate height every time. Combine our lift table with our PartsCaddy mobile platform truck and workers can easily move fully-loaded lift tables from one station to the next without physical strain. With 16 hours of battery life, DJ Products’ electric movers can stay in continuous operation through two shifts with ease. 

Ergonomic Solutions for Warehouse Order Fulfillment

If your business relies on a warehouse to ship goods to your customers then you know that getting orders is only half of the battle. Once you have secured a customer’s order, it is then up to you and your team to see to it that the order reaches that customer in good condition as quickly as possible. We have no doubt that you have stressed the importance of filling orders quickly to your employees…but have you given them the right equipment to make this happen? It is important to give your employees the supplies so they can carry out your vision.

When employees are working as quickly as possible but using outdated or inadequate machinery, they are more prone to injury. In addition to this, rickety carts, unstable dollies, and overused scissor lifts can result in spilled or damaged merchandise. Having employees out on leave because of injury and losing merchandise to accidents can eat away at your profits and you do not want that.

DJ Products offers and entire lineup for industrial ergonomic material handling solutions including:

• Carts with casters
• Carts with 4-swivel casters or wagon-wheel style of turning
• Carts in a straight line
• Platform Trucks & Scissor Lifts

Our ergonomic cart pushers, electric cart pullers and other solutions eliminate the strain of manually pulling heavy product, parts carts, or wheeled equipment. Your employees can continue to work efficiently with a reduced chance of injury or product damage.

Our products are not one-size-fits-all. Contact us at 800-686-2651 to discuss exactly what you need and the customization options that will work for your industry.

Five Important Dock Safety Tips

Warehouse safety begins at the receiving and shipping docks. Safe dock procedures set the stage for the safe unloading, handling and storage of materials as well as the packing, loading and shipping of product. Identifying and addressing ergonomic challenges on the dock can directly impact worker safety and dock productivity. “You have to look at everything from what kind of trailer you’re going to receive, to whether the load is floor-loaded or unitized to what happens to it after it comes off the truck. Even the temperature inside the facility and the weather are important,” explained Brent Tymensky, VP of design engineering for Fortna Inc.

Dock safety begins with attention to five important issues:

  • Trailer access. The length, width, height and suspension system of a trailer generally determine the dock equipment needed. Other considerations include whether the trailer is dry or refrigerated and whether the load is unitized and fully cubed.
  • Dock conditions. Temperature and weather impact dock worker safety and efficiency. A canopy that keeps out cold, heat, wind, rain and snow improves working conditions and worker comfort. Air-inflatable dock seals can form a tight barrier around a trailer, keeping out the weather and reducing energy costs.
  • Personnel issues. The age, experience and physical condition of your workforce are factors that determine how and when automated and manual equipment are used. Adjustable conveyors that reach into a trailer can assist with manual unloading and loading procedures, reducing the physical strain on workers. While some palletized loads can be off-loaded as is, many pallet loads must be broken down manually into their components for use or proper storage. Adjustable carts and tuggers can make this work both easier and safer for dock workers.
  • Dock safety equipment. Vehicle restraint devices prevent trailers from exiting prematurely while workers are still on the trailer. Restraint devices range from simple wheel chucks to automated systems that bolt into the cement dock and attach to the trailer’s rear guard. A newly marketed interlocking device attaches to the trailer brake emergency airline to prevent the trailer from moving until the dock ramp is removed and the dock door closed.
  • Productivity and efficiency. Dock levelers, extendable conveyors and palletizing equipment all increase efficiency in retrieving and loading materials and goods. Trailer drop can significantly hinder the transition from the trailer to the dock. Levelers and vehicle restraints that support the rear of the trailer can eliminate trailer drop as equipment is moved into the trailer for loading or unloading.

Products to Help Your Business Go Forklift-Free

There’s a growing trend, particularly in manufacturing, warehousing and logistics environments to go forklift-free (see our June 11 & 13 posts). An increasing number of businesses are choosing to replace forklift trucks with safer, ergonomic material handling products that are cheaper to own and operate. As we noted, going forklift-free can result in considerable savings in production and maintenance costs while significantly decreasing worker accidents and injuries and their associated medical, insurance, workman’s compensation and lost man-hour expenses. DJ Products can help your business transition to a safer forklift-free work environment.

At DJ Products we manufacture a full line of electric cart pullers and motorized cart pushers and tugs. Our products are ergonomically designed to eliminate the pain and strain of manually pushing and pulling heavy carts and wheeled equipment. Smaller and more maneuverable than traditional equipment like forklift trucks, walkies and riding tugs, you’ll also find our products to be less costly to purchase and maintain. Implementing forklift-free solutions with DJ Products equipment offers multiple benefits, including:

  • Decreased operating costs, particularly equipment purchase and maintenance costs,
  • Decreased floor space needed to maneuver equipment,
  • Decreased worker injuries and attendant medical, insurance, workman’s compensation and lost man-hour costs,
  • Decreased liability,
  • Increased plant safety, 
  • Increased worker morale, and
  • Increased efficiency and productivity. 

