Working conditions are a major issue in logistics. Remember that on average an order picker can walk up to 15 kilometres and carry 1 to 8 tons every day! Once we realize that searching for and fetching products can account for as much as 70% of an operator's unproductive time, we understand the value of Goods to Man robotics: an automation solution that improves productivity and working conditions for operators.
To be truly effective, however, the automatisation solution must include workstations adapted to the characteristics of each installation. Scallog enlists the assistance of experts in ergonomics to reduce incorrect handling postures and hazardous movements.
An ergonomic workstation by design
Since its creation, Scallog has partnered with its customers to provide the best possible experience:
- The storage zone is robots-only, reducing the risk of collision.
- The robots move silently when fetching the shelves needed for order picking.
- A green light indicates that the operator can access the shelf unit. This light is placed at eye level to limit head movements.
- The operator then picks out the products and places them in the buffer rack.
The buffer rack allows several dozen orders to be picked at the same time: the operator can pick several identical articles and drop them in the pigeonholes corresponding to the orders. The result: a 70% reduction in operator movement.
Order picking station in the Polyflame fulfilment centre - © Scallog /Polyflame
In every installation, Scallog takes customer feedback into account to improve the ergonomics of order picking stations:
- The article’s location in the shelf unit is indicated by a spot-to-light
- The corresponding pigeonhole in the buffer rack is indicated by a put-to-light
- The monitor is mounted on an articulated arm, allowing each operator to adjust it according to his or her height or posture. Result: less eye fatigue, less back and neck pain.
- The picking station is fitted with an anti-fatigue mat and a retractable footboard.
The use of pointer lights (spot-to lights and put-to lights) has significantly reduced the mental burden of order picking operations.
Finally, during the restocking process, operators are reminded that heavy loads must be placed on the lower shelf levels.
Virtual reality (VR) to finesse key picking station functions
In 2017, Laboratoires Boiron decided to conduct a detailed analysis of various workstation parameters so these could be fine-tuned to the actual working environment. To do this, Scallog and Boiron worked with the ergonomics consultant AF’ergo Conseil.
AF’Ergo Conseil uses the Ergo-Wide solution by Clarte to finely plot movements and postures using virtual reality. In a simulated workstation, an operator fitted with an array of sensors takes up his/her normal position. Workstation and avatar are analysed in detail to plot posture positions and suggest changes.
This simulation goes well beyond the obvious metrics like shelf height or depth, and helps us determine optimum positions for all the different elements of the workstation (touch screen, scanner, printer etc.).
VR simulation allows us to:
- Facilitate the handling of boxes located at the top of the shelf unit
- Adjust the angle of inclination of the bins/crates of the buffer rack according to the level
- Make recommendations on operator movements (avoid twisting the upper body, prefer crouching posture for low positions)
Ergonomic analysis thus allows us to optimize storage parameters by taking weight, bulk and turnover class into account.
Books are not handled in the same way as medicines or cosmetics, which are not handled in the same way as clothes: that’s why Scallog systematically offers this innovative service to all customers who express an interest.
Order picking in Decathlon fulfilment centre - © Scallog /Décathlon
Although operators no longer need to move from one zone to another, they still have to perform certain movements and bodily rotations. They are therefore exposed to the risks associated with prolonged standing. To reduce foot pain, our picking stations are fitted with ergonomic anti-fatigue mats.
In the end, however, order picking is always going to require a degree of effort, both physical and mental. We recommend regularly rotating operators around different workstations, performing activities such as the transfer of orders to the packing zone, handling operations in non-automated zones, and order consolidation.
To optimize workstation ergonomics, it’s therefore essential to involve your workforce in the deployment of your automation project. Their active participation will ensure their workstations meet their needs.
The operator at the centre of the solution
Scallog takes a reasonable approach to automation. The aim is not to eliminate jobs but to provide jobs of better quality.
Therefore, operators are systematically involved in the rollout of the automation solution - their contributions go well beyond ergonomic design. The different processes are analysed as a whole. So tasks such as evacuating empty or full packages are also taken into account.
By reducing the need to move from one zone to another, enabling simultaneous picking of many orders thanks to the buffer rack system, and by reducing the number of errors, goods to man automation makes operators more efficient. And that means load spikes are easier to absorb. With optimized workstation ergonomics, new operators are also quicker to reach working proficiency. All these factors increase the versatility of operators, who may be required to rotate around several workstations such as packaging or palletized stock handling (in the case of operators authorized to drive a forklift).
Improved working conditions offer many benefits both for operators and company: lower incidence of MSDs (musculoskeletal disorders), fewer accidents, fewer illnesses and less absenteeism - and employees who are more motivated and loyal.
Each customer has its own specific requirements. Our approach is to carry out a thorough analysis designed to stick as closely as possible to these needs. We systematically propose an ergonomic assessment that’s considerably enhanced by the use of VR. –Pierre-Yves Minarro, Chief Operations Officer, Scallog
The need to improve working conditions becomes all the more pressing in view of the difficulties encountered by the logistics sector in recruiting personnel. Modernizing your distribution centre allows you to stand out in an increasingly demanding field of candidates.
Younger generations do not have the same expectations as their parents. Technology comes naturally to them, and they’re more likely to be fussy about their working conditions. Thanks to a detailed ergonomic assessment, operators can easily get to grips with the working environment offered by Scallog. And because the automation solution we offer is flexible and scalable, you’re also preparing for the future.
Making recruitment easier
The pandemic from which we are only just emerging has shown the importance of logistics. We are faced with a surge in e-commerce and the affirmation of omnichannel. And above all, consumers - professionals and individuals alike - are becoming increasingly demanding, especially when it comes to delivery times. All of these factors have caused an explosion in retail order picking volumes. Modernizing your warehouse with a goods to man solution is therefore an economic necessity. And offering increasingly ergonomic workstations becomes a real differentiating factor in many ways, including recruitment.
The recent study by Dares and France Strategy confirms the trend: the recruitment difficulties currently faced by the logistics sector are not going to go away.
By 2030, it’s estimated the sector will be short of 150,000 skilled order fulfilment workers. Young recruits are entering the sector in numbers only just enough to fill new jobs, while many older workers are approaching retirement.
Now is the time to invest in improved logistics. The good news is that the automation solutions offered by Scallog are flexible, scalable, and affordable even to SMEs.
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