On paper, palletizing appears like a primary process: stack bins, repeat. In actuality, it’s one of many most injury-prone jobs in manufacturing—and one of many best to automate.
In case you’re in search of a low-risk, high-reward place to start out with automation, look no additional than the top of your line. Right here’s why handbook palletizing is inflicting extra harm than you suppose—and the way automation turns it right into a strategic benefit.
One employee, one hour, countless danger
Meet Julia. She works in packaging and spends a part of her shift lifting bins onto pallets. Some weigh 12 lbs, others extra. On day, she handles over 700 lifts in a single hour. No twisting, simply repetitive movement—again and again.
Now zoom out.
Multiply Julia’s routine throughout a number of employees, throughout a number of shifts. Then add:
- Fatigue
- Missed rotations
- No time for breaks
- Various field weights and pallet heights
This is not only a robust job; it is a setup for accidents. And never the sort that heal in a single day. We’re speaking muscle strains, nerve harm, continual again ache, and long-term incapacity. It’s no surprise handbook palletizing ranks excessive on the harm charts.
The maths behind the mayhem
Let’s break it down:
- 33% of overexertion accidents come from lifting/reducing duties.
- Accidents to the again and shoulders account for 79% of those instances.
- One single pressure harm can price a enterprise $67,000+.
- The oblique price (productiveness loss, turnover, morale) can push that over $2 million in misplaced gross sales.
Guide palletizing doesn’t simply pressure your group. It quietly eats away at your revenue margins and manufacturing reliability.
The repair? Take away the chance completely
Not like different advanced automation initiatives, palletizing is a no brainer. It’s repetitive. It’s constant. It’s begging for a cobot.
Right here’s what occurs if you automate:
✅ You remove the ergonomic danger altogether
✅ Your employees transfer into safer, higher-value duties
✅ You get predictable efficiency and fewer downtime
✅ You future-proof one in all your most susceptible processes
And with Robotiq Palletizing Options, setup takes only a few days. No customized engineering. No additional coding. Only a safer, extra productive line.
Why this issues now
Labor shortages. Insurance coverage hikes. Tight margins. In case you’re feeling the stress, you’re not alone, and handbook palletizing isn’t serving to. Each harm is a setback. Each delay, a value.
However with automation, each pallet turns into a chance to do higher.
Take the following step
💻 Do not miss our Ergonomics webinar with licensed security knowledgeable Carla Silver – register as we speak!
📘 Want extra particulars and statistics? Obtain our Ergonomics e-book, additionally by Carla Silver.
