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Home / Article / Material handling

Material handling

Material Handling Safety - Techniques, Guidelines & Ergonomics

Key Takeaways

  • Materials handling is the art and science of moving, packing and controlling materials in a system, with a focus on safety, efficiency and minimizing waste. By using appropriate material handling methods organizations can both reduce risks and increase productivity.
  • Choosing the right material handling equipment, such as forklifts, conveyor belts, or hand trucks, is key to meeting specific operational needs. By keeping up with regular maintenance, you can rest assured that your equipment will be running smoothly and safely.
  • Safe lifting practices, such as maintaining proper posture, stable footing, and planning lifts ahead of time, are crucial to preventing workplace injuries. Training employees on these techniques should be a priority.
  • A focus on ergonomics can help lessen physical strain, create a more comfortable workforce, and increase productivity. Investing in ergonomic tools and workspace design can help make processes more efficient.
  • Keeping clean and clutter-free workspaces with proper lighting and room for movement prevents injuries and keeps operations flowing efficiently. Routine safety inspections and training for employees are critical.
  • By practicing good material handling, operators can save costs, improve efficiency, and reduce waste. Businesses need to focus on investing in training along with equipment and continuously evaluating position processes to maximize efficiency.

Additionally, material handling is an integral part of creating greater efficiency and safety in the workplace across many industries. It includes the movement, storage, and control of materials and products during manufacturing, distribution, or storage operations.

Whether in warehouses or on construction sites, efficient material handling means less downtime, improved organization, and increased workflow productivity. Prioritizing the right material handling equipment, including forklifts, conveyors and pallets protects inventory from costly damage.

In addition to increasing efficiency, it lessens the physical burden on workers, simplifying their tasks. Pairing today's technology, such as automated storage and retrieval systems, can maximize productivity and accuracy even more so.

Whether in logistics, retail, or manufacturing, material handling provides tangible solutions that increase productivity and help address ever-increasing consumer demands. By learning about its importance, companies can begin to build safer, more productive workplaces.

What is Material Handling?

Material handling is the art and science of the movement, storage, protection and control of materials, goods and products throughout the manufacturing and distribution process. It's not a trivial matter, it's an important function that takes place every day in warehouses, factories, and distribution centers across the nation.

Material handling is key to ensuring that raw materials flow productively in the course of production. It further ensures that finished goods arrive safely at their end locations. Forklifts transport pallets quickly and easily throughout the warehouse. At the same time, conveyor belts allow mass production on the manufacturing plant floor.

Great care in storage and protection must be taken during material handling to prevent damage and protect product quality. Without proper oversight, mismanagement can cause inventory loss, delays, and even workplace injuries. Lifting loads over the safe weight limit of 23 kilograms is detrimental to a worker's back.

Moreover, chaotic storage increases the likelihood of injury. Over 650,000 Americans work as material handling operators. They bring in an average of R603,000 annually, further ensuring this is a crucial operator in the workforce.

The move from manual to automated handling methods has been one of the biggest improvements in terms of safety. Technologies like autonomous mobile robots navigate facilities with precision, reducing injuries like strains and sprains.

Bad material handling breeds waste, inefficiency, and increased costs, so effective systems are critical and should be of primary importance.

Types of Material Handling Equipment

Material handling equipment is a critical component of virtually every industry, helping ensure the timely transport, storage, and organization of goods. Here are the major types and what they do.

Forklifts, pallet jacks, walkie stackers, and cranes are essential types of material handling equipment. With the ability to lift loads up to 5,000 pounds to heights of 10-15 feet, forklifts are perfect for warehouses. Walkie stackers and pallet jacks are great at moving lighter loads. Actually, walkie stackers can easily lift between 2,000 and 4,000 lbs!

Cranes handle very heavy loads in confined areas or when flow is low enough to warrant low flow volume. Conveyor belts are great for horizontal transportation of materials in a facility, reducing the number of steps in an operation.

Physical stress is alleviated with manipulators, as operators are responsible for lifting just 1% of the load's weight. These tools increase capacity, efficiency, accuracy and safety in material handling applications. Equipment such as pallets and skids group products into larger, safer, more manageable loads to move, lessening the chance of falls and injuries.

