Labor shortages continue to create challenges for manufacturers, warehouses, distribution centers, and other industrial operations. When fewer workers are available to perform physically demanding tasks, companies can face slower production, increased overtime costs, employee fatigue, and greater safety risks.
In the materials handling industry, the solution is not always to hire more people. Companies can also improve productivity by making better use of equipment, automation, and ergonomic lifting technologies.
From automated handling solutions to specialized bulk handling material equipment, the right combination of technology and process improvements can help businesses move, lift, position, and transport materials with fewer manual interventions.
Here are five practical ways businesses can address labor shortages while improving material handling efficiency.
1. Automate Repetitive Material Handling Tasks
One of the most effective ways to reduce the impact of labor shortages is to automate repetitive tasks that traditionally require significant manual effort.
Material movement often involves repetitive lifting, positioning, loading, unloading, and transferring. These activities can consume valuable employee time without directly increasing production output.
Automated handling solutions can help reduce the amount of manual intervention required for certain processes. Depending on the application, businesses may use powered lifting equipment, conveyors, automated positioning systems, or other engineered material handling technologies.
Automation does not necessarily mean completely replacing manual operations. Even partial automation can help employees spend less time performing repetitive tasks and more time on skilled responsibilities that require human judgment.
Key benefits include:
- Reduced dependence on manual labor
- More consistent material movement
- Improved workflow efficiency
- Reduced physical strain on employees
- Better utilization of skilled workers
Before automating, companies should identify the tasks that consume the most labor hours and determine whether equipment can safely and efficiently perform those functions.
2. Invest in Ergonomic Lifting Equipment
Labor shortages can become even more challenging when experienced employees are unavailable or when physically demanding work contributes to fatigue and injuries.
Ergonomic material handling equipment can make lifting and positioning tasks easier for employees while helping reduce unnecessary physical effort.
Lift tables, ergonomic lifts, positioners, tilters, and other powered equipment can help workers bring materials to a more accessible working height or position. This can be particularly useful in manufacturing environments where employees repeatedly handle components, containers, pallets, or other heavy materials.
For example, instead of requiring workers to repeatedly bend, reach, or manually reposition a load, a lift table can raise the material to a more appropriate working height.
The goal is not simply to make a job easier. Ergonomic equipment can help companies create more sustainable workflows while allowing available employees to handle more work efficiently.
3. Improve Bulk Material Handling Processes
Bulk material movement can require substantial labor when materials must be repeatedly loaded, unloaded, transferred, or positioned manually.
This is where appropriate bulk handling material equipment can provide significant operational value.
The right equipment depends on the material, load characteristics, facility layout, required capacity, and movement requirements. Companies handling large or heavy materials should evaluate where manual handling occurs and determine whether powered equipment can eliminate unnecessary steps.
For example, specialized lifting and positioning equipment can help move heavy loads into the correct orientation without requiring several employees to manually reposition them.
A useful starting point is to map the complete material flow:
Receiving → Storage → Processing → Assembly → Packaging → Shipping
At each stage, identify where employees are spending the most time moving materials. These areas can become opportunities for equipment upgrades or process improvements.
Improving bulk material handling is often about eliminating unnecessary movement rather than simply moving materials faster.
4. Use Equipment That Makes One Worker More Productive
When staffing levels are limited, increasing the productivity of each available employee becomes increasingly important.
Equipment that allows one operator to safely perform a task that previously required multiple workers can help companies manage labor constraints without compromising operational requirements.
Industrial cranes, jib cranes, workstation cranes, lift tables, upenders, positioners, and other lifting systems can help reduce the amount of manual effort required to handle heavy or awkward loads.
For example, a properly configured lifting system can allow an operator to position a component without relying on additional employees to manually guide or support the load.
However, equipment should be selected based on the actual application rather than simply choosing the highest-capacity option. Load weight, dimensions, lift height, frequency of use, workspace limitations, operator interaction, and required positioning should all be considered.
Application-specific engineering can also help businesses address unusual lifting or handling requirements that standard equipment may not solve efficiently.
5. Modernize Aging Material Handling Systems
Older material handling systems can require more manual intervention, maintenance, and operator involvement than newer equipment.
