Ergonomic Automation and Warehouse Robots

Modern warehouses look like something from a science fiction movie compared to warehouses from years ago. They’re equipped with automated material handling solutions like ergonomic workstations, AI-driven warehouse robots, and depalletizing systems. These tools increase productivity, reduce operational costs, and create a safer work environment.

However, even as automated systems become the norm, warehouse employees still face the risk of workplace injuries. The US Bureau of Labor Statistics reports 2.6 million nonfatal workplace injuries and illnesses in 2023 alone. The incidence rate in the transportation and warehousing sectors was 4.5 cases per 100 full-time workers.

Overexertion is to blame for many of these warehouse injuries. Heavy lifting, repetitive stress, and bending over lead to everything from minor joint pain to severe back injuries.

Employers are responsible for reducing the chance of injury in their warehouses, and ergonomics makes this possible. By implementing ergonomic workstations, companies promote a safe work culture and increase their labor pool. It’s a win-win situation.

The Role of Ergonomics in Warehouse Workstations

Traditional warehouses rely on extreme physical labor, with productivity and output tied directly to worker performance. Heavy lifting, repetitive motions, standing for long periods, and walking miles during a shift are part of the job.

This traditional approach to warehouse work goes against the science of ergonomics, which examines the human body's limitations and creates workspaces and tools that fit these limitations. Companies with warehouses and distribution centers are responsible for implementing innovative ergonomic solutions to protect employees and make their jobs easier.

Poor ergonomics contributes to high turnover and workplace injuries, specifically musculoskeletal disorders (MSDs). These injuries affect muscles, nerves, tendons, ligaments, joints, or spinal disks.

Examples of MSDs include:

Herniated disks
Tendinitis
Lower back injuries
Carpal Tunnel Syndrome
Rotator cuff injuries

[Translate to North America:] warehouse robots

How Automation Expands the Labor Pool

America’s current labor shortage is challenging for companies that rely on distribution centers for product fulfillment. The physically demanding nature of warehouse work and the risk of injury discourage many people from applying for these jobs. These elements also make warehouse work an impossibility for older people or those with physical limitations.

Warehouse automation solves these problems. While some view automated systems as a replacement for human workers, they actually increase the labor pool in several ways.

Tools like warehouse robots and automated conveyors reduce physically demanding tasks, opening jobs up to more people.
Automation creates new technical roles involving software, maintenance, and artificial intelligence.
More efficient workflows enable companies to offer flexible schedules.
The opportunity to learn new skills makes warehouse jobs more attractive as a long-term career path.

TGW Logistics’ partnership with Leroy Merlin is a perfect example of automation’s positive impact on labor force expansion. The French home improvement and garden retailer needed a new fulfillment center to meet growing demand. However, they faced several challenges, including labor shortages and an unsustainable workload due to the bulky nature of their products.

We designed the new fulfillment center to include our FlashPick goods-to-person solution. A shuttle system equipped with warehouse robots provides fast, accurate order picking. Automated depalletizing stations support smooth inbound logistics, and ergonomic workstations reduce physical strain. With these systems in place, Leroy Merlin attracted more female employees, solving their labor shortage issue. They also experienced higher retention.

Technology Spotlight: TGW Logistics’ Ergonomic Solutions

TGW Logistics’ ergonomic workstations create a safe work environment by optimizing the workspace to fit the task and the employee’s capabilities. These highly flexible solutions support goods receipt, picking, packing, and delivery preparation.

This height-adjustable goods-to-person workstation allows workers to set the best layout for them. This eliminates the need to strain to reach items arriving in cartons on an automated conveyor. Workers can also adjust the height of the touch-screen control panel so it’s at eye level, reducing the risk of back or neck strains.

This goods-to-person solution consists of autonomous warehouse robots that transfer items from an automated storage system to picking workstations. Employees no longer have to walk long distances to search for items and bend over or reach to retrieve them. LivePick also allows for the addition of warehouse robots during peak periods, saving workers from overexerting themselves to keep up with demand.

Mobile warehouse robots, such as autonomous mobile robots (AMRs) and automated guided vehicles (AGVs), are the new heavy lifters in distribution centers. Camera technology, sensors, and line-bound navigation allow these robots to react to their surroundings while transporting loads across a warehouse, reducing the need for heavy lifting, pulling, or pushing.

In addition to minimizing physical strain, TGW Logistics’ ergonomic workstations and mobile robots improve speed, accuracy, and efficiency.

Addressing Labor Shortages With Ergonomic Innovation

The global warehouse labor shortage significantly strains companies trying to meet rapidly growing demand. Ecommerce businesses offering an omni channel experience find it particularly difficult to attract and retain employees.

Automation with ergonomic design solves this issue. By eliminating the obstacles of a traditional approach to warehouse work, ergonomics opens the door to new opportunities for businesses and workers.

Ergonomic automation improves working conditions at every stage of the material handling process. It enhances the overall work experience by reducing physical strain and fatigue. This supports more inclusive hiring, making job roles that previously required physical strength available to more people. Plus, employees are more likely to remain with a company that provides a safe work environment.

Automation shifts the approach to warehouse work from physical to technical labor. While many tasks in an automated warehouse still require manual procedures, employees also work directly with technology, such as warehouse management software. This creates upskilling opportunities, making job roles more attractive to potential employees.

These conditions lead to long-term benefits.

Fewer workplace injuries and workers’ compensation claims
Higher productivity
Lower turnover
Easy scalability due to modular automated systems
A reduction in labor and operational costs
Compliance with safety standards

Ergonomic automation transforms warehouses into more sustainable environments for workers. This exciting technology helps companies create a culture of safety that workers are proud to be a part of. It also supports a highly productive operation with an infrastructure to meet and exceed business goals.

Make Ergonomic Automation Your Secret Weapon

Overcome labor shortages and maximize warehouse efficiency with an automated system to meet your needs. Adding ergonomic automation to your warehouse puts you on a fast track to employee satisfaction and operational success.

TGW Logistics makes this possible with innovative warehouse automation tailored to your business. Contact us today and learn how our workstation solutions enhance productivity and safety.

Ergonomic Automation: Promoting Safety and Increasing the Labor Pool