Tag: Material Handling

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.

Tips for Increasing Service Life of Material Handling Equipment

During a recession, the reality is that many companies are forced to made do with aging material handling equipment until business improves and funds become available for new equipment. It is possible to improve equipment performance while cutting costs by following three cost-saving strategies, says Cliff Holste, Supply Chain Digest’s material handling editor, in a June 11, 2009 article on SupplyChainDigest online. Holste’s magic formula for decreasing downtime and increasing equipment service life without straining your budget: reduce, reuse and recycle.

Reduce. Performing preventative maintenance will extend the life of your material handling equipment and can effectively reduce equipment repair costs. Setting a schedule for regular maintenance checks of your material handling equipment will ensure that it is running properly and allow any problems to be discovered and repaired before breakdown occurs. Regular preventative maintenance will keep equipment running at peak performance, minimizing expensive downtime and high-cost emergency repairs.

Reuse. Retrofitting current equipment so it can be reused in new applications is a cost-effective alternative to replacement. Modernizing existing equipment by upgrading components, increasing speed, improving capacity, augmenting safety features or adding new technology can increase its versatility, value and useful work life. A well-considered retrofit can allow existing material handling equipment to be used in new settings or perform new tasks at considerable savings. Retrofits can also bring older equipment into compliance with changing federal and state safety regulations. Ergonomic retrofits can be performed to improve the safe operation of existing equipment, reducing worker injuries and the medical, insurance and workers’ compensation expenses that accompany them.

An excellent example is DJ Products’ new ergonomically-designed Retrofit Cart Kit. This motorized retrofit cart kit can be adapted and mounted to almost any cart and can be customized to any application or environment from transporting hospital linens to moving oversized lumber. The powerful, heavy-duty, battery-powered 24-volt motor is capable of powering carts up to 4,000 pounds. Ergonomic variable-speed twist grips eliminate the risk of carpal tunnel syndrome while allowing operators to easily maneuver loads both forward and backward at speeds from 0 to 3.2 mph. DJ Products’ motorized retrofit cart kit can be field installed by the customer or DJ Products can provide onsite installation services. Visit the DJ Products website to find out more about our new motorized retrofit cart kit and to watch a video of this product in action.

Recycle. A fairly new offshoot of the “green” environmental movement, remanufactured material handling equipment can be an affordable alternative to buying new equipment for some. In the remanufacturing process, used equipment is disassembled and cleaned and worn parts are replaced before the unit is refinished and reassembled. Remanufactured equipment generally comes with a warranty.

Body Posture Plays Significant Role in Ergonomic Design

Body posture affects the amount of force that must be exerted to move and maneuver industrial carts and equipment. The human musculoskeletal system functions like a complex system of mechanical levers. Posture determines the positioning of our joints which, in turn, determines the reach of each muscle and the force needed to exercise it. Ergonomic design seeks to produce maximum force from each exertion by optimizing body posture. In creating a more efficient piece of equipment, the goal of ergonomic design is to minimize wear and tear and the threat of injury to the human body.

Optimal body posture generally changes a piece of equipment is moved. The horizontal force necessary to put equipment in motion gives way to a more upright stance as less force is needed to keep it in motion. Handle placement can affect the amount of horizontal push a worker is able to supply. Any angle above or below the horizontal plane will diminish the amount of force a worker can produce. The greater the angle, the less direct force can applied to horizontal movement. Due to variations in worker size, adjustable handles or multiple handholds will allow optimal force production for a greater percentage of your workforce.

Foot positioning can also have a significant impact on the amount of force a worker can produce. The greatest push force is generated when the body is in a lunging posture with feet separated, one foot some distance ahead of the other. Because this position places the rear foot beyond the body’s center of gravity, it unbalances the body, placing workers at increased risk for falls and injury. The risk of serious injury increases if push force must be executed on either an incline or decline.

The use of electronic or motorized carts eliminates the burden of force and the risk of potential injury from your workforce. Equipment rather than the worker’s body provides the push force to necessary initiate and maintain movement. Optimal force can be applied regardless of worker size and strength, maximizing the efficient use of your workforce and optimizing task completion.

