You can reduce absenteeism due to physical strain in a warehouse by implementing ergonomic handling solutions that eliminate or significantly reduce heavy lifting, awkward postures, and repetitive motions. This requires a combination of the right equipment, a well-designed workstation layout, and regular maintenance of the equipment. The questions below provide specific answers to each part of that process.
What are the most common causes of physical absences in a warehouse?
The most common causes of physical injuries in a warehouse are strain on the back and shoulders from heavy lifting, repetitive movements during sorting or packing, and prolonged work in uncomfortable positions. These three factors account for the vast majority of work-related injuries in logistics settings.
Physical strain in the warehouse is rarely the result of a single incident. More often, it is the cumulative effect of daily tasks that eventually lead to health issues. Consider, for example, an employee who repeatedly lifts boxes off a low pallet, or someone who has to place boxes above shoulder height. The strain per task may seem limited, but over the course of a full workday and workweek, it adds up.
In addition to lifting, pulling and pushing also play a role. Maneuvering heavy pallet trucks on uneven floors or manually moving full racks puts strain on joints and muscles in a way that only becomes apparent in absenteeism rates after months or years.
Which workplace hazards are most likely to lead to long-term absenteeism?
The workplace hazards most likely to lead to long-term absenteeism are herniated discs and back injuries caused by heavy lifting, shoulder problems caused by working above shoulder height, and knee problems caused by prolonged kneeling or working in a crouched position. These conditions typically involve a long recovery period and carry a high risk of recurrence.
Herniated discs are particularly problematic in the logistics sector because they not only require a long recovery period but can also result in permanent limitations. An employee who has had a herniated disc is more vulnerable when resuming the same tasks.
Shoulder problems, such as a rotator cuff injury, typically occur during activities that involve reaching for or lifting loads above shoulder height. This is a common situation when stacking tall pallets or working with warehouse racks. Treatment often requires physical therapy over several months, and in severe cases, surgery.
Knee problems are underestimated in warehouse environments. Employees who regularly work on their knees to unload low pallets or inspect products develop wear and tear that doesn’t manifest as a problem until later in life. Prevention at a young age is most effective in this case.
Less effort, more performance
Lift more efficiently with ergonomic lifting solutions. Our specialists are happy to work with you to find the right solution.
How does ergonomic material-handling equipment help reduce physical strain?
Ergonomic handling equipment reduces physical strain by relieving employees of the heaviest and most strenuous tasks. Instead of manually lifting, carrying, or moving a load, the equipment takes over that effort. The result is less muscle tension, less strain on the joints, and a lower risk of work-related injuries.
A vacuum lifter allows you to move boxes, sheets, or bags without having to exert significant lifting force. The worker guides the load but does not bear the weight themselves. A mobile lifter or electric pallet jack handles the vertical lifting when moving pallets. These types of solutions are particularly valuable in pallet handling because pallets can be very heavy.
Ergonomic equipment also helps ensure a better working height. When an employee can always work at a comfortable height, without having to bend over or reach, the strain on the spine is significantly reduced. This principle applies to virtually every warehouse task, from unloading trucks to handling individual packages.
Which material handling solution is best suited for which warehouse task?
The right material-handling solution depends on the type of load, its weight, the required movement, and the work environment. Vacuum lifters and hoists are suitable for lifting loose items such as boxes or bags. Pallet trucks and mobile lifters are the best choice for moving and positioning pallets.
An overview of common tasks and corresponding solutions:
- Moving or Stacking Boxes: Box Handling with Vacuum Lifters or Gripper Attachments
- Lifting and Moving Bags: Bag Handling with Customized Vacuum or Clamping Solutions
- Moving Sheets and Panels: Sheet Handling with Vacuum Lifters for Flat Loads
- Moving or tilting pallets: electric pallet jacks, pallet inverters or mobile lifters
- Handling drums: drum handling using specialized drum clamps or lifters
- Moving Coils: Coil Handling Using Coil Carriers or Vacuum Systems
Choosing the right device also depends on how often the task is performed. If the task is performed frequently, investing in a specialized solution is more worthwhile than for occasional use. A complete product overview provides a good picture of the available options for each application.
When is a job analysis useful?
A workstation analysis is useful whenever employees regularly report physical complaints, when absenteeism rises for no apparent reason, or when a new task or work environment is introduced. An analysis is also a logical first step when purchasing new equipment or redesigning the warehouse.
A job analysis identifies which tasks cause the greatest strain, which postures are problematic, and where ergonomic improvements will have the greatest impact. This makes the analysis useful not only for employee health but also for process efficiency.
In practice, workstation analyses are still too often postponed until after an incident has occurred. However, conducting them proactively is much more effective: the costs of an analysis are significantly lower than those associated with long-term absenteeism, staff replacement, or retroactive modifications to an already established workstation.
An analysis doesn't have to be complex. A specialist who observes the workstation, maps out the tasks, and makes specific recommendations can already provide valuable insights. This may result in a simple adjustment to the work height, or it may lead to the introduction of a specific lifting aid.
How do you maintain material-handling equipment to ensure safety?
You maintain material handling equipment through a combination of periodic inspections, preventive maintenance, and prompt resolution of minor malfunctions. Equipment that does not function properly increases the risk of accidents and may force an employee to manually support the load, which is precisely the strain the equipment was designed to prevent.
Preventive maintenance involves inspecting equipment at regular intervals, even if there are no visible problems. Wear and tear on the suction cups of vacuum lifters, the brakes of pallet trucks, or the hydraulic systems of lifters is not always immediately visible, but can cause sudden failure.
A structured maintenance plan also offers benefits in terms of availability. Equipment that suddenly breaks down causes lost time and sometimes forces employees to resort to unsafe alternatives. Planning maintenance helps avoid unplanned downtime. More information about maintenance options can be found on the service page.
In addition to technical maintenance, user training is also essential. Equipment that is used incorrectly wears out faster and exposes employees to risks. A brief introduction when the equipment is first put into service and periodic refresher sessions on the operating instructions make a clear difference.
How Logitrans Handling Helps Reduce Absenteeism Due to Physical Illness
At Logitrans Handling, we view ergonomics as a concrete investment, not as an additional cost. We guide companies through the entire process, from analysis to implementation, with the goal of systematically reducing physical strain in the warehouse and preventing work-related injuries. Our approach includes:
- Free Workstation Analysis: Our specialists analyze the workstation and identify the greatest ergonomic risks
- Customized solution: We select the equipment that best suits the specific task, load, and work environment
- Extensive product range: from vacuum lifters and mobile lifters to pallet trucks, pallet inverters , and electric tow tractors
- Demonstration area in Drongen: Customers can test out equipment with their own materials before making a decision
- Maintenance Contract: Preventive and Proactive Maintenance to Keep Equipment Safe and Operational
- User Training: Upon installation or delivery, we ensure that employees operate the device correctly and safely
Would you like to know which ergonomic solution best suits your warehouse environment? Contact us for a no-obligation consultation or a free workstation analysis.
Less effort, more performance
Lift more efficiently with ergonomic lifting solutions. Our specialists are happy to work with you to find the right solution.
