You try to run away as fast as you can, aware of the scary apparition chasing you with each breath. You turn to look back, and stumble onto the ground. Paralyzed with fear, you watch as the shape moves closer and closer. Suddenly up close, you can see that there was no way you could escape, as safety issues could not be stopped.

Blumhouse horror movie? Not really. Warehouses can be dangerous places to work in. It is important to understand common warehouse dangers and hazards because they can cause injuries and in extreme cases death, haunting your warehouse for years to come. The US Bureau of Labor Statistics reported an average of 16 fatalities every year in the US warehousing and storage sector and a reported injury and illness rate of 5 out of every 100 warehouse and storage workers. With these ghastly statistics in mind, we review some of the most common warehouse safety bogeymen and offer tips and resources to help you avoid there terror.

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Adjustable workstations make operations like packing, picking, assembly and inspection safer, more comfortable and more productive because they easily let operators work in the ergonomic “golden zone” suitable for their own needs – the same station can be used by someone 6’4″ as someone 5/2″ on multiple shifts, or if the load or work varies in height, like multiple sized boxes or various motors that may be different sizes. These workbenches are adjustable, usually by crank or by powered switch or pushbutton. What might suit you best?

That said, having to utilize a crank to adjust the height is inherently counter to the fundamentals of ergonomics, and it’s slow. To combat this, consider electric adjustable workstations, which provide multiple advantages over their cranking counterparts.

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Ergonomics should be wired into the design of all the processes of a modern industrial operation. Whether that means designing conveyor workstations with ergonomics in mind, utilizing work benches and stations that are adjustable for “right height” operations, adding turntables to rotate product, finding ways to reduce order pickers’ bending and stretching, or designing storage areas so that bending and stretching are minimized, well-designed operations bake ergonomics into their work processes.

One of the common areas you can attack is hand tool use. In many operations, strong younger workers may not complain about using heavy, hand-held tools for 8+ hours a day, but that stress is taking its tolls.

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Providing employees with a comfortable, ergonomic, and efficient workspace is a necessity in any picking, packing, assembly, inspection, quality control, manifesting or other industrial operations. A proper industrial workstation, tailored to the task and employee, goes a long way toward creating a healthier and more productive workspace and environment.

There are dozens of options for workstations, ranging from a simple bench to a more elaborate set up designed with the job in mind. Let’s take a look a few industrial workstations and their unique benefits.

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As your business grows, the flow of materials tends to bog down as demand increases, forced through the same channels and processes. Throughput grinding slowly down is a story as old as warehousing itself.

Frequently the operations that lag behind the rest of the process are in the picking, packing and shipping areas of your facility. What’s difficult is that these inefficiencies evolve over time, where they can almost be hidden from an analytical view. It seems that no matter how many people you throw at the problem they never catch up, and error rates escalate. Often the solution is in simple steps toward organizing your packing areas and putting supplies conveniently at hand.

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Reducing steps and wasted time

How many steps do your floor managers take going back and forth to the computer and print stations in the plant as they do their jobs? How much time does all that walking take over a year’s time? How much more work could be done if computers and printers could go where they do? If you’re managing materials going to and from storage, all that travel time is taking valuable people assets away from what should be their primary function. Read the rest of this entry »

I received a newsletter the other day that really hit home during this busy Christmas season. It was about keeping warehouse order pickers motivated in their work and I thought, “That’s really key during peak seasons when highly stressed workers can get burned out quickly.” So, how do you keep order pickers moving when they’re already under the gun?

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Based on 5 Japanese words that begin with ‘S’, the 5S Philosophy hones in on effective work place organization and standardized work procedures. When correctly implemented, it reduces waste, increases efficiency, and overall work quality. You’ll also have a safer, more effective operation and employees who are more checked in than they were before. It simplifies work flow and helps you find inefficiency.  You may see things like empty flow racks, needless processes, over stocking, redundant operations,  looming maintenance problems, and more.

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It ought to be fairly simple, but specifying the right workbench for your application is something that requires thought and pre-planning if you want to maximize your time and labor. Minor differences in the type of bench can provide critical benefits that add up to major productivity gains over time. Benches aren’t the simple, static equipment many believe. Here are some traits to consider.

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There isn’t enough room at your average industrial workstation. In fact, many order pickers, packers, shippers, and other professionals might tell you that you could have a 10′ long workbench, and they’d still be squeezed for space. In a busy operation, it’s a constant battle between availability of materials and space for doing the actual work. So what’s the solution? A larger workbench top? According to Packmaterials.com (registration required, but a pretty useful resource from Dehnco – we have reprinted the entire piece here, with permission), if there is not enough workstation storage area a bigger table won’t help – and may hurt.

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