Back Strain in the Workplace

Only the common cold results in more lost work days than back strain. Overexertion is responsible for 25% of all workplace injuries, according to the National Safety Council. One worker in every 200 experiences an overexertion injury, indicates data compiled by the National Institute for Occupational Safety and Health (NIOSH). Annually, overexertion injuries cost American business more than 12 million lost workdays and over $1 billion in compensation costs. The majority of overexertion injuries — 60% — result in back strain, particularly in the lower back.

Statistics show that one in five disabling workplace injuries are back injuries and that more than 25% of workers’ compensation claims are for back injuries. Back strain occurs when the back muscles are overused or ligaments and tendons are overstretched. Recovery can be lengthy; and once damaged, the back is particularly susceptible to re-injury.

Back injuries most often occur during lifting, pulling, pushing, carrying, bending or twisting activities. These are the same activities most likely to be carried out by workers on a daily basis. According to OSHA studies, preventive measures that include weight restrictions on loads and personnel safety training have proved inadequate in reducing injuries. However, coupling preventive measures with ergonomically designed equipment can significantly reduce the incidence of back injuries in the workplace.

By studying the actions used to complete a task, ergonomic engineers are able to design equipment that eliminates or minimizes lifting, pulling, pushing, carrying, bending and twisting actions. Ergonomic cart puller equipment that reduces the potential for overexertion or extension reduces the risk of back injury.

Automated Products Will Lead Future Material Handling Growth

Automation and third world development are expected to drive the 5% annual global growth predicted in the material handling industry, according to a new study released by The Freedonia Group, Inc., a Cleveland-based industry research firm (see our previous post). Durable goods will continue to lead demand, but opportunities in nondurable goods are also anticipated.

In 2007, durable good manufacturers led global demand for material handling equipment. Over the next five years, material handling growth will be led by a massive worldwide increase in motor vehicle production followed by increased demand for durable consumer goods, particularly electronics. However, rapid scientific and technological advances in nondurable goods, particularly the chemical and food and beverage industries, are also expected to create new demands for material handling products around the world.  

Rapid industrialization in developing countries in Asia, the Pacific, Eastern Europe, Africa, the Mideast and Latin America will increase demand for conventional material handling products such as industrial carts, tugs, trucks, lifts, conveyors, hoists, production line movers, cranes, etc. However, the Freedonia Group expects automated material handling products, including robots and automated guided vehicles (AGV), to post the best gains as industries in the U.S., Western Europe and Japan move to increase automation. Software, systems design, project management and other high-end services to these markets are also expected to post significant increases. Economic and manpower issues will drive the march toward automation and increased productivity in western markets with an emphasis on automated equipment and systems that can be easily integrated into large-scale automated factory and warehouse environments. 

High fuel prices, environmental concerns and worker health and safety issues will also play an increasing roll in shaping material handling demand, particularly in U.S. markets. The current shift away from fuel-intense gas-powered trucks to more energy-efficient battery-operated material handling movers and tugs that was sparked by high fuel prices is expected to accelerate. Escalating medical, insurance and workers’ compensation costs will likewise drive a move toward ergonomically designed material handling equipment and systems.

It’s Buyer Beware When Buying Used Equipment

Economic woes have everyone pinching pennies and looking for bargains. Buying used material handling equipment can seem like a good way to save money, but while there are good bargains to be had, industry watchers warn that there are a lot of unscrupulous people out there trying to cash in on the potential profits. You know you’re getting a high quality product when you buy new material handling equipment from its manufacturer; but if you’re considering buying used equipment, it’s buyer beware.

Business consolidation, poor sales and bankruptcies have forced more material handling equipment onto the used market than usual, so it pays to do your homework and thoroughly investigate both the product and the seller before putting your money down, caution industry experts. Anyone can sell used equipment. No certification is required to sell used equipment, and authorization by original manufacturers is not required. Used equipment shouldn’t be confused with remanufactured equipment that is rebuilt, often by the original manufacturer, and refinished for resale, usually with a manufacturer’s warranty.

