Abstract
A study of the mental and physical workload at the Material Handling (MH) department of the polymer plant of Borealis in Beringen, Belgium, pointed out that reversing a forklift causes neck and back pain. Hence, it was decided to use another type of forklift, to put aside the pallets in the stock yard and to bring back the pallets for loading. Following market research, the management opted for a forklift with raised cabin, which enables the driver to look over the pallet and thus drive forward. In relation to the increasing pressure of work, it was decided to develop a system to manipulate two pallets at the same time. To steer this project Borealis set up a project team, in which workers of the Material Handling department participated actively. An employee from Barlow Handling, a firm that sells, rents and adapts existing Hyster forklifts, also took an active part in the discussions. Finally, an ergonomist and the physician of IDEWE, an external prevention service, added his expertise to the multidisciplinary study group.
Starting from the analysis of an existing situation, the project group formulated ergonomic recommendations, which were integrated in the design conditions together with technical and safety demands. Based on these demands Barlow Handling adapted an existing Hyster forklift.
By actively involving the ergonomist from IDEWE in all phases and the forklift drivers as participants, the project produced a satisfying ergonomic result within the established budget. A forklift was constructed according to ergonomic and production demands.
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