What Does OSHA Say About Depalletizing & Worker Safety? | Apex Safety Spotlight
Cost-Effective Depalletizing Tips Save You BIG in Worker Comp Claims
$20 Billion… yes, that’s a “B,” and it represents the direct annual cost of musculoskeletal disorders (MSDs) in the American workplace. With over 400,000 injuries per year, MSDs are a leading cause of excess operating costs. Since depalletizing activities are practically a poster child for MSD risk, it’s worth looking at ways to address the challenge. For their part, OSHA holds business owners responsible for a “safe and healthful” workplace, but they also provide guidance to mitigate MSDs.
Before we dive into solutions, it’s important to note that by implementing and supporting an ergonomic process, businesses gain much more than directly associated costs. Workers who are trained and supported improve efficiency and productivity and have more positive job satisfaction, leading to lower absenteeism and job turnover rates… which results in less money spent hiring and training new staff. So the question isn’t, can I afford to train my team, but can I afford to ignore the risk?
What are the MSD Risks Associated with Depalletizing Activity?
- Repetitive movement
- Poor posture
- Muscle & joint overexertion
- Cold temperatures increase risk
Fixing the Problem- Phase 1 Low-Cost Recommendations
Support – Commit to the safety of your team –from the top management levels all the way down. Train managers or appoint a health & safety manager to monitor worker activity. Getting worker buy-in helps them understand the risks and improves compliance.
Training – OSHA offers support for small- to mid-size businesses for on-site consultation. Still, any business can put together a comprehensive training program outlining proper lift techniques, risk identification, and early-injury reporting steps. Signs are an excellent supplemental, cost-effective tool to enhance worker understanding.
Use Reason – Implement reasonable work/rest schedules and set realistic productivity goals.
Evaluation – Periodically check with your team and review any injury reports to ensure workers thoroughly understand proper depalletizing lifting techniques and make any adjustments needed.
If you find that your team requires additional support, consider racking styles or features that support your team’s safety.
Depalletizing Tools to Prevent Musculoskeletal Disorders
Pallet Flow Rails
Depalletizing a unit load by hand typically requires lots of reaching, twisting, and bending. Depending on the application and load specs, consider pallet racking that can promote positive ergonomic positioning.
- Pallet flow rack
- Lift tables & work positioners
- Pallet rack sliding cart
 Lift Table |
 Sliding Pick Cart |
Pallet Flow Rack
Pallet flow rack comes in a variety of wheeled or roller track styles. The traditional design features the tracks on a slight pitch to automatically flow pallets from a load aisle to the forward pick position. Pallet flow can also be floor-mounted on an incline or as a simple push-assisted application. Floor-mounted pallet flow allows access to unit loads from multiple sides, which can be valuable for mixing centers. You also have the option to add conveyors near the workstation to limit load-carry strain.
Industrial Lift Tables & Work Positioners
Whether used independently or integrated into your pallet flow system, industrial lift tables and work positioner tables significantly enhance depalletizing ergonomics. Lift tables are versatile, coming in different load capacities and equipped with features that enable workers to effortlessly rotate or incline pallets to easily access items at the back of a pallet or container.
Industrial lift tables use hydraulic, pneumatic, or spring mechanisms, offering a range of height options. Providing height adjustments is crucial for achieving ergonomic positioning and promoting comfort and efficiency in the workplace.
Pallet Rack Sliding Cart
Items with low turnover rates and lower volumes make excellent candidates for a sliding cart solution. These wheeled carts fit standard pallet racks and enable workers to pull pallets away from the bay using a handle. Sliding carts improve access to the entire pallet, reducing the risk of injury and the possibility of dropping items.
While pallet racking solutions can help improve depalletizing MSD risk, high-volume facilities may want to consider implementing automated assistance.
Automation Solutions for Palletizing & Depalletizing
High-volume depalletizing may simply be more economical with automation tailored to your application and throughput goals. Here are a few options to consider, but the Apex Automation experts can help identify and scale your equipment to ensure it meets your expectations.
Exoskeleton Equipment
These wearable devices could be a game changer for depalletizing activities in reducing strain on the back, arms, and legs. When lifting heavy pallets or boxes in depalletizing actives, these devices can bear a substantial portion of the load, minimizing the potential for MSD injuries. Moreover, exoskeletons promote proper lifting techniques by encouraging workers to maintain correct posture and discourage risky movements that could lead to accidents.
Exoskeleton equipment also reduces fatigue, allowing workers to maintain their energy levels over extended periods. This results in better concentration and fewer errors, reducing the likelihood of accidents due to fatigue-related lapses. Varieties include passive and powered –so contact Apex Automation Solutions to get the right tool for the job.
Cobots (Collaborative Robots)
Whether you choose a cobot to assist or entirely take over your depalletizing task, you will benefit from reduced physical strain on workers and enhanced efficiency. Cobots are uniquely designed for easy installation, programming, and training. Once in operation, your workers can perform more skilled and strategic roles, providing the flexibility to manage labor demand effectively and control costs.
Layer Palletizer/Depalletizer
Layer automation equipment offers several advantages for depalletizing, particularly in high-speed operations with product uniformity, such as beverage and packaged food production. These systems handle a full product layer per pick, delivering exceptional efficiency and stacking consistency. They can quickly handle large volumes, requiring minimal adjustments between batches –ideal for high-throughput operations. Its capacity to optimize workflow, minimize downtime, and ensure consistent, precise depalletizing contributes significantly to streamlined warehouse and distribution operations.
Addressing the challenges posed by musculoskeletal disorders (MSDs) in depalletizing activities is not only a matter of compliance with OSHA regulations but also a smart investment in your workforce and overall operational efficiency. By prioritizing worker safety through ergonomic processes, businesses can reduce the staggering $20 billion annual cost of MSDs in the American workplace.
Discover Your Ideal Depalletizing Solution with Apex: Your Partner in Safety and Efficiency
When it comes to depalletizing tools and equipment, options like pallet flow rails, push-back racks, lift tables, work positioners, and sliding carts offer ergonomic solutions to mitigate MSD risks. For high-volume operations, automation with exoskeleton equipment, cobots, or layer depalletizers can significantly reduce physical strain, enhance efficiency, and ensure stacking consistency. Investing in safety is not necessarily a hard sell but more like an intimidating one –that’s where the Apex team does the heavy lifting!
Let us work with you to find the right tools and ensure proper installation and training –whether racking or equipment. We Got This! Call to schedule a consultation with our warehousing experts today.
Related Materials:
