Author: christopher Harper

Ergonomic Design Reduces Equipment Injury Risk

In our last post, we discussed the results of a three-year study of musculoskeletal injury risk factors in the trucking industry. While that study focused on long-haul truckers who are forced to maintain the same postures for hours at a time and the toll such limited activity takes on the body, the study provides an instructive lesson for any business owner who uses material handling equipment to move materials and products in the workplace. Any time workers spend long periods of time performing similar tasks, any time workers repeat the same physical movements during their shift, any time workers must adapt their bodies to “fit” the equipment they operate, any time workers must use their own body muscles to move or maneuver materials, the risk of sustaining damaging musculoskeletal injuries increases significantly. Ergonomics is the solution.

The recent study by Atlas Ergonomics reported in EHS Today online evaluated musculoskeletal injury risk factors for commercial truckers by demographics, height, weight, age and gender. Risk factors significantly increased whenever drivers had to stretch or contort their bodies to reach and operate controls. Injuries also increased with the length of time uncomfortable positions had to be maintained. Atlas found that making ergonomic improvements to truck cab designs, control placement and operator actions, could significantly reduce the risk of musculoskeletal injuries across all driver populations.

Atlas President James Lansman told EHS Today, “Fortunately, as our historical data and work in transportation have shown, driver risk can be measurably reduced through simple, low-cost adjustments to the cab and the drivers’ routines. The data show that sound ergonomics can have a direct, significant impact on trucking companies’ financial performance — which executives may find particularly encouraging in this difficult economy.”

DJ Products ergonomically-designed material handling equipment provides the same benefits to businesses that utilize material handling equipment to move materials, equipment and products in the workplace. Our motorized carts and battery-powered cart movers are engineered to take the burden off workers’ bodies and allow materials and equipment to be transported and maneuvered without musculoskeletal strain or injury. DJ Products’ ergonomically-designed material handling equipment allows equipment to be adjusted to optimal height for use by workers of any size, age or physical ability, ensuring maximum production during every shift.

Next time: Benefits of ergonomic design

Material Handling Equipment Choices Make the Difference in Safety and Productivity

Effective material handling — and material these days can be anything from stone to steel — translates to efficient completion of the project, perhaps with performance bonuses attached. But inefficient material handling can slow down job progress, cause duplication of effort, detract from efficiency, and may even lead to accidents and injuries.

Most contractors think of a material handler as a variable-reach telescoping boom forklift. These machines, usually seen at many building construction sites, feature a telescoping boom and typically include forks for easy handling of materials such as block, mortar, sheetrock, and plywood. But they can also be fitted with coupler systems for many different types of attachments that can increase versatility on the job. Whether unloading materials from trucks or delivering them over the phases of a project, telehandlers continue to be what most people think of when the subject is equipment for material handling.

But there’s more to material handling than telehandlers. For example, cranes are another class of material handling equipment. When heavy lifting is needed, a crane is usually preferred. That is why cranes take on most material handling for major projects such as bridges, where the loads can be heavy, or on high-rise buildings, where telehandlers cannot offer a tall enough reach. Cranes also assist on many sites with unloading trucks — an important part of material handling on just about any job.

But whatever machinery is used for material handling, the most important element remains the operator. Safety is paramount. Remember, material handlers handle material — and to do so safely, the load must be under their complete control at all times. This necessity drives not only load handling and maneuverability but also affects cab design and control positioning. For example, cabs on many modern material handlers are being designed with more glass to give the operator more visibility.

Designing machines that an experienced operator can safely and effectively control certainly are a key consideration, particularly in these days of scarce manpower, when selecting material handling machinery. But without question, an effective merging of operator and machine will increase safety which maximizes productivity — and that always mean a better bottom line.

Recognizing Opportunity in the Marketplace

The economic slow down has certainly presented its challenges, but it’s also presented business owners with a unique opportunity to reassess both their products and the marketplace. Savvy business owners are making good use of down time necessitated by decreased sales and lowered production to shift more resources into market analysis and research and development. It’s a move geared to discover new opportunities in the marketplace and position businesses to compete more strongly as the market recovers.

While it’s stripped to its bare bones, this is an excellent time to focus on the most essential aspects that drive the market in which you compete. And that’s a smart thing to do periodically, but a chore that is easily put off in the hustle and bustle of meeting customer demands and production schedules when the market is thriving and you’re focused on sales. While the economy is slow, you have time to focus on the essential needs of your customers and that can sharpen your insight into the primary forces that ultimately drive your business. The process provides opportunities to discover new and innovative ways to meet those needs.

In every industry there are core needs that drive business. Applying new technology to address those core needs allows you to offer customers a competitive advantage they can’t get from your competitors. A down market allows you the time to research and develop new technologies and applications that will allow your business to stand out from the competition and offer your customers a way to compete more effectively in their own markets. This is also a time to explore new applications for your products that can open new, untapped markets for your products. The creation of multiple revenue streams through diversification minimizes your business risk when the economy tightens up.

DJ Products’ own story provides an excellent example of how analysis of core market needs can lead to the innovative application of technology to create unique new products. Early on DJ Products saw a need for the development of ergonomically-designed material handling equipment. You have only to look at U.S. Bureau of Labor and Workman’s Compensation statistics to recognize the high cost in both production losses and worker medical expenses caused by musculoskeletal injuries from moving equipment and products in the workplace. Applying ergonomic design techniques to material handling equipment provided a unique solution that successfully resolved these issues, providing practical and affordable solutions to a core industry need. DJ Products’ continued dedication to developing unique solutions to meet customers’ needs has made us an innovative leader in the material handling industry.

Key Elements to Seek in Material Handling Equipment

No matter what business or industry you are in, you need to move materials. Whether you’re dealing with raw materials, parts and supplies or a finished product, you need equipment that can move materials from point A to point B. When choosing material handling equipment, there are a number of key features to consider that will maximize your investment and the use you get from your equipment.

  • Flexibility. The more jobs a piece of equipment can perform, the more workers who can easily utilize it, the greater the number of environments in which it can operate, the more useful it is to you and the greater its value. DJ Products’ carts and movers are designed for maximum versatility. Ergonomic design ensures that workers of every size, age and physical ability can operate our equipment safely and without effort. DJ Products’ electric lift option and customized attachment eliminate the need to fabricate multiple attachments for each cart or piece of equipment. The mover arm on our tugs quickly attaches to any cart or piece of equipment and can even accommodate loads that overflow the cart bed.
  • Safety. Safety in the workplace is paramount. All of DJ Products’ equipment is ergonomically designed to protect the health and safety of workers. Ergonomic design decreases worker injury and is proven to significantly cut medical/disability costs. Our twist grip protects against carpal tunnel syndrome while allowing forward and reverse movement. Designed as walk- or ride-behind units, DJ Products’ equipment provides maximum operator control of the vehicle with safe lines-of-sight.
  • Productivity. Material handling equipment that promotes comfortable and efficient use increases productivity. Workers accomplish more per shift with less effort, meeting and exceeding production goals. Ergonomic design makes DJ Products’ equipment easy and comfortable to use, decreasing worker fatigue while increasing productivity.
  • Comfort. Operator comfort decreases fatigue and the stretch breaks that accompany tired muscles. The ergonomic design of DJ Products’ equipment maximizes worker comfort, eliminating the need for unnecessary breaks and maximizing production.
  • Service and reliability. DJ Products builds its carts and tugs to maximize uptime. Our electric and battery-operated equipment is cable of operating for two full shifts before recharging.

DJ Products makes a full range of ergonomically-designed powered carts in a wide range of shapes and sizes to handle any application. From compact, light-weight carts that can be easily and safely maneuvered down a crowded hospital corridor to heavy-duty carts capable of pulling more than 50,000 pounds across a production floor or down an assembly line, DJ Products has a material handling solution to fit your needs. Contact one of our ergonomic sales engineers today to see what we can do for you.

Motorized Dump Hopper Solves Waste Hauling Problems

Need a smart, safe, easy way to haul trash, waste and debris around your facility? DJ Products’ motorized dump hopper is the perfect solution. This heavy-duty, battery-powered tilt truck is designed to haul 2,000 pounds of trash or debris. Eliminating the manual pushing and pulling of heavy trash carts that can cause debilitating and costly musculoskeletal injuries in your work force, DJ Products’ motorized dump hopper is ergonomically designed to allow a single operator to effortlessly transport and relocate trash and waste materials. Easily operated via a conveniently-placed, ergonomically-designed twist handle grip, this battery-powered tilt truck does all the work, taking the load off your workers and preventing the risk of musculoskeletal injury.

