Page 50 - OHS, October 2023

TRAINING: MATERIALS HANDLING Rethinking Manual Material Handling in Warehouses Current challenges and future trends impacting manual material handling training, and the strategies warehouse managers can use for a safer, more efficient workplace. BY HOLLY PUPS, CSP, MSP Manual material handling is critical to warehouse operations, but it can be extremely challenging and dangerous for employees. Warehouse managers can implement best practices to improve safety and ef- ficiency and embrace emerging technologies to make manual material handling more efficient and ergonomic. Among the various tasks involved in warehouse management, manual material handling plays a key role in ensuring goods are properly stored, organized and transported within the facil- ity. While automation and technology have brought significant changes to the industry, manual material handling remains essen- tial due to its flexibility, cost-effectiveness and adaptability. Challenges in Manual Material Handling Manual material handling involves workers physically moving goods and materials without the aid of machinery such as fork- lifts. This can include order picking and loading pallets by hand, as well as using pallet jacks and carts to move products. While this process has its advantages, it also presents several challenges that warehouse managers and workers need to be aware of and address: ■ Ergonomic hazards ■ Worker inefficiency and inconsistent performance ■ Safety concerns ■ Labor costs One of the most significant challenges of manual material handling is the risk of physical strain and other ergonomic inju- ries to workers. Repeatedly lifting, carrying, and moving heavy objects can lead to musculoskeletal disorders, back injuries, and other health issues. Manual material handling can be time-consuming and less efficient than to automated processes. Workers may need to cover longer distances and expend more energy to move goods, leading to reduced productivity. It is also important to note that work capabilities from worker-to-worker can vary greatly, leading to differences in employee performance in handling, lifting, and transporting goods. This can result in errors, damaged products, and uneven workloads among workers. Warehouse environments can be hazardous due to factors such as slippery floors, limited visibility, and the presence of powered industrial trucks. Manual material handling increases the risk of accidents, especially when workers are not adequately trained on the hazards in their work areas or when safety proto- cols are not followed. While manual labor can be cost-effective in some cases, it also comes with associated labor costs. These costs include employee wages and overtime, training time, insurance, correcting errors, and potential medical expenses resulting from injuries. 50 Occupational Health & Safety | OCTOBER 2023 www.ohsonline.com Chay_Tee/Shutterstock.com