Tag: Material Handling

Risk Factors Linked to Pulling Tasks

Injuries from pushing and, particularly, pulling tasks cost U.S. businesses tens of billions of dollars each year, yet are largely preventable when ergonomic equipment and ergonomic practices are introduced into the workplace. In our last post, we talked about how these two common work tasks place workers at risk for potentially debilitating musculoskeletal injuries. Today, we take a closer look at the risk factors associated with pulling heavy carts and equipment.

One-handed pulling tasks. When facing the direction of travel, pulling must be done one-handed, significantly decreasing the operator’s control of the load. The worker must stretch his arm out behind him and twist his body unnaturally to face the direction of travel. This places undue strain on the back, shoulder, arm and wrist muscles, increasing the chance injury.

Changing direction or maneuvering a wheeled cart while pulling it behind you with one hand is not only awkward and difficult, it focuses pressure on wrist, elbow and shoulder joints and on the tender muscles of the lower back, increasing muscle strain to dangerous levels. There is also danger that the operator may lose control of the load, particularly when on inclined grades. If the cart “overruns” the operator, there is risk of additional injury to the operator or others in the cart’s path.

Two-handed pulling tasks. When using two hands to pull a load, the operator must walk backwards, facing away from the direction of travel. Pulling places significant stress on the arm, shoulder and wrist muscles. While using two hands allows the operator to maintain better control over the cart, particularly when maneuvering around turns or in tight spaces, the inability to see the travel path invites disaster.

Facing away from his direction of travel, the operator remains unaware of obstacles in his path. He cannot prepare for dips or rough spots in the travel path that can affect his balance or the balance of the equipment he is pulling. He remains unaware of traffic sharing the same path, inviting collision.

The risk of stumbling and being overrun by the equipment he is pulling is increased when the operator is facing away from his direction of travel. Constantly looking over his shoulder twists the body, increasing strain on lower back, shoulders, arm, wrist and neck muscles and inviting injury.

Preventing injury from pulling tasks. DJ Products’ ergonomically-designed, motorized carts, tugs and movers take the strain out of pulling tasks. Battery operation allows a single worker to move loads without physical effort. Walk-behind design allows a full view of the path ahead, guaranteeing maximum operator control and safety. For more information about our full line of ergonomically-designed carts, tugs, and movers, visit the DJ Products website.

Battery Powered Tugger Reduces Injury at Food Processing Plant

At a major food processing plant, workers had to manually push heavy meat carts to maneuver them between processing stations. Concerned about injury risk and worker safety, plant executives turned to DJ Products for ergonomic solutions to their material handling problem. Our experts recommended the CartCaddyShorty battery powered tugger, a motorized cart mover designed to push, pull and maneuver carts that require turning. The battery powered tugger is the most maneuverable tug on the market today with the power to handle most push/pull applications. Most commonly used with carts that have two front swivel casters and two straight casters, the ergonomically-designed CartCaddyShorty attaches to the swivel end of the cart to provide the power necessary for easy pushing, pulling, turning and intricate maneuvering. Heavy carts that usually require two workers to maneuver can be easily managed by a single employee. The battery powered tugger takes the physical burden off your workers, eliminating the exertion and straining that can cause serious and expensive musculoskeletal injuries.Musculoskeletal injuries cost U.S. businesses billions of dollars in medical, insurance, workers’ compensation and lost man-hour costs each year. According to OSHA statistics, back injuries alone cost businesses $12 million in lost workdays and $1 billion in compensation costs annually. The time-lost cost of a single back injury is estimated at $26,000.Through proactive use of the CartCaddyShorty, this major food processer was able to eliminate potential musculoskeletal injury risk at its facility. They also realized an increase in productivity and improved employee moral after introduction of DJ Products’ battery powered tugger. The CartCaddyShorty has also proved effective in hospital, hospitality and retail applications.Click here to learn more and to watch a video of the CartCaddyShorty in action. The world leader in providing battery powered tuggers and equipment movers to the manufacturing, hospital and retail markets, DJ Products offers a full line of ergonomically designed, powered carts, tugs and movers.

Your Turn to Talk: Where Do You Stand on Ergonomic Debate?

We’ve spent some time this week talking about the changing climate in Washington with regard to ergonomics and ergonomic legislation. On the campaign trail, President Obama repeatedly promised workers a healthier, safer workplace, saying he would use the full weight of his office to attack the problem of musculoskeletal injuries. Confirmation this week Hilda Solis as Obama’s new Labor secretary is expected to get the ball rolling.