Popular with a diverse group of our customers, DJ Products’ ergonomically-designed powered dump hopper is being used to haul heavy trash and debris in factories, schools, distribution facilities, convention centers, hospitals and warehouses effectively and efficiently. Even filled with heavy trash, our dump hopper is designed for safe and easy turning and maneuvering in tight and narrow spaces by workers of any size or physical ability. Ergonomic design insures that the cart, not your workers, carries the burden, removing risk of injury to sensitive arm, shoulder, back, and leg muscles.

When material handling equipment forces a worker to contort his body to push, pull, maneuver tooperate it, muscle fatigue sets in. Workers take more breaks to alleviate sore muscles, decreasing work efficiency and production. Repeated muscle strain most often leads to potentially debilitating musculoskeletal injuries and the high medical bills, insurance costs, worker’s compensation and lost man-hour expenses such injuries entail. Ergonomically-designed material handling equipment is made to conform to the worker, allowing workers of various sizes and physical abilities to comfortably and easily perform the same task using the same equipment. Ergonomic equipment improves worker efficiency, productivity and morale.

A heavy-duty, 24-volt motor easily moves heavy loads up to 2,000 pounds. The ergonomic variable-speed twist grip allows operators to quickly maneuver forwards or backwards at speeds from 0 to 3 mph without risking carpal tunnel injury. Powered by two 12-volt batteries, this powered tilt truck can perform for an entire 8-hour shift without recharging, ensuring efficient waste hauling for the duration of the shift. DJ Products’ highly versatile dump hopper is available in a variety of sizes and can be customized to any application or environment. Click here for more information and to view a video of DJ Products’ motorized dump hopper in action.

Tips for Increasing Service Life of Material Handling Equipment

During a recession, the reality is that many companies are forced to made do with aging material handling equipment until business improves and funds become available for new equipment. It is possible to improve equipment performance while cutting costs by following three cost-saving strategies, says Cliff Holste, Supply Chain Digest’s material handling editor, in a June 11, 2009 article on SupplyChainDigest online. Holste’s magic formula for decreasing downtime and increasing equipment service life without straining your budget: reduce, reuse and recycle.

Reduce. Performing preventative maintenance will extend the life of your material handling equipment and can effectively reduce equipment repair costs. Setting a schedule for regular maintenance checks of your material handling equipment will ensure that it is running properly and allow any problems to be discovered and repaired before breakdown occurs. Regular preventative maintenance will keep equipment running at peak performance, minimizing expensive downtime and high-cost emergency repairs.

Reuse. Retrofitting current equipment so it can be reused in new applications is a cost-effective alternative to replacement. Modernizing existing equipment by upgrading components, increasing speed, improving capacity, augmenting safety features or adding new technology can increase its versatility, value and useful work life. A well-considered retrofit can allow existing material handling equipment to be used in new settings or perform new tasks at considerable savings. Retrofits can also bring older equipment into compliance with changing federal and state safety regulations. Ergonomic retrofits can be performed to improve the safe operation of existing equipment, reducing worker injuries and the medical, insurance and workers’ compensation expenses that accompany them.

An excellent example is DJ Products’ new ergonomically-designed Retrofit Cart Kit. This motorized retrofit cart kit can be adapted and mounted to almost any cart and can be customized to any application or environment from transporting hospital linens to moving oversized lumber. The powerful, heavy-duty, battery-powered 24-volt motor is capable of powering carts up to 4,000 pounds. Ergonomic variable-speed twist grips eliminate the risk of carpal tunnel syndrome while allowing operators to easily maneuver loads both forward and backward at speeds from 0 to 3.2 mph. DJ Products’ motorized retrofit cart kit can be field installed by the customer or DJ Products can provide onsite installation services. Visit the DJ Products website to find out more about our new motorized retrofit cart kit and to watch a video of this product in action.

Recycle. A fairly new offshoot of the “green” environmental movement, remanufactured material handling equipment can be an affordable alternative to buying new equipment for some. In the remanufacturing process, used equipment is disassembled and cleaned and worn parts are replaced before the unit is refinished and reassembled. Remanufactured equipment generally comes with a warranty.

