Material Handling Equipment (MHE) industry manufactures products like conveyors, forklifts, cranes, and more. But just like any other manufacturing industry, MHE industry also has its own challenges like managing tight budgets, meeting client demands, and maintaining high product quality while staying compliant with industry standards.
These common mistakes not only affect the quality of the equipment but also have a direct impact on customer satisfaction and operational efficiency.
In this blog post, we will talk about 5 common mistakes made in MHE manufacturing and offer solutions and suggestions on how to avoid them.
Read more about Material Handling Equipment: Types, Use Cases, And Application.
Common Material Handling Equipment Mistakes
Sometimes the smallest of the mistakes can cause huge losses in a manufacturing business. Let’s learn about them in detail.
1. Overlooking Customization Needs
Different businesses have unique requirements and need special storage material handling equipment. Thus, it is important to know that one size doesn’t fit all. You have to make sure that your products handle the required material and fit within the required spaces.
If you choose a generic design without considering the specifications, it might lead to equipment that is functional but fails to operate in the required environment. The lack of customization can lead to various issues, such as increased lead time, frequent adjustments, increased maintenance costs, and disruptions.
How To Avoid?
- You should properly check the equipment specifications, like load capacity, material types, fitting spaces, and more.
- You can invest in advanced designing tools such as CAD/CAM, 3D printing, ERP software, and more.
- You can work closely with clients to understand their operational challenges.
- You can implement a modular design approach to customize components easily.
2. Neglecting Ergonomic Design
Ergonomics in the MHE manufacturing industry means building equipment that increases the operator’s comfort, safety, and workflow. Ergonomically designed equipment not only reduces physical stress on operators but also reduces the risks of injury and improves their overall productivity.
Ignoring ergonomic designs in your MHE manufacturing and only focusing on the functionality and durability of the machine may lead to the operator’s fatigue and injuries, resulting in lost work time and increased healthcare costs. Equipment that is uncomfortable to use can also lead to operators working slowly and taking more breaks to avoid discomfort.
How To Avoid?
- You can implement ergonomic principles in the early phases of designing.
- Make sure the controls and interfaces are easy to reach and operate, reducing the need for repetitive motion.
- You can make sure that the equipment can easily be adjusted to fit different operators’ strengths and sizes.
- Implement adjustable features into your equipment designs, such as height-adjustable controls, seats, or handles.
- Make sure to design and manufacture equipment with less vibration and noise reduction.
3. Underestimating Maintenance Requirements
Regular maintenance is important to make sure that your machines, such as conveyor systems and overhead cranes, performs well and are durable. Well-maintained equipment will work smoothly, have fewer breakdowns, and have a longer lifespan, reducing your overall manufacturing costs.
Failing to trin your staff, workers, or operators about regular maintenance or avoiding regular maintenance can lead to improper equipment upkeep and the occurrence of injury. This can also result in frequent breakdowns, costly repairs, unplanned downtime, reduced machinery lifespan, and accidents.
How To Avoid?
- Implement regular maintenance schedules for your staff and operators.
- Provide training programs and guides on methods of material handling for your staff and operators.
- Use condition monitoring systems and predictive maintenance technologies such as IoT sensors and AI-driven analytics.
- Use equipment with easy access to components that require regular upkeep.
- Invest in high-quality components and materials, including CNC machines and laser cutters.
4. Failure to Integrate with Existing Systems
When it comes to equipment manufacturing, its integration with existing material handling processes and systems is important. The equipment must work smoothly with other systems, whether integrating with an existing conveyor system, warehouse management software, or safety protocols.
A major mistake is choosing equipment that does not fit your current operations and systems at MHE manufacturing. This can happen if you only focus on the equipment’s functionality and avoid its integration capabilities. The lack of integration can also cause safety issues, as the equipment might operate unpredictably.
How To Avoid?
- Conduct a detailed gap analysis of existing material handling systems before designing or implementing new equipment.
- Design equipment with communication protocols and standardized interfaces to make sure it integrates with existing systems easily.
- Work with IT and operation teams early in the design and planning process.
- Conduct system simulations and pilot testing to fine-tune the integration before full-scale implementation.
5. Ignoring Regulatory Compliance and Safety Standards
You must comply with industry regulations and safety standards for the operator's and public’s safety. These regulations are set by departments such as the Bureau of Indian Standards (BIS) and the Ministry of Labour and Employment. These specific guidelines include different types of equipment and related safety regulations under the Factories Act 1948.
In addition to the risk of accidents and injuries, you might face legal penalties like fines and lawsuits. This can also lead to your equipment getting banned from use and cause significant losses for you and your clients.
How To Avoid?
- Stay informed about regular updates from the BIS and directives from the Ministry of Labour and Employment.
- Prioritize safety-first designs in your manufacturing process, including safety guards, emergency-stop functions, and more.
- Develop a detailed compliance checklist during the design and production stages to make sure every piece of equipment meets regulatory and safety standards.
- Conduct regular internal audits or get third-party inspectors to cover design, production, and post-production-related directives.
MHE Manufacturers and TranZact
Avoiding all the mentioned mistakes, from overlooking customization needs to ignoring regulatory compliance, is necessary. These help you make sure the equipment you manufacture is effective, safe, and ergonomic. It can be achieved by investing in advanced technology, including robotics, IoT, cloud ERP, and automated material handling systems.
It will help you simplify your manufacturing processes, reduce costs, stay competitive in the market, and improve productivity. You should also implement the best material handling practices and technology to produce the high-quality equipment your clients demand.
Read How Does TranZact Help The Material Handling Industry?
TranZact is an effective cloud-based solution dedicated to Indian manufacturers. It allows you to in-process quality checks, work collaboratively with teams, and stay compliant with GST and industry regulations.
It takes only 14 days for implementation in your material handling equipment manufacturing company with 24*7 dedicated customer support. Implement TranZact today to get real-time data access, effectively manage resources, improve your operational processes, and much more.
FAQs
1. What are the most common mistakes in material handling equipment manufacturing?
The most common mistakes in material handling equipment manufacturing are:
- Not considering comfort and safety in equipment designs
- Ignoring customization needs
- Avoiding regular maintenance
- Having poor integration with operational systems
- Not being compliant with regulatory standards
- Avoiding safety regulations
2. What are the challenges of material handling that equipment manufacturers should consider?
Common challenges of material handling that equipment manufacturers should consider are:
- Space limitations
- Lack of scalability
- Work safety and efficiency
- Unstable processing speed
- Irregular inspections
- Ignored maintenance needs
- Weak production planning
3. Why is ergonomic design important in material handling equipment?
Ergonomic design is important in material handling equipment as it improves the operator’s comfort and safety while reducing the risks of fatigue and injury. It also improves operational productivity.
4. How can manufacturers ensure compliance with regulatory and safety standards for material handling equipment?
Indian manufacturers can ensure compliance with legal and safety regulations for material handling equipment by staying updated on the BIS (Bureau of Indian Standards) and directives of the Ministry of Labour and Employment.
5. How can customization improve the performance of material handling equipment?
Customization helps you improve the performance of your material handling equipment by addressing unique challenges, and workflow, and reducing downtime. With proper customization, you can overcome space limitations, improve work safety, and gain stable operations.
