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Material Handling Systems: 7 Steps to Safer Factories in 2024

Author : alan aman | Published On : 29 Apr 2024

Material handling, or material handling systems – the movement, storage, control, and protection of materials – is the backbone of any manufacturing operation.  Efficient material handling keeps production lines flowing smoothly, but safety should never be compromised for speed.  Accidents involving material handling equipment are a leading cause of workplace injuries, and with an increasing focus on worker safety, optimizing these processes is crucial.  Let's explore seven key practices to ensure your factory's material handling applications are as safe and efficient as possible in 2024.

 

1. Understanding Material Handling

 

  • Loading and Unloading: 

 

Moving materials from trucks, containers, or pallets into the warehouse and vice versa. This stage requires careful planning to ensure efficient use of dock space and manpower. Utilizing ergonomic equipment like dock levelers and lift tables can minimize strain on workers' backs, while proper training in safe lifting techniques reduces the risk of injuries. Implementing dock scheduling software can further optimize the flow of incoming and outgoing materials.

 

  • Storage and Retrieval: 

 

Organizing and storing materials in a way that facilitates easy access and retrieval. Effective storage strategies maximize warehouse space utilization by considering factors like product size, weight, and access frequency. Clear labeling systems with bin locations and identification codes ensure quick and accurate retrieval of needed items, minimizing wasted time searching for materials. Utilizing vertical space with shelving units or automated storage and retrieval systems (AS/RS) can significantly increase storage capacity.

 

  • Transportation: 

 

Moving materials within the warehouse between different processing zones. Choosing the right equipment, such as forklifts or conveyor belts, for the specific materials and distances involved is crucial for efficient workflow. Maintaining clear pathways and designated traffic areas for both equipment and pedestrians minimizes congestion and potential accidents. Implementing a warehouse management system (WMS) can help optimize transport routes and track materials throughout the warehouse.

 

  • Packing and Shipping: 

 

Preparing finished products for shipment to customers. This involves proper packaging to protect products during transport, considering factors like product fragility and shipping distance. Accurate labeling and documentation are essential to ensure timely and accurate deliveries, including information like customer addresses, contents, and handling instructions. Streamlining packing processes and integrating them with order fulfillment systems can significantly improve efficiency and reduce fulfillment errors.

 

2. Types of Material Handling Systems

 

There are numerous material handling systems available, each suited to specific needs and warehouse layouts. Here's a breakdown of some common types:

 

  • Manual Handling: 

 

This involves using human labor to move materials, often with the help of simple tools like hand trucks and dollies. While cost-effective for small operations, it can be physically demanding and pose safety risks.

 

  • Powered Equipment:  

 

This category includes machinery like forklifts, pallet jacks, and overhead cranes.  Powered equipment significantly improves efficiency and allows for handling heavier loads, but requires proper training and safety protocols.

 

  • Conveyor Systems:  

 

These automated systems use belts, rollers, or chains to continuously transport materials.  They are ideal for high-volume operations and repetitive tasks, maximizing efficiency and minimizing manual handling.

 

  • Automated Storage and Retrieval Systems (AS/RS):  

 

These are computer-controlled systems that utilize cranes and shuttles to store and retrieve materials from high-bay shelving.  AS/RS offers high-density storage and efficient retrieval but requires a significant investment.

 

3. The Need for Material Handling in Your Warehouse

 

An optimized material handling system is crucial for any successful warehouse operation. Here's why:

 

  • Improved Efficiency:  

 

Efficient movement of materials reduces processing times, keeps production lines flowing smoothly, and allows for faster order fulfillment. By minimizing bottlenecks and delays in material movement, companies can expedite production and meet customer demands more quickly.  This can lead to increased customer satisfaction and a competitive advantage in the marketplace.

 

  • Enhanced Safety:  

 

Proper material handling techniques and equipment minimize manual lifting and reduce the risk of workplace injuries.  Investing in ergonomic equipment like lift assists and utilizing proper lifting techniques can significantly decrease musculoskeletal disorders and back injuries among employees.  This not only improves employee well-being but also reduces worker downtime and associated costs.

 

  • Optimized Space Utilization:  

 

Effective storage strategies and space planning maximize available warehouse space. Utilizing vertical space with high-bay shelving or installing automated storage and retrieval systems (AS/RS) can significantly increase storage capacity without expanding the physical footprint of the warehouse. Additionally, proper layout design with designated storage zones and clear aisles optimizes space utilization and facilitates efficient movement of materials.

 

  • Reduced Damage:  

 

Safe handling practices and proper packaging minimize damage to materials during storage and transportation.  Implementing procedures for secure loading and unloading, using appropriate packing materials for different product types, and storing materials in designated areas can significantly reduce product damage.  This not only minimizes financial losses but also ensures customers receive products in pristine condition.

 

  • Cost Savings:  

 

By minimizing labor costs, reducing product damage, and improving overall efficiency, a well-designed material handling system can lead to significant cost savings.  Optimizing material movement reduces labor hours required for handling tasks, while proper packaging minimizes product returns and reworks.  Additionally, efficient workflows can lead to lower energy consumption within the warehouse.  These factors combined contribute to substantial cost reductions over time.