Despite the fact that ergonomic systems and equipment have been repeatedly proven to significantly reduce worker injury and the exorbitant medical, insurance, disability and lost man-hour costs associated with musculoskeletal injuries, recent news reports give the impression that business owners fear the financial burden of government-regulated ergonomics. Admittedly, as one of the nation’s premier manufacturers of ergonomically-designed electric carts and motorized cart pushers, DJ Products is a bit biased on the subject. However, our considerable experience with customers from large manufacturers to small business owners indicates that rather than fearing ergonomics, savvy businessmen are embracing it, not only to protect the health and safety of their employees, but to streamline production and reduce production costs. In our experience, most purchasers of our ergonomic carts, tugs and movers recoup their investment within the first year, noting savings in medical and production costs.

In news reports of ergonomic panic, the leadership of the U.S. Chamber of Commerce appears to be fanning the flames of dissent. The chamber cites cost and potential for abuse (i.e., paying the cost of worker injuries suffered off the job) as its two main reasons for opposition. There are always some people who will try to abuse the system, but we don’t imagine that abuse will be any greater with ergonomic rules than without them. If potential abuse were the deciding factor, there wouldn’t be any government programs, so this argument is negligible.

The issue of cost, particularly in the current economy, is, of course, a consideration. However, throughout industrial history, new innovations have required some re-tooling to reap greater profit. With ergonomics, considerable benefits can be realized from minor changes: a change in position, routine or tool placement. Ergonomic equipment can be introduced gradually, a sector at a time, allowing businesses to realize immediate gains without tremendous financial outlay.

The chamber argues that regulation is unnecessary because businessmen recognize the value of ergonomics and are implementing programs without government intervention. If that’s true, then what’s the harm in regulation? The fact is that forward-thinking businessmen do recognize the value of ergonomics and they are integrating ergonomics into their operations. But many are not and their workers suffer so government acts for the common good.

But enough from us, we want to hear from you on this issue. Where do you stand on the ergonomic debate? Let us know and we’ll share your thoughts with our readers.

Move Stalled Vehicles Quickly in the Cold with a Car Pusher

We have mentioned that it can be quite a chore to move a stalled vehicle in the heat of summer but it is also no fun to need to move a stalled vehicle in the bitter cold of winter. If your company has a fleet of vehicles we are sure you work to keep them well maintained but that doesn’t guarantee that you won’t need to move one of these vehicles when the temperatures drop. Or perhaps the vehicles you need to move aren’t yours but belong to customers—if that is the case then you need something that can move the staled vehicle without the kind of damage that occurs when you use one vehicle to push another.

Either way, if your cart, car, or piece of equipment has all straight wheels or is on a rail, then DJ Products ergonomic solutions help solve material handling applications where no turning is required.

Our CarCaddy car pusher can push stalled vehicles across the lot at a service center or along a highway. And as we’ve mentioned, it will not damage the vehicle since the front push pad of the CarCaddy car and vehicle pusher is made of a soft, durable, padded material designed to preserve the paint and integrity of the back end of the stalled vehicle while also protecting the car and vehicle pusher.

Push or pull buses, trucks, and cars up to 10,000 lbs. with the DealerCaddy truck pusher. Its adjustable push pad was designed to contour the bumper on the back of any vehicle.

Material Handling Safety Tips

Avoid Injury[/caption]The nature of material handling work involves a number of situations with the potential to cause injury. Large, heavy carts and other equipment are being transported through aisles that can be narrow and congested. In addition, there are often other employees moving around the same areas who may not be paying as careful attention as you are.

As the saying goes, an ounce of prevention equals a pound of cure. Being sensible and vigilant can keep you and others injury-free.

Here are some tips to promote a safer work environment:

  • Always check your route to make sure it’s clear of potential blockage or other hazards. Help yourself and others by keeping the workplace clutter-free.
     
  • If you’re passing through doorways, make sure there’s enough clearance. Getting your hand or fingers caught can be painful.
     
  • Wear appropriate footwear such as steel-toed boots. This is a requirement at most companies, but if it’s not you should take this precaution yourself. Heavy-duty gloves can also be useful.
     
  • Make sure the load you’re transporting is evenly distributed. If it’s stacked too high you run the risk of objects falling on you or others.
     
  • Use good posture to support your back. Bend at the knees and lift with your legs.
     