Racks, shelves, and bins represent a fundamental, but important, grouping. Better storage reduces the risk of damage to materials while utilizing space more efficiently.

Human-Powered Moving Equipment

Carts and hand trucks are widely used for lighter loads and in restricted work spaces. They allow you to lift heavy loads efficiently and safely, but you need the right training to prevent injuries associated with manual lifting.

As with any such tool, overuse can lead to potential health hazards, making proper safety practices and ergonomic designs a key component.

Automated Material Handling Equipment

Automation—be it conveyor belts or robotic arms—reduces labor costs and increases workflow efficiency. Integrating these systems into current operations requires foresight and planning, as well as training for workers so they can adapt to a new process seamlessly.

Storage and Handling Equipment

Storage solutions like racks, shelves, and bins store materials in an orderly and secure manner. Proper storage lowers the risk of damage and increases efficiency within your warehouse.

Pairing material handling equipment with inventory management software takes tracking a step further and helps optimize operations.

Key Principles of Safe Lifting

Assessing the Weight of Objects

You should know the weight of any object you lift before picking it up. Heavy items should be weighed using credible means, such as industrial scales, to eliminate estimating. For instance, a box might seem like an okay weight until the moment you pick it up and find out it's much more than you thought.

Just as critical is knowing how that weight is distributed. Uneven loads are more likely to shift while being lifted, which can cause them to become more difficult to carry. Think about lifting a long steel rebar; the weight would be easy to lift, but the length will be a factor of imbalance.

By sharing this information with your entire team, you can make sure everyone is prepared, minimizing risks even more.

Evaluating the Characteristics of Materials

The size, shape, and material of what you are lifting impact how you approach lifting it. Large or bulky items, such as furniture, might require disassembly to fit through doorways or hallways. Cumbersome or fragile materials, like glass panels, need to be handled with even more caution to avoid cracking or breaking.

Appropriate labeling is key, as it indicates to workers that special handling requirements are necessary. An example would be that a “Fragile” sticker indicates the item needs to be handled gently, and a “Heavy” sticker indicates lifting could cause injury.

Understanding Proper Body Mechanics

Proper lifting position begins with bending at the knees and maintaining a neutral spine. Tighten your core abdominal muscles and keep the item as close to your body as possible. Don't twist when carrying and grip the load firmly using the power grip to stabilize the load.

Routine training makes these habits second nature, preventing back injuries before they happen.

Safe Lifting Techniques

1. Plan the Lift in Advance

Taking time to plan is essential to safe lifting. Begin by looking around your environment for hazards such as wet floors, cluttered areas, or not having a clear path. An unimpeded route for moving the load is important, so remove any barriers in advance.

Planning and visualizing your movements first makes it easier to avoid supporting dangerous positions or potential collisions. If your lift requires teamwork, make sure everyone is on the same page about the lifting plan. Ensure all stakeholders have buy-in and are on the same page.

This step doesn't just create greater efficiency—it helps avoid accidents too.

2. Use Proper Posture While Lifting

Keeping a neutral spine and shoulder alignment goes a long way in preventing injury. Bend at the knees and use the strength of your legs, not your back. Modify your technique depending on the load's size and shape, and don't bend over or twist when you lift.

Regular training and reminders on good posture can help make these behaviors second nature.

3. Maintain a Stable Foot Position

A wider, more stable base prevents falls and improves safety. Keep your feet about shoulder-width apart to ensure weight is evenly distributed. Wear shoes that are closed toe and have non-slip soles for support.

Maintaining the correct position of your feet on the pedals will give you greater control of your vehicle and help prevent accidents.

4. Hold the Load Close to Your Body

Holding the load close helps protect your back and arms from strain. Centering the weight helps maintain balance, particularly for items that are irregularly shaped or bulky.

A good grip with your entire hand provides more control and minimizes the chances of dropping the item.

5. Avoid Twisting or Sudden Movements

These twisting or jerking motions lead to permanent injuries. Turn by pivoting your feet, not by twisting your upper body. Avoid lifting or moving quickly, as quick movements can cause you to lose your balance or run into something.