 

4. Matching the Right Caster to the Machine and Load

 

Casters, those small but essential wheels on the bottom of carts and equipment, play a critical role in safe material handling.  Using the wrong caster for the weight or application can lead to instability, tipping, and even equipment failure.  Here are some factors to consider when selecting casters:

 

  • Load Capacity:  Exceeding a caster's weight rating is a recipe for disaster.  Carefully assess the weight of the fully loaded cart or equipment to ensure the casters can handle it.

  • Wheel Material:  Different materials are suited for various environments.  For example, polyurethane casters offer good floor protection and shock absorption, while steel casters are ideal for heavy-duty applications.

  • Tread Design:  Consider the type of floor surface.  Polyamide treads work well on smooth concrete, while pneumatic tires are better suited for uneven or rough surfaces.

  • Swivel vs. Rigid:  Swivel casters allow for greater maneuverability, while rigid casters provide better directional control for heavy loads.

 

5. Conducting Regular Maintenance and Inspection

 

Just like any other piece of equipment, casters and material handling machinery require routine maintenance and inspection to ensure they function safely.  A well-defined preventative maintenance program should include:

 

  • Visual Inspections: Regularly check for signs of wear and tear, such as cracked or broken wheels, loose bearings, or bent forks on lift trucks. 

 

  • Lubrication:  Follow the manufacturer's recommendations for lubricating casters and other moving parts to minimize friction and prevent premature wear.

 

  • Scheduled Maintenance:  Perform more in-depth maintenance tasks as outlined in the equipment manuals. This might involve replacing worn components or performing adjustments.

 

6. Ensuring Timely Replacement of Faulty Casters

 

Even with proper maintenance, casters will eventually wear down and need replacing.  Don't wait for a complete failure that could lead to an accident.  Be proactive and replace casters that show signs of damage, such as excessive wear, cracks, or bends.  Investing in high-quality casters and replacing them promptly is a cost-effective way to prevent costly downtime and potential injuries.

 

7. Investing in Training and Best Practices

 

Employees who handle materials need to be properly trained on safe operating procedures.  This training should cover:

 

  • Selection and Use of Equipment:  Workers should understand how to choose the right equipment for the job, such as the appropriate size and weight capacity of a cart or lift truck.

 

  • Loading and Unloading Techniques:  Proper loading techniques help prevent overloading and ensure stability.  Training should cover load distribution, weight limits, and securement methods.

 

  • Ergonomics:  Material handling tasks can involve lifting, pushing, and pulling.  Educate employees on proper lifting techniques and the importance of using ergonomic principles to prevent musculoskeletal injuries.

 

8. Implementing Safe Work Procedures

 

Establishing clear and concise work procedures for material handling activities is essential.  These procedures should address:

 

  • Traffic Flow:  Define designated pathways for equipment and pedestrians to minimize the risk of collisions.

 

  • Clearance Requirements:  Maintain adequate clearance around machinery and ensure proper stacking heights for materials.

 

  • Housekeeping:  A clean and organized workspace minimizes clutter and tripping hazards.

 

  • Personal Protective Equipment (PPE):  Depending on the materials being handled, employees may require gloves, safety glasses, or steel-toed boots.

 

9. Utilizing Automation and Assistive Technologies

 

Automation and assistive technologies can significantly improve material handling safety and efficiency. Here are some examples:

 

  • Automated Guided Vehicles (AGVs): These self-driving vehicles can transport materials without human intervention, reducing the risk of operator error.

 

  • Lift Assist Devices:  Exoskeletons or mechanical lifting aids can help support workers during heavy lifting tasks, reducing strain and preventing injuries.

 

  • Overhead Cranes and Hoists:  These can safely move heavy or bulky materials, eliminating the need for manual lifting.

 

10. Engaging a Professional Consultation and Engineering Review

 

For complex material handling operations, consider engaging a professional consultant or engineer.  They can help you:

 

  • Workflow Design: Developing efficient workflows that minimize travel distances and manual handling. This could involve strategically placing materials closer to production zones or implementing pick-to-light systems for order fulfillment.

 

  • Ergonomic Considerations: Recommending ergonomic equipment and designing workstations to minimize strain on worker bodies. This may involve lift assist devices for heavy loads or adjustable workstations for packing tasks.

 

  • Safety Implementation: Developing and implementing safety protocols for all material handling activities. This includes training employees on proper lifting techniques, ensuring clear pathways for equipment and pedestrians, and enforcing the use of personal protective equipment (PPE).

 

By implementing these ten practices, you can create a safer and more efficient environment in your factory.  Remember, investing in proper material handling is an investment in your workforce, your productivity, and your bottom line.


 

Wrapping Up

 

Optimizing your material handling systems is not just about moving materials efficiently – it's about creating a safer and more productive work environment for your employees. By following these ten key practices, you can ensure your factory runs smoothly while prioritizing worker safety. 

 

From evaluating your current processes to investing in proper training and equipment, these steps will help you design a customized material handling system that minimizes risk, maximizes efficiency, and keeps your operations running at peak performance. Remember, a well-designed material handling system is an investment in your most valuable asset – your workforce.