  • Ask for assistance with loads that are too difficult to handle on your own. An even better solution is using a battery-powered material handling tug. For example, our CartCaddy5WP enables one person to easily move loads of up to 10,000 pounds.

DJ Products offers a full line of material handling tugs for use in applications from hotels and hospitals to airplane hangers. Contact us for more information about how we can simplify your job.

Part 6: Why Businesses Fail, the Conclusion

Today we conclude our six-part series on Why Businesses Fail (see our posts starting July 14). One of the primary reasons businesses fail is:

  • Faulty attitudes and objectives. Businesses fail when personal or company desires are placed ahead of customers’ wants and desires. You don’t run your business; your customers run your business. Customer satisfaction is the single-most important factor in driving business and repeat business to your door. Businessmen who forget that don’t remain in business long.

    Employee satisfaction goes hand-in-hand with customer satisfaction. When businesses fail to value their employees, employee satisfaction plummets, taking with it production quality and efficiency and customer satisfaction. It’s a downward spiral from which businesses don’t recover without an attitude adjustment. The bottom line is that it’s the human element that guarantees business success.

DJ Products understands the value and importance of customer and employee satisfaction — both ours and yours. That’s why we manufacture and use ergonomically designed electric carts and motorized cart pushers and equipment movers. Our equipment is smaller, more maneuverable and less costly to purchase and operate than traditional powered equipment like fork trucks, walkies and riding tugs. And our equipment is designed to eliminate the pain and strain of manually moving heavy carts and wheeled equipment. We value the health and safety of our workers — and yours.

DJ Products’ expert sales staff can assist you in assessing your material handling needs. On our website you’ll find a handy Ergonomic Load Calculator designed by experts to estimate the amount of horizontal force needed to move wheeled loads. Our sales staff can help you calculate load factors and recommend material handling products designed to protect the health and safety of your workers. Visit the DJ Products’ website for detailed specs on our complete line of products. If you have a material handling problem, DJ Products can provide the solution.

Ergonomic Equipment Benefits Aging Workforce

America’s workforce is aging. According to the U.S. Bureau of Labor Statistics, employment of workers aged 65 and older increased 101% from 1977 to 2007, nearly twice the rate for total employment — and that doesn’t even reflect the aging Baby Boomer population, the first wave of which is just hitting 65 this year. Slightly more than 50% of older workers now work full-time. From 2006 to 2016, the Bureau of Labor Statistics expects older workers aged 55 to 64 to increase by 36% and workers over the age of 65 to increase by 80%.

The graying of America’s workforce means that business and industry will increasingly need to accommodate the physical strength and endurance limitations of older bodies. Ergonomic equipment and practices will become increasingly important, both to protect workers’ health and welfare and to enable workers of variable abilities to perform the same job. Ergonomics allows businesses to fit the job to the person — no matter the worker’s size, age, gender or physical abilities — instead of forcing the worker to torque his body into unnatural and uncomfortable positions to make the equipment work or get the job done.

Manual material handling injuries account for approximately 35% of workers’ compensation claims. Injuries to the back and upper extremities caused by reaching, lifting and carrying result in an estimated 44% of all lost time injuries. As workers age, the risk of injury increases. The bottom line is that without ergonomically-designed equipment and the institution of ergonomic practices at workstations, you can expect your injury rate — and medical/disability costs — to increase as the age of your workforce goes up. However, ergonomic equipment can level the playing field.

Ergonomic equipment that helps to lift, position and move materials and finished products takes the burden off workers, insures worker safety, and increases worker productivity. Ergonomic equipment improves worker safety and productivity when bending, twisting and reaching are required. Ergonomic design can also allow the height and tilt of containers to be adjusted for easier access. Ideally, you should utilize ergonomic principles in every aspect of your workplace operations to promote worker safety and productivity. As a bonus, you’ll build good morale and save money.

DJ Products is the national leader in ergonomically-designed motorized and battery-operated material handling carts and cart movers. We offer a complete line of powerful, compact, ergonomically-designed material handling products for every application. Contact us today for personalized help meeting your material handling needs.

2009 Ends on Material Handling High Note

2009 seemed like the year that would never end. For manufacturers, the bad news just kept on coming. But hope seems to have finally struggled above the horizon. From the depths of last winter’s discontent, 2009 has risen to end on a high note for material handling manufacturers and, indeed, most U.S. manufacturers. Reports indicate that U.S. manufacturing has finally turned the corner, and we can expect 2010 to be a far more productive and more profitable year. Break out the champagne!

