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How Packing Tables Can Improve Your Fulfillment Operation

How Packing Tables Can Improve Your Fulfillment Operation

by | Dec 16, 2020 | Productivity

Is your fulfillment operation performing the way it should be? How do you know if it’s not? Are your packing tables contributing to reaching your business’s  full potential, or could they be improved?

COVID-19 has brought unprecedented change to almost all areas of life, and one unexpected impact it has had on the economy is driving a dramatic increase in e-commerce volume.

A rise in online orders has put pressure on warehouses, many of which must now process packages faster than usual, to keep up with demand. You can make some changes to deal with the increase in output without the investment in a new facility.

From upgrading your packing tables to adding conveyor systems, there are various options to consider for your warehouse to be performing at its best.

If you’d like to keep productivity levels up, keep your workers engaged, and make sure you’re getting the most out of your warehouse, read on for ways you can improve your packaging operation.

Perform an Audit

To improve your packing operation, you need to be very familiar with it. You might think you know all the processes your warehouse or fulfillment facility performs, and you probably are. But conducting an audit runs deeper.

It requires studying and analyzing the functions, processes, and outputs of a given area of operation—in this case, packaging—and using your findings to identify any areas that could be improved.

Listen to Employee Feedback

As well as performing your research and working off of your own findings, you should make sure to speak directly with your employees. After all, who better to tell you about what processes could be improved than the people who have been carrying them out, all day every day, for a significant time.

Your employees will be well placed to let you know about any finer details an audit might have missed.

Replace or Update Equipment Such as Packing Tables 

You might not have the resources or time to move to a new facility. One thing you should never shy away from, however, is top-quality equipment.

Replacing items before they have a chance to break or malfunction will mitigate any unnecessary breaks in production. It will also most certainly reduce the number of workplace accidents you’re likely to have.

Ergonomically well-planned workbenches or packing tables can significantly improve your work process and productivity and, at the same time, reduce the ergonomic risk for your employees.

Integrate Packing Tables and Conveyor Systems

This year especially, we have seen a trend in fulfillment and warehouse operations of adding or upgrading conveyor systems. Conveyors can help to reduce warehouse waste, speed up throughput, and improve lean operations in your warehouse. Conveyors can also do a lot to improve ergonomics in your workplace. Consider integrating your packing tables into the conveyor process for even better results. 

Improve Employee Comfort

Taking the comfort of your employees into consideration will help to improve employee retention rates. It will also allow your employees to work for more extended periods and in a more productive manner.

Improving workplace ergonomics is essential in any warehouse environment. The packaging department, where heavy items are being handled and moved continuously, should not be overlooked.

Avoid liability, reduce workplace injuries, and keep your workers happy and healthy. Invest in ergonomic equipment for your warehouse.

Put Strict Health and Safety Standards In Place

Health and safety are two of the most critical terms for any warehouse operation. Your first job is to make sure all employees are aware of and adhering to the health and safety standards you have in place. Second, you need to make sure you’re reviewing and updating these protocols regularly.

According to the US Bureau of Labor Statistics, warehouses have an especially high rate of injuries. In 2017, the rate of injury or illness in warehouses was around 1 in 20.

Many warehouse employees know safety protocols but will sometimes circumvent them to get a job done more quickly. Ensure that in your workplace, you have instilled a safety culture among your workers. Safety should come first, and there should be no uncertainty surrounding this.

The Last Word in Warehouse Operations

The packaging operation plays a critically important role in any warehouse and distribution center. COVID-19 has sent e-commerce sales through the roof, and there is every chance that this trend will continue, even in a post-pandemic world.

One way to ensure you’re able to handle any sudden increases in demand life may throw at you? Make sure you’ve outfitted your operation with the latest equipment and technology.

From packing tables and workbenches to protective barriers, BOSTONtec has everything you need to make sure your team is ergonomically supported. Get in touch today to see how we can help.

 

4 Ways We Are Improving Our Packaging Process of Industrial Workbenches

4 Ways We Are Improving Our Packaging Process of Industrial Workbenches

by | Nov 23, 2020 | Company News

Have you ever wondered how we package our industrial workbenches so they arrive at your work site in perfect condition? When workbenches are shipped with LTL trucks, they often go from one hectic terminal to another. They endure a tremendous amount of handling before reaching their destinations. It is a challenge to keep them intact after such a bumpy journey.

