DJ Products, Inc.

2009 seemed like the year that would never end. For manufacturers, the bad news just kept on coming. But hope seems to have finally struggled above the horizon. From the depths of last winter’s discontent, 2009 has risen to end on a high note for material handling manufacturers and, indeed, most U.S. manufacturers. Reports indicate that U.S. manufacturing has finally turned the corner, and we can expect 2010 to be a far more productive and more profitable year. Break out the champagne!

The fourth quarter of 2009 saw strong manufacturing growth. With the job market showing signs of stabilization and housing prices beginning to climb toward normal, November brought a cautious increase in consumer spending. Manufacturing benefitted from increased orders for durable goods during the fourth quarter as customers started restocking their shelves. While durable goods orders in November were less than robust, they were twice the amount forecast by economists. Overall, the U.S. economic picture looks hopefully optimistic for the first time since the recession hit.

“We are seeing progress in a number of areas, from increases in consumer spending and business spending to growth in exports,” Brian Bethune, an economist at IHS Global Economics told the Associated Press last week. “It all adds up to a recovery that is gaining some momentum.”

Bethune and other economists are predicting a 4% annual rate of economic growth (as measured by gross domestic product) for the final quarter of 2009. In addition to durable goods, particularly a growing increase in high ticket items, industrial growth into the new year is expected to come from increased equipment and software purchases. Ergonomic material handling equipment sales are expected to increase as manufacturers and business owners seek out ways to increase worker productivity and decrease healthcare costs. Expected new regulatory requirements aimed at protecting worker health and safety are also expected to drive up sales of ergonomic carts and tugs.

Ford is using Hollywood’s latest special effects gimmick to help design its cars and make them more ergonomic and driver friendly. You may have heard of motion-capture technology where a person’s body is hooked up to a slew of sensors that record individual muscle movements. It’s the revolutionary technology behind Hollywood director James Cameron’s sleek blue beings in the holiday movie hit Avatar. Ford Motor Co. has started using the same motion-capture technology to tweak the ergonomic design of its cars.

Since the early 1900s time-motion studies of ergonomics pioneers Frank and Lillian Gilbreth to movie-maker Cameron’s impressive high-tech sensors, industrial designers have been studying how workers move their bodies to accomplish different work tasks in an effort to create more efficient designs. Greater productivity may have been the early goal, but concern for worker health and safety has become an equally motivating challenge, one that gave birth to the field of ergonomics.

“Just like in the movies, we hook people up with sensors to understand exactly how they move when they are interacting with their vehicles,” Gary Strumolo, Ford manager of research and engineering, told Motor Trend magazine in a recent online article (click here to read the Motor Trend article and see pictures of the process). “Once we have all that motion captured, we create virtual humans that we can use to run thousands of tests that help us understand how people of all sizes and shapes interact with all kinds of vehicle designs. It’s an incredibly efficient way of engineering tomorrow’s vehicles.”

We may not have lithe blue aliens darting around our manufacturing plant, but DJ Products has long been a leader in the design and manufacture of ergonomic material handling carts and tugs. Long before James Cameron and Ford started sticking wired sensor pads on test subjects, DJ Products was investigating and studying how the body moved and applying it to material handling design. Nice to see the rest of the world starting to catch up!

In this space we’ve often extolled the value of ergonomics and ergonomic equipment. Ergonomically-designed material handling equipment like DJ Products’ CartCaddy motorized carts and tugs offer multiple benefits in the workplace, including:

• Reducing worker injuries and ensuring a safe work environment
• Improving worker morale by decreasing physical stress and strain during task performance
• Decreasing medical, insurance and worker’s compensation costs
• Decreasing time-lost costs due to worker injury and recovery/rehabilitation
• Increasing productivity, efficiency and profitability

But as Anne Kramer, CEO and President of Ergo Works, Inc., pointed out in a recent article posted on DiversityBusiness.com, ergonomics also opens the workplace to a more diverse workforce by improving accessibility.

Ergonomics is the science of fitting the task to the worker, rather than forcing the worker to contort his body to perform the task. Ergonomic design recognizes that workers come in all sizes of varying physical ability. Recognizing the great diversity among workers, ergonomic design allows equipment to be positioned and used by a maximum number of workers. 

Ergonomic equipment is designed to minimize the overexertion or cumulative trauma of manual lifting, pushing, pulling, stretching and other repetitive tasks that can injure soft muscle tissues. Kramer notes that back and shoulder injuries account for one-third of all missed work days. When the burden of a task is assumed by the equipment instead of the worker’s back, the need for inappropriate exertion is eliminated and the risk of injury is reduced. Ergonomics allows a more diverse group of workers to perform the same task or use the same piece of equipment, keeping injury rates low and productivity high. Use of ergonomic equipment allows employers to satisfy their legal responsibility to accommodate workers, maximizes use of their workforce and reflects a commitment to diversity in the workplace.