DJ Products can help you plan your transition to a forklift-free environment. We specialize in solving ergonomic material handling applications with battery-powered, walk-behind tug and tugger solutions. Many of our motorized cart products can be custom configured for adaptation to almost every heavy cart pushing or pulling application. Click here to request a free brochure or video about DJ Products’ ergonomic solutions. We also offer a free demo trial program so you can try out a CartCaddy cart pusher at your facility before purchase. Our expert Sales Engineers can discuss the details of your particular application and suggest ergonomic products that will provide the appropriate solution. Click here to contact a DJ Products Sales Engineer and begin your transition to a safe, cost effective, forklift-free work environment today.

2010 Applied Ergonomics Conference Slated for March

Scheduled for March 22-25, the 2010 Applied Ergonomics Conference (AEC) to be held in San Antonio, Texas is slated to be North America’s biggest and most impressive gathering of ergonomics experts, applications and equipment providers. What sets AEC apart from other ergonomic conferences is its emphasis on the practical application of ergonomic principles and discoveries to real world industrial problems. This is not an esoteric meeting of high-brow academics, though you’ll find the more practical of their ilk in attendance. This is a working man’s conference. A meeting of industrialists, ergonomic experts and others involved in day-to-day efforts to improve the health and safety of American workers through the application of ergonomics to real world problems.

 The 2010 AEC conference will be held at the Marriott San Antonio Hill Country Resort and Spa with early registration discounts available through January 15, 2010. Ergoweb is offering a special 50% discount to its followers until this Friday, December 18 on registrations for the conference and host hotel. (Click here for registration form and more information from ErgowebM [Expired].)

Keynote speakers scheduled include Y. Ian Noy, vice president and director of Liberty Mutual Research Institute for Safety, and Guy Fragata, senior advisor for Ergonomics Patient Safety Center of Inquiry. Multiple educational tracks and numerous informational exhibits by leaders in the ergonomics industry will also be featured at the conference.

As a leader in the design and manufacture of ergonomically-designed material handling equipment, DJ Products is intimately involved in solving daily ergonomics problems in a wide variety of U.S. industries including manufacturing and heavy industry, hospitality, hospital and health care, automotive and commercial retail. We understand the critical need for ergonomic systems and ergonomic material handling equipment that protects the health and safety of American workers. To find our more about our full line of ergonomic motorized carts and tugs, visit the DJ Products website.

Ergonomic Design Makes the Motorized Cart Workhorse of Future

Ergonomic design, energy efficiency and versatility make DJ Products’ motorized cart the material handling workhorse of the future — or at least the next decade. Our battery-powered and motorized carts and cart movers seem tailor-made for the federal government’s push to improve workplace safety, reduce medical costs, save energy and put more people back to work.

  • Improve workplace safety. The Obama administration is poised to increase governmental regulation of workplace safety issues. Ergonomics will play an important role in creating safe working environments. The science of designing equipment to fit the physical attributes and abilities of the worker, ergonomics reduces discomfort and fatigue and prevents repetitive strain injuries that can lead to long-term disability.
  • Reduce medical costs. With Congress revamping the national health care system, businesses will be working even harder to bring down medical costs. By preventing expensive musculoskeletal injuries, ergonomics helps businesses drastically reduce medical costs, worker’s compensation expenses and medical insurance premiums.
  • Save energy. The President’s promise at the U.N. Copenhagen climate conference to drastically cut the nation’s carbon dioxide production places renewed emphasis on equipment that isn’t powered by CO2-producing fossil fuels. DJ Product’s motorized carts and tugs use clean, green battery or electric power. Just like the Energizer Bunny, our tugs keep going and going, operating through two full shifts on a single charge.
  • Put people back to work. With most of the country starting the year with double-digit unemployment, putting people back to work is the government’s primary 2010 goal. Ergonomic design makes it possible for workers of any size, age or sex to easily operate any of DJ Products’ versatile motorized carts. Intuitive design and conveniently placed controls make for safe operation with minimal training.

To find out more about DJ Products’ ergonomically designed motorized carts and tugs, visit our website.

How Ergonomics Increases Productivity and Quality

In our last post we talked about how ergonomically designed material handling equipment improves worker health and safety by reducing expensive and potentially debilitating musculoskeletal injury. Business owners also realize measurable increases in worker productivity and product quality when ergonomic equipment and procedures are introduced into the workplace.

Most industrial equipment and work procedures were originally designed for occasional use, not the high-pressured, repetitive, long shifts found in the modern work place. By designing equipment that adjusts to the physical size and capabilities of each individual worker and by structuring work procedures to eliminate uncomfortable body positions during task performance, ergonomics decreases fatigue on muscles while increasing worker comfort. This enables workers to continue working comfortably without the frequent breaks they would otherwise need to stretch and rest tired muscles. Workers remain fresh and energized and can work comfortably through an entire shift. The result is decreased injury, better worker morale and increased worker productivity resulting in improved product quality. Ergonomics produces a win-win scenario for business owners and their employees.

