Top Ten Benefits of Fork Truck Free with One Piece Flow and Small Lot: Delivery Improves Safety

October 20, 2017 0 Comments Fork Truck Free Info 394 Views
  1. Improves safety by reducing motion, handling, and forklift movement
  2. Improves quality by first defecting defects instead of creating a bad batch
  3. Improves flexibility by shortening lead-times through processes (connected processes, smaller lot sizes)
  4. Improves scalability by making equipment that is efficient with smaller lot sizes.
  5. Reduces inventory by connecting processes and reducing lot sizes through quick changeover
  6. Improves productivity by working on one thing at a time and cutting out wasted motion
  7. Simplifies material replenishment by making the speed of material consumption steady and paced to a takt time
  8. Frees up floor space by opening space used for inventory
  9. Makes kaizen take root by exposing hidden problems and making them more visible
  10. Improves morale by promoting cross-training and skill enhancement, as well as identifying and solving problems more quickly and reducing frustration

 

That is the big picture overview.  Over the next several months Topper Industrial will use this blog to take a deep dive and look at this issue and benefits.  We look forward to meeting many of our blog readers in Atlanta, GA during MODEX 2018, April 9 – 12.

Fork Truck Free Benefit: Improves safety.

According to insurance studies, a leading cause of workplace injuries is overexertion. According to a study from the National Safety Council, overexertion costs employers $13.4 billion a year, making it one of the top three costliest and disabling work-related injuries in the United States. In addition, overexertion causes fatigue, which results in less productive employees, increased quality errors, and more accidents.

Controlling Overexertion Injuries
Statistics show that overexertion injuries can happen to any worker, at any age, and in any work situation. There are effective measures to successfully reduce the incidence and severity of overexertion injuries:

Optimize storage practices. In many cases, overexertion injuries can be prevented by storing heavier, manually-lifted parts in the lifting “power zone” between the knees and the shoulders. A great first step for many organizations is to simply raise the storage height of heavier parts to waist level, where equipment can be slid directly onto a cart and pushed to the desired location.

Use material-handling aids. The cost of a back-injury averages more than $40,000 according to the U.S. Department of Labor, which determined that there were 4.6 injuries per 100 fulltime employees in the workplace. Injured employees required an average of 19 therapy visits (Worker’s Compensation Research Institute). The average number of work days lost to work injuries was nine days. Sprains or strains accounted for 40 percent of the injuries. A work-related injury resulted in an average loss of approximately $38,000 including wages, productivity loss, and medical expenses. Furthermore, the National Safety Council documented that the longer manufacturers wait to treat worker’s compensation injuries, the greater the cost.

Use accident investigation as a learning tool. Rather than scolding employees to be more careful when lifting heavy objects, conduct a root cause analysis of each injury. Finding a permanent corrective action, such as going Fork Truck Free, is much more effective than simply telling employees to be careful.

Controlling overexertion injuries goes beyond focusing on compliance alone and should be incorporated into all components of an injury management program. It will help control claim costs, improve productivity, and provide a safer work environment for employees.

Smaller Lot Sizes and Fork Truck Free Reducing Injury and Fatalities

 Lifting heavy containers and moving large pallets of materials are reduced when lot sizes are smaller. The reduction of just these two activities creates a statistically significant reduction in injuries.

Forklift fatality is common. OSHA statistics indicate that there are roughly 85 forklift fatalities and 34,900 serious injuries each year, with 42 percent of the forklift fatalities from the operator’s being crushed by a tipping vehicle. With fewer or no forklifts, manufacturers and distribution centers are reducing forklift accidents, a major cause of injuries and death in factories.

by Chris Mosby

Chris Mosby, LSSMBB is the Lean Manager for Topper Industrial. Mosby has been a Lean/Six Sigma trainer for more than 20 years in multi-faceted, fast paced manufacturing environments. His experience includes management assignments in Quality, Production, Logistics, Healthcare, and Maintenance/Engineering.

 

Topper Industrial (www.topperindustrial.com) is a leading manufacturer of material handling equipment. Topper provides lean material handling solutions to the supply chain.

Topper Industrial is able to engineer and design Industrial Carts (Mother / Daughter Cart Systems, Quad Steer Carts or Tracking Carts, Specialized Delivery Carts, Transfer Carts with Roller Deck, Static Carts, Rotation Carts, Tilt Carts or Kitting Carts), Industrial Cart Components (Parts Department), Industrial Containers (Corrugated and Wire Mesh Containers), PalletsLift/Tilt Systems, and Racking. Topper Industrial designs all products with ergonomics in mind, focusing on ease of use and best positioning of material to get the job done.

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