Work factors affecting manual materials handling in a warehouse superstore

Abstract

An ergonomic analysis of the job of stocker was conducted in a warehouse superstore. The main determinants of the handling activity and related constraints were described. These pertain to the physical layout, containers, equipment, management of stocks and arriving merchandise. The simple physical layouts observed are designed to increase sales but do generate several physical constraints that were described. Product-related constraints were also documented. Manual materials handling activities are performed during an average of 74% of the work shift duration. During a shift, stockers perform an average of 200 handling operations and the total average cumulative weight is 2000kg. The merchandise handled is often fragile and unstable. The pallet jack, the stockers’ only equipment, is used on average 54 times during a work shift. Its main problem is one of incompatibility with some of the pallets used which results in either increased effort or time pressure. Stockers’ work involves significant planning related to stock movements and arriving shipments. In this regard, four problem situations were identified which generally result in additional handling operations and time pressure. Results are discussed in light of the inherent characteristics of the warehouse superstore concept. Relevance to industryThe study provides new knowledge on manual materials handling activities in an emerging sector, namely that of warehouse superstores. A proper identification and description of the determinants of the handling activities is useful for defining prevention activities in this sector.