We have been working with our preferred carriers, FedEx and XPO, on evaluating our packaging process of industrial work benches. Recently we kick started a new initiative with a series of packaging improvements.

Bigger and stronger pallets

All BOSTONtec stations are shipped assembled upside down on a pallet. Accessories are packaged separately and shipped either with the work bench or on its own pallet depending on the project size.

After evaluating the pallet size, we found out that increasing the clearance on each end of pallet can provide extra protection to the workstation especially the countertop.

We also looked at the quality of our pallets and the ways metal banding is used to hold the product in place. We have invested in strong pallets and boards at the ends of pallet to withstand the pressure from the metal banding.

Extra protection for the table top

To avoid scratch marks at the edge of the countertop, we are using sturdy 1/8” thick cardboard corner material. We surround the entire countertop with this durable material that is not easily pierced through by fork trucks. 

Additional reinforcement

For tables eight foot and larger, our pallets are reinforced with a 1 ¼ -inch thick laminate board. We also double band work benches that are six feet and larger and add two by fours as our banding at the top of the pallet. The metal banding goes across the two by fours to prevent breaking in transit. On top of that, we shrink wrap everything thoroughly to hold the products tightly to the pallet.

Sustainable packaging

While protecting our products during transit is a top-priority, we stay eco-friendly. At BOSTONtec we make sure to reduce our environmental footprint whenever possible. The bulk of our packaging materials are recyclable. We also use scrape materials from our parent company Case Systems to strengthen pallets. We stopped using a heat sealer machine to package our accessories because it generated too much waste. For large orders that ship in a dedicated truck, we reduce the packaging because it goes directly from our dock to the end user with minimum handling.

As you decide among different brands to be your provider of workstations, ask about their packaging process.  How we take care of our workstations in transit shows how much BOSTONtec cares about your experience when you receive them in tip-top shape.

We continue to work on getting our products to you safely, and look forward to your feedback which will help us evaluate the effectiveness of these measures and come up with even better solutions. Share your insights with us!

BOSTONtec produces affordable, high-quality, height-adjustable packing tables, assembly work benches, medical stations, and lab tables. We strive for continuous improvement of our product offering and customer service.

Spine Health: How Workstations Can Support Your Employees Wellbeing

by | Nov 12, 2020 | Productivity, Ergonomics

When it comes to workstations, people don’t automatically think about how they can influence your employees’ well-being.

However, studies have shown that lower back pain and spine health is the most common cause of workplace injury and disability for people under the age of 45. So what can be done to prevent this?

In this article, we will discuss how important a proper ergonomic workstation is for your employees’ spine health. Back pain doesn’t need to be an issue for your workplace with the correct equipment.

Read on to find out more.

What Causes Back Pain and Poor Spine Health?

In a manual job, there are stresses placed on the body every day in terms of heavy lifting or repetitive movements.

These can manifest over time and become an issue to backs, spines, and joints. There is also a risk of injury from slips and falls, causing muscle strains, broken bones, or fractures.

The same can be said when using workstations in industrial and other settings. Pain is commonly caused by poor body posture and the mechanics of the body when using a workstation.

When sitting, this prolonged stationary movement can play havoc on spine health. It can also cause back problems that affect employees’ daily lives. But the same pain can be caused when standing at the wrong kind of workstation.

What’s the Effect of Poor Spine Health?

By not having good posture a person can develop problems such as lower back pain, neck strain, and leg pain. This can lead to issues with a person feeling pain in their body when sitting for extended periods of time and also walking around.

It can mean that people are unable to come to work and have to take time off due to the levels of pain they are experiencing. They also might have to undergo several sessions of seeing a chiropractor or take pain medication to alleviate the symptoms. 

Constant back pain and poor spine health can leave people feeling depressed and unfocused in their careers. This means their productivity will be lower and they will have more days off sick.

How Can Ergonomic Workstations Help?

Ergonomic workstations and workbenches help to solve issues such as poor spine health in a warehouse or factory. Ergonomics follows the principles of identifying the body’s natural posture. This means that the workstation can be aligned to suit the individual.

It allows their body to be placed comfortably in a neutral position that will put the least amount of strain and pressure on its joints and muscles. This will then, in turn, support the body without it having to deal with bad posture and the negative effects that come with that. 