The boon market is attracting legitimate sellers who specialize in used material handling equipment sales; but it’s also attracting brokers, auctioneers and folks looking to make a quick buck. These Johnny-come-latelies generally lack any knowledge about the products they are selling or the maintenance they require. Equipment is sold “as is” or sometimes spruced up for resale; but it’s like buying a used car, you don’t know what you’re getting unless you perform a thorough inspection.

Even used, material handling equipment can represent a serious investment. When you buy used, you may get a great bargain; but it’s equally probable that you’ll get an expensive lemon. Follow these tips from Stafford Sterner for Material Handling Management online to ensure that when you buy used material handling equipment, you get what you’re paying for:

  • Deal with reputable, established businesses. In the competitive used equipment market, longevity is a sign of customer satisfaction, reputable business practices, adherence to industry standards, and fair prices. Beware of internet sales unless you can physically verify the business and inventory. A legitimate dealer will carry inventory in stock, be knowledgeable about his stock, allow inspection of equipment before purchase, and provide delivery assurance.

 More tips on Friday

Predicted Material Handling Slowdown to Be Short Lived

The predicted slowdown in the material handling industry is expected to be short lived, said Material Handling Industry of America (MHIA) executives in a news conference last week. After a strong period of growth, contraction and consolidation are expected for 2008 and 2009 before the industry resumes growth in 2010.

“We have had double-digit growth for the last few years,” said MHIA executive VP of business development Hal Vandiver. “But there is a business cycle.” The slowdown is expected to be felt hardest in logistics sectors of the $156 billion material handling industry.

Overall consumption of material handling equipment is expected to contract by 5% over the next two years with new orders decreasing by 5% to 7% and shipments declining by 2% to 4%. High fuel costs are one factor contributing to declining diesel forklift sales. Industry is switching to more energy-efficient and maneuverable electric and battery-operated motorized carts and tugs.

The poor economy is also having an effect on the material handling industry. Many companies are deferring capital equipment purchases until the economy picks up. Fewer system-wide equipment purchases are expected in the next couple of years in favor of individual item and small order solution-specific purchases.

The graying of the American workforce as Baby Boomers aged, coupled with escalating health and insurance costs focused emphasis on ergonomic design in the material handling industry. As the Boomer generation retires, the importance of ergonomic design is expected to increase as the available workforce shrinks. Equipment that can be used safely and efficiently by workers of varying body type, height and strength will be vital to industry success.

Ergonomics Can Help Decrease OSHA Reporting

One way to keep your company out of OSHA’s crosshairs (see our previous post) is to embrace ergonomics. Using ergonomic principles to design equipment, plan workstations and structure task performance has been proven to significantly decrease worker injuries and fatalities. Businesses reap additional benefits in decreased medical, insurance, disability and worker’s compensation costs. Fewer man-hours are lost to injury where ergonomics are practiced.

Lifting, repetitive motion, overextension and overexertion are common injuries in material handling, warehousing and logistics environments.  Injuries to the back, neck, shoulders, hands and wrists can result in serious, long-term disabilities — and the hefty medical and insurance expenses that go with them. Back injury is the most cited injury in worker’s compensation claims. Many of these injuries are preventable when ergonomic equipment and strategies are employed.

Making an investment in ergonomics is making an investment in your workforce. Demonstrating concern in your employees’ health and welfare has a direct and highly positive effect on worker morale and productivity. DJ Products can help you determine your ergonomic needs. Use our handy Ergonomic Load Calculator to estimate the force needed to move loaded carts, castered equipment and wheeled machinery. Our experienced staff can help evaluate your ergonomic needs and recommend ergonomically designed carts and tugs geared to improve the safety of your facility and protect the health of your employees. Your initial investment in ergonomics will be quickly balanced by savings in medical, insurance and disability expenses. Visit our website today for complete information.