When labor availability is limited, outdated processes can become even more noticeable. A system that once worked adequately with a larger workforce may become inefficient when fewer employees are available.
Modernization does not always require rebuilding an entire facility.
Businesses can start by identifying individual bottlenecks and upgrading the equipment associated with those processes. This could include replacing manually operated lifting equipment, adding powered positioning equipment, improving workstation ergonomics, or integrating automation into a specific stage of material movement.
A phased modernization strategy can allow companies to prioritize improvements based on labor requirements, operational impact, safety considerations, and return on investment.
How Can Companies Reduce Labor Requirements in Material Handling?
Companies can reduce labor requirements by combining automation, ergonomic equipment, improved workflow design, and application-specific lifting solutions. The objective is to reduce repetitive manual handling while allowing employees to focus on higher-value tasks.
The most effective approach will vary by facility. A warehouse may benefit from different technologies than a manufacturing plant, bulk handling operation, or distribution center.
Turning Labor Challenges Into an Efficiency Opportunity
Labor shortages are unlikely to be solved by a single equipment upgrade. Instead, manufacturers and material handling operations should look at the entire workflow and identify where available employees are spending time on repetitive, physically demanding, or inefficient tasks.
The right combination of materials handling equipment, ergonomic solutions, automation, and process improvements can help businesses make better use of their existing workforce.
Air Technical Industries provides engineered lifting and material handling equipment for a wide range of industrial applications. From lift tables and cranes to positioning and specialized handling equipment, the right solution can be designed around your application, load requirements, and operating environment.
If labor constraints are affecting your material movement processes, evaluating where equipment can reduce manual handling may be a practical first step toward improving productivity and operational efficiency.
Request a Quote for Material Handling Application
Labor shortages can make inefficient lifting and material movement processes even more costly. The right equipment can help reduce manual handling, improve workflow efficiency, and make better use of your existing workforce.
Air Technical Industries can help you identify the right lifting, handling, or positioning solution for your application. Whether you need ergonomic lifting equipment, bulk handling material equipment, cranes, lift tables, positioners, or automated handling solutions, our team can work with your requirements to develop an appropriate solution.
Ready to improve your material handling process? Request a quote today and tell us about your application, load requirements and operational challenges.
Frequently Asked Questions (FAQ’s)
1. How can material handling equipment help reduce labor shortages?
Material handling equipment helps reduce labor shortages by automating repetitive lifting, transporting, positioning, and loading tasks. Solutions such as lift tables, cranes, upenders, and positioners allow businesses to maintain productivity with fewer workers while improving efficiency and workplace safety.
2. What are the best material handling solutions for improving workforce productivity?
Common productivity-enhancing solutions include ergonomic lift tables, jib cranes, workstation cranes, pallet positioners, upenders, and automated handling systems. These tools reduce manual effort, streamline workflows, and help employees accomplish more in less time.
3. Can automation improve material handling efficiency without replacing workers?
Yes. Automation is often used to support employees rather than replace them. By handling repetitive and physically demanding tasks, automated material handling systems allow workers to focus on higher-value activities such as quality control, equipment operation, and process management.
4. What is the ROI of investing in material handling equipment during a labor shortage?
The ROI can come from reduced labor costs, lower overtime expenses, improved productivity, fewer workplace injuries, and increased throughput. Many companies see long-term operational savings by reducing manual material handling and improving workflow efficiency.
5. How can manufacturers prepare for future labor shortages in material handling?
Manufacturers can prepare by investing in ergonomic lifting equipment, modernizing outdated handling systems, improving workflow design, and implementing automation where appropriate. These strategies help businesses maintain productivity while reducing dependence on manual labor.
Vida Novak is the President of Air Technical Industries (ATI). With his over 25-year tenure at ATI Vida has earned progressive career advancements with increasing levels of responsibilities, including in engineering, technical sales, and operations management. Vida has gain keen insights into complex industrial material handling challenges. An endless number of manufacturers count on ATI’s ingenuity to solve complex and challenging material handling issues, whether for an international space station, a nuclear power plant, automotive plant, food factory, or a military base, among many others.