5 Important Factors to Consider When Developing Material Handling Systems

By focusing on five key factors—efficiency, a holistic system view, worker ergonomics, attention to detail, and equipment selection with sustainability—you can design a flexible, scalable solution that thrives in today’s dynamic material handling industry.

Factor 1 – Efficiency

Streamlined Workflow

Efficient handling material processes begin with mapping your existing workflows. Identify redundant steps—such as unnecessary lifts or transfers—and eliminate them. Adopt layouts that follow a logical sequence: raw materials in, processing at work cells, then finished goods out. Use portable cranes to bridge long spans and reduce manual transport over distances, ensuring heavy loads move swiftly without blocking floor space.

Space and Flow Optimisation

• Vertical Utilisation: Don’t neglect overhead capacity. Incorporate suspended cranes or hoists to free up aisles.

• Unit-Load Right-Sizing: Choose pallet dimensions that maximise rack occupancy without forcing extra handling. Oversized pallets waste floor space; undersized ones require batching smaller loads, adding steps.

• Pathway Design: Implement U-shaped or straight-line flows. Minimising cross-traffic reduces congestion and cycle times, especially when integrating conveyors or robotic conveyors.

By refining material travel paths and leveraging gravity-fed or powered conveyors, you’ll see immediate gains in throughput and a smoother flow of goods through every stage.

Factor 2 – A Holistic System View

End-to-End Evaluation

Rather than focusing on individual machines, assess the entire production pipeline—from inbound receiving to shipping docks. Document every touch point:

1. Receiving: How are raw pallets unloaded?

2. Storage: Are racks laid out for FIFO or LIFO?

3. Processing: What equipment moves parts between workstations?

4. Dispatch: How do finished goods reach trucks or containers?

Pinpoint bottlenecks by tracking lead times and cumulative delay. A single delayed lift at one station can ripple across shifts, so map wait times and idle equipment.

Cross-Functional Collaboration

Success hinges on input from operations, maintenance, safety, and logistics teams. Frontline operators can highlight ergonomic pain points—such as repeated bending—while maintenance staff spot frequent breakdowns in lifting equipment. Engage stakeholders early to co-design improvements and build consensus, avoiding costly retrofits later.

Factor 3 – Worker Ergonomics and Safety

Ergonomic Equipment Selection

Manual handling remains a major source of injuries. Mitigate risks by specifying:

• Scissor Lifter Platforms: Adjustable height tables position loads at optimal working levels.

• Lifting Clamps: Rigid grips secure odd-shaped or heavy items, reducing the need for awkward manual holds.

• Vacuum Lifters and slab lifter systems: With minimal physical exertion, operators can handle large panels of glass, stone, or metal safely and efficiently.

Investing in ergonomic aids not only boosts productivity—operators tire less quickly—but also cuts back on compensation claims and lost-time incidents.

Load Securing Best Practices

Proper load restraint is critical when moving materials between areas. Provide high-visibility ratchet straps for quick, reliable tying of pallets and skids. Their bright colours help operators spot any loosened straps before a shift begins, reducing the likelihood of dropped loads or material damage.

Factor 4 – Attention to Detail

Unit-Load and Storage Standards

Define clear specifications for every unit load:

• Weight limits aligned with rack and conveyor capacities.

• Dimensional tolerances to fit automated sorters and pallet dispensers.

• Stacking rules to prevent tipping or overhang.

By standardising these parameters, your automation and manual workflows will run seamlessly—no more halts due to jams or overhung pallets.

Housekeeping and Preventive Maintenance

A clean, well-maintained facility is a safe facility. Adopt 5S principles:

1. Sort: Remove clutter and obsolete materials.

2. Set in Order: Label aisles, racks, and workstations.

3. Shine: Keep floors and equipment free of debris.

4. Standardise: Document cleaning and inspection routines.

5. Sustain: Audit compliance and reward teams for excellence.

Couple this with a preventive maintenance schedule for all material handling equipment—from conveyors to hoists—to preempt breakdowns and extend asset lifespans.

Factor 5 – Equipment Selection & Sustainability

Balancing Manual, Semi-Automated, and Automated Solutions

Not every operation requires full automation. Evaluate returns on investment for:

• Manual Aids: Hand pallet jacks, lift tables, and lifting clamps for low-volume or infrequent lifts.

• Semi-Automated Systems: Powered conveyors, automated labelers, and sortation modules that integrate with human operators for intermediate volume lines.

• Fully Automated Cells: Robotic pick-and-place or automated guided vehicles (AGVs) for high-volume, repetitive tasks.

Leverage industrial wall-mounted jib cranes to handle localized lifting without the footprint of floor-mounted cranes. For heavier loads and longer reaches, hybrid gantry solutions or use advanced material handling cells can offer the throughput of automation with the flexibility of manual intervention.

Modular, Future-Proof Infrastructure

Choose scalable, modular equipment that adapts as your business grows:

• Horizontal Scissor Lifter Systems offer simple plug-and-play installation and can be moved or expanded to new work zones as needed.

• Slab Lifters Systems handle large stone or metal plates and can be transferred across cells without disassembly.

• Vacuum Heavy Lifter units minimise fibre-optic connections and mechanical complexity, making them easy to maintain and redeploy.

By standardising on modular interfaces—power, data, and mechanical—your facility can pivot quickly to new product lines or market demands.

Environmental and Energy Considerations

As sustainability becomes a competitive differentiator, design equipment selection with eco-efficiency in mind:

• Energy-Efficient Drives: Specify variable-frequency drives (VFDs) on conveyors and cranes to match power consumption to load, reducing idle energy waste.

• Renewable Power Integration: Wherever feasible, supplement warehouse roofs with solar panels to offset electric forklift or AGV charging.

• Waste Reduction: Eliminate single-use plastics by switching to reusable totes or bulk bag systems; recycle damaged pallets and scrap materials through internal or third-party programs.

Conclusion

Developing world-class material handling systems is a multifaceted endeavour. By concentrating on five critical factors—efficiency, holistic system design, worker ergonomics, meticulous standards, and thoughtful equipment selection with sustainability in mind—you’ll create a resilient operation ready for the challenges of the modern material handling industry. Whether you’re integrating vacuum lifter cells, deploying scissor lifter platforms, ratchet straps or refining your material-handling roles, these guiding principles will help ensure safety, productivity, and profitability.

For expert guidance or to discuss your next project, connect with leading material handling companies today and transform your facility into a benchmark of industrial excellence.