It also prevents overreaching and strain of how some workstations can be set up. This means the employee will overextend past their comfortable range of movements.

Ergonomics means fitting the task to the worker – not the other way around.

In manual labor job roles, this is doubly important. Your employees will already be putting a lot of strain on their bodies to do their jobs. You don’t want to add to this strain unnecessarily by using poorly adjusted workstations. 

Electric Ergonomic vs Crank Workstations

When looking at ergonomic workstations for your workplace, you may not realize there are different types to choose from.

Both electric and crank workstations have adjustable work surfaces that can be raised and lowered. They also come in a range of sizes to fit a variety of different purposes. Depending on the style of your workplace, there will be an ergonomic workstation that will be perfect for your needs.

The main difference between electric and manual ergonomic workstations is that the electric height adjustable workstation is adjustable through the touch of a button. A crank workstation, in comparison, takes some effort and time to crank to the correct height.   We dive deeper into the difference between crank and electric height adjustability in one of our previous blog posts.

If your workplace is a multi-shift multi-operator organization or has multiple people working at the same station, an electric workstation is usually preferable.

Technical and Specialty Workstations

If you are working in a very specialized distribution center or manufacturing setting that isn’t classed as a ‘typical’ working environment, you might be concerned that you can’t source workstations that are compatible with your requirements. Luckily, that is not the case at all!

If you need a workstation that caters to special application challenges these can also be set up ergonomically in a way that promotes good posture and without placing strains on their muscles. 

If necessary these workstations can be customized entirely for employees’ individual needs. There are many popular accessories that can be added to support a variety of job specifications. 

How to Promote Good Spine Health in Your Industrial Workplace: Where Can I Find Out More?

We hope this article on how spine health in the workplace is an integral part of keeping employees healthy has been informative.

Bad posture and lower back problems can be so detrimental to workplace morale and the overall health of your staff members. Providing them with an ergonomic and electric height-adjustable workstation is key in preventing health problems from occurring. 

If you would like to inquire about any of our products, contact us directly! Or check out our blog posts! 

Designing an Industrial Workbench for Adjustability

Designing an Industrial Workbench for Adjustability

by | Oct 21, 2020 | Custom Solutions, Productivity, Ergonomics

There are three different principles to designing a space – designing for average, for extreme, and for adjustability. What would be the best strategy when it comes to an industrial workbench?

Design for Average

This approach bases the design on the average anthropometric data of the users. It comes up with a one-size-fits-all solution. A typical example is public transportation in which the seats are identical with the same distance between rows of them. Human beings are unique. The “average” person doesn’t exist. It would be difficult to find people who are average in more than a few of the body dimensions. In addition, the proportion of body dimensions could vary too. Although designing for average seems like accommodating 50% of users, it is not optimal for anyone. It might be okay to sit in an uncomfortable seat on a plane for a few hours because you only fly occasionally. However, in industrial environments, a fixed workstation could cause repetitive stress injuries for the operator who works on it day in and day out.  

Design for Extreme

It is not practical to design for all users. In some situations, design for extreme individuals is necessary to accommodate the 5th percentile or 95th percentile users. For instance, the length of beds in some hotels is long enough, even for NBA athletes. Is it ideal? Not always. For example, if the height of a packing table is set for a small 5th percentile woman so that she can reach everything, it won’t be optimal for most of the other operators. Constant bending could lead to neck and back problems over time.  

Design for Adjustability

It is the most inclusive design strategy that we advocate for at BOSTONtec. It accommodates 5th to 95th percentile users or 90% of employees. It recognizes the uniqueness of each person and strives to meet their individual needs with flexible configurations. One example from daily life is the driver’s seat in a car. The height, position, tilt angle, back support, head support are adjustable to fit as many users as possible. 
workforce diversity

How to Design an Industrial Workbench for Adjustability

For industrial workbenches, design for adjustability applies basic ergonomic principles to ensure that the workstation fits the worker, not the worker to the workstation. It influences how the workers interact with the workbench and ultimately determines their overall efficiency, accuracy, comfort, and well-being. It takes into consideration the following when planning a workstation:

  • Size and shape of the operator
  • Type of task being performed and frequency
  • Space needed
  • Workflow
  • Items needed to complete the task such as tools, equipment, components, products, reference materials etc.
  • Importance of the items – how and where to place them relative to the operator

After the planning process, the items on the workstation will be assigned to appropriate ergonomic zones based on their priorities. The higher the priority, the closer the item should be placed to the operator. The four ergonomic zones can fit most operators by using a height adjustable work surface and flexible accessories.

