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Lack of appropriate warehouse ergonomics is one of the leading causes of worker injuries in industry environments. As management teams are trying to reduce the cost of doing business, they look to worker’s health statistics and realize they must improve their way of operating. The paper presents a warehouse analysis done at the request of the management team of a Belgian manufacturing plant. The factory’s warehouse was audited with focus on Kanban bin weight, storage rack height and rack width to assess the ergonomic strain it causes on workers. The paper then presents possible automation options in order to find the best fit to reduce ergonomic impact, while also optimizing the total investment cost.

Automation possibilities in a low rotation warehouse of a Belgian manufacturing plant. A case study