On paper, palletizing seems 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 the event you’re on the lookout for a low-risk, high-reward place to begin with automation, look no additional than the top of your line. Right here’s why guide palletizing is inflicting extra injury than you suppose—and the way automation turns it right into a strategic benefit.
One employee, one hour, infinite threat
Meet Julia. She works in packaging and spends a part of her shift lifting bins onto pallets. Some weigh 12 lbs, others extra. On a very good 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 powerful job; it is a setup for accidents. And never the sort that heal in a single day. We’re speaking muscle strains, nerve injury, persistent again ache, and long-term incapacity. It’s no marvel guide palletizing ranks excessive on the damage 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 circumstances.
- One single pressure damage can price a enterprise $67,000+.
- The oblique price (productiveness loss, turnover, morale) can push that over $2 million in misplaced gross sales.
Handbook palletizing doesn’t simply pressure your crew. It quietly eats away at your revenue margins and manufacturing reliability.
The repair? Take away the chance solely
In contrast to 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 get rid of the ergonomic threat altogether
✅ Your employees transfer into safer, higher-value duties
✅ You get predictable efficiency and fewer downtime
✅ You future-proof certainly one of your most susceptible processes
And with Robotiq Palletizing Options, setup takes just some 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 the event you’re feeling the stress, you’re not alone, and guide palletizing isn’t serving to. Each damage is a setback. Each delay, a price.
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 skilled Carla Silver – register at this time!
📘 Want extra particulars and statistics? Obtain our Ergonomics book, additionally by Carla Silver.
