Material Handling Processes & Equipment

📦 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)

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)

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)

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)

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)

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)

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)

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)

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)

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)

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)

⚠️ 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