The fourth quarter of 2009 saw strong manufacturing growth. With the job market showing signs of stabilization and housing prices beginning to climb toward normal, November brought a cautious increase in consumer spending. Manufacturing benefitted from increased orders for durable goods during the fourth quarter as customers started restocking their shelves. While durable goods orders in November were less than robust, they were twice the amount forecast by economists. Overall, the U.S. economic picture looks hopefully optimistic for the first time since the recession hit.

“We are seeing progress in a number of areas, from increases in consumer spending and business spending to growth in exports,” Brian Bethune, an economist at IHS Global Economics told the Associated Press last week. “It all adds up to a recovery that is gaining some momentum.”

Bethune and other economists are predicting a 4% annual rate of economic growth (as measured by gross domestic product) for the final quarter of 2009. In addition to durable goods, particularly a growing increase in high ticket items, industrial growth into the new year is expected to come from increased equipment and software purchases. Ergonomic material handling equipment sales are expected to increase as manufacturers and business owners seek out ways to increase worker productivity and decrease healthcare costs. Expected new regulatory requirements aimed at protecting worker health and safety are also expected to drive up sales of ergonomic carts and tugs.

MHIA Funds Distribution Ergonomics Research

The Material Handling Industry of America (MHIA) has awarded a $50,000 research grant to Ohio State University researchers in Columbus, Ohio. The grant will be used to help fund creation of a research center focused on distribution ergonomics. Provided through MHIA’s College Industry Council on Material Handling Education, the grant represents MHIA’s maiden effort in direct funding of material handling and logistics research.

In their award-winning grant application, Dr Carolyn Sommerich and Dr. Stephen Lavender of OSU proposed:

  • To create a research center that develops and devaluates ergonomic methods, tools and processes that will allow distribution center workers to work more safely and efficiently; and
  • To develop partnerships between regional distribution centers and material handling equipment manufacturers to assist the distribution centers in becoming workplaces of excellence via the proper utilization of ergonomics and lean engineering.

“MHIA is proud to support this important research which will contribute significantly to the body of knowledge on ways to improve the safety and productivity of warehouses and distribution centers,” said Daniel Quinn, MHIA Vice Chairman for Education Planning & Professional Development. “Going forward MHIA is anxious to support research such as this which will benefit the safety and productivity of factories and warehouses in the United States.”

In making the grant announcement, MHIA voiced a commitment to supporting material handling and facility logistics research and teaching in the future. Increased funding will be available for such research in the 2009-10 academic year. A call for proposals is expected to go out late this year.

DJ Products applauds MHIA’s new initiative. We recognize the importance of ergonomics in the workplace and are dedicated to the design and production of ergonomic material handling solutions. Visit the DJ Products website for more information about ergonomic products that can make your plant or business safer, more efficient and more productive.

Human Factors Affect Push-Pull Equipment Design

Humans come in all shapes and sizes. And that’s the challenge in designing safe, effective ergonomic equipment. There is no such thing as “one size fits all” when you’re designing equipment that will be used by a diverse workforce. However, there are a number of specific human factors that affect a person’s ability to execute a pushing or pulling task. Ergonomics strives to incorporate these factors into equipment design to ensure that workers can safely and effectively complete required tasks.

  • Biomechanics use gender, body size (anthropometry), posture and push/pull force to calculate muscle force requirements and bone/joint compression forces. Biomechanics are useful in examining exertion, but generally fail to consider dynamics, repetition and duration of the task.
  • Physiology considers physical work capacity (a measurement of maximum aerobic capacity) and fatigue, particularly in tasks that are repetitive, fast paced or that require forceful exertion. Since each person is unique, his or her physical work capacity will be different. Factors considered include age, fitness, gender and maximum heart rate, as well as the energy demands and duration of the job. Physiology also factors in the necessary dissipation of body heat as affected by clothing, temperature, humidity and air movement. In designing equipment, ergonomic engineers consider the expected user population and generally design for the least physically capable individuals within that population.
  • Psychophysics takes human perception of the task into account. It evaluates the type, frequency, distance and hand height of the task, as well as the type of force required to execute the task. Also considered are the gender and characteristics of the average worker who will perform the task.

By considering these three types of human factors, ergonomic engineers strive to design an electric tug that can be safely and efficiently used by workers.