Facility Safety Management

Despite the tremendous advances in technology over the last 30 years, a significant portion of American industry still handles materials without the benefit of ergonomic assist equipment or devices.

The materials handling industry has long understood the importance of ergonomics in the design of jobs and equipment. The re-design of traditional equipment such as powered and manual lift trucks, order-picking rack systems, conveyors, containers and workbenches have been proven to re-duce ergonomic related injuries and in-crease productivity.

The industry’s focus on developing this equipment is reflected in the mission of the Material Handling Industry of America’s Ergonomic Assist Systems and Equipment (EASE) Council, which is to broadly promote the benefits of ergonomic assist systems and equipment together with the advantages derived from and the considerations for the use of this equipment in the workplace.

It is also the mission of the Council to promote the general safety and health aspects of work environments for people with or in the vicinity of mechanical equipment. Some ergonomic lift assist equipment made by members of the MHIA includes the following:

(AWEP) are used to provide signiﬁcant ergonomic benefits by positioning the worker to the job. There are many deﬁned workstations in manufacturing facilities with points of human interaction at an elevation above the plant ﬂoor, requiring that the operator be positioned on a raised platform. Often times, these platforms are makeshift and can present safety hazards.

It is also common for the plant maintenance department to fabricate non-adjusting platforms conﬁgured for the “average employee.” These ﬁxed-height platforms do not correctly accommodate the 5’4” employee and the 6’4” employee.

Multiple-shift operations, where three different operators interact with the same process machine in a 24-hour period, complicate the accommodation issue. Job rotation with operators changing jobs every couple of hours adds even more challenges to the workplace ergonomics issue. Job rotation may spread the risk of worker injury over a larger worker population, but does not eliminate the risk.

Modifying the the chacteristics of a workstation to reduce he number of bad choices an operator can make for providing operator control over the physical characteristics of workstation are proactive methods for addressing inplant ergonomics issues.

AWEPs provide each operator with the ability to control their own position in relation to the task at hand, and position the task so that the operator can gain a biomechanical advantage over the task. AWEPs are typically mechanically-driven devices that are manually adjusted. Platform sizes vary from 2’ x 3’ one-person units to larger runways parallel to assembly lines. Heights start as low as 2 feet above the shop floor. Most units have 12 inches of vertical adjustment. AWEPs can e pit-mounted, if necessary. Capacities are typically 400 lbs. Powered AWEPs can be activated using electricity or shop air.

Balancers Typical Application
These overhead devices provide and perform functions similar to overhead hoists in that they can lift and lower a load. The balancer configurations and suspensions are similar to a hoist.

This feature allows the operator to maneuver the load easily. Balancers are often used for awkward and/or rapid load movements. Balancers can also be used to suspend equipment which is used in repetitive

Both air-powered and electronically driven balancers are commonly available. Balancers can weigh up to approximately 100 lbs. and have approximate lifting capacities of 500 lbs.

Industrial scissors lifts are used in a wide variety of ergonomic applications where bottom-up movement is required. They are used in industries such as manufacturing, assembly, warehousing, distribution, sheet feeding and printing, just to name a few.

Generally, scissors lifts, or lift tables (as they are sometimes called), may be used to position material so operators do not have to lift excessive loads, lift repetitively, or bend to do their jobs. These tables can include variations to facilitate horizontal movement on the deck such as conveyors or ball transfers. In addition, portability options for the base allow the complete unit to be moveable. Tilting devices can be added so loads can be positioned both vertically and angularly.

Scissors lifts can be adapted to any plant situation by choosing from different power options. For example, lifts can be powered with electric or air-powered hydraulic pump units, pneumatic lift systems or full mechanical lift systems.

Scissors lifts can be installed in any number of ways to meet speciﬁc requirements. Generally, they will be surface mounted or pit mounted. They can be either ﬁxed in position or moveable in either case.

Vacuum tube lifters are ergonomically designed to reduce back strain, injuries and accidents therefore reducing or eliminating workers compensation claims. When using a lifter on a daily basis, worker fatigue should be greatly reduced and productivity increased. The lifter impact on the work place, because of its versatility, should help reduce absenteeism and downtime. Using the vacuum lifter can accomplish many repetitive lifting tasks ergonomically, quickly and skillfully, without delay.

Vacuum tube lifters have a wide range of capacities from as little as 40 pounds to 1,000 pounds. These units are powered by anywhere from 3.5 h.p. to 7.5 h.p. regenerative blower.

Most vacuum lifters offer many standard vacuum heads. These heads usually twist or snap on or off to change one head to another and can be done in a matter of seconds. There are a variety of standard vacuum heads designed for speciﬁc applications from situations involving narrow spaces with little room to maneuver, to load destinations which are higher than the op-erator’s head, loads form sacks, to cartons, to 55 gallon drums, or large wood or metal sheets. Other standard heads enable the handling of different package shapes and surface types. There are even heads which can enable the operator to reorient cargo vertically or horizontally, with integral vacuum pump or pneumatic assist devices.

Enclosed track workstation cranes are ergonomically designed for lighter loads, from 150 lbs. to 4,000 lbs. capacities. Horizontal movement is usually push, but can be powered. The high strength enclosed track design keeps rolling surfaces clean, which contributes to easier crane movement and longer wheel and track life. The tracks’ low weight per foot reduces the dead weight, which makes for easier movement, increased worker safety and increased productivity.

Enclosed track workstation bridge cranes push very easily — typically one pound of force for 100 pounds of load. This is much easier than I-beam crane systems that typically takes 3 pounds of force to move every 100 pounds of load.

Ergonomically designed, easy to move workstation cranes put less stress on operators. They offer precise load positioning, signiﬁcant productivity improvements, fewer injuries and less fatigue. Equipment conﬁgurations include single or double girder bridge cranes, jib cranes and monorails. Both steel and aluminum cranes are available. Suspension is varied. The options include free standing floor support, ceiling suspended cranes or a combination of the two.

Load suspension trolleys, which ride on wheels inside the enclosed track, have devices that hang below the track opening to support vertical lift devices. These vertical lifting options include hoists, balancers, vacuum lifters and manipulators which contain holding and orienting devices such as hooks, slings, grabs, spreader bars, vacuum devices, custom end effectors and magnets.

Enclosed track workstation cranes and monorails can offer ergonomic solutions to a single operation or an entire material handling system. FSM