Manejo y Almacenamiento de Material

Presentación del tema: "Manejo y Almacenamiento de Material"— Transcripción de la presentación:

1 Manejo y Almacenamiento de Material
Welcome to Material Handling and Storage training.

2 Este material fue producido bajo la donación numero 46B4-HT15 de la Seguridad Laboral y la Administración de Salud pertenecientes al Departamento del Trabajo de los Estados Unidos. El material no representa necesariamente los puntos de vista o políticas del Departamento del Trabajo de los Estados Unidos. La mención de marcas, productos comerciales, o de organizaciones no implica ninguna aprobación o apoyo con el gobierno de los Estados Unidos.

3 Manejo y Almacenamiento de Material
Warehouse facilities are exposed to many hazards due to the inherent nature of materials shipped, stored, and distributed. Warehouse operations perform three main functions: receiving bulk goods from suppliers; order picking to select desired goods from within the warehouse; and shipping goods to the customers. Information in this module describes example ergonomic hazards and solutions related to order picking, which accounts for a large number of musculoskeletal disorders (MSDs). The areas addressed are Transport, Storage, Packaging, and Work Practice.

4 Objetivos Discutir lo básico de la ergonomía y las funciones de la columna vertebral Describir los diferentes sistemas para recoger ordenes Describir las técnicas apropiadas para levantar objetos Identificar los riesgos asociados con el manejo de materiales en diferentes tipos de almacenes, depósitos, o bodegas Técnicas de transporte Almacenamiento Empaquetado Practicas de trabajo

5 Funciones Básicas de la Columna Vertebral
Soporta el peso del cuerpo Le da estructura el cuerpo Flexibilidad para doblar y rotar Mantiene una curva natural en forma de S lo cual da el soporte máximo The back is a very complex mix of muscles, ligaments, bones, discs, and nerves. It carries most of your body's weight and maintains the structure of the torso, acts as a shock absorber, protects the spinal cord and nervous system, and allows body flexibility. The spinal column has natural curves that act like arches of a bridge and allow us to load the spine 10 times more that if it were straight. The key to preventing back injuries is trying to maintain these natural curves in our daily activity. The spine is an "S" curve that in its natural state provides strength and balance to our daily activities and evenly distributes our body weight throughout its length. By maintaining the spine's natural "S" curve, we keep our backs in alignment and minimize stress and trauma.

6 Técnicas apropiadas para levantar objetos
Eliminar objetos que puedan causar tropiezos o resbalones Planear paradas de descanso Seleccionar la ruta mas fácil Evitar las escaleras Si esta demasiado pesado – ¡BUSQUE AYUDA! Planear el trabajo Lifting no-no’s Lifting loads across obstacles Lifting with one hand Fighting to recover a dropping object

7 Técnicas apropiadas para levantar objetos (continuado)
Identifique el objeto Doble las rodillas Agarre firmemente Hace la fuerza con las piernas para levantar Address the item Firm footing Shoulder width apart Staggered stance Straddle the object Bend at the Knee Not your waist Get a Good Grip Use whole hand Use gloves if necessary Raise with the Legs One of the largest muscles in the body. Using this approach will keep you from using another of the largest muscle groups in the body: the diaphragm in a scream of pain.

8 Mantenga el peso cerca Cerca al cuerpo Menos fuerza en la espalda
Una carga de 10 libras con los brazos estirados es una carga de 100 libras en la espalda Remember the lever principle. The longer the lever, the more force is applied.

9 Técnicas para Levantar
Levantamiento Diagonal Fuerza de levantar The Diagonal Lift is used when lifting moderately heavy objects. This lift is the most common and allows for full use of good body posture. Use the following steps when using this lift: Straddle the object by using a wide diagonal foot placement and assume a full squat position. Lift the object by standing straight up, keeping the back in a neutral "S" curve position throughout the lift. The head and shoulders are held upright and the legs actually provide the strength for the lift. People with knee problems may have difficulty using this lifting style. The key to this lift is keeping the back arched. Using an improper technique will generally allow the hips to rise first, thus bending (arching) the back forward. The Power Lift is used when lifting moderately heavy objects. This is the lift preferred by most employees. It's more efficient because it requires less time and energy. Since it requires only a partial squat, people with knee problems may find it useful. Use the following steps when using this lift: Begin with the same diagonal foot placement as before. This time, bend mostly at the hips rather than doing a full squat. Bend the knees partially, keep the head and shoulders up. Grasp the load and stand up by lifting the head and shoulders up, keeping the lower back in a neutral "S" curve position.

10 Gire…No se Tuerza Gire sus pies De la vuelta con todo el cuerpo

11 Riesgos asociados con el manejo de materiales en un almacén, depositó, o bodega
Consiste de características del trabajo que potencialmente podrían dañar al cuerpo Planteamiento en el lugar de trabajo Métodos de trabajo impropios Herramientas inapropiadas Problemas con el diseño del trabajo Falta de limpieza Material handling hazards in warehouse - consists of job features which have a potentially harmful effect. These hazards can be the result of: Faulty workstation layout/environment: poor lighting, excessive reaching for phone or mouse, sitting or standing continuously. Improper work methods: application of excessive force to get the job done, high repetition rate, improper lifting techniques. Improper tools: tool does not match task, extreme or awkward postures when using tool, tools that dig into the palm. Job design problems: inadequate work/rest regimens, pace of work is too fast.

12 Técnicas de Transporte
Poner cajas sobre una plataforma usada para cargar en soldadura y corte, paleta, jergón, o estiba. Hay varios nombres que se puede usar para este plataforma. Así que por el resto de esta presentación, vamos a usar la palabra “paleta”. Mantenimiento During this session we will be discuss the various hazards and solutions related to Order Picking, which accounts for a large number of musculoskeletal disorders (MSDs) in a warehouse. The areas addressed are Transport, Storage, Packaging, and Work Practice. During this process, employees usually move materials through the warehouse on pallet jacks. A pallet is placed on a pallet jack, and merchandise is removed from a storage area called a slot or pick bin, then placed on the pallet. Many of these loads, especially in refrigerated or freezer warehouses, are extremely heavy. Weights upwards of 80 to 100 pounds are not uncommon. Ver:

13 Poniendo Cajas sobre paletas
Agacharse constantemente doblando la cintura para poner cajas en el nivel mas bajo de las paletas Las unidades mas pesadas se ponen en la parte mas baja para dar estabilidad Requiere que los empleados levanten las cargas mas pesadas usando las peores posturas

14 Soluciones Elevar la altura del nivel mas bajo
Proporcionar un equipo de trabajo en el cual se puede ajustar la altura Educar a los empleados sobre los riesgos de agacharse al mover cargas pesadas Colocar paletas vacías sobre el gato de palanca o montacargas para subir la carga. Colocar las paletas en el gato de palanca o montacargas para subir el producto a la altura de la cintura Utilizar equipo eléctrico Raise the height of the bottom level. This allows employees to keep the load close to the body, and minimizes bending of the torso. Provide height-adjustable picking equipment. Enables loads can be maintained at a height that minimizes bending at the waist. Educate employees about the hazards of bending while moving heavy loads, and ensure the use of proper lifting techniques. Utilize power equipment to reduce ergonomic stresses. Back belts: The effectiveness of back belts in reducing the risk of back injury among healthy workers remains unproven. If workers falsely believe they are protected when wearing belts, they may attempt to lift more than they would without a belt. This poses a risk of injury to the worker (See Back belts: Do They Prevent Injury? (DHHS) (NIOSH) Publication No ). Ver:

15 Almacenamiento Lugares bajos Lugares altos
Ranuras o aberturas dobles o triples Alcanzar Ancho del pasillo Most goods in a grocery warehouse are stored for a period of time. Racking is used to expand the amount of storage that is possible. Metal racks are used for storage and the area created within the racking is called a pick bin or slot. Slots range in size, depending on the products stored.

16 Lugares bajos Las paletas se guardan en compartimentos a unas cuantas pulgadas del piso Los estantes bajos requieren que los empleados se agachen doblando la cintura Es un problema significativo debido a que la carga mas pesada esta en la pila mas baja Almacenar las paletas en ranuras o aberturas mas altas aun requiere que los empleados se agachen Palletized products in warehouses are often stored in pick bins that are typically placed on the floor. This requires employees to bend at the waist to access loads that come to the warehouse stacked only a few feet high, or may be unloaded to the point where they are only a few feet high. Even when these pallets are stored in taller slots, employees must bend at the waist to access product. This is a significant problem since the heaviest product is usually in the shortest stacks. Low racking can force employees to bend at the waist to access loads. Loads in the bottom bins, require forward torso bending to reach under the rack, even when the top levels of the stack are at waist height or higher.