Implementation of an effective ergonomic plan requires a three-pronged approach that involves engineering, administration and work practice modifications.

  • Engineering modifications may include changes in equipment and tools used, workstation modifications and changes in the way tasks are performed. Because engineering modifications produce the greatest reduction or elimination of physical risk, they also result in the greatest cost savings. Reduced physical risk reduces the medical, insurance, disability and lost man-hour costs of potentially debilitating musculoskeletal injury. On its website, DJ Products provides an invaluable Ergonomic Load Calculator that can be used to estimate the force needed to move loads in a variety of workplace environments and recommend ergonomic solutions to your material handling problems.
  • Administration modifications involve alterations to the work organization and/or workplace culture. While less expensive to implement, results are also less reliable in that they depend entirely on human compliance. Administrative modifications may include education and training in ergonomic procedures, restructuring job responsibilities to minimize repetitive tasks, worker/task rotation, increasing the frequency or duration of break periods for certain tasks, improving workers’ physical conditioning and developing oversight programs.
  • Work practice modifications include the development of ergonomic procedures for the performance of each individual task, worker training and oversight.

The initial investment in ergonomics may seem to be considerable, but the benefits — and long-term savings — far outweigh the costs and continue long after the initial investment is recouped.

Monday: How ergonomics saves money

Prevent Back Pain with a Power Puller

When your employees pull or tug on carts and dollies that are too heavy the result can be pain, back strain, and a number of other injuries. WebMD categorizes these injuries as:

Sudden (acute) injuries: These kinds of injuries are “sudden and severe” and include things like compressed nerves, ligament and muscle injury, spine fracture and torn or ruptured discs. Although WebMD notes that the “pain from an acute injury usually does not last longer than 6 weeks,” that is quite a long time to be hurting if you need to perform physical labor for work. And it is possible for a worker to become re-injured during that time.

Overuse injuries: With these, an employee may not remember a specific incident such as ‘throwing his/her back out,” but the pain stiffness and muscle spasm are certainly memorable, lasting 4 weeks if there is no treatment.

Material handling solutions such as a DJ Products power puller is an invaluable for preventing the injury and re-injury that can occur when employees strain their backs. Wheeled equipment such as dollies, hand trucks, linen carts, and hospital carts may be overloaded or the weight on them may not be distributed evenly. This is where a CartCaddyLite Shorty power puller comes in handy: it’s designed with enough power to maneuver carts with less than 1500 lbs. through confined environments where tight maneuverability is of a huge concern. You don’t want your employees to injure themselves or end up with tipped over carts.

Contact one of our Sales Engineers at 1-800-686-2651 to learn more about power pullers and our other useful material handling solutions.

OSHA Stepping Up Enforcement Efforts

While comprehensive action probably won’t occur until a permanent head of OSHA is named sometime this fall, the feds are gearing up for an expected battle on ergonomics. In addressing an assembly of safety professionals Monday, Acting Assistant Secretary of Labor Jordan Barab said, “You are not alone. We have your back and your fight is our fight . . . there’s a new sheriff in town.”

The Obama administration seems poised to make good on the President’s campaign promise to toughen ergonomic standards and beef up enforcement to ensure safe working conditions for the nation’s workers. According to the online edition of OH&S, a magazine targeting occupational health and safety professionals, OSHA will continue its Voluntary Protection Programs, but is initiating what Barab called safety inspector “SWAT teams” that can be sent into areas in force to insure compliance with OSHA standards. OSHA’s first SWAT teams are poised to sweep through Texas in the coming weeks to add muscle to the U.S. Department of Labor’s construction enforcement program.

According to OH&S, Barab also said OSHA is reviewing behavior-based incentive programs. OSHA is concerned that such programs punish workers who report workplace injuries, thus encouraging non-reporting of accidents and injuries.

Ergonomics will be back on the table after measures introduced during the Clinton years were swept away by the Bush administration. Barab acknowledged the challenges OSHA will most likely face in any attempt to implement ergonomic standards, saying, “It’s a big political football that others don’t want on the field.” He urged safety professionals to lobby their congressmen to vote for the passage of tough ergonomic standards.

Statements made by Barab seem to indicate that OSHA is in the process of revamping its entire standards process. During his speech, he called on safety professionals to share their experiences and expertise with the agency, saying, “OSHA compliance standards, as far as I’m concerned is the floor, they’re irrelevant. You all know better than we do how to move on.” Barab also warned that the agency plans to revise its penalty structure, making good its threat to criminalize grievous non-compliance. “We’re looking at what we can do under the law to increase those penalties . . . and, where it’s appropriate, introduce criminal penalties, as well,” Barab said.

Smart business owners will act proactively to forestall coming under OSHA’s scrutiny by upgrading to ergonomic material handling equipment now and implementing ergonomic practices. To find out how you can protect the health and safety of your workers and make a positive impact on your bottom line, contact a DJ Products’ sales engineer today to find out what ergonomically-designed material handling products can do for your business.