Safe Material Handling in a Warehouse Environment

Written by Staff Writer | Edited by Michael Purser

Practicing safe material handling techniques helps workers avoid common stress injuries. In warehouses and other work environments where employees must regularly move goods or supplies, everyone needs to know how to move tools, supplies and other equipment correctly to ensure optimal safety, productivity and performance.

Human factors engineering (HFS), also known as ergonomic design, offers proven methods for protecting the human body during strenuous work motions. Read on to learn about ergonomic interventions and their effectiveness in reducing injuries and improving.

Understanding Ergonomics and Its Guidelines

According to the Bureau of Labor Statistics, approximately 30% of the 900,000+ annual injury cases involving days away from work involve musculoskeletal disorders (MSDs). Many of these injuries could likely have been prevented through improved ergonomic design and workplace practices.

Workplace ergonomics focuses on fitting the job to the worker instead of forcing the worker to fit the job. This means designing workflows to minimize the strain on the person doing the job. With the right tools and procedures, moving objects can be easier and less physically stressful. This kind of approach reduces the risk of injury.

Every time an employee lifts, carries or moves an object in an awkward position or improper posture, they are at risk for causing a musculoskeletal injury or exacerbating an MSD. The heavier the object, the greater the risk. Heavy is also relative to the size and strength of the individual.

Repetitive motion is another major consideration. Objects don’t have to be heavy or even awkward to injure workers if the motion must be repeated frequently. Carpal tunnel syndrome is a good example of this.

This debilitating musculoskeletal disorder often affects workers who use keyboards frequently. Typing doesn’t require bulging biceps, but doing it daily can still lead to serious injuries over time.

As a supervisor, you can learn to identify high-risk movements, from loading pallets to typing at a keyboard, and make practical adjustments to help prevent injuries. Proper training in ergonomics will help you understand the simple but effective interventions, such as raising work surfaces to waist height, using adjustable ergonomic equipment and reducing the weight of loads, to minimize injury risk and protect your crew.

Material Handling Techniques That Support Occupational Safety

Each industry has specific equipment designed to help complete tasks more efficiently. Warehouses are full of lifting equipment that rapidly shift huge loads. Hospitals employ adjustable beds and gurneys to keep patients at the ideal height for staff to administer a variety of treatments. Hotels utilize modern ergonomic keyboard trays to minimize strain for desk staff.

While specific equipment is important for each industry, the principles of proper manual handling techniques are universally applicable across industries. Every supervisor should be aware of these techniques and train staff to follow them every time moving or storing items is required. Some of these ergonomic solutions include:

Think Before Lifting

Plan the entire lift or move before you attempt to transfer the item. Identify where you will place it and determine if any aids are available, such as a pallet jack or dolly. Will you need help with the load? Remove any obstructions along the route so you aren’t tripped up while under strain. If the lift is going to be long or the load is heavy, consider resting the load midway.

Keep the Load Close

Try to keep the load close to your body as much as possible. Ideally, place the heaviest side of the cargo next to your body. If you can’t bring it against your body, at least try to slide the item closer before you attempt to pick it up.

Adopt a Stable Position

When you lift, it’s best to keep your feet apart in a medium stance, shoulder-width apart —either one in front of the other or side by side, depending on the position. Be prepared to move your feet carefully during the transfer to maintain stability.

Avoid wearing clothing that restricts motion and always wear proper footwear that offers sufficient traction.

Hold the Load Securely

Get a firm grip on the load that you can maintain throughout the lift (unless you have a place to rest the load while changing grip). If you can hug the load to your body instead of just gripping it with your hands, even better.

Reduce Bending

Instead of bending at the waist, it is better to squat slightly when you start lifting as opposed to bending fully at the waist or going into an unnecessarily deep squat.

Avoid Twisting

Twisting at the waist with a heavy load can put excessive strain on the body, especially the vulnerable spine. Try to keep a relatively straight back with level shoulders while you move. Use your feet to turn instead of leading with your back.

Don’t Lift More Than You Can Easily Manage

A safe lift is one that you can manage with relative ease. If the size or weight is too great to lift easily, you should seek other ways to complete the transition. For example, you could ask for help from another person or seek out equipment to reduce the strain.

Put It Down, Then Adjust

If you need to place the load in a specific spot or orientation, put it down where it’s easy to do so and make fine adjustments afterward. Sliding a box into the exact position is much safer than bending and stooping to get it just right on the first try.

Learning How to Meaningfully Improve Ergonomics in the Workplace

An education on the importance of basic ergonomic lifting techniques and the effectiveness of ergonomic interventions is important. You can learn how to recognize and prevent ergonomic hazards throughout the workplace and protect your team in the process.

But supervisors and other workplace leaders can do more to improve overall workplace safety.

Our Industrial Ergonomics Certificate course is a primer on the fundamentals of industrial engineering for occupational health. Topics covered include:

• Common injuries. Learn to recognize and help workers avoid some of the most common injuries that occur in industrial and other workplaces.
• Preventing hand and wrist problems. The hands and wrists are especially vulnerable to a range of injuries, including both traumatic and repetitive motion injuries.
• Taking care of the neck and back. The human spine is remarkably flexible and adaptable. But heavy and repetitive lifting can cause excessive strain and lead to potentially crippling injuries.
• How to lift safely. Good form requires some patience and attention to detail, but, once learned, it provides a solid foundation for a lifetime of safe lifting.
• Understand the structure of the human body. To design a safe and ergonomically sound workplace, you first need to understand how the human body functions.
• Recognizing and teaching good posture. Identify when workers are moving in an unsafe manner and how to correct that movement.

Why Choose OSHA Education Center?

As an industry leader in workplace safety education, we are well-equipped to help you create and lead an ergonomically sound workspace. Our courses teach you exactly what you need to know in a format that makes sense for your busy life. We combine quality education with convenience so you can earn your certificate and get back to work.

Every course is fully online, so you don’t have to step into a classroom to get your education. Access your course 24 hours a day, seven days a week and log on and off as many times as you want — we save your progress automatically.

Work anytime from anywhere to improve workplace ergonomics. All you need is a device with internet access. Engaging lessons include full-motion video, audio, text and colorful graphic elements to help you learn and retain information. Once you’re done, you can download your Certificate of Completion instantly.

Understanding how to create a safe and healthy workplace for your employees will benefit both you as a worker or a supervisor — and those you manage. It’s an investment in your future and the future of your team. We encourage you to sign up today!