Tag: Material Handling

Material Handling Solutions Are a Win-Win for Employers and Employees

When people discuss ergonomics these days, much of the discussion centers on ergonomics for the office environment. This is an important topic, however, people that work in warehouses, hospitals and other environments that require pushing and pulling heave loads have long been aware that having the right tools makes all of the difference.

Many workers have a can-do attitude and this is great except when their desire to work quickly and efficiently leads to injury. Many of us overestimate our own strength. We see a cart with wheels and figure that we can push or pull that cart with no problem. What we don’t take into account is the load that is on the cart or the construction of the cart itself—it may have been designed to transport a lot of materials but it was probably not designed to ease strain on the human musculoskeletal system.

At DJ Products, our mission is to provide solutions for material handling situations that are ergonomically correct, safe and cost effective.

All of our products are battery powered “walk-behind” units, allowing better control by the operator, even in tight, difficult spaces. Because of this operating flexibility, our electric cart movers can be used in more applications than standard material handling equipment.

Call us at 800-686-2651 and speak to one of our Sales Engineers about our cart pushers, cart pullers, vehicle pushers, industrial tuggers and motorized carts. If you have not pinpointed the exact product you want, a Sales Engineer will be happy to explore custom applications where our base products match primary criteria.

Risk Factors Linked to Pulling Tasks

Injuries from pushing and, particularly, pulling tasks cost U.S. businesses tens of billions of dollars each year, yet are largely preventable when ergonomic equipment and ergonomic practices are introduced into the workplace. In our last post, we talked about how these two common work tasks place workers at risk for potentially debilitating musculoskeletal injuries. Today, we take a closer look at the risk factors associated with pulling heavy carts and equipment.

One-handed pulling tasks. When facing the direction of travel, pulling must be done one-handed, significantly decreasing the operator’s control of the load. The worker must stretch his arm out behind him and twist his body unnaturally to face the direction of travel. This places undue strain on the back, shoulder, arm and wrist muscles, increasing the chance injury.

Changing direction or maneuvering a wheeled cart while pulling it behind you with one hand is not only awkward and difficult, it focuses pressure on wrist, elbow and shoulder joints and on the tender muscles of the lower back, increasing muscle strain to dangerous levels. There is also danger that the operator may lose control of the load, particularly when on inclined grades. If the cart “overruns” the operator, there is risk of additional injury to the operator or others in the cart’s path.

Two-handed pulling tasks. When using two hands to pull a load, the operator must walk backwards, facing away from the direction of travel. Pulling places significant stress on the arm, shoulder and wrist muscles. While using two hands allows the operator to maintain better control over the cart, particularly when maneuvering around turns or in tight spaces, the inability to see the travel path invites disaster.

Facing away from his direction of travel, the operator remains unaware of obstacles in his path. He cannot prepare for dips or rough spots in the travel path that can affect his balance or the balance of the equipment he is pulling. He remains unaware of traffic sharing the same path, inviting collision.

The risk of stumbling and being overrun by the equipment he is pulling is increased when the operator is facing away from his direction of travel. Constantly looking over his shoulder twists the body, increasing strain on lower back, shoulders, arm, wrist and neck muscles and inviting injury.

Preventing injury from pulling tasks. DJ Products’ ergonomically-designed, motorized carts, tugs and movers take the strain out of pulling tasks. Battery operation allows a single worker to move loads without physical effort. Walk-behind design allows a full view of the path ahead, guaranteeing maximum operator control and safety. For more information about our full line of ergonomically-designed carts, tugs, and movers, visit the DJ Products website.

Battery Powered Tugger Reduces Injury at Food Processing Plant

At a major food processing plant, workers had to manually push heavy meat carts to maneuver them between processing stations. Concerned about injury risk and worker safety, plant executives turned to DJ Products for ergonomic solutions to their material handling problem. Our experts recommended the CartCaddyShorty battery powered tugger, a motorized cart mover designed to push, pull and maneuver carts that require turning. The battery powered tugger is the most maneuverable tug on the market today with the power to handle most push/pull applications. Most commonly used with carts that have two front swivel casters and two straight casters, the ergonomically-designed CartCaddyShorty attaches to the swivel end of the cart to provide the power necessary for easy pushing, pulling, turning and intricate maneuvering. Heavy carts that usually require two workers to maneuver can be easily managed by a single employee. The battery powered tugger takes the physical burden off your workers, eliminating the exertion and straining that can cause serious and expensive musculoskeletal injuries.Musculoskeletal injuries cost U.S. businesses billions of dollars in medical, insurance, workers’ compensation and lost man-hour costs each year. According to OSHA statistics, back injuries alone cost businesses $12 million in lost workdays and $1 billion in compensation costs annually. The time-lost cost of a single back injury is estimated at $26,000.Through proactive use of the CartCaddyShorty, this major food processer was able to eliminate potential musculoskeletal injury risk at its facility. They also realized an increase in productivity and improved employee moral after introduction of DJ Products’ battery powered tugger. The CartCaddyShorty has also proved effective in hospital, hospitality and retail applications.Click here to learn more and to watch a video of the CartCaddyShorty in action. The world leader in providing battery powered tuggers and equipment movers to the manufacturing, hospital and retail markets, DJ Products offers a full line of ergonomically designed, powered carts, tugs and movers.