17 Soluciones Elevar las paletas dentro del compartimento de ranuras o aberturas Poner las paletas vacías debajo de la carga Levantar el nivel mas bajo de los estantes de tal forma que las cargas se encuentren a una altura donde no sea necesario agacharse Proporcionar un montacargas o un gato de palanca o de paleta con un chupon integrado NIVELADOR DE CARGA Whenever possible, elevate the pallets within a slot bin. The best technique is to place a palletizer into a tall bin. A palletizer will lower in height under the weight of a full pallet, then will raise the load as items are removed. The use of a turntable allows employees to reposition the load. This keeps the load close to the body. Pallets that do not have product stacked above waist height may be elevated by placing these empty pallets under the load. Care must be taken so the top level of the heavy product is not raised higher than mid-chest height. Raise the bottom level of racking so loads are at heights where torso bending is not necessary. Provide a device such as a forklift with a built-in vacuum hoist . The strong suction can lift up to 150 lbs. ESTO en lugar de ESTO

18 Soluciones (continuado)
Paletas vacías apiladas para elevar el producto a la altura de la cintura Estantes elevados

19 Soluciones (continuado)
El gato de palanca o montacargas con chupon

20 Alcanzando sobre el nivel de los hombros
Lugares altos Alcanzar con los brazos arriba de los hombros para acceder a productos en los estantes superiores Resulta en tensión o estrés a los hombros y espalda Requiere posiciones incomodas de las manos y muñecas Lifts above shoulder height often require awkward hand and wrist postures. Alcanzando sobre el nivel de los hombros

21 Soluciones Usar estantes elevados
Proporcionar ganchos o bastones para mover las cargas Use elevated rack locations as the overstock storage area. Pallets of product should be lowered to more appropriate heights prior to being selected. Selections should be  performed with arms close to the body. Provide employees with "Pick Sticks" or "Bow Peep" hooks to pull small, light-weight product closer to the edge prior to lifting Gancho

22 Riesgos de las ranuras o aberturas múltiples
Aumentar al máximo el espacio en los estantes Aumentar los factores que generan tensión o estrés ergonómico Obligar o forzar a los trabajadores a agacharse para alcanzar el producto Alcanzar sobre el nivel de los hombros para acceder a materiales Ranuras o aberturas dobles Double or triple slotting is used to maximize shelving space so the greatest amount of product can fit in the smallest amount of space may increase ergonomic stressors such as bending and elevated reaches. Workers may be forced to bend at the torso to reach under low racking to access product. Stacking product at more desirable heights which would not interfere with racking system would eliminate worker bending. Workers must reach above shoulder height to access materials placed on three-tier racking or to access tall, palletized loads placed on two-tiered shelving. In general bottom and top racking in three tiered systems creates significant access issues. Las ranuras o aberturas triples requieren alcanzar productos elevados

23 Estantes que fluyen con el peso de los objetos
Soluciones Proporcionar ranuracion completa Utilizar estantes que fluyen con el peso de los objetos para productos de movimiento lento Ranuracion completa Provide full slotting, especially for product that is heavy or bulky, so employees can have better access without undue reaching or bending. Slower moving product that is fairly compact can be warehoused using gravity fed flow racks. These racks allow highly condensed usage of warehouse space. However, hazards are created by this type of racking since it must be loaded by hand from the back of the rack. This can require repeated elevated reaches, repeated bending of the torso, as well as using box openers to cut open shipping boxes. Also, Selectors must pull product over the stop lips that keep the product from sliding out onto the floor. Heavy product in the slot creates additional pressure when lifting boxes over the stop lips. Estantes que fluyen con el peso de los objetos

24 Alcanzando la parte trasera de la paleta
Alcanzar El producto normalmente se quita de la parte delantera de las paletas primero Dejando así el producto de la paleta en la parte trasera Creando tensión o estrés adicional en los hombros y espalda Hazards due to reaching are usually the result of product that has often been removed from the front of pallets first. This leaves the remaining product stacked in the back of pallets, where employees must reach to access and lift product. This creates additional stress on the shoulders and back. Alcanzando la parte trasera de la paleta

