Common Mistakes to Avoid When Using Material Handling Equipment

Date Posted:21 August 2024

Avoiding these common mistakes can significantly enhance the safety and efficiency of your material handling operations. By prioritising maintenance, training, safety protocols, and proper equipment use, you can create a productive and safe working enviro

Material handling equipment is the unsung hero of warehouses, manufacturing plants, and distribution centres. From forklifts to conveyor belts, these tools ensure that products are moved efficiently, safely, and swiftly. However, even the best equipment can be rendered ineffective, or worse, dangerous, if not used correctly. Here, we outline common mistakes to avoid when using material handling equipment to ensure smooth operations and maintain a safe workplace.

1. Neglecting Regular Maintenance

Mistake: Skipping scheduled maintenance checks and servicing.

Impact: Just like any machinery, material handling equipment requires regular maintenance to function optimally. Neglecting maintenance can lead to unexpected breakdowns, safety hazards, and costly repairs.

Prevention: Establish a routine maintenance schedule. Ensure that all equipment is inspected, serviced, and repaired as needed. Keep detailed records of maintenance activities to track the health of your equipment.

2. Overloading Equipment

Mistake: Exceeding the weight limits of forklifts, pallet jacks, or conveyor belts.

Impact: Overloading can cause equipment failure, leading to accidents and injuries. It also reduces the lifespan of the equipment.

Prevention: Always adhere to the manufacturer’s recommended load capacity. Train employees on the importance of following these guidelines and provide clear signage indicating maximum load limits.

3. Inadequate Training

Mistake: Allowing untrained or improperly trained personnel to operate equipment.

Impact: Lack of proper training increases the risk of accidents, equipment damage, and inefficiency in operations.

Prevention: Invest in comprehensive training programs for all employees who will be using material handling equipment. Regularly update training to include new safety protocols and equipment features. Consider certification programs for operating heavy machinery.

4. Ignoring Safety Protocols

Mistake: Not following established safety protocols and procedures.

Impact: Safety protocols are in place to protect workers and equipment. Ignoring them can lead to serious accidents and injuries.

Prevention: Reinforce the importance of safety protocols through regular training and reminders. Conduct safety drills and audits to ensure compliance. Create a culture where safety is a top priority and encourage employees to report any safety concerns.

5. Improper Loading and Unloading

Mistake: Incorrectly loading or unloading materials on equipment.

Impact: Improper loading can lead to load shifts, tipping, and damage to both the equipment and the goods being transported.

Prevention: Train employees on the correct methods of loading and unloading. Use appropriate tools like straps and braces to secure loads. Ensure that loads are evenly distributed and do not exceed the equipment’s capacity.

6. Poor Equipment Selection

Mistake: Using the wrong type of equipment for a specific task.

Impact: Using inappropriate equipment can lead to inefficiencies, increased risk of damage, and potential safety hazards.

Prevention: Assess the specific needs of each task and select the appropriate equipment. Consult with experts if unsure about the best equipment for a particular job. Regularly review equipment usage to ensure it remains suitable for your needs.

7. Lack of Communication

Mistake: Failing to communicate effectively between team members.

Impact: Poor communication can lead to misunderstandings, errors, and accidents.

Prevention: Establish clear communication channels and protocols. Use radios, signals, or other communication devices to ensure everyone is aware of ongoing operations. Foster a team environment where open communication is encouraged and valued.

8. Inadequate Workspace Organisation

Mistake: Cluttered and disorganised workspaces.

Impact: Disorganisation can lead to accidents, slow down operations, and make it difficult to locate necessary tools and equipment.

Prevention: Implement a clean and organised workspace policy. Regularly audit and reorganise the workspace to ensure it remains clutter-free. Use labelling and signage to clearly mark storage areas and pathways.

9. Ignoring Ergonomics

Mistake: Not considering ergonomic principles in the design and use of equipment.

Impact: Poor ergonomics can lead to worker fatigue, repetitive strain injuries, and decreased productivity.

Prevention: Choose equipment that supports ergonomic principles, such as adjustable handles and controls. Train employees on proper lifting techniques and encourage regular breaks to reduce strain. Regularly review and adjust workstations to maintain ergonomic standards.

10. Failing to Update Equipment

Mistake: Using outdated or obsolete equipment.

Impact: Older equipment may not meet current safety standards, leading to increased risk of accidents and inefficiencies.

Prevention: Regularly review and update your equipment inventory. Stay informed about advancements in material handling technology and consider upgrading to newer, safer, and more efficient models as needed.