ploy | Warehousing Insights | Material Handling Systems - Part 2
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Why Warehouse Employees Ignore Safe Lifting Advice – and How to Help Them

December 5, 2010
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lifting boxes and cartons correctly

The most common advice that ergonomics experts, OSHA, and other researchers provide to people in warehousing or other jobs that require manual lifting is that you should always bend your knees and lift that way, rather than bend at the waist to pick something up. Repetitive stress on the lower back is staggering: 20% of workplace injuries are related to lower back issues. Lifting right is essential to employee safety, and also to preventing Worker Compensation claims.

Even when you train employees to lift right – and we know that not everyone does – they frequently ignore the advice. Why?

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Posted in Safety & Ergonomics|

Evaluation: Pallet Rack Storage Density, Access, Safety and Costs

April 24, 2025
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High bay selective rack pallet storage.

Just how many pallets can you store in a 100′ x 100′ area? It can range from not that many–X with selective racks that let you pick or place any pallet at any time–or “Y” using incredibly dense, using pallet flow or drive-in systems that restrict how and when you can access pallets. The balance between storage density and selectivity is always critical, but there are other factors in play: cost, efficiency and safety.

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Posted in Pallet & Warehouse Racks|

2025 Warehousing Survey

April 15, 2025
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warehouse workers reviewing production flow

It started with a simple question: What’s your biggest operational challenge?

We didn’t expect leaders in manufacturing, warehousing, and distribution to respond with such clarity, but they did. And what we heard wasn’t vague. It was precise, urgent, and reflective of a sector that’s evolving in real time.

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Posted in Industry Insights|

An Ergonomic Labor Strategy

March 4, 2025
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worker in hard hat pushing box

As we’ve discussed previously, labor is hard to find these days – and it will get harder every year. Cultivating your labor pool eases the need (and high costs) of hiring, training and retaining workers. One of the best ways to do this is to optimize as much as possible for ergonomics.

As the saying goes, what you appreciate appreciates.

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Posted in Safety & Ergonomics|

2025 Industrial Trends: What to Expect

February 25, 2025
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2025 Warehousing Outlook

As we mentioned last month, you can expect increases in 2025 shipping costs and fees, particularly in the heavy package sector. What else can you expect in 2025 in the manufacturing, warehousing and distribution spaces?

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Posted in Industry Insights|

Automation and Space: Conveyor Layouts

February 4, 2025
by

Conveyor system extends overhead, above a busy shipping area to conserve floor space.

Above: Belt conveyors hang from the ceiling of a busy e-commerce distribution center, feeding shipping operations from a pick module while leaving the space below for traffic and shipping activities.

Conveyor systems transform picking, transport, assembly, and more, but occupy space in fixed positions. Tight layouts, low ceilings, facility structures and equipment compromise and compete for that square footage.   Don’t worry, though—there are creative ways to work circumvent those limitations–and in some cases make them strengths.

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Posted in Conveyor Optimization|

Package Shipping Fee Increases: How to Cope with Surcharges

January 28, 2025
by

Morning coffee with Cisco-Eagle photo

write an introduction for this article

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Posted in Industry Insights|

OSHA’s Top Violations for 2024

January 23, 2025
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OSHA Top 10 Violations 2024

Ensuring workplace safety is an ongoing challenge, especially in fast-paced manufacturing, warehousing, and material handling operations. Every year, the Occupational Safety and Health Administration (OSHA) publishes its list of the most frequently cited workplace safety violations, a snapshot of the most pressing hazards that can lead to injuries and serious fines.

While the list results don’t have many changes from year to year, it’s important to review annually. Comparing your safety processes and training to what’s included can help to create a more robust system that can save lives and protect what matters.

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Posted in Safety & Ergonomics|

Loading Docks, Security and Truck Drivers

January 14, 2025
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Truck drivers at the receiving docks of a busy warehouse

Truck drivers often need to enter warehouses when they deliver or pick up shipments. When they do, many warehouses have installed secure driver cages that let the driver into the facility, but not into the building at large. This can seem “driver-unfriendly” because they contain the driver. However, there are good reasons to install them while ensuring drivers have a good experience at your facility.

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Posted in Docks & Shipping|

Double-Post Pallet Rack Systems: When, Why and How

January 7, 2025
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Pallet rack system with two posts used for each rack bay

Most pallet rack systems are installed with a starter-adder design, which shares a common rack upright between consecutive storage bays. The alternative is a double-post rack system, where each bay has two independent uprights. Most of the time, starter-adder is used because it’s more economical and uses space more efficiently.

Given that it’s costlier and uses more space, why–and where–would you use a double-post design?

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Posted in Pallet & Warehouse Racks|

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