1 Rochester Institute of Technology Material Handling and Storage.

11Rochester Institute of TechnologyRochester Institute of Technology

Material Handling and StorageMaterial Handling and Storage


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Material Handling and StorageMaterial Handling and Storage


ObjectivesObjectives

Discuss the basics of ergonomics and functions of the Discuss the basics of ergonomics and functions of the spinespine

Describe the various types of order picking systemsDescribe the various types of order picking systems Describe proper lifting techniquesDescribe proper lifting techniques Identify material handling hazards associated with Identify material handling hazards associated with

various warehouse operationsvarious warehouse operations– Transport techniquesTransport techniques– StorageStorage– PackagingPackaging– Work practicesWork practices


Basic Functions of the SpineBasic Functions of the Spine

Supports the body’s weightSupports the body’s weight

Structure for bodyStructure for body

Flexibility to bend and rotateFlexibility to bend and rotate

Maintains natural Maintains natural SS curve for curve for maximum strengthmaximum strength


Proper Lifting TechniquesProper Lifting Techniques

No tripping or slipping No tripping or slipping hazardshazards

Plan rest stopsPlan rest stops

Easiest routeEasiest route

Avoid stairsAvoid stairs

If it is too heavy - GET If it is too heavy - GET HELP!HELP!

XPlan the JobPlan the Job


Proper Lifting Techniques Proper Lifting Techniques (cont’d)(cont’d)

A ddress the itemA ddress the item B end at the kneeB end at the knee

G et a good gripG et a good grip R aise with the legsR aise with the legs


Keep the Load CloseKeep the Load Close

Closer to your spineCloser to your spine

Less force on backLess force on back

10 pound load at arms’ 10 pound load at arms’ length is 100 pounds on length is 100 pounds on the backthe back


Lifting TechniquesLifting Techniques

Diagonal liftDiagonal lift

Power liftPower lift


Pivot…Don’t TwistPivot…Don’t Twist

Pivot your feetPivot your feet

Turn entire bodyTurn entire body


Materials Handling Hazards in Materials Handling Hazards in WarehousesWarehouses

Consist of job features which have a Consist of job features which have a potentially harmful effect on the bodypotentially harmful effect on the body

– Work station layout/environmentWork station layout/environment

– Improper work methodsImproper work methods

– Improper toolsImproper tools

– Job design problemsJob design problems

– Poor housekeepingPoor housekeeping


Transport TechniquesTransport Techniques

Placing boxes on Placing boxes on palletspallets

MaintenanceMaintenance

See: http://www.osha.gov/SLTC/etools/grocerywarehousing/transport_techniques_animation.html


Placing Boxes on PalletsPlacing Boxes on Pallets

Repeated bending at the waist to Repeated bending at the waist to place boxes on the lowest level of place boxes on the lowest level of palletspallets

Heaviest units are placed on the Heaviest units are placed on the bottom layer for stabilitybottom layer for stability

Requires employees to lift the Requires employees to lift the heaviest loads using their worst heaviest loads using their worst body posturesbody postures


SolutionsSolutions Raise height of the bottom level Raise height of the bottom level Provide height-adjustable picking Provide height-adjustable picking

equipmentequipment Educate employees about the hazards of Educate employees about the hazards of

bending while moving heavy loadsbending while moving heavy loads Stack empty pallets on the pallet jack to Stack empty pallets on the pallet jack to

elevate bottom of loadelevate bottom of load Place palletizer on forks of pallet jack to Place palletizer on forks of pallet jack to

keep product at waist heightkeep product at waist height Utilize power equipmentUtilize power equipmentSee: http://www.osha.gov/SLTC/etools/grocerywarehousing/transport_techniques_animation2.html


StorageStorage

Low locationsLow locations High locationsHigh locations Double or triple slotsDouble or triple slots Reaching Reaching Aisle widthAisle width


Low LocationsLow Locations

Pallets are stored in pick bins Pallets are stored in pick bins a few inches from the floora few inches from the floor

Low racking requires Low racking requires employees to bend at waist employees to bend at waist

Is a significant problem since Is a significant problem since the heaviest load is in the heaviest load is in shortest stackshortest stack

Storing pallets in taller slots Storing pallets in taller slots still requires employees to still requires employees to bend at waist bend at waist


SolutionsSolutions

Elevate pallets within slot bin Elevate pallets within slot bin Place empty pallets under Place empty pallets under

load load Raise bottom level of racking Raise bottom level of racking

so loads are at heights where so loads are at heights where bending is not necessary bending is not necessary

Provide a forklift with built-Provide a forklift with built-in vacuum hoistin vacuum hoist


Solutions Solutions (cont’d)(cont’d)

Empty pallets stacked to raise product to waist height

Raised shelving



Vacuum hoist


High LocationsHigh Locations

Reaching above shoulder to Reaching above shoulder to access products on upper access products on upper shelvesshelves

Results in stress to back and Results in stress to back and shoulders shoulders

Requires awkward hand and Requires awkward hand and wrist postureswrist postures

Reaching above Reaching above shoulder heightshoulder height


SolutionsSolutions

Use elevated rack locationsUse elevated rack locations

Provide "Pick Sticks" or Provide "Pick Sticks" or "Bow Peep" hooks "Bow Peep" hooks

“Bow Peep” hook


Multi-slot HazardsMulti-slot HazardsMaximizes shelving space Maximizes shelving space Increases ergonomic Increases ergonomic

stressors stressors Forces workers to bend to Forces workers to bend to

access productaccess productWorkers must reach above Workers must reach above

shoulders to access shoulders to access materials materials

Double slotting

Triple slotting requires elevated reaches to access product


SolutionsSolutions

Provide full slottingProvide full slotting

Use gravity feed flow rack Use gravity feed flow rack for slow moving productfor slow moving product