Electric Carts Ease Strain of Push-Pull Tasks

Pushing and pulling are the two most required actions in industrial and business settings. Unfortunately, pushing and pulling can place extreme stress on a worker’s body, often resulting in back, groin and other musculoskeletal injuries. Injuries can cost an individual business thousands of dollars each year in medical, insurance, disability and lost man-hour costs. An ergonomically designed electric cart pusher and motorized cart puller eliminates the physical strain of manually pushing and pulling heavy carts and wheeled equipment. An investment in ergonomic equipment is a sound investment in the health and safety of your workforce that can save your business thousands of dollars in unnecessary medical and insurance costs.

In manufacturing and distribution settings, the most common solutions to material handling tasks are:

  • to place products, parts and equipment on pallets for handling or
  • to utilize racks, carts and casters to move materials.

Electric carts come in a variety of shapes, sizes and configurations to fit the demands of the task and the capabilities of your workforce. An ergonomically-designed cart mover reduces the amount of force that must be exerted by the operator to maneuver a load. Various cart and wheel configurations are available to meet the needs of any task.

  • Carts, racks or equipment with casters can be easily turned and maneuvered with a CartCaddy power tug that feature a 5th wheel turning method.
  • Carts, racks or equipment with 4 swiveling casters require a cart with back end control.
  • Specialized CartCaddies and an electric tug have been designed to handle carts or equipment that have straight wheels or are on a rail.

Visit the DJ Products website to view our complete line of ergonomic electric carts, trucks and lifts. We offer ergonomic solutions for material handling applications.

Overseas Jobs Could Be Headed Back to America

The tide could be turning. Following up on a campaign promise to stop the flow of manufacturing jobs overseas, President Obama has proposed closing loop holes in the U.S. tax code and raising corporate taxes on offshore earnings to encourage U.S. manufacturers to keep jobs in America. The President is pressuring Congress to eliminate certain tax breaks that he says encourage U.S. companies to move jobs overseas. At the same time, the President’s recently-released budget initiative proposes to increase corporate taxes on overseas earnings.

Proponents say the President’s plan would not only keep more jobs in America, it would raise more than $100 billion in much needed revenue over the next decade. Current tax laws allow U.S. firms to defer taxes on overseas profits if they invest those profits in their foreign subsidiaries. Critics say that practice encourages businesses to fund their foreign operations at the expense of those located on U.S. soil. And, of course, there’s considerable debate on both sides about what the amount of the tax rate should be if the rules are changed. Many consider the current 35% rate (which few actually pay) unsustainable, particularly in the current economy. Some industry experts have suggested a more realistic 15% to 20% tax rate. The debate is expected to be energetic. If your company has a global reach, you might want to weigh in with your Congressional representatives.

Any move to keep U.S. jobs on U.S. soil will be a positive one for America’s manufacturing industry, American workers, and the U.S. economy. Hard-hit by the economic recession and the problems of Detroit’s Big Three auto manufacturers, the future of U.S. manufacturing has been painted as bleak by many. But the real story is much more complex and, fortunately, rosier. While U.S. manufacturing jobs have moved overseas, particularly to China, to take advantage of lower labor costs; over the past 15 years, the number of Chinese manufacturing jobs has not increased, leading industry experts to believe we’re on the downslope of the outsourcing peak, at least with regards to China. In fact, according to the Material Handling Industry of America, the percentage of workers employed in manufacturing is higher in the U.S. than it is in China. Good news for U.S. workers.

