Using a lifting aid saves you, on average, between 30 and 60 percent of the time required for the task compared to lifting entirely by hand, depending on the type of product and the frequency of the tasks. The heavier the load and the more repetitive the task, the greater the time savings. In this article, we answer the most frequently asked questions about time savings when using an ergonomic lifting aid.
Which daily tasks actually take the most time?
Most time is lost during repetitive lifting tasks involving heavy or awkwardly shaped items: think of moving pallets, stacking boxes, or handling drums and rolls. It is precisely with these tasks that every second counts, because they are repeated dozens or even hundreds of times a day.
An employee who manually lifts and moves boxes doesn’t just spend time on the lifting itself. He or she must grasp the product, stabilize it, move it, set it down, and then start over. With products that are irregularly shaped or heavy, each step takes more time. When handling pallets or heavy rolls, the time required per operation can quickly double compared to what a lifting aid would require.
Tasks in which time loss is greatest:
- Stacking and unstacking boxes or bags at height
- Moving Pallets Without Mechanical Assistance
- Tilting or Turning Over Drums and Rolls
- Positioning sheets or large flat materials
How fast does a lifting aid work compared to manual lifting?
A lifting aid typically performs a lifting or moving operation two to three times faster than manual lifting, especially with loads over 20 kilograms. With vacuum lifters and mobile lifters, picking up and setting down products takes only a matter of seconds, whereas an employee needs more time to get a grip, stabilize the load, and move it safely.
In addition, stamina plays a major role. An employee who lifts manually all day will inevitably slow down as the day progresses. A lifting aid performs consistently, regardless of the time of day or the number of lifts. This difference in speed becomes increasingly pronounced toward the end of the workday.
In applications such as box handling or bag processing, the time saved per operation may be small, but over hundreds of repetitions per day, that adds up to a significant difference in total production time.
What are the hidden time losses associated with manual lifting?
The hidden time losses associated with manual lifting include fatigue, recovery time, increased absenteeism due to illness, and the need to have two people work together when handling heavy loads. These factors are less visible than the direct time spent performing the task, but they have a major impact on overall productivity over the course of a workday, week, or year.
Specifically, these are the following hidden time costs:
- Rest breaks due to fatigue: Employees who do heavy lifting need more break time to recover
- Two-person requirement: For loads exceeding a certain weight, two people are required, which halves the available capacity
- Repositioning: Products lifted by hand are more likely to be placed incorrectly and need to be repositioned
- Absenteeism: Back pain and other physical ailments lead to absenteeism, which increases the workload on coworkers
- Longer training period: New employees need more time to perform physically demanding tasks safely and quickly
These indirect time losses are often underestimated in a cost-benefit analysis of an ergonomic lifting aid, even though in practice they contribute significantly to the total time savings.
When does a lifting aid pay for itself in terms of time saved?
A lifting aid typically pays for itself within six to eighteen months, depending on the frequency of use, the type of application, and the labor costs of the employees performing the task. The more tasks performed per day and the heavier the load, the shorter the payback period.
The calculation is simple: add up the number of lifting operations per day, multiply that by the time saved per operation, and convert this to working hours per week. With 100 operations per day and an average time savings of 30 seconds per operation, this quickly adds up to 50 minutes of production time saved per day. That’s more than four hours per week per employee.
When reduced absenteeism due to illness and the lower risk of workplace accidents are also taken into account, the payback period is further shortened. An investment in a vacuum lifter or a mobile lifter therefore makes sense not only from an operational standpoint but also from a financial one.
Which lifting aid saves the most time for your application?
The lifting aid that saves the most time is the one that best suits the specific task, the weight of the load, and the work environment. There is no one-size-fits-all solution: for boxes on a conveyor belt, a vacuum lifter works faster, while for moving pallets, an electric pallet truck or automated pallet handler offers the greatest time savings.
An overview of the most common applications and the corresponding lifting aids:
- Boxes and packaging: vacuum lifters for fast picking and setting operations
- Moving Pallets: Electric Pallet Trucks or Automated Pallet Handlers for Efficient Logistics
- Drums and rolls: specialized drum-handling or roll-handling solutions
- Sheets and large flat materials: vacuum lifters or mobile lifters with adjustable grippers
- Bags of bulk material: lifting aids with saddle-shaped supports for stable transport
The right choice also depends on the available space, the floor layout, and the frequency of use. A thorough analysis of the workstation is therefore the first step toward finding the most efficient solution. View the full product lineup for an overview of available lifting aids by application.
How Logitrans Handling Helps Save Time by Using the Right Lifting Equipment
At Logitrans Handling, we help companies choose the right ergonomic lifting aid that delivers tangible time savings in their daily processes. Our approach is practical and customer-focused:
- Free Workstation Analysis: We assess your current lifting operations and identify where the biggest time losses occur
- Customized solution: Based on your products, weights, and workspace, we’ll recommend the most suitable lifting aid
- Demonstration area in Drongen: You can test the lifting solution with your own materials before making a decision
- Implementation support: including user training and post-installation support
- Maintenance Contracts: To Ensure Your Lifting Aid Always Performs at Its Best and Saves You Time
An ergonomic lifting solution is an investment that pays for itself through increased productivity, reduced absenteeism, and a safer work environment. Would you like to know how much time your company can save? Feel free to contact us, and we’ll analyze your situation together.