It’s Buyer Beware When Buying Used Equipment

Economic woes have everyone pinching pennies and looking for bargains. Buying used material handling equipment can seem like a good way to save money, but while there are good bargains to be had, industry watchers warn that there are a lot of unscrupulous people out there trying to cash in on the potential profits. You know you’re getting a high quality product when you buy new material handling equipment from its manufacturer; but if you’re considering buying used equipment, it’s buyer beware.

Business consolidation, poor sales and bankruptcies have forced more material handling equipment onto the used market than usual, so it pays to do your homework and thoroughly investigate both the product and the seller before putting your money down, caution industry experts. Anyone can sell used equipment. No certification is required to sell used equipment, and authorization by original manufacturers is not required. Used equipment shouldn’t be confused with remanufactured equipment that is rebuilt, often by the original manufacturer, and refinished for resale, usually with a manufacturer’s warranty.

The boon market is attracting legitimate sellers who specialize in used material handling equipment sales; but it’s also attracting brokers, auctioneers and folks looking to make a quick buck. These Johnny-come-latelies generally lack any knowledge about the products they are selling or the maintenance they require. Equipment is sold “as is” or sometimes spruced up for resale; but it’s like buying a used car, you don’t know what you’re getting unless you perform a thorough inspection.

Even used, material handling equipment can represent a serious investment. When you buy used, you may get a great bargain; but it’s equally probable that you’ll get an expensive lemon. Follow these tips from Stafford Sterner for Material Handling Management online to ensure that when you buy used material handling equipment, you get what you’re paying for:

  • Deal with reputable, established businesses. In the competitive used equipment market, longevity is a sign of customer satisfaction, reputable business practices, adherence to industry standards, and fair prices. Beware of internet sales unless you can physically verify the business and inventory. A legitimate dealer will carry inventory in stock, be knowledgeable about his stock, allow inspection of equipment before purchase, and provide delivery assurance.

 More tips on Friday

More Tips for Buying Used Material Handling Equipment

Buying used material handling equipment is an attractive option in today’s difficult economic climate. While good bargains are available, the used equipment market is full of charlatans, warns Stafford Sterner in an article on Material Handling Management online. Today we continue the used equipment purchasing tips started in our last post. You’ll find they’re pretty good tips for investigating any company you’re considering doing business with. 

  • Beware the internet. On the internet it’s easy for a seller to project false impressions about the size of his operation, inventory availability and his experience in the industry. Making an onsite visit may not be practical in the early stages of your equipment search. Sterner suggests viewing satellite images of the seller’s business address on Google Earth to determine whether it’s a legitimate business with onsite inventory or someone arranging sales out of his basement.
  • Avoid part-time sellers. Dealing with a one-man band, people who sell used equipment in their spare time, generally means you’re dealing with an unknowledgeable amateur. Such sellers lack the industry experience to guide you and the resources for post-sale support. Sterner recommends asking for a business phone number in addition to an email address or cell phone number. If calls go to voice mail or the seller isn’t available during business hours, beware.
  • Deal with owners. Avoid brokers who flip equipment with a couple of phone calls, warns Sterner. A legitimate dealer will have invested money in the equipment he sells and will carry inventory you can inspect. Beware if sellers only offer photos.
  • Check financials. If making a large purchase, order a Dun & Bradstreet report (about $100) to check the seller’s financial bona fides. Owners and officers should be clearly listed, along with payment record, any lawsuits filed, incorporation date and number of employees.
  • Ask about follow up. Deal with someone who can service what they sell and check out the repair facilities personally. Beware of companies that outsource repair work, Sterner warns. Outsourcing adds one more layer of cost, scheduling headaches and communication problems to repair issues.
  • Check reputation. Beware of voluntarily offered references which may be carefully screened, instead call local customers or competitors.

When buying used material handling equipment, the take home message seems to be “Buyer Beware!” Purchasing used equipment from a reputable dealer may seem like a practical stop-gap during the recession, but when you add in the cost of increased maintenance and major repairs, it may be more cost-effective to buy new. Whether you buy new or used, it pays to thoroughly investigate prices, equipment and the dealers themselves to ensure you’re getting the best material handling equipment at the best price.

