Heavy lifting with two employees takes time, requires planning, and makes your staff dependent on one another. Yet for many companies, this is still the standard approach for products that are too heavy or too unwieldy for a single person to handle. It doesn’t have to stay that way. With the right approach and the right lifting aid, you can resolve this situation once and for all, so that a single employee can perform the task independently and safely.
In this guide, you’ll go through five specific steps: from assessing the lifting situation to maintaining your solution. Follow the steps in order, and you’ll lay a solid foundation for ergonomic lifting in your warehouse or workshop.
Assess the lifting situation
Before choosing a solution, you must thoroughly understand the lifting situation. A vacuum lifter that works perfectly for glass panels will not be effective for porous bags. Therefore, start with an objective analysis of exactly what is happening at the workstation.
- Record the weight and dimensions of the product being lifted.
- Describe the shape and surface: Is the product smooth, porous, irregular, or fragile?
- Map out the movement: from where to where is the product being moved, and over what distance?
- Note the lifting frequency: how often per hour or per day is this action repeated?
- Identify the challenges: Why are two employees needed right now? Is the weight, size, grip, or height the problem?
After this analysis, you will have a clear picture of the lifting operation. You will know what requirements the solution must meet, and you will avoid purchasing a lifting aid that does not address the actual problem. Also check whether there are any safety risks associated with the current work method, such as awkward postures or narrow passageways, as these factors help determine which solution is feasible.
Choose the right lifting aid for your product
With the lifting analysis in hand, you can conduct a targeted search for the right ergonomic lifting aid. The choice depends heavily on the product, the lifting frequency, and the available space. Below are the most common options for each product type.
- Smooth, flat products such as sheets, panels, or glass: a vacuum lifter or hoist offers a safe and fast solution for these items. The suction cups adhere to the surface, allowing a single employee to lift and position the product effortlessly.
- Pallets and heavy load units: A pallet truck or mobile lift takes the full weight off your hands and makes it possible to move them over longer distances.
- Boxes and packaging: For repeatedly lifting boxes, a vacuum lifter or an ergonomic lifting arm is an efficient choice that significantly reduces strain on the back.
- Drums and rolls: Special clamps or rotating attachments on a mobile lifter allow a single person to safely handle round and heavy objects.
- Bagging: A vacuum lifter with a specialized head for porous materials or an automated palletizer provides a solution for repetitive tasks.
When making your selection, also review the applications by product type to see which systems are available for your specific situation. When making your choice, consider the maximum lifting capacity, the reach, and the controls: a lifting aid that is too complex to operate will quickly be ignored by employees.
Adjust the workstation to the lifting solution
A lifting aid will only perform optimally if the workstation is designed to accommodate it. There is little point in installing a vacuum lift if the lift height, the floor, or the space around the workstation make it difficult to use.
- Make sure the floor is level and free of obstacles for mobile equipment such as mobile lifters or pallet trucks.
- Adjust the product’s infeed and discharge positions so that the lifting aid can perform the entire movement without the employee having to take any additional actions.
- Make sure there is sufficient headroom above the workstation when using a vacuum lifter or hoist.
- Remove any unnecessary obstacles from the path between the pickup and drop-off locations.
- Mark the floor clearly to indicate the positions of pallets, crates, or other unit loads so that the lifting device can always be used in the same way.
A well-organized workstation also shortens the training period for new employees. When everything has a designated place and the movement of the lifting aid logically aligns with the flow of incoming and outgoing materials, the system operates intuitively. This increases employee acceptance and ensures that the aid is actually used.
Validate the solution using a test setup
Now that the workstation has been set up and the lifting aid has been selected, it’s time to test the solution in practice. A test setup prevents you from investing in something that makes sense in theory but doesn’t work in practice.
- Test the lifting aid with the exact product that is lifted during daily operations, including the maximum weight.
- Have the employee who performs the task on a daily basis conduct the test. His or her feedback is crucial.
- Perform the lifting operation several times to assess whether the system operates smoothly and effortlessly even with repeated use.
- Check whether the employee can perform the task completely on their own, without assistance from a second person.
- Make a note of any issues that arise and adjust the setup or settings of the device for a second round of testing.
After the trial setup, you’ll know for certain whether the chosen solution actually resolves the issue. A successful test is one in which the employee reports being able to work comfortably and independently, and in which the lifting task is completed more quickly than it was previously with two people. Only then is the solution ready for full-scale implementation.
Keep the lifting aid in top condition
A lifting device that is not properly maintained gradually loses its performance and can eventually become a safety hazard. Preventive maintenance is therefore not a minor issue, but an essential part of the solution.
- Develop a maintenance schedule based on the frequency of use and the manufacturer's recommendations.
- For vacuum lifters, regularly check the suction cups for wear or damage, as a defective suction cup can cause a load to come loose.
- Inspect mobile systems to check the condition of the wheels, brakes, and hydraulic components.
- Train employees to report minor irregularities or unusual noises promptly so that problems can be identified early on.
- Document all inspections and maintenance services in writing to ensure traceability and safety compliance.
Proper maintenance significantly extends the service life of the lifting device and ensures that employees can work safely with it day after day. You can find more information about service and maintenance for material-handling equipment on the service page. A maintenance contract can be a practical solution to ensure this on an ongoing basis without requiring a significant amount of internal administration.
How Logitrans Handling Helps Ensure Ergonomic Lifting by a Single Employee
Logitrans Handling guides companies through every step—from the initial analysis to the implementation and maintenance of the right lifting solution. Whether it’s a vacuum lifter for sheets, a mobile lifter for pallets, or a custom solution for drums or rolls, we offer a tailored approach for every situation.
- Free workstation analysis: Our specialists will analyze your lifting situation on-site and provide specific recommendations.
- Extensive product range: from vacuum lifters and hoists to mobile lifters and automated pallet handlers, tailored to your product and workflow.
- Demonstration Room in Drongen: Test the lifting aid with your own materials before you make a decision.
- Training during installation: Employees learn how to use the system correctly and safely from day one.
- Maintenance Contracts: Preventive and proactive maintenance to keep your lifting equipment in top condition.
Would you like to know which solution is best suited to your specific lifting situation? Contact our specialists for a no-obligation consultation or a free workstation analysis.
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