As noted in the previous post, inspectors from the Occupational Safety and Health Administration (OSHA) are conducting unscheduled inspections of distribution centers (DCs) and warehouses as directed by its National Emphasis Program (NEP). Among the areas OSHA inspectors are examining is ergonomics. Should an OSHA inspector identify the presence of an ergonomic hazard, the agency may opt to conduct a health inspection of the facility. By prioritizing warehouse ergonomics and implementing equipment that improves ergonomic practices, an operation can ensure OSHA NEP compliance.

Equipment Helps Improve Warehouse Ergonomics

The members of the Ergonomic Assist Systems & Equipment (EASE) Council frequently collaborate to recommend comprehensive solutions to help improve warehouse ergonomics. Among the diverse range of available equipment, some of the most commonly deployed solutions include:

Height-Adjustable Workstations

These work surfaces adjust to match different individuals’ height and posture. This ensures all items needed to do a job are within easy reach, minimizing stretching, bending, or twisting. Workstations allow workers to perform tasks more productively and efficiently by reducing wasted search time and movement.

Rolling Carts

Outfitted with smooth rolling wheels and casters, industrial carts minimize the pushing and pulling forces required to start and stop the load. For optimal warehouse ergonomics, carts should sport adjustable handles, comfortable grips, and wheels constructed to easily navigate the floor surface under a full load.

Motorized Material Transfer Solutions

Although OSHA provides guidance to limit lifting loads to less than 50 pounds, the agency does not offer insight on push or pull forces when moving loads. To help, The Ohio State University Spine Research Institute (SRI) developed an online tool for the Ohio Bureau of Worker’s Compensation (BWC). This free resource provides pushing and pulling guidelines to help operations assess workers’ potential injury risks.

“Motorized material transfer solutions are another option to reduce injuries and prevent excessive lifting, pushing, or pulling forces,” said Ray Erbe, President and Chief Technical Officer at EASE Council member Electro Kinetic Technologies.

“Traditional options used in warehouse and distribution centers include forklifts, motorized pallet jacks, and stackers,” he explained. “More recently, operations are replacing manually powered carts with motorized carts or electric tuggers for transporting single or multiple carts. For moving and lifting loads up to 40,000 pounds there are heavy-duty motorized transfer carts.”

Overhead Lift Assist Devices

Mounted overhead, lift assist devices — including vacuum lifters, intelligent lifting devices, and workstation cranes — dramatically reduce the amount of physical effort needed to lift heavy objects. These ergonomic solutions support loads for positioning, lift unusually shaped objects, and allow a single operator to handle lifts that previously required two staffers.

Lift Tables

To eliminate bending and lifting items from floor level, lift tables raise and lower a load. They keep the work at a convenient height, so the associate does not need to reach down repeatedly. Many of these ergonomic systems integrate a turntable to rotate the work so it’s always in front of the associate.

Portable Ergonomic Conveyors

Used to help associates load or unload floor stacked parcels, powered, self-contained, portable ergonomic conveyors use motorized drive wheels to enter and exit a shipping container or trailer. They feature a powered conveyor belt, operator platform, and a mechanical lift and lower function.

“The operator controls the conveyor, raising or lowering it to the optimal height for placement or removal of the cartons,” said Rob Beightol, Director of Marketing at Gorbel, an EASE Council member.

“That eliminates the need for bending, stretching, reaching, pulling, or otherwise manipulating the carton,” he explained. “Ergonomics improve because the platform is adjustable based on the height and location of the load. Most of the time, the materials simply slide onto the conveyor, thus significantly reducing the strain on the body.”

Proper Lighting

The right combination of ambient, overhead, and task lighting reduces eye strain and improves visibility — both of which improve warehouse ergonomics. Proper lighting also minimizes fatigue and errors, as well as the risk of trips and falls.

Storage Solutions

Storage systems such as carton flow minimize bending, reaching, and lifting. These systems install directly into existing static pallet rack. That, in turn, creates a dynamic storage system that uses gravity to advance items forward. As a result, associates can easily access inventory for order fulfillment while avoiding ergonomic strains caused by reaching, stretching, and straining to pull inventory toward themselves.

Discover More Solutions to Improve Warehouse Ergonomics

Operations seeking more information about how to improve ergonomics in their warehouses or DCs, can turn to the EASE Council. Via its website, the group offers a broad range of free educational resources, such as case studies, videos, and seminars. Additionally, its members are always willing to consult, answer questions, and offer advice on ergonomic best practices and equipment use.