The majority of supply chain and logistics leaders continue to struggle with achieving adequate headcount to meet productivity goals. According to recent industry research, 76% report that their operations are experiencing a shortage of workers; 37% describe that shortage as either “high” or “extreme.” Another 68% report that filling open warehouse positions continues to be hard. Moreover, a lack of labor negatively impacted both peak season performance and customer service for 89% and 88% of respondents, respectively. But there is a way to boost productivity in understaffed operations: ergonomic solutions.

For those who think ergonomic improvements only reduce injury risks, it may come as a surprise to learn that ergonomic solutions also improve productivity.

“These days, labor shortages are ever-present and increasing staffing to be more productive isn’t always an option. Therefore, businesses across the supply chain that need to get more orders out the door have to find ways to increase efficiency with the workforce they have. Ergonomic improvements can help,” said Megan Baker, Director of Marketing at UNEX Manufacturing. UNEX is a member of the Ergonomic Assist Systems & Equipment (EASE) Council.

“There are lots of ergonomic solutions that eliminate unnecessary strain as well as reduce fatigue,” she continued. “They not only prevent injuries, but also improve efficiency and performance when hiring more workers isn’t possible.”

Dynamic Storage Enhances Ergonomics, Productivity

One workflow that always has room for both ergonomic and productivity improvements is picking. It’s frequently the most labor- and cost-intensive First, associates spend as much as 70% of their time traveling between static inventory storage locations to pick items to fill orders. Then, they must stretch, reach, twist, lift, bend, or otherwise physically tax themselves to reach those items.

Instead, said Baker, an operation can cut both travel time and physical strain by replacing static storage systems with dynamic solutions.

“Dynamic storage equipment offers a more ergonomic solution to order or part picking,” she noted. “For example, carton flow tracks play a huge role in ergonomics. Constructed with metal or plastic rollers or skate wheels, they utilize gravity to advance products to the pick face. This eliminates a worker’s need to stretch, reach, or pull items forward, avoiding injury while saving both time and energy.”

Carton flow tracks install directly into existing pallet rack, allowing previously static systems to become dynamic. Some dynamic storage solutions are mobile, allowing them to roll to a new location as needed. Both options support ongoing reconfiguration of product locations, allowing an operation to minimize travel time between the most frequently picked items.

“It’s all about compounding seconds,” Baker added. “Dynamic storage equipment supports order fulfillment based on inventory velocity. By strategically designing storage and picking areas to support faster order selection, an operation can enhance associate productivity. Using dynamic storage to shave seconds off fulfillment time translates into increased pick capacity and higher employee performance — without an increase in headcount.”

Ergonomic Solutions for Lifting Increase Productivity

Other ergonomic solutions that boost the productivity of an existing workforce are lift assist devices. This equipment — including vacuum lifters, intelligent lifting devices, and workstation cranes — allows a single operator to lift and lower heavy objects with minimal effort.

They also enable lifts that previously necessitated two employees to perform in tandem now be safely handled by just one. This doubles productivity while halving staffing requirements, said Grant Welch, National Sales Manager of Handling Systems at EASE Council member Schmalz.

“Lift assist devices also allow a single operator to maintain the same level of productivity throughout a shift,” he added. “When considering overall operator fatigue, look at the total volume of work they’re doing throughout the day. Often, their throughput rate — such as the number of cases handled per hour — slowly diminishes as the day goes on and they get more tired.”

With a lift assist device, however, Welch said those declines disappear. “Because the ergonomic equipment reduces fatigue, they stay fresher as they perform the lifting tasks and the rate holds steady instead of declining,” he explained. “The devices also allow associates of any size, strength, or body type to perform lifting tasks. That makes a workforce much more flexible and lets an operation maximize their labor resources more efficiently instead of adding more staffers.”

Casters and Wheels Reduce Pushing and Pulling Effort

Many operations give their associates carts or pallet jacks to push or pull along picking paths. These mobile ergonomic solutions allow operators to transport more items as they travel through the facility but may not be sporting the optimal wheels or casters. If their construction or materials are not optimized for the loads or facility, they could hamper productivity, noted Rob Jorden, Vice President of Engineering at Blickle Wheels & Casters USA, also an EASE Council member.

“With the right casters and wheels an associate can move a lot more weight with a lot less effort and less fatigue,” he said. “Fortunately, they are a fairly simple thing to change for a fast improvement in productivity.”

Factors that determine the maximum capacity and number of wheels or casters include the total weight of the cart, the weight of the load, and whether the cart will travel inside or outdoors. Additionally, having the right tread material impacts the pushing and pulling forces required to start and stop the cart’s momentum. Powered drive wheels enhance associate productivity even further by allowing them to guide larger, heavier loads effortlessly.

Find More Ergonomic Solutions for Labor-Strapped Operations

The members of the Ergonomic Assist Systems & Equipment (EASE) Council frequently collaborate to help operations improve both ergonomics and productivity. Members recently presented a panel discussion of tips for successful ergonomic equipment installations. The association also offers complimentary educational resources, case studies, videos, and seminars on its website.