Ergonomic effects of manual parcel handling

Abstract

The purpose of this master thesis has been to evaluate the physical, cognitive, and organizational ergonomic effects of parcels that cannot be handled in the normal parcel flow at DB Schenker, called Ugly-parcels. Further the purpose of this master thesis is to suggest improvement suggestions to reduce or remove these effects. To estimate the effects a current state analysis was performed, where terminal visits at six terminals were conducted. At the terminals, KIM I and III evaluation were performed and at least three interviews. During the visits, a statistic study was made to gain information about which type of parcels that could not be handled on the parcel sorting conveyor. It was found that the Ugly-parcels were handled at a straight conveyor belt at the larger terminals, and by the side of the parcel sorter at the smaller terminals. The number of parcels that couldn’t be handled in the normal flow was, on average 3,6% of the total volume. The risk rates for physical injury at the largest terminals were high for all three larger terminals and at an acceptable level for the smaller terminals. It was found that both cognitive and organizational ergonomics could be improved for Ugly-parcel handling. This was reveled by the interviews performed and observations made during the visits.To suggest improvements for physical ergonomics, evaluations have been made for combinations of several enhancements. Based on the evaluations, the thesis suggests that a combination of four improvements should be introduced. Some methods to ensure that all parcels that can be handled at the parcel sorting conveyor are proposed there. Thin and round parcels should be handled at the parcel sorting conveyor by us-ing a fixture. A cage lifter should be used at the straight conveyor belt. Lastly, especially ungainly parcels, which are; long, big and unstable should be handled as groupage. With these changes, the risk rate in KIM I and III can be lowered to an acceptable level for five of the six terminals. The adequate level has been set to a risk rate of two to maximum four. To support the cognitive ergonomics, the information on what to do with a parcel when the conveyor stops should be made clearer. The noise level should be decreased. The need to memorize the sorting by heart should be minimized. Standardization of work tasks and work introductions should be used. Lastly, the risk of sorting errors should be decreased. It is suggested that the process to leave improvement suggestions should be made clearer to support the organizational ergonomics. The performance demands should be matched to the available resources. The physical environment should be improved. The learning process for new employees should be clarified. It is recommended that the normal parcel handling also should be evaluated from an ergonomic perspective.