Auto Industry Retooling Should Include Ergonomics

The U.S. auto industry is starting to make its comeback. The U.S. Department of Energy has awarded the first loans from the $25-billion Advanced Technology Vehicles Manufacturing Loan Program authorized by Congress to support the U.S. manufacture of energy-efficient cars and automotive components: 

  • Ford Motor Co. was granted $5.9 billion to retool factories in Illinois, Kentucky, Michigan, Missouri and Ohio to manufacture fuel-efficient vehicles.  
  • Nissan North America received $1.6 billion to retool its Smyrna, Tennessee manufacturing plant to produce electric vehicles.
  • Tesla Motors got $465 million for production of advanced electric vehicles in California.

Other signs of industry recovery include Gestamp Corporation’s $90 million investment in a Chattanooga, Tennessee stamping operation to produce parts for Volkswagen’s new mid-sized sedan, and Ralco Industries’ $6.4 million expansion of its Pontiac, Michigan facility to increase production of welded assemblies  for the auto industry.

It’s a relief to finally see the first twitch of life in the U.S. auto industry. And it’s exciting to see the industry retooling for what promises to be a robust future. But along with forward-thinking changes in their product line, the auto industry should be implementing innovation changes in their production practices. Retooling initiatives should include ergonomic material handling equipment on the assembly line, on plant floors and in factory storage lots to ensure the protection of workers’ health and safety. The workers who made concessions in pay and health benefits to keep the auto companies alive deserve to work in an environment that promotes good health. The citizens who provided the cash that the government is using to fund the loans that are jump-starting new life into the auto industry deserve to know that every possible measure is being taken to create a financially lean manufacturing operation. Ergonomic material handling equipment accomplishes both goals.

Ergonomic equipment like DJ Products’ CarCaddy car and vehicle pusher pushes heavy equipment down an assembly. The CartCaddyLH electric tug can push a vehicle down a rail or be used to push/pull from station to station heavy carts of raw materials or parts weighing 10,000 to 50,000 pounds. The DealerCaddy car and truck pusher easily maneuvers cars and trucks around storage and dealer lots. All DJ Products’ material handling carts and movers are ergonomically designed to prevent expensive and debilitating musculoskeletal injuries. Ergonomic equipment and practices have been proven to cut production time and costs, protect workers’ health and safety, improve worker morale, and significantly reduce the musculoskeletal injury expenses that cost U.S. businesses more than $150 billion each year. Including ergonomics in auto industry retooling efforts just makes sense — for the auto industry, for workers, and for taxpayers.

New Line of Aircraft Tugs Introduced

Expanding territory, reducing vendor costs, eliminating underperforming products, layoffs and salary reductions were the cost-cutting measures most cited by Manufacturing & Technology eJournal readers in a recent online poll (see our August 3, 2009 post). Surprisingly, innovation didn’t make the list. At DJ Products we’ve had marked success in finding new applications for our ergonomically-designed material handling products and redesigning existing products to meet the specific needs of new applications. A case in point is the new line of Lindy’s Aircraft Tugs and Tractors manufactured by DJ Products’ subsidiary Lindbergh Aircraft Tug Co.

As the world leader in the manufacture of battery-powered, walk-behind carts and tow tugs, we saw an opportunity to apply current technology to a new problem. Working with Fortune 500 companies including Exxon Mobil, GM, GE, Ford, Cardinal Health, Home Depot, Wal-Mart, P&G, Boeing, Pfizer and Caterpillar, our engineers have successfully adapted our CartCaddy products to numerous unique applications to meet our customers’ specific requirements. Drawing on years of experience developing and manufacturing thousands of powered carts, equipment and tow tugs, our engineers applied their expertise to the problem of safely towing aircraft through crowded hangers, busy airports or FBOs. Our ergonomically-designed CartCaddy tugs proved perfectly adaptable to this new application and the Lindbergh Aircraft Tug Co. was born.

Named for famed aviator Charles Lindbergh, who made the first non-stop solo flight from New York to Paris, Lindbergh Aircraft Tug Co. is located in Little Falls, Minnesota, “Lucky Lindy’s” childhood home, where three AircraftCaddys are manufactured:

To learn more, we invite you to visit the new Lindbergh Aircraft Tug Co. website.