Ergonomic considerations when slotting piece-pick operations in distribution centers

Area of Science:

• Occupational Ergonomics
• Industrial Engineering
• Biomechanics

Background:

• Warehouse slotting algorithms often neglect worker ergonomics.
• Optimizing item placement is crucial for efficient and safe warehouse operations.

Purpose of the Study:

• To develop ergonomic slotting guidelines based on biomechanical data.
• To assess the impact of shelf height on worker postures and muscle activity during picking and replenishment tasks.

Main Methods:

• Two studies were conducted: one with small item picking and another with full case replenishment.
• Electromyography (EMG) and postural analysis were used to measure muscle responses (deltoid, erector spinae) and body positions.
• Tasks were performed at various shelf heights to evaluate ergonomic impacts.

Main Results:

• Shelf height significantly influenced all measured postural and EMG variables.
• A trade-off in muscle activity between the back and shoulders was observed across different shelf heights.
• Data indicated distinct biomechanical loads associated with specific shelf heights.

Conclusions:

• Ergonomic slotting guidelines can be developed from biomechanical and postural data.
• These guidelines can help reduce biomechanical load exposures for distribution center workers.
• Optimized slotting based on ergonomics can enhance worker well-being and safety.