How to Build and Design an Ergonomic Warehouse
Have you ever wondered how to build and design an ergonomic warehouse? Whether you’re starting from scratch or starting over, this task can feel overwhelming. What is the ideal layout for maximum safety and productivity? How do you mitigate risk and optimize output? Are there any vital considerations that must be given priority?
The intentional design of your warehouse will help determine functionality, productivity, profit, and most importantly, ensure the health and safety of workers and those entering the warehouse space. But where do you begin to start building and designing an ergonomic warehouse? It all comes down to careful planning.
Planning to Build and Design an Ergonomic Warehouse
According to Camcode, preparation is all about defining your objectives for an ergonomic warehouse and then developing a cohesive warehousing strategy. If key stakeholders are aligned on specific project goals and desired outcomes, the planning process becomes much more streamlined. With that said, there are some key factors for everyone to consider when planning to devise an effective ergonomic warehouse:
- Building Codes – Be aware of regulatory compliance and local building codes (regulations often differ based on geographical location). Safety considerations may include such factors as egress paths, forklift aisles vs. foot traffic, etc.
- Professional Advice – Don’t be afraid to solicit advice from seasoned professionals, such as managers and contractors. Their experience in warehouse operations could save you both time and money (not to mention the probability of enhanced safety for frontline workers).
- Spatial Relationships – Take time to determine the right amount of space for each area. In fact, it pays to test your layout design in advance. For example, you could try using masking tape to delineate specific work areas and ask workers to simulate the required activity.
- Adequate Lighting – Be sure to install proper lighting to avoid safety issues caused by poor visibility of potential hazards such as cross-aisle traffic, trip hazards, and others.
- Product Knowledge – Take stock of your inventory to foster a deeper understanding of warehouse logistics. For example, consider the shape, size, type, and number of items being handled, the material handling equipment used to transport these items, and other considerations.
- Internal Layout – Ensure that the following elements are given due consideration when planning your internal layout: Throughput efficiency, building utilization, safety, and environmental aspects. Traffic flow is a major consideration when planning for an ergonomic warehouse.
- Amount of Movement – Limit the amount that workers are required to bend, reach, and twist on-the-job. Inventory should not have to be moved more than once. Workplace injuries frequently result from the physical strain of repetitive awkward movements. Installing ergonomic handling equipment can help reduce repetitive strain for workers.
- Temperature Control – Remember heating, cooling, and humidity controls when it comes to warehousing products and increasing worker comfort and safety. Without an appropriate temperature to work in, workers may be more prone to health complications and productivity will also suffer. Environmental due diligence should also factor into this decision.
- Forklift Operations – In order to maintain an efficient environment for forklift operations, operators must be given a wide berth. Space is critical to this core function.
- Load Integration – If increased speed is one of your warehouse objectives and space is readily available, consider integrating loading and unloading areas to create a faster and more seamless transition.
- Dock Selection – Since trucks are connected to the warehouse via docks, determine which type of dock works best for your specific needs: flush docks or docks that are separated by an immediate platform? Choose the right dock for the right job to ensure maximum productivity, safety, and efficiency.
- Warehouse Zones – There are four functional warehouse zones that should be included in your layout: storage, yard/dock, picking, and VAS/kitting zones. Each zone deserves equal consideration to function at optimal capacity.
Top Benefits of Building and Designing an Ergonomic Warehouse
Once an individualized plan for designing and building an ergonomic warehouse is put into action, a number of benefits will follow. As you know, every business is unique. A warehouse designed to accommodate your specific needs and objectives can only enhance workplace ergonomics. Here are some of the top benefits of building an ergonomic warehouse:
- Increased safety and productivity
- Healthy workplace culture
- More presenteeism and employee retention
- Reduced risk of on-the-job injuries and liability
- Elevated manufacturing speed
- Higher profit with fewer payouts
- Greater compliance with building regulations
- Enhanced reputation in the community
Your Ergonomic Warehouse Design
There are many advantages to building and designing an ergonomic warehouse. Although the initial planning process itself may seem cumbersome, your investment of time, energy, and money will surely pay dividends down the line. Ultimately, an ergonomic warehouse is a safe and efficient working environment that benefits all those involved, including the customer.