📦 Warehouse Material Handling Guide
Step-by-Step Physical Material Handling Procedures
1
Essential Material Handling Tools
Forklift
Use: Lifting and moving heavy pallets (500-5000 kg)
Best for: Loading/unloading trucks, stacking high shelves
Pallet Jack (Hand Truck)
Use: Moving palletized goods short distances
Best for: Moving loads up to 2500 kg on flat surfaces
Hand Trolley / Dolly
Use: Transporting boxes and small items
Best for: Order picking and moving cartons
Reach Truck
Use: Accessing high shelves in narrow aisles
Best for: Warehouses with high-density storage
Barcode Scanner
Use: Tracking inventory movement
Best for: Receiving, picking, and shipping verification
🖼️ Warehouse Tools Comparison Chart
(Forklift, Pallet Jack, Hand Trolley, Scanner)
(Forklift, Pallet Jack, Hand Trolley, Scanner)
2
Receiving Materials
Step 1: Prepare Your Receiving Area
- Clear the unloading dock of any obstacles
- Ensure your pallet jack is charged and ready
- Keep your barcode scanner and receiving documents nearby
- Mark the staging area with floor tape for organized placement
🖼️ Clean Receiving Dock Area
(Organized space with marked zones)
(Organized space with marked zones)
Step 2: Unload Using Proper Equipment
- Use a forklift for palletized cargo from trucks
- Operate the pallet jack for moving goods to the inspection area
- Place heavy items on the bottom of your trolley
- Never overload equipment beyond its rated capacity
Always check the weight rating sticker on your equipment before loading. A standard pallet jack handles 2000-2500 kg safely.
Step 3: Inspect and Scan Materials
- Scan the barcode on each item or pallet
- Match the scanned data with your purchase order
- Check for visible damage (dents, tears, moisture)
- Record discrepancies immediately in your system
🖼️ Worker Scanning Barcode on Pallet
(Using handheld scanner)
(Using handheld scanner)
3
Proper Lifting Techniques
✅ Correct Method
- Bend your knees, keep your back straight
- Hold the load close to your body
- Lift with your leg muscles, not your back
- Keep your head up and look forward
❌ Avoid These Mistakes
- Never bend from your waist
- Don't twist while carrying items
- Avoid lifting above shoulder height alone
- Don't rush or jerk the load
🖼️ Safe Lifting Posture Diagram
(Correct vs Incorrect techniques)
(Correct vs Incorrect techniques)
If an item weighs more than 25 kg, ask a colleague for help or use mechanical equipment. Team lifting prevents injuries.
4
Storing Materials Efficiently
Step 1: Categorize Your Inventory
- Separate items by product type and SKU
- Place fast-moving items near the picking area
- Store slow-moving products in deeper locations
- Keep hazardous materials in designated zones
Step 2: Use Storage Tools Correctly
- Forklift: Stack pallets on high racks (2-8 meters)
- Reach Truck: Access narrow aisle locations
- Step Ladder: Retrieve items from mid-level shelves
- Label Maker: Create clear location labels
🖼️ Organized Warehouse Racking System
(Labeled shelves with proper spacing)
(Labeled shelves with proper spacing)
Step 3: Apply FIFO Method
- Place new stock behind existing inventory
- Pick oldest items first (check manufacturing dates)
- Rotate stock weekly for perishable goods
- Mark expiry dates clearly on storage bins
Use colored stickers for quick date identification: Green (fresh), Yellow (use soon), Red (urgent).
5
Order Picking Process
Step 1: Prepare Your Picking Equipment
- Get a hand trolley or picking cart
- Grab your barcode scanner and pick list
- Bring tote bins for small items
- Wear your safety gloves and vest
🖼️ Worker with Picking Cart and Scanner
(Ready for order fulfillment)
(Ready for order fulfillment)
Step 2: Follow the Pick Path
- Start from the location closest to your packing area
- Move systematically through each aisle
- Scan each item to confirm the correct product
- Place items in separate bins for different orders
Step 3: Verify Your Pick
- Double-check quantities against the pick list
- Ensure you scanned all items correctly
- Set aside any damaged products for replacement
- Transport completed picks to the packing station
Batch similar orders together to reduce walking distance. This can improve picking speed by 30-40%.
