Stress in a distribution center: symptoms, effects, and solutions
A distribution center is a bustling place filled with trucks, forklifts, conveyor belts, pallet jacks, order-picking carts, personnel, noise, and more. This by itself can be a source of stress. Additionally, there is a need for all these elements to work together seamlessly, like a well-oiled machine – day in and day out. This applies even during peak times, which is reason enough to monitor your employees for stress. It may cause them to become careless – and you will have to deal with the consequences.
In the world of e-commerce, speed and efficiency are invaluable. With online stores promising short delivery times (sometimes the same day as the order), customers now take this for granted. This requires a well-thought-out logistics plan and a workforce that doesn't succumb to stress. However, reality sometimes disrupts the theory, leading to intense periods of stress.
Stress comes with health risks in both the short and long term. A stressed employee is more likely to take risks than someone who has the time to follow all procedures. During peak activity periods, the likelihood of workplace accidents increases.
No distribution centre is immune to this, so make sure your infrastructure is optimally prepared thanks to protective polymer materials. No shipment is worth risking your employees' safety for.
Symptoms:
1. Inappropriate driving behavior by forklift operators
Safety is the first casualty of stress in a distribution center, especially when forklifts are part of the process. Example: When a major Dutch brewery conducted a risk assessment, it discovered that stress was the biggest risk factor in the company. Not only did stress itself lead to dangerous maneuvers, but the hectic pace was causing the forklift operators to tire more quickly and lose focus. Put simply: one risk leads to another.
2. Unhappy or disgruntled employees
In every distribution center, there are times when employees are under time pressure and hurry their work. Periods of peak activity essentially serve as a stress test for the company's operations. If these peak periods result in the same problems occurring repeatedly, employees start to become frustrated. In the long run, this has an overwhelmingly negative impact on their overall attitude, leading to reduced involvement, less communication, more mistakes, and increased absences. Frequent clashes or internal conflicts also indicate that something is amiss.
Minor incidents with physical consequences
Shipments fail to depart on time
This is one of the most serious consequences of stress running rampant through the ranks. Not only can an error in judgment or control cause significant (economic) damage, but it can also result in personal injury or worse. Make safety a top priority in the distribution center. Install safety barriers and use handrails, bollards, rack protection, and column protection.
Obstructions in aisles
Stress and a lack of focus also lead to traffic problems. If the rules outlined in the traffic plan are not followed at work, this can cause accidents as well as congestion in the aisles. This applies to forklifts, pallet jacks, and order pickers. Consequently, the risk of damage and injury increases. This is why it is important to install adequate safety barriers, column, and rack protection.
Minor incidents with physical consequences
Accidents do not always involve vehicles. A distressed person makes errors in judgment. While these mistakes may be minor on their own, they can have far-reaching consequences. Rushing down the stairs or moving quickly across a slippery floor, for instance, can cause a person to slip or take a hard fall.
Shipments fail to depart on time
Stressed employees are less focused and more fatigued, causing parcels to miss their specified deadlines and enter the logistics chain much too late.
Shipping mistakes
It is not just the shipping process that experiences delays. Mistakes are also made when parcels are assembled or when the address is written on them. The issue is that these mistakes are usually not discovered until the recipient has them in their hands. And by then, it's too late.
However, there are solutions...
Design an efficient workspace
Traffic schedule
When a warehouse's layout and traffic flow are optimized for the distribution process, it significantly reduces the risk of work-related stress. A traffic plan is an important factor to take into consideration here. When everyone knows their role, it reduces the risk of forklift accidents and increases efficiency on the shop floor. This directly impacts the behavior of the workers involved. Physical boundaries, supplemented by floor markings, are also very useful.
Driving and walking distances
When organizing a distribution center, space plays a key role. The walking and driving distances involved in your employees' work have to be factored into this. Ensure these distances are always tailored to your workers and their tasks. This holds particularly true for order pickers. The longer the distance they have to travel, the higher the cost. Do you think that's too simplistic? Quite the opposite: If employees have to travel longer distances, it increases your lead times. This means that workers accomplish less within a given time frame and daily budget.
Adequate space
If space is limited, this can cause the warehouse to become cluttered and prompt forklift operators to perform irresponsible maneuvers. Expanding a warehouse or relocating to a larger facility is not an easy task. This is why it is crucial to allocate the space you already have as efficiently as possible.
Take into account the width of the aisles that a forklift needs to navigate. Typically, 200 mm to 350 mm of free space is required around the forklift. You can calculate the minimum aisle width based on the forklift's dimensions. For some aisles, remember that a forklift may need to turn 90° depending on the task it is performing.
Appoint a confidential advisor
In an environment where everyone is racing against the clock, it's important to discuss work-related stress. This can be done by appointing a supervisor, a prevention advisor, or a coworker. With a coworker, the threshold for discussion is lower. This person can then inform the organization, which can take measures as needed.
Allow people the freedom to do things their way
Someone who is deeply involved in the distribution process every day has a clear view of how it works and what its shortcomings are. It can be worthwhile to allow this person the freedom to organize the process as they see fit. Encourage people to think about how to improve specific processes and make clear agreements together.
Establish a stable workflow
Every distribution center has to manage periods of peak activity. The goal is to reduce them as much as possible. And when they do occur? Stay practical. Which shipments are a priority and which have some flexibility? This will help you prevent stress from building up.
Call for a time-out in high-stress situations
If you notice that your employees are in overdrive during a period of peak activity, don't hesitate to pause work for a moment. During this short break, talk with the people involved and, if possible, adjust the approach to the process. As pressure decreases, focus increases, which is essential in a distribution center.
Prepare for risky behavior fueled by stress
Even the most disciplined order picker isn't immune to extended heavy workloads. As their stress levels rise, their behavior and judgment will be affected. They will think less about the potential consequences of risky behavior, which can lead to dangerous situations, especially for forklift operators.
In a warehouse where the infrastructure is protected against risky behavior, damage and injuries will be minimized. This is why polymer safety solutions are definitely worth considering. Explore the safety options for your warehouse in this white paper.