In the manufacturing sector, success depends on optimizing every phase of the production process. However, one crucial function is often overlooked: material handling.
Many companies invest time and resources in design, planning, procurement, production, and quality control… but neglect how materials move within their facilities.
This mistake can silently undermine profitability, causing inefficiencies, injuries, and delays. Let’s look at the most common mistakes and the practical solutions to avoid them.
Industrial manipulators: the backbone of efficient handling
Industrial manipulators, such as handling and assisted lifting devices, are designed to help operators lift and position heavy or bulky loads safely and efficiently.
Unlike cranes and forklifts, they offer greater precision, flexibility, and ergonomics. They consist of a mechanical arm, an end effector, and an intuitive control system, and are powered by compressed air or electricity.
In sectors like manufacturing, automotive, packaging, textile, or food, they reduce physical strain, prevent injuries, and boost productivity.
5 common material handling mistakes (and what they really cost you)
1. Relying too much on manual lifting
Manual lifting is one of the leading causes of injuries (back pain, strains, musculoskeletal disorders).
In addition to insurance costs and sick leave, manual handling is slow, imprecise, and can delay production.
Associated costs:
Increased injuries
Reduced productivity
Higher insurance premiums
Legal issues
Lower employee morale
2. Inefficient workflows
Disorganized layouts and poorly designed paths cause wasted time, unnecessary movements, and bottlenecks.
Every unnecessary move is a potential product damage and financial loss.
Associated costs:
Labor waste
Rework due to damage
Delivery delays
Lower customer satisfaction
Lost business opportunities
3. Ignoring ergonomics
The absence of ergonomic solutions leads to fatigue, pain, and reduced productivity. Repetitive movements and poor posture cause long-term health issues.
Associated costs:
Increased absenteeism
Healthcare expenses
Difficulty retaining skilled workers
Negative reputation
4. Lack of process optimization
In a competitive market, process optimization is essential.
Associated costs:
Higher labor costs
Slowed growth
Loss of competitiveness
5. Inadequate or poorly maintained equipment
Using the wrong or poorly maintained tools leads to breakdowns, accidents, and downtime.
Many companies overlook technical consulting or after-sales service, risking additional business costs.
Associated costs:
Equipment damage
Production interruptions
Emergency maintenance
Safety risks
Practical solutions for a more efficient workflow
✅ Invest in ergonomic solutions
Analyze your processes, identify critical points, and integrate manipulators or assisted lifters to reduce physical strain and boost productivity. Dalmec designs custom solutions for every need.
✅ Optimize layout and flows
Redesign your plant layout with a lean approach. Use simulation software to prevent bottlenecks before they happen.
✅ Optimize where it matters
Streamline repetitive tasks to cut costs and improve quality. Focus on areas with the highest return on investment.
✅ Choose the right equipment and maintain it
Select the right devices for each task and implement a preventive maintenance plan with regular inspections.
✅ Embrace a culture of continuous improvement
Train your staff, update your equipment, and promote safety and ergonomics as core company values.
In conclusion
Efficient material handling is not just a technical issue: it’s a strategic investment in your company’s future.
Dalmec designs custom manipulators to optimize ergonomics, efficiency, and safety in every industry.
Partnering with us means relying on an experienced and trustworthy team, ready to find the right solution for every challenge.
💬 Want to discover how to improve load handling in your company? Contact us — we’ll be happy to help.