Mastering Materials Handling: Essential Skills for Industry Success

Materials handler training is critical for safe and effective warehouse operations.

If overlooked, workers risk severe injury while businesses suffer significant financial loss due to lost productivity. The figures don’t lie – 20% of all workplace injuries result from handling, lifting or carrying activities.

That’s an enormous proportion of entirely preventable accidents and injuries.

The good news is that high quality materials handler training can significantly reduce workplace accidents while also driving improved productivity and efficiency across the entire operation.

How? Read on…

Contents

• Why Materials Handling Training is Important
• Essential Skills for Materials Handlers
• Equipment Operation
• Creating a Safety Culture
• Opportunities for Career Advancement
• Training Pitfalls to Avoid

Why Materials Handling Training is Important

Before we get into the details, let’s cut to the chase.

Untrained materials handlers are hazardous to themselves, their colleagues and the business. This is evidenced by the serious injury risks, health and safety penalties and lost working days they cause.

In the UK, it’s been estimated that 473,000 workers are off work as a result of musculoskeletal disorders every day. This represents a total of over 6.6 million working days lost annually.

Stop reading and let that really sink in for a moment…

Those aren’t just statistics, those are people being unable to work, dealing with constant and chronic pain and watching their careers grind to a halt as a result of entirely avoidable and preventable injuries.

And the cost to business? UK businesses lose an estimated £675 million annually to musculoskeletal disorders alone.

And when workers are not properly trained and equipped to handle materials safely, they all pay the price.

Essential Skills for Materials Handlers

So what makes a good materials handler great?

It comes down to mastering a certain set of skills. But this isn’t rocket science, it’s a tried and tested combination of technical know-how and practical application.

Training handlers on the specific skills outlined below protects both the worker and the wider operation. Most of these skills aren’t complicated, but they do need instruction and regular practice.

Manual Handling Techniques

The absolute bedrock of all materials handling is the ability to lift, carry and move objects safely. This includes:

• Assessing loads before lifting
• Practicing good posture and position
• Understanding personal lifting limits
• Knowing when to ask for assistance or use equipment

Weak or incorrect lifting techniques are the cause of thousands of back injuries every year. Bad posture at one moment can mean months of recovery time.

Load Assessment and Planning

Trained materials handlers never approach a lifting task without first assessing the situation. Weight, shape, size, destination and any potential obstacles are considered before touching the item. This planning prevents accidents from occurring.

Environmental Awareness

Warehouses and distribution centers are dynamic environments. There’s always something moving around and changing from moment to moment. As such, trained handlers are always on the lookout for potential hazards including wet floors, obstructions and other personnel.

Equipment Operation

Today, materials handling would simply not be possible without a suite of equipment.

From the humble pallet truck to more specialist reach stackers, forklifts and order pickers, the ability to safely operate machinery is essential. Certifying workers to operate equipment isn’t just a safety measure, it’s also a legal requirement.

Forklift Training

Let’s talk forklifts, these machines are the true workhorses of the industry but they also represent one of the biggest causes of workplace fatalities every year.

As such, complete forklift training is non-negotiable and should include all of the following:

• Pre-operation safety checks
• Load capacity and weight understanding
• Maneuvering in tight spaces
• Pedestrian awareness
• Emergency and rescue procedures

Conveyor Systems

Automated conveyor systems are extremely common these days but they also require a certain level of knowledge to work safely. This includes understanding emergency stop procedures, lockout/tagout safety and even maintenance.

Reach Equipment

Working at height presents additional challenges and risks to materials handlers. This is true whether working with order pickers, reach trucks or other specialized machinery. All equipment that is used at height must be covered in specialized training first.

Creating a Safety Culture

Materials handling training isn’t a one off event.

The most successful operations are the ones that ingrain safe working practices into the very DNA of the culture. In practical terms, this means regular refresher training, toolbox talks and environments where workers are able to raise concerns freely.

But there’s a vital missing ingredient that is the foundation of all this…

Safety culture begins at the top. When management lead by example and make it clear that they are investing in quality training programs and prioritizing safe working practices, the message resonates throughout the entire organization.

Workers who see their employers going to these lengths feel valued. They are much more likely to consistently follow procedures and look out for their fellow workers.

The key elements of a strong safety culture include:

• Regular training updates and refreshers
• Open communication about hazards and near-misses
• Rewarding safe behavior
• Clearly defined reporting procedures
• Active management presence on the warehouse floor

Opportunities for Career Advancement

Here’s a final thing to consider…

Materials handling is not a dead end job, far from it. With a clear career path available to those who invest in the right training and certification, the opportunities to progress are significant.

Entry level materials handlers can move into roles such as:

• Team leader
• Warehouse supervisor
• Health and safety coordinator
• Training and development specialist
• Operations management

Each new role requires additional qualifications and those workers who are prepared to put in the time and effort with continuous professional development will see doors opening up as their careers advance.

There are also many specialist routes in the industry. Dangerous goods handling, cold chain logistics, automated systems management, are all areas that require specific knowledge and in-demand skills that demand higher salaries.

Common Training Mistakes to Avoid

Not all training programs are created equal.

It’s very easy to tick the boxes of “completed training” while not actually developing competent materials handlers. Be aware of these pitfalls that will render any training ineffective:

Rushing the Process

Trying to complete a training program by squeezing in too much information over a short period leads to little retention. Quality training takes time and includes practical application of skills as well as theory.

Ignoring Refresher Needs

Skills and knowledge erode without regular use and application. Annual refresher training is crucial to keep knowledge fresh and behaviors reinforced.

One-Size-Fits-All Approach

Different materials handling roles require different skills and training. There’s a big difference between a picker and a forklift operator. Tailored training programs that reflect the needs of specific roles lead to better outcomes.

Neglecting Soft Skills

Neglecting communication, teamwork, and problem-solving skills is a mistake that is easily made. The best materials handlers have both technical and soft skills and are able to apply them effectively.

Wrapping Things Up

Materials handling training is not optional.

It is a fundamental requirement for safe and successful warehouse operations. The stats make this very clear. With MSDs affecting hundreds of thousands of workers and costing businesses millions of pounds each year, quality training represents a significant return on investment.

Let’s quickly recap the key points:

• Training significantly reduces workplace accidents and injuries
• Core skills include safe manual handling, load assessment and planning, and environmental awareness
• Equipment operation requires specific certification
• Safety culture requires ongoing commitment and reinforcement
• Career progression is available to those who upskill

Whether starting out in the industry fresh or looking to upskill your current teams, the decision to invest in quality materials handler training can reap huge benefits.

The alternative – untrained workers operating in hazardous environments – is simply not worth the risk.

Start assessing your current training programs today and consider where the gaps might be. The sooner you can make improvements, the sooner you will start to see the benefits.