25 Para un acceso optimo, colocar el producto en soportes giratorios
Soluciones Desarrollar un proceso para rotar el producto Colocar las paletas en placas giratorios Usar dispositivos o aparatos con canales o rodillos Proporcionar ranuras o aberturas mas amplias para los productos mas pesados Entrenar a los almacenistas a dejar suficiente espacio para mover la paleta durante la selección Develop a product rotation process where pallets are regularly turned using a forklift or pallet truck after the majority of product has been removed. This involves pulling the pallet out of the slot, turning it 180 degrees and replacing it into the slot. Place pallets on turntables so the pallet can be turned and optimal access to the product can be maintained at all times. Use roller and channel devices These devices allow the load to be pulled out for better access. The addition of a turntable at the end of such device will allow the pallet to be turned and then replaced into the slot with the load closer to the front. Provide wider slots, especially for heavier product. This will allow selectors to walk into the slot and access all sides of the pallet. Stockers should be trained to leave at least 16 inches between pallets so there is enough space for Selectors to move around the pallet during selection. Para un acceso optimo, colocar el producto en soportes giratorios

26 Ancho del pasillo Acceso insuficiente a producto de movimiento rápido
Crear congestión Obligar o forzar a los escogedores a parar mas lejos de la ranura y cargar el producto mas lejos al gato de palanca o de paleta. Para ahorrar tiempo, los escogedores pueden estar tentados a cargar varios paquetes a la vez. Pasillo congestionado The width of aisles in many warehouses is often insufficient for access to fast-moving product. This may be due to the size of the aisles, or the congestion of products on skids that are being loaded or unloaded into supply bins.

27 Soluciones Ampliar los pasillos donde se encuentren los productos con mas movimiento. Permitirá a los gatos de palanca o de paletas llegar mas cerca y reducir la distancia que las cargas tienen que transportar. Alternar los tiempos de salida al comienzo del día De esta forma menos escogedores estarán en las mismas ranuras o aberturas al mismo tiempo Increase the width of aisles where fast-moving product is located. This will allow more pallet jacks to get closer and will reduce the distance that loads must be carried. Stagger the start times for Selectors at the beginning of the day so that fewer selectors hit the same slots at the same time. Five to 10 minute start differentials should provide adequate spacing for sufficient disbursal of Selector

28 Empaquetado Contenedores pesados Agarraderas inadecuadas
Envoltura de plástico Paletas de madera Envoltura de paletas Abiertas cajas Products vary in warehouse can vary in weight by up to 100 pounds — and are shipped to the warehouse in a variety of containers, including boxes, bags, and cans. The shape, weight, and/or material of these package can greatly affect the stress that a grocery warehouse employee experiences. 5-Galones (40 libras)

29 Contenedores Pesados Las cajas son extremadamente pesadas en un almacén, deposito, o bodega frías o de congeladas Pesan hasta 100 libras Levantarlas manualmente produce tensión o estrés en los músculos de los empleados Levantar de manera repetitiva puede resultar en lesiones de la espalda, tirones musculares y lesiones en los discos In cold or freezer warehouses many boxes are excessively heavy; they may weigh as much as 100 pounds. Manually lifting loads in this weight range places great stress on the employee's muscles. Back injuries, such as muscle strains and disc injury, can occur when repeatedly lifting these heavy objects.

30 Soluciones Domino Reduce Paquetes de Azúcar
Azúcar Domino redujo sus paquetes de 60 a 40 libras, debajo del limite, recomendado por OSHA, de 50 libras. Este cambio hará a los paquetes mas fáciles de manejar y reduce el peso de los mismos en un 33 por ciento. Las tres plantas de la compañía han ajustado su equipo de empaquetado para acomodar la modificación de peso. Los primeros envíos de los paquetes de 40 libras comenzaron a llegar en Junio. Trabajar con los proveedores para que proporcionen el producto en contenedores mas pequeños y ligeros Mejorar el acceso a los objetos mas pesados Proporcionar manijas o agarraderas para todos los productos pesados Trabajar con los proveedores para asegurar la integridad de los contenedores Cargar las paletas con productos mas ligeros en el centro y productos mas pesados en las orillas Work with suppliers to provide product in smaller, lighter containers. Improve access to heaviest items. Employees should be able to access these items without bending at the waist, pulling the elbows away from body while reaching, or twisting. Redesigning storage racks and transport devices can greatly improve the employee's ability to maintain these neutral postures. Provide handhold cutouts or handles on all heavy products. Work with suppliers to ensure that container integrity will be adequate so the box, bag, or bucket will not accidentally break, rip, or pull apart during lifting operations. Load pallets with lighter product in the center and heavier on the outer edges to ensure easier access and lifting of the heavier items. Algunos proveedores están dispuestos a modificar el peso de los paquetes