Being aware of your surroundings will help prevent accidents while in transport.

6. Use Tools or Assistance for Heavy Loads

When lifting heavy objects, the use of hoists, dollies, or trolleys can limit physical overexertion. If loads are greater than 50 pounds, get help from at least two other people to help share the weight.

Teaching training techniques on how to use these tools properly makes sure they're used effectively and safely. Working with a coworker prevents consecutive heavy lifts, lowering fatigue and injury risk.

Key Techniques for Safe Lifting

  • Keep the load close to your body
  • Use your legs for strength, not your back
  • Avoid twisting or bending over
  • Ensure a stable foot position with proper footwear
  • Use tools or ask for help with heavy loads

Back injuries accounted for 38.5% of all work-related musculoskeletal disorders in 2016. Regular breaks and listening to our bodies when we feel tired can eliminate the chance of overexertion, but good lifting practices are still important to our lifelong health.

Importance of Ergonomics in Handling

Reducing Physical Strain on Workers

Ergonomics plays a key role in reducing the risk of physical strain on workers while performing material handling activities. It's not that poor practices don't cause injuries. Yet as per a 2001 report from the Bureau of Labor Statistics, shoulder and back trauma comprise over 36% of lost workdays.

Protect the back by lifting heavy loads with an erect posture. If the load is more than 50 pounds (approximately 22 kilograms), get one or more people to assist to reduce exposure to hazards. Regular breaks and job rotation help by preventing fatigue from repetitive motion.

Workplace training sessions on ergonomic practices help make sure workers know the safest ways to handle products, creating a culture of safety. Collecting employee feedback can identify the most pressing challenges, allowing for focused improvements that make a real difference.

Improving Workplace Comfort and Safety

This is because comfortable and safe workplaces lead to happier employees and fewer accidents. Having an organized workspace can help cut down on clutter and the risk of tripping or falling.

Having adequate lighting, particularly in lowly lit spaces, increases visibility and lessens eye fatigue, making tasks more precise and lessening the risk of accidents. Ergonomic furniture and tools, such as adjustable desk chairs or anti-fatigue mats, promote comfort in workers.

Manufacturers such as Linde and Palamatic offer industrial vacuum lifters that help alleviate heavy lifting tasks. For us, their solutions increase workplace efficiency along with safety.

Enhancing Productivity Through Ergonomic Design

Ergonomics enhances productivity by making processes more efficient and minimizing wasted motion. Smart workspace designs that maximize workflow paired with ergonomic tools get the job done faster and more accurately.

Regular audits help to identify areas where ergonomic upgrades are needed, making sure the work environment is always improving.

Environmental Factors in Material Handling

In short, material handling isn't simply moving something from point A to point B. It aims to develop the safest, most efficient, and most environmentally sustainable surface transportation system. Evaluating environmental factors is imperative in this area, as they play a direct role in influencing both productivity and safety.

For instance, warehouses typically consume a large amount of energy for illuminating, powering equipment, and other operations.

Saving Energy

Transitioning from internal combustion forklifts to electric-powered models is an energy saver. Additionally, it cuts out harmful emissions—particularly when deployed with lithium-ion batteries.

This transition reduces both environmental impacts and long-term operational costs.

Identifying Hazards in the Workplace

Systematic regular inspections are the most effective way to identify and correct workplace hazards. Things like slippery ground, cluttered workspaces, and lack of visibility are all red flags.

Safety audits are a great way to identify these dangers, and training is crucial to ensure employees know how to identify and eliminate hazards properly.

A proactive, safety-first approach creates a culture of safety where workers feel comfortable and are empowered to identify potential issues and address them quickly.

Ensuring Adequate Lighting and Space

Good quality natural or artificial light improves visibility, lowering the risk of accidents with material handling equipment. LED lights, even with a higher initial investment, last longer and reduce energy consumption by up to 70%.

Proper space promotes a better workflow and less chance of collision. Complementing this with bright signage can go a long way to ease navigation through storage areas.

Maintaining Clean and Organized Work Areas

Tidy work environments not only foster productivity but contribute to a safer workplace. Frequent cleaning routines eliminate the buildup of materials, and clearly labeled and attended storage locations help to prevent workplace clutter.

