How can I process more orders during peak periods without hiring additional staff?

It’s possible to process more orders during peak periods without hiring additional staff by making smarter use of the people and machines you already have. The key lies in eliminating time wasted on the shop floor: less manual handling, faster operations, and a warehouse layout that promotes workflow. In this article, we answer the most frequently asked questions about more efficient order processing during busy periods.

Why does order processing get bogged down during peak periods?

Order processing grinds to a halt during peak periods because the volume of operations increases exponentially, while the available workforce and warehouse layout have not been adapted to handle this. Every operation that normally runs smoothly becomes a bottleneck as soon as the influx of orders doubles or triples. The problem rarely lies with the people, but rather with the processes.

Specifically, there are three common causes:

• Bottlenecks in the movement of goods: when pallets, boxes, or drums are moved manually, each operation takes longer than necessary.
• Insufficient flexibility in staffing: employees who specialize in a single task cannot be quickly reassigned to another position.
• Absenteeism due to physical overexertion: During peak periods, the risk of injury and fatigue increases, which actually reduces available workforce capacity at the very moment you need it most.

Peak periods in logistics therefore call for a structural approach, not temporary solutions such as overtime or temporary workers who are unfamiliar with the job.

Which tasks in the warehouse take the most time?

The most time-consuming tasks in a warehouse are manually moving pallets, rotating and tilting heavy goods, and repositioning products between workstations. These movements may seem minor, but they add up to a significant loss of time when order volume is high.

Experience in industrial settings shows that the following activities most often cause delays in lead time:

• Manually lifting and moving boxes, bags, or drums
• Turning or tilting pallets for quality control or packaging
• Picking and delivering goods over longer distances within the warehouse
• Positioning products at the correct height for processing or packaging

Each of these tasks is a candidate for ergonomic handling solutions that drastically reduce the time required to complete them. When an employee spends less time on physical labor, processing capacity is immediately freed up.

How does semi-automation help process more orders?

Semi-automation helps process more orders by taking over repetitive, time-consuming tasks from employees, without requiring a full automation infrastructure. These are machines that handle a specific step in the process—such as moving pallets or tilting products—while the employee remains in control.

The advantage of semi-automation in the warehouse is that the investment is targeted and scalable. You don’t have to completely overhaul the entire warehouse: you identify the tasks that take the most time and address them with the right machine. A pallet handler that automatically changes pallets, an electric tow tractor that effortlessly moves heavy loads, or a vacuum lifter that lifts boxes at lightning speed are examples of solutions that have a direct impact on processing capacity.

In addition, semi-automation makes employees more flexible in terms of deployment. When the physical strain decreases, people can switch between tasks and workstations more quickly, which is a major advantage during peak periods.

Which handling machines increase processing capacity the fastest?

The handling machines that increase processing capacity the fastest are those that address the biggest bottlenecks in your specific process. In most warehouses, these are pallet transport, lifting operations, and the repositioning of goods. Machines that take over or speed up these tasks yield the fastest time savings.

Machines for Faster Pallet Transport and Changeover

Electric pallet trucks and pallet trucks significantly speed up internal transport compared to manual handling. Pallet handling machines fully automate pallet changes, resulting in substantial time savings at high volumes. Pallet tilters make it possible to rotate or tilt an entire pallet in a single motion, without manual intervention.

Machines for Faster Lifting and Positioning

Vacuum lifters and hoists are ideal for quickly moving boxes, sheets, or drums without requiring physical effort from the employee. Mobile lifters offer flexible use at various workstations. Electric tugs eliminate the physical strain of pulling or pushing heavy loads, allowing employees to work faster and more frequently without getting tired.

When is a maintenance contract essential during peak periods?

A maintenance contract is crucial during peak periods because a malfunctioning machine at the wrong moment can bring the entire workflow to a standstill. It is precisely when volume is at its highest that reliance on material-handling machines is greatest and downtime is most costly.

Preventive maintenance ensures that machines are in optimal condition before the peak season begins. A good maintenance contract typically includes regular inspections, rapid response to malfunctions, and the timely replacement of wear-and-tear parts. This not only prevents unexpected downtime but also ensures safety in the workplace, even when employees are working more intensively and at a faster pace than usual.

Anyone who wants to be able to rely on their machines to the fullest during peak periods would be wise to view the maintenance contract as insurance for processing capacity, rather than as an additional cost.

How do you determine which solution is right for your workstation?

To determine the right solution for your workstation, start by identifying the specific task that is time-consuming or physically demanding—not by focusing on the machine itself. Identify which products are being moved, how much weight is involved, how often the task is repeated, and how much space is available. Based on that analysis, the choice of the right equipment will follow naturally.

Ask yourself the following questions for each workstation:

1. Which task takes the most time or effort?
2. Are we talking about boxes, bags, pallets, drums, rolls, or sheets?
3. How many operations are performed per hour or per day?
4. Is there room for a stationary machine, or is mobile deployment required?
5. Are there any employees with limited physical capacity working in this position?

A free workstation analysis by a specialist is the fastest way to move from those questions to a concrete solution. This way, you avoid investing in a machine that doesn’t match the reality on the shop floor.

How Logitrans Handling Helps Process More Orders During Peak Periods

We support companies that want to process more orders during peak periods without hiring additional staff. Our approach is practical and tailored to each client’s needs:

• Free Workstation Analysis: Our specialists will analyze which tasks take up time and energy at your specific workstation.
• Wide product range: from vacuum lifters and pallet trucks to palletizers and electric tow tractors, we offer the right material handling machine for every challenge.
• Demo Room in Drongen: You can test the solution with your own materials before making a decision, so you know exactly what you're buying.
• Maintenance Contracts: We ensure that your machines perform at their best and remain safe even during the busiest periods.
• Semi-automation solutions: As part of the ATS Group, we also offer more comprehensive automation solutions for time-consuming warehouse processes.

Would you like to know which solution will save you the most time in your situation? Contact us for a no-obligation consultation or a free analysis of your workstation.

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