The Challenge:
A Third-Party Logistics (3PL) provider faced a bottleneck in their shipping and receiving operations. They managed supply chain solutions for a diverse customer base. The facility’s inbound and outbound docks processed an average of 5-8 floor-loaded containers per week. Demand remained steady. However, the manual nature of the work created operational risks.
Workers performed constant repetitive motions. They had to lift, twist, carry, and reach overhead to stack and unstack product. This manual handling capped throughput. It also led to a rise in reported injuries and muscle strain. To sustain growth and meet delivery windows, the 3PL needed a solution. They required a system to increase productivity while eliminating the ergonomic hazards threatening their workforce.
The Solution:
The 3PL evaluated standard power and gravity roller conveyors. They determined that a simple conveyance method could not handle the vertical challenges of floor loading. They selected the Restuff-it™ Bi-Directional Portable Ergonomic Conveyor.
Unlike traditional conveyors, the Restuff-it is a self-propelled, battery-operated machine. It fits specifically in the confined space of shipping containers. It features a hydraulic operator platform capable of lifting personnel up to 27.5 inches. It also has a pivoting conveyor belt that adjusts to the optimal working height. This "bi-directional" capability was essential. It allowed the facility to use a single asset for both unloading and loading operations.
The Execution:
Visual analysis of the project demonstrates the change in workflow. Workers no longer climb on step stools or reach overhead to build high walls of boxes.
The operator drives the Restuff-it unit directly into the trailer using integrated DC drive controls. As the container fills or empties, the operator adjusts the platform height. This positions them directly level with the "box wall." Instead of lifting boxes from the floor or throwing them to the top, workers simply slide product laterally onto the pivoting belt. The belt handles 165 lbs at a 30-degree incline. It transports goods directly to the dock’s flexible conveyor system. This continuous flow eliminates the "micro-breaks" workers previously took due to fatigue. It maintains a steady case rate throughout the shift.
The Result:
The trial period yielded immediate success for the 3PL.
- Labor Efficiency: The operation reduced the required team size by one full-time worker per container. This reallocated labor to other value-added tasks.
- Ergonomic Safety: The facility minimized the risk of twisting and overhead lifting injuries by keeping workers in the "power zone" between shoulders and knees.
- Throughput: The hourly case rate increased significantly. This allowed for faster trailer turns and potentially reduced the total number of dock doors required for operations.