The work load of warehouse workers in three different working systems

An investigation was conducted in five companies in the distribution branch. These companies were divided into three different working systems, i.e., highly mechanized (HM), moderately mechanized (MM), and slightly mechanized (SM). The three systems differed in logistics and kind of appliances used. The purpose of this study was to compare the three working systems with different degrees of mechanization concerning the time spent on tasks, activities during the working day, postures that occurred, physiological work load, perceived exertion and recovery from work. To investigate the different tasks, activities and working postures, 50 warehouse workers, originating from the three working systems, were observed by means of a direct observation method, called: ‘TRAC’. To investigate the physiological work load the heart rate was recorded continuously during the working day and related to the individually determined relation between heart rate and oxygen uptake. This relation was constructed with the results of a cycle ergometer test done in the laboratory. During lunch and at the end of the working day the warehouse workers filled in a questionnaire concerning their perceived exertion and recovery from work.

In the slightly mechanized system more time was spent with the trunk flexed more than 75° as compared with the other two systems. This posture was very common during lifting of objects, and lifting was done more often in this system than in the other systems. In the MM system the warehouse workers had the highest estimated oxygen uptake and reported the highest perceived exertion at the end of the working day. The workers in the HM system had a shorter working day and had less problems with recovery from work than the workers of the other two systems. Poor working postures like rotation and lateroflexion were commonly found in the HM working system. An important explanation was the difference in time spent driving an electric car. This activity was done mostly in the HM system. In conclusion, the HM system was considered most favourable when it concerned work load and recovery from work. The appliances used in the HM system, and especially the electric car, need to be designed according to ergonomic guidelines to avoid poor working postures.