More on Friday

How Force Affects Pushing and Pulling Activities

Pushing and pulling tasks are among the most common industrial activities. Pallets of goods need to be moved from one point to another and equipment needs to be moved to a usage point. Workers at factories, hospitals, distribution centers, grocery stores and many other businesses engage in pushing and pulling activities numerous times a day. The Ergonomics of Manual Material Handling – Pushing and Pulling Tasks provides a useful overview of the costs and consequences of neglecting ergonomics in common industrial tasks that involve pushing and pulling. Click here to read the white paper published by Darcor, an industry leader in the design and manufacture of ergonomic casters and wheels, and Ergoweb, an ergonomic web resource.

While often taken for granted, wheeled carts and equipment are integral to the operation of nearly all manufacturing and distribution facilities as well as many businesses. Musculoskeletal disorders from pushing and pulling injuries cost American businesses billions of dollars each day in medical, insurance, disability and downtime costs. Ergonomically-designed carts, wheels and casters can significantly decrease the incidence of musculoskeletal disorders.

To be effective, ergonomic design for push/pull tasks must consider:

  • Human factors such as height, weight, age, gender, strength, posture and physiological capacity.
  • Task factors including distance moved, forces required to initiate and sustain movement, direction and nature of movement and task duration.
  • Cart/equipment factors such as size, weight, stability, caster/wheel specification and handhold type, height and orientation.
  • Floor/ground factors including surface characteristics, slope and contaminants.

Contrary to popular belief, horizontal push force is more significant than load weight in pushing and pulling tasks. Proper wheel or caster selection and equipment design can enable workers to move thousands of pounds safely and efficiently. Caster/wheel choice alone can reduce push force significantly. Rolling resistance refers to forces that resist movement and defines the amount of force a person must generate and apply to move wheeled equipment.

This force — called the starting or initial force by ergonomists — is always greatest at the start, just before movement begins. Fortunately, starting force must only be exerted briefly. Once acceleration is achieved, less force — called the sustained or rolling force — is required to maintain movement. The final major force that affects cart movement is turning force which can occur while the cart is in motion or during positioning.

Next time: How ergonomics mitigates force.

Ergonomics Opponents Girding for Battle

California Democratic Representative Hilda Solis was confirmed yesterday as President Obama’s Secretary of Labor by a Senate vote of 80-17. The U.S. Chamber of Commerce is already said to be marshalling its forces. With a very pro-labor Solis at the helm, the chamber is anticipating a pitched battle over reinstatement — and probably toughening and expansion — of ergonomics laws instituted under Clinton but quickly wiped off the books by Bush.

Solis hails from California, the only state with ergonomics laws that have any bite to them — though Michigan is struggling to pass similar measures. California forces employers into compliance when workplace practices are found wanting. Business leaders and chamber executives fear that Solis will use the tough California model to craft national laws mandating ergonomic practices. Solis has been a persistent champion of labor rights and national ergonomics laws since her election to the U.S. House in 2001.

Solis can expect to have the President’s backing. On the campaign trail last year, Obama discussed the need to address musculoskeletal injuries, telling the Charlotte Observer that OSHA “must attack this problem with all of the tools at its disposal — regulations, enforcement, training and compliance assistance.” He is expected to reverse the Bush administration’s stance on national ergonomic standards.

The chamber considers national ergonomics standards to be “the mother of all regulations,” charging that they would cost businesses millions of dollars, which they call unconscionable at any time, but particularly given the current economy. In stumping against ergonomics regulations, the Chamber cites not only prohibitive expense, but suggests potential for substantial abuse. Opponents of ergonomics laws fear that businesses will be held legally liable for employee musculoskeletal and repetitive motion injuries that happen off the job.

“Let’s fact it: We all go through things in our lives as simple as bad sleeping habits or exercise or recreational activities that would cause our bodies to feel discomfort,” Mare Freedman, director of labor law policy for the chamber told Rob Hotakainen, a reporter with McClatchy Newspapers.

Supporters of national ergonomics laws cite rising health care costs and continuing workplace hazards that take a serious toll on U.S. workers as compelling reasons for instituting national ergonomics standards. Freedman said the chamber doesn’t dispute that providing a safe and healthy workplace is good business practice; however, the group thinks efforts should be voluntary, not mandated. Supporters of ergonomics, charge that many employers won’t act unless forced.

The Cost of Ignoring Ergonomics

Back in industry’s dark ages, equipment was designed to do a task without much thought to the comfort or safety of the worker who would be operating it. Back injuries, tendonitis, carpal tunnel syndrome and other stress and repetitive motion injuries were an aggravating and often debilitating part of the job. The toll wasn’t just on the workers, industry paid a price in decreased productivity, poor product quality, increased medical and workers’ compensation costs, low morale and high absenteeism. The annual price tag for workplace injury and illness is estimated at $171 billion.