31 Soluciones (continuado)
Los paquetes mas pesados en las orillas

32 Las cajas sin manijas son difíciles de agarrar
Manijas Inadecuadas Muchos paquetes no tienen manijas o agarraderas Hace difícil agarrar cajas pesadas Obliga a los empleados a que usen posturas incomodas Many packages that come into warehouses do not have adequate handles or handle cut-outs. This makes heavy cases difficult to grasp and/or retrieve, which forces employees to use awkward postures when lifting these packages. Without hand cut-outs or handles, employees must press on the sides of boxes, slip fingers under the lips of products, or grasp the loose material of bags to gain control. These techniques place strain on the hands and shoulders. Las cajas sin manijas son difíciles de agarrar

33 Ejemplos de dispositivos o aparatos agarraderas
Soluciones Motivar a los proveedores a que entreguen sus productos en cajas estables con manijas o agarraderas Esto es especialmente importante para productos que sean extremadamente pesados Ejemplos de dispositivos o aparatos agarraderas

34 Paletas de Madera Pesan ente 40 y 70 libras
Se levantan muchas veces durante un turno de trabajo El constante levantamiento causa tensión o estrés a la parte inferior de la espalda Las astillas que salen de la madera también son un peligro para los trabajadores Los trabajadores se agachan muchas veces para recoger las paletas durante su turno

35 Soluciones Requerir paletas de plástico mas ligeras
Se anidan fácilmente para reducir espacio al apilar Se eliminan las astillas y superficies desiguales Proporcionar un dispensador de paletas para reducir el manejo de las paletas Las paletas pesan entre 20 y 30 libras Request that suppliers provide product on lighter, plastic pallets. The employees of both the warehouse company and supplier will benefit from the reduced weight. Plastic pallets easily nest together to reduce the space of stacking. They also eliminate splinters and uneven surfaces that employees may step on when walking over pallets. Provide a pallet dispenser to reduce handling of pallets. This device allows Selectors to drive their pallet jack to the dispenser. An empty pallet is then automatically loaded onto the forks without manual lifting. Dispensador de paletas

36 Entrenando empleados nuevos
Puede ser que los empleados nuevos no reconozcan los riesgos ergonómicos o entiendan las técnicas efectivas utilizadas para minimizar estos riesgos.

37 Soluciones Proporcionar entrenamiento especifico sobre el trabajo y en ergonomía durante la orientación Explicar los factores de riesgo y técnicas de trabajo apropiadas para minimizar los riesgos Proporcionar videos sobre practicas apropiadas de trabajo par que vean los empleados Re-entrenar empleados lastimados sobre los riesgos ergonómicos pertinentes a sus lesiones Usar a trabajadores con experiencia como mentores de los trabajadores nuevos Explicar el sistema de manejo medico Provide general ergonomics training and work-task specific training at the time of new-hire orientation. Explain the risk factors and proper work techniques to minimize these hazards. Provide appropriate video tapes of proper work practice for employees to review on a regular basis. In addition to regularly scheduled refresher training, injured employees should be retrained regarding ergonomic risks pertinent to their injuries. Provide Post Incident Refresher Training after injuries. Mentor new employees with an experienced worker who can provide insights on the proper and most efficient methods to perform their tasks. Explain the medical management system to new-hires. This will let employees understand how to report an injury and how the company prefers its employees to seek medical attention. This can expedite assistance, reduce costs, and improve lines of communication.

38 Resumen Se discutió lo básico de la ergonomía y las funciones de la columna vertebral Se describieron los diferentes sistemas para recoger ordenes Se describieron las técnicas apropiadas para levantar objetos Se identificaron varios riesgos de manejo de materiales asociados con operaciones en almacenes, depósitos, o bodegas Técnicas de transporte Almacenamiento Empaquetado Practicas de trabajo