Ergonomic zones

Design for Adjustability in Action

Below is an example of a custom material handling workbench designed for adjustability. The height of workstation can be adjusted with the touch of a button making it suitable for multiple operators and shifts. Accessories mounted on the uprights are also designed with adjustability in mind. They can be set up to fit individual needs and are out of the way when not in use. They allow each worker to access and handle the materials easily, have the optimal lighting to perform task, maintain neutral positions, and minimize non-value added movements.
custom assembly workbench with feature calloutsIncorporating adjustability in this design improves productivity significantly. It also helps prevent work-related musculoskeletal disorders (WMSDs) caused by lifting, bending, reaching, pushing, working in awkward body postures, and performing repetitive tasks. WMSDs are among the most frequently reported causes of lost or restricted work time. They cost employers $20 billion a year according to OSHA estimates.

Designing for adjustability benefits both employees and bottom line. It is a must have for your business. Thinking of implementing it in your own applications? Our experts in ergonomic workstations are here to help!

Crank or Electric Height Adjustable?

Crank or Electric Height Adjustable?

by | Sep 28, 2020 | Ergonomics, Productivity

The focus of applied ergonomics is to make the workplace a safer, more comfortable and more productive environment for each individual operator. Crank versus electric height adjustability? We compare the two options in industrial workstations under 5 criteria:

1. Operator Stress

Mechanical and hydraulic height adjustable tables that use manual hand cranks are not easy to adjust. The loading on the table is felt at the crank. Keep in mind that the weight of an industrial workbench includes the work surface, uprights, shelves, lights, drawers, and everything on the table top. The heavier the load, the more effort needed to turn the crank.

A lightly loaded workstation can require up to 60 pounds of force per turn. This poses ergonomic risks to the operator if the workstation height needs to be adjusted frequently during a shift as it is required by some tasks. An operator would choose to avoid the cumbersome operation whenever possible. This could cause additional ergonomic issues due to suboptimal workstation settings. 

In comparison, the height of electric height adjustable workbenches is controlled with a programmable switch. It can be activated with just the touch of a button. Ease of use will motivate the operators to optimize workstation height.  It enhances their performance and wellbeing.

2. Non-Value Added Time

For convenience and safety, manual hand cranks are usually stored out of the way when not in use. The operator often has to extract the crank before making the necessary turns to adjust the workstation height, not always an easy task especially for a 5th percentile woman.

Turning the crank is not only difficult but also time-consuming. Mechanical and hydraulic cranks require about 7 turns for every inch of height change. Height adjustment is even more challenging when the load on the work surface is not evenly distributed. Rearrangement might be necessary which costs extra time.

crank adjustment requirement

Time lost on cranking equals lost productivity. It means less boxes or sub-assemblies out the door and potentially cranky employees for you.

Electric height adjustable industrial workstations change height quickly with just the touch of a button.  Multiple presets can be saved for different operators. It is a big time saver for multi-operator, multi-shift applications. Within a single shift, the operator can adjust the height anytime to fit the task better or enjoy the health benefits of switching between sitting and standing positions effortlessly.

3. Operator Safety

Hydraulic crank workstations utilize fluid-filled, pressurized cylinders in each leg. The lines are susceptible to collapse causing the fluid to spray onto the workstation, operator or floor creating safety hazards. Due to the potential fluid release, hydraulic crank tables are undesirable in cleanroom environments. Electric height adjustable workstations require no messy fluid.

4. Reliability

Manual and hydraulic crank tables are less dependable resulting in unnecessary operator down time and lost productivity. Electric height adjustable workstations have a 99.5% reliability rating.

5. Maintenance Expenses

Unlike electric height adjustable workstations, crank tables require routine maintenance. Repairs can take a hydraulic table out of service to rebuild cylinders and drain fluids. Mechanical designs utilize non-precision jacks which are inefficient and require regular upkeep. Electric height adjustable workstations have sealed actuators that require no maintenance.

Electric height adjustable industrial workbenches are clearly the winner here. It’s time to ditch the crank to improve your productivity and employee health!

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