Employees who value their workspaces play a role in achieving a safer, more productive workplace.

Benefits of Effective Material Handling Practices

Preventing Workplace Injuries and Accidents

No matter the material handling equipment, preventing injuries begins with education. It's important that employees are aware of how to operate equipment safely and how to correctly handle materials. By investing in effective tools, such as forklifts or conveyor systems, physical strain is minimized and risk of injury is decreased.

Safety procedures, such as wearing protective equipment and taking predetermined paths, are crucial. That's because proactive safety measures are almost always more effective. Having a robust equipment maintenance program that includes regular inspections helps catch hazards before they become accidents.

Keeping safety policies under constant review will ensure they remain effective. When you foster a culture of open communication, workers can feel free to raise concerns or questions, making every workplace a safer space.

Enhancing Efficiency and Productivity

More efficient workflow means more time to focus on the important stuff. Automated systems like AS/RS increase the speed at which goods are processed while reducing the physical labor required to process them. Technology such as barcoding provides real-time inventory tracking, which helps improve efficiency.

When employees are trained properly, they get the job done right, the first time, reducing mistakes. Continuous improvement always should be the goal. By analyzing workflows and determining places where there are bottlenecks, organizations work to streamline processes.

Better equipment means less downtime and greater production. Taken together, these strategies help improve productivity throughout operations.

Reducing Operational Costs and Waste

Inefficient handling increases costs. Automation cuts labor costs by 20 to 30 percent, and optimized storage helps to keep overstock at bay. Equipment might look expensive upfront but it pays dividends by saving you space and helping your cash flow.

Data analytics plays a role in identifying those inefficiencies, making it easier to make best decisions. Consistent review of strategy will ensure that good practices become sustainable ones, minimizing waste and safeguarding profits in the long run.

Conclusion

It means proper receiving, storage, pick and pack procedures. It increases efficiency and safety, which minimizes risks and helps create a safer workplace. From operating the proper material handling equipment, to using proper lifting techniques, to being mindful of ergonomics – every action counts. Simple solutions, such as redesigning the workflow within a workspace or educating employees, make a substantial difference.

When you prioritize safety and efficiency, you don't just keep your team safe — you keep your operation moving. This new approach saves time and significantly reduces costs, while establishing a more stable workflow.

Look in-depth at your existing procedures, and identify opportunities to improve. Even the most minor changes can make a long-term difference. Download this material handling guide and start planning today to see how improved material handling solutions can really improve safety and productivity in your workplace.

Frequently Asked Questions

What is material handling?

Material handling is the movement, storage, control, and protection of goods and materials during manufacturing, distribution, consumption, and disposal. It ensures effective and safe operations in logistics and supply chain activities.

What are the types of material handling equipment?

Referred to as movement equipment, material handling equipment consists of conveyors, forklifts, pallet jacks, cranes, as well as storage equipment such as racks and bins. These are the tools that allow us to move and store materials efficiently in warehouses and industrial settings.

Why are safe lifting techniques important?

Proper safe lifting techniques help prevent injuries such as back strain and muscle sprains. Safe lifting practices prevent accidents in the workplace, create increased productivity, and ensure the health and safety of your employees.

How does ergonomics improve material handling?

By designing tools, equipment, and workflows that take into consideration the needs of workers, ergonomics reduces the physical strain on workers. It reduces worker fatigue, reduces workplace injuries, and increases employee productivity, resulting in a more efficient and safer workplace.

What are the benefits of effective material handling practices?

Not only does effective material handling help avoid workplace injuries, it's more efficient, costs less and overall increases productivity. It creates a more hassle-free movement of goods and materials that helps employees and businesses flourish.

How do environmental factors affect material handling?

Environmental conditions such as temperature, humidity, and lighting significantly affect material handling workplaces. With the right planning, you can keep your crew safe, protect your materials, and stay efficient even when the weather doesn't cooperate.

What are the key principles of safe lifting?

Four key principles are evaluating the load, adopting the right posture, lifting with your legs and avoiding twisting movements. These measures prevent serious worker injuries and help employers develop safe material handling procedures.