How Do Gravity Conveyors Boost Ergonomics & Safety at Manufacturing Facilities?

Moving materials play a vital role in manufacturing processes, yet they also stand as one of the leading causes of worker injuries. Heavy lifting, awkward postures, and repetitive motions can result in strains, sprains, and other musculoskeletal disorders, causing employees to miss work and hinder production flow. According to the U.S. Bureau of Labor Statistics, the manufacturing sector is responsible for 15% of all private-sector injuries, ranking it as the second most injury-prone sector.

To reduce the risk of workplace injuries, a comprehensive approach is necessary; however, one of the simplest yet effective solutions is the implementation of gravity conveyors from FlexMation. By facilitating a smooth and controlled flow of materials, these ergonomic conveyor systems help facility managers and owners:

• Safeguard Workers

• Lower Injury Rates

• Maintain Steady Production Rates

 Before we dig into how gravity conveyors make those benefits feasible, let’s first look at the dangers of material handling in warehouses and other industrial production facilities.

Understanding the Safety Risks of Material Handling

Material handling consistently ranks among the predominant causes of workplace injuries within the manufacturing sector. Workers regularly contend with substantial risks related to heavy lifting and maneuvering in tight, congested production environments. These hazards are further exacerbated by just-in-time (JIT) production methodologies, which compel teams to execute tasks rapidly and frequently manipulate components, often in ergonomically unfavorable positions.

The impact of these injuries extends beyond minor cases. The National Safety Council (NSC) reported that overexertion and bodily reaction injuries accounted for the highest number of Days Away, Restricted, or Transferred (DART) cases in 2022. The financial implications are significant, transcending mere productivity losses. As detailed in the latest Liberty Mutual Workplace Safety Index, incidents of overexertion linked to external sources alone result in an annual economic burden of $12.49 billion for U.S. businesses. Additionally, other forms of exertion and bodily reactions, which include injuries stemming from awkward postures, contribute an estimated $3.68 billion to this total.

It’s crucial for employers to acknowledge their responsibility for these injuries and the associated financial toll. The Occupational Health and Safety Administration (OSHA) underscores the necessity for employers to not only provide adequate training and support for their workforce but also to implement proactive workplace interventions that mitigate hazards at their origin.

Top 3 Ways Gravity Conveyors Help Solve Safety & Ergonomics Issues

Gravity conveyors represent an effective solution to mitigate the risks associated with manual handling, thereby ensuring compliance and fostering safer, more ergonomic workflows on the manufacturing floor. By harnessing gravitational forces to transport materials efficiently throughout the production process, these systems significantly reduce many prevalent hazards linked to manual handling practices. This not only enhances workplace safety but also streamlines operations, optimizing material flow and reducing the physical strain on personnel.

1. Facilitate Ergonomic Workflows

Gravity conveyors can be meticulously designed to position components at ideal heights and angles, minimizing unnecessary bending, stretching, and awkward postures. By placing materials directly at the point of use, these systems facilitate more natural body mechanics, enhancing ergonomic efficiency. Over time, updating to an ergonomic conveyor system results in a significant reduction in injury incidence, decreased fatigue levels, and heightened productivity.

2. Reduce Unnecessary Travel and Touch

In manufacturing environments, unneeded walking, lifting, and the repetitive manipulation of heavy or awkward components are significant contributors to workplace injuries. Gravity conveyors help facilitate the seamless transfer of materials between workstations, thereby reducing the need for manual handling and enabling workers to maintain more ergonomic postures.

These systems are engineered to optimize transit times and minimize handling steps, fostering lean workflows that enhance the efficiency of part movement while simultaneously decreasing the risk of strain and overexertion among operators.

3. Reliable Operation Without Energy Use

In contrast to powered conveyor systems, gravity conveyors utilize a straightforward, energy-independent mechanism that lacks motors and electrical components. This design minimizes the risk of injury associated with powered equipment and significantly reduces ambient noise levels on the production floor.

The controlled gravity-driven movement of materials enhances operational efficiency by fostering a more structured and predictable workflow. Ultimately, this approach mitigates disorder, allowing operators to prioritize value-added activities instead of continually handling material logistics.

Introducing UNEX Gravity Conveyors from FlexMation

UNEX conveyor rollers are rugged, low-maintenance, and can be easily implemented into your existing conveyor systems. Some benefits of these rollers include:

• Conveyors are Constructed Entirely of Steel or Aluminum

• Capability to Fit Many Spaces and Layouts

• Perfect as Permanent or Temporary Fixtures

• Easy Installation

• Much More!

Outdated conveyors can malfunction, cause damage to equipment and materials, and slow down productivity. UNEX conveyor rollers can improve your efficiency and create a state of constant flow in production.

Discover Custom Gravity Conveyor Solutions at FlexMation

At FlexMation, we aim to be trusted partners who advance your lean manufacturing performance. Simply put: We’ll help you make things better, safer, faster, and smarter. If you’re interested in learning more about how gravity conveyor rollers can increase productivity and improve ergonomics in your facility, contact us today. Let’s find your solution.