6
Safe Material Movement
Operating a Pallet Jack
- Position the forks completely under the pallet
- Pump the handle to raise the load 1-2 inches
- Pull the jack backward (never push heavy loads)
- Look in the direction you're moving
- Lower the load gently at the destination
🖼️ Pallet Jack Operation Steps
(Fork placement and pumping technique)
(Fork placement and pumping technique)
Operating a Forklift
- Complete your pre-operation safety checklist
- Approach the pallet straight-on, forks lowered
- Slide forks fully under the pallet
- Lift the load 6 inches and tilt back slightly
- Drive slowly with your load low to the ground
- Sound the horn at corners and doorways
⚠️ SAFETY FIRST
👷 PPE REQUIRED
🚨 CERTIFICATION NEEDED
Never carry passengers on forklifts. Keep your arms and legs inside the operator compartment at all times.
7
Packing and Dispatch
Step 1: Gather Packing Materials
- Boxes: Various sizes for different orders
- Tape Gun: For sealing packages quickly
- Bubble Wrap: Protect fragile items
- Void Fill: Air pillows or packing paper
- Label Printer: Shipping labels
🖼️ Packing Station Setup
(Organized materials and tools)
(Organized materials and tools)
Step 2: Pack Items Securely
- Choose a box size that fits snugly with minimal space
- Place heavier items at the bottom
- Wrap fragile products individually
- Fill empty spaces to prevent shifting
- Seal all edges with strong packing tape
Step 3: Load for Delivery
- Use a hand trolley to move packed boxes to the loading dock
- Stack boxes in the delivery vehicle by route order
- Place the last delivery stop at the front
- Secure the load with straps to prevent movement
- Scan all packages as "shipped" in your system
🖼️ Properly Loaded Delivery Vehicle
(Organized and secured packages)
(Organized and secured packages)
8
Safety Equipment & PPE
Steel-Toed Boots
Protects feet from falling objects
Required: All warehouse areas
Work Gloves
Prevents cuts and improves grip
Required: Material handling tasks
High-Visibility Vest
Makes you visible to forklift operators
Required: Areas with vehicle traffic
Hard Hat
Protects head from overhead hazards
Required: High-stacking areas
🖼️ Worker Wearing Complete PPE
(Hard hat, vest, gloves, steel-toed boots)
(Hard hat, vest, gloves, steel-toed boots)
9
Daily Equipment Maintenance
Before Each Shift Checklist
- ✓ Check battery charge on electric equipment
- ✓ Inspect wheels for damage or wear
- ✓ Test brakes and steering controls
- ✓ Look for fluid leaks under forklifts
- ✓ Verify horn and warning lights work
- ✓ Clean debris from forks and platforms
After Use Care
- Park equipment in designated areas
- Lower forks to the ground
- Turn off power and remove keys
- Plug in electric equipment for charging
- Report any damage or malfunction immediately
Keep a maintenance log book with each piece of equipment. Note any issues to track recurring problems.
10
Key Safety Rules
🚨 Critical Safety Guidelines
- Never stand under raised loads - Always maintain safe distance
- Keep aisles clear - 3-feet clearance minimum
- Report all accidents - Even minor incidents matter
- No shortcuts - Follow procedures every time
- Stay alert - Avoid distractions and fatigue
- Communicate - Use hand signals and verbal warnings
🖼️ Warehouse Safety Signage
(Warning signs and floor markings)
(Warning signs and floor markings)
⚠️ Emergency Contacts
- Supervisor: [Contact Number]
- Safety Officer: [Contact Number]
- First Aid Station: [Location]
- Emergency Exit Routes: [Posted on walls]
📋 Quick Reference Summary
✅ Always Do:
- Wear proper PPE
- Use correct equipment for each task
- Scan items for accuracy
- Keep work areas clean
- Report equipment issues
❌ Never Do:
- Overload equipment
- Operate without certification
- Rush through tasks
- Ignore safety warnings
- Work alone with heavy items