Full slotting

Gravity fed flow racks


ReachingReaching

Product is often removed Product is often removed from the front of pallets firstfrom the front of pallets first

Leaves remaining product Leaves remaining product in the back of palletsin the back of pallets

Creates additional stress on Creates additional stress on the shoulders and backthe shoulders and back

Reaching to the back of the pallet


SolutionsSolutions

Develop product rotation processDevelop product rotation process Place pallets on turntables Place pallets on turntables Use roller and channel devicesUse roller and channel devices Provide wider slots for heavier Provide wider slots for heavier

productsproducts Train stockers to allow sufficient Train stockers to allow sufficient

space to move pallet during space to move pallet during selectionselection

For optimal access, place product on turntable


Aisle WidthAisle Width

Insufficient access to faster-Insufficient access to faster-moving productmoving product

Creates congestion Creates congestion Forces selectors to stop farther Forces selectors to stop farther

from pick slot and carry from pick slot and carry product longer distances to product longer distances to pallet jackpallet jack

To save trips, selectors may be To save trips, selectors may be tempted to carry multiple tempted to carry multiple parcels at the same time parcels at the same time

Congested aisle


SolutionsSolutions

Increase aisle width of aisles where fast-Increase aisle width of aisles where fast-moving product is locatedmoving product is located

Will allow pallet jacks to get closer and reduce Will allow pallet jacks to get closer and reduce distance loads must be carrieddistance loads must be carried

Stagger the start times at beginning of dayStagger the start times at beginning of dayResults in fewer selectors hitting the same Results in fewer selectors hitting the same

slots at the same timeslots at the same time


Packaging Packaging

Heavy containersHeavy containersInadequate handholdsInadequate handholdsPlastic wrappingPlastic wrappingWooden palletsWooden palletsWrapping palletsWrapping palletsOpening boxesOpening boxes

5-Gallon (40 lbs)


Heavy ContainersHeavy Containers

Boxes are extremely heavy in Boxes are extremely heavy in cold or freezer warehouses cold or freezer warehouses

Weigh as much as 100 lbs.Weigh as much as 100 lbs. Manually lifting places stress on Manually lifting places stress on

employee’s musclesemployee’s muscles Repeated lifting can result in Repeated lifting can result in

back injuries, muscle strains and back injuries, muscle strains and disc injurydisc injury


SolutionsSolutions

Work with suppliers to provide Work with suppliers to provide product in smaller, lighter product in smaller, lighter containerscontainers

Improve access to heaviest itemsImprove access to heaviest items Provide handhold cutouts or Provide handhold cutouts or

handles on all heavy productshandles on all heavy products Work with suppliers to ensure Work with suppliers to ensure

container integrity is adequate container integrity is adequate Load pallets with lighter product Load pallets with lighter product

in center and heavier on outer in center and heavier on outer edges edges

Some suppliers are willing to modify weight of packages



Heavier packages on the outside


Inadequate HandholdsInadequate Handholds

Many packages do not Many packages do not have handles or handle have handles or handle cut-outs cut-outs

Makes heavy cases Makes heavy cases difficult to graspdifficult to grasp

Forces employees to use Forces employees to use awkward postureawkward posture

Boxes without handles are difficult to grasp


SolutionsSolutions

Encourage suppliers to Encourage suppliers to provide product in stable provide product in stable boxes with hand hold cut-boxes with hand hold cut-outs or handles outs or handles

Is especially important for Is especially important for product that is extremely product that is extremely heavyheavy

Examples of handhold devices


Wooden PalletsWooden Pallets

Weigh between 40 and Weigh between 40 and 70 pounds 70 pounds

Lifted several times Lifted several times during work shift during work shift

Repeated lifting causes Repeated lifting causes stress to lower backstress to lower back

Splinters from handling Splinters from handling wood is also a hazard to wood is also a hazard to workerworker

Workers bend to lift pallets several times during a shift


SolutionsSolutions Request lighter, plastic Request lighter, plastic

pallets pallets Easily nest together to reduce Easily nest together to reduce

space of stackingspace of stacking Eliminates splinters and Eliminates splinters and

uneven surfaces uneven surfaces Provide a pallet dispenser to Provide a pallet dispenser to

reduce handling of palletsreduce handling of pallets

Pallets weigh 20 to 30 lbs.

Pallet dispenser


Training New EmployeesTraining New Employees

New employees may not New employees may not recognize ergonomic recognize ergonomic hazards or understand hazards or understand effective techniques used to effective techniques used to minimize these hazardsminimize these hazards


SolutionsSolutions

Provide general ergonomics and work-task specific Provide general ergonomics and work-task specific training at time of orientationtraining at time of orientation

Explain risk factors and proper work techniques to Explain risk factors and proper work techniques to minimize hazardsminimize hazards

Provide video tapes of proper work practice for Provide video tapes of proper work practice for employee reviewemployee review

Retrain injured employees regarding ergonomic risks Retrain injured employees regarding ergonomic risks pertinent to their injuriespertinent to their injuries

Mentor new employees with experienced workers Mentor new employees with experienced workers Explain the medical management systemExplain the medical management system


Summary Summary

Discussed the science of ergonomics and functions of Discussed the science of ergonomics and functions of the spinethe spine

Described the various types of order picking systemsDescribed the various types of order picking systems Described proper lifting techniquesDescribed proper lifting techniques Identified various material handling hazards Identified various material handling hazards

associated with warehouse operationsassociated with warehouse operations– Transport techniquesTransport techniques– StorageStorage– PackagingPackaging– Work practicesWork practices

1 Rochester Institute of Technology Material Handling and Storage.

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Transcript of 1 Rochester Institute of Technology Material Handling and Storage.