Best Practices for Enhancing Workplace Safety Through Smarter Material Management

Employing smarter material management techniques, such as minimal push force, motorized casters, regular maintenance, and comprehensive training, enhances workplace safety and efficiency in manufacturing.

• By Doug Backinger
• Nov 13, 2024

“Safety first.” That’s the manufacturing mantra.

It’s both the right thing to do and a practical necessity.

Top talent is hard to find. So sector leaders prioritize keeping them safe, productive and engaged. As a result, manufacturers invest heavily in advanced safety protocols, cutting-edge technology and continuous training programs to ensure a secure and efficient work environment for everyone.

Speed, efficiency and ergonomic efficacy are often overlooked in this process. Moving heavy machinery or material-handling carts may not put someone’s life on the line, but less efficient caster designs or outdated movement methodologies make it more difficult for workers to transport materials and finished goods in the best position and with the least push-force effort for assembly and loading.

It’s a safety issue that, when addressed appropriately, meaningfully improves workplace conditions and worker efficiency—a win-win for manufacturers and their teams.

Here are four best practices for achieving optimal material handling efficiency while enhancing safety and ergonomics in the manufacturing process.

#1 Prioritize Minimal Push Force

Push force—the amount of effort required to move an object by pushing it—needs to be minimal. Fortunately, with the right wheel design, even large, heavy objects can be safely and efficiently transported throughout a manufacturing space.

Start by looking at the wheel size. Taller and narrower wheels create less resistance and are easier to start rolling. The taller profile helps overcome cracks, dips and other floor imperfections as well.

Additionally, consider the wheel material. Hard materials, like polyurethane, can significantly improve mobility and durability since softer materials require more initial force to get an object moving. Softer materials often wear faster, eroding movement efficiency and requiring additional push force to propel materials.

#2 Schedule Regular Maintenance and Inspection

Manufacturing floors contain dirt, dust, debris and other contaminants that make wheels and casters progressively less efficient.

Regular maintenance and inspections can address common issues that contribute to a less efficient, ergonomic and safety-focused manufacturing facility, including:

• Wear and tear. Locating wear and tear allows maintenance teams to repair or replace casters before they undermine core priorities.
• Wheel blockages. Regular maintenance will keep casters free of debris and build-up so that they are always optimally operating.
• Cart overloading. Identifying evidence of cart overloading allows leaders to rearrange workflows to protect people and facility investments, ensuring that small oversights don't damage carts, casters and equipment.

These are preventable problems, and monitoring and resolving these issues will help prevent accidents, enhance efficiency and boost productivity across the manufacturing floor.

#3 Consider Motorized Solutions

The right wheels and casters can significantly improve an object's movability, but even the best products won’t make pushing an excessively heavy or large load reasonable.

Motorized casters are a popular solution, introducing new operational efficiencies and enhancing employee safety.

For instance, a motorized caster not only reduces the level of physical exertion but also eliminates the need for multiple employees to push the same cart, combining safety and efficiency in a way that benefits manufacturers and their employees. This approach often provides significant long-term cost savings and return on investment through increased efficiency and reduced workplace injuries.

#4 Teach Employees Safe Materials Handling Best Practices

Whether equipping a new workforce to navigate the manufacturing floor or reminding seasoned employees of best practices, training is a necessary part of an employee safety initiative.

That’s why manufacturers need to provide timely and comprehensive training in material handling best practices, including the proper use of carts and the maintenance of caster wheels. This makes everyone more capable of handling equipment safely and efficiently.

Highly-effective training will include:

• Regular training sessions for all employees
• Comprehensive coverage of proper use of carts, maintenance schedules and safe material handling techniques
• Hands-on practice with equipment
• Documentation of training completion for each employee.

In other words, safety and efficiency aren’t contingent on caster material alone. It’s the product of the training and the right materials together.

Safety First for Everyone

The manufacturing sector is booming, but its long-term success is predicated on employee safety.

Safety first. It’s the path to success.

Ergonomics and efficiency might not be the first thing that comes up when considering workplace safety, but optimizing material handling is critical to both safety and efficiency.

By implementing these four best practices—minimizing push force, scheduling regular maintenance, considering motorized solutions and providing comprehensive employee training—manufacturers can create a safer, more efficient work environment.

These cost-effective and safety-improving efforts reflect the forward-looking advancements leaders can make with the use of ergonomic technology and customized design for casters, whether human-operated or heavy-duty applications.