That’s a pretty hefty price tag considering that America spends about $170 billion a year on cancer and $164 billion on cardiovascular disease, the country’s two biggest killers. According to an American Medical Association study, each year in America there are 6,500 deaths from workplace injuries and more than 60,000 deaths from workplace-related diseases. Non-fatal workplace injuries number 13.2 million annually with 862,000 illnesses. That’s a staggering price in human suffering and industry dollars. The total cost of workplace injuries is nearly equal to the combined annual profits of America’s 20 largest companies.

But that’s just part of the picture. Workers’ compensation claims already cost American businesses $60 billion annually, according to the U.S. Department of Labor. More than 50% of those claims are for back injuries from lifting, pulling, pushing and straining, says the National Council on Compensation Insurance. In fact, workplace back injuries, which involve lengthy and costly treatment, affect more than 1.75 million workers each year, according to the Bureau of Labor Statistics. Add in the estimated time-lost cost per injury of $26,000 per incident and the prevention of a single injury can result in an immediate savings of $26,000.

This staggering cost and the desire to provide American workers with healthier and safer working conditions gave rise to ergonomics and the beginning of a radical change in the way industry approaches equipment design.

Next time: The rise of ergonomics in industrial design.

Making the Most of Your Space

A few years back, when business was booming, the answer to the need for increased space because of increased business was simple – upgrade to a larger facility that can handle the increase of inventory.  Now things aren’t quite so simple, increases in margins remain slim and there is constant competition to attract and keep new customers, so many business are leery about taking on greater overheads to try and meet customer demands – instead businesses are being forced to recreate the space that they are in an effort to hold the necessary inventory to satisfy customer demands.

This may mean changing storage racks, warehouse aisles and converting office space in order to make room for additional product storage and this restructuring of space may also mean that the equipment being used may no longer be as effective with the more constrained spaces.  Traditional forklifts can be bulky and may need a good deal of space to  maneuver  around a warehouse  – if you decrease the amount of room for travel there may no longer be enough room for a large forklift to effectively operate.

Though upgrading to smaller, safer and more efficient equipment will bring about an initial investment, unlike assuming a new lease for a larger space, this investment will immediately begin to pay for itself.  The powered carts and lifts from DJ Products allow a single employee to move heavy loads around in the smallest places easily – meaning that your employees won’t struggle at all in the smaller and more cramped spaces and that your business will maintain the same level of productivity despite the fact that your employees have less space to move around in.

Your new equipment will cost less to operate and allow your employees to get the job done quicker, which is exactly the formula you need to attract and keep more customers without having to move into a larger facility.

Is OSHA Underreporting Injuries?

At a recent Congressional hearing, critics charged that OSHA is underreporting injuries. In questioning the competence of the federal agency designated to protect the health and safety of American workers, critics cited several independent studies, contending that nearly half of all workplace injuries go unreported to OSHA.

Independent studies cited both reviewed the impact of changes to OSHA’s injury-reporting rules and compared injury data reported to OSHA by employers with that reported to state workers’ compensation plans. In one study, a Michigan State University professor of medicine noted that while workplace fatalities have not declined over the years, reported injuries have declined significantly. He found the data suspect. According to the professor, a decline in injuries should have resulted in a similar decline in fatalities. 

The significant data discrepancies between OSHA and state worker’s compensation plans were attributed to numerous possible causes, including the underreporting of injuries to employers by immigrant workers concerned about job retention, reclassification of workers by employers into non-reporting job descriptions, managers discouraging injury reporting, and several other causes. Reports came just shy of charging employer fraud, criticizing OSHA for relying solely on employer statistics.

OSHA defended its reporting procedures, pointing out that in addition to employer submitted data, each year its agents conduct 250 record-keeping audits of employers. OSHA said audits indicate that 90% of employer-submitted data on injuries and illness is accurate. Defending OSHA before the House Committee on Education and Labor, OSHA assistant secretary Edwin Foulke, Jr. said, “In Fiscal Year 2008, of the almost 57,000 violations issued so far, 80% have been categorized as serious, willful, repeat or failure-to-abate, the highest percentage ever recorded by the agency. We are also effectively targeting our inspections.” While Foulke noted that violations were found on 78% of the construction worksites inspected this year, he contended that OSHA’s diligence is responsible for the lowest workplace injuries, illnesses and fatalities in U.S. history.