First avoid unnecessary handling
Article 3 of Spain’s Royal Decree 487/1997 prioritises avoiding manual handling through technical or organisational measures, particularly mechanical handling equipment. Before purchasing an aid, review whether the load needs to move, how often and why.
Changing layout, supply format or delivery height may eliminate a transfer. Where handling remains necessary, the aid must reduce risk under actual conditions.
Choose by function and task
Transporting, lifting, rotating, holding and placing are different functions. Trolleys, pallet trucks, lifting tables, conveyors and manipulators offer different solutions. Selection cannot be based only on maximum permissible mass.
The load’s dimensions, stability, gripping points, fragility and variations must be understood. The destination also matters: an aid may bring a part to the workstation without solving how it is removed or positioned in the machine.
Check the route and space
- Available width, turns, doors and access.
- Floor condition, slopes, joints and obstacles.
- Pickup, delivery and storage heights.
- Interaction with other people and equipment.
- Visibility during movement and positioning.
- Where the aid is kept when not in use.
These conditions must be reviewed during normal shifts and situations, including the busiest periods. A demonstration in an empty space may conceal everyday operating difficulties.
Assess the remaining effort
Wheels do not necessarily eliminate physical workload. Initial and sustained pushing or pulling effort, postures needed to attach an aid and repetition may remain significant.
Assessment should compare the task before and after using appropriate criteria. Asking whether equipment seems comfortable is not enough. Grips, reaches, forces, frequency and the ability to adjust the pace must be observed.
Control new hazards
An aid introduces or changes risks of trapping, falling loads, collision or unexpected movement. Royal Decree 1215/1997 requires suitable equipment and safe conditions of use.
Accessory compatibility, stability, instructions, safeguards and maintenance must be checked. Training should cover limitations and anomalies. A device intended for loads must not be assumed suitable for lifting people merely because its capacity is sufficient.
Trial before implementation and review afterwards
A trial with representative loads and participation by the people doing the work can reveal difficulties before purchasing is expanded. It should cover the complete operation, cleaning, storage and assistance needs.
Afterwards, check whether the aid is actually used and why it may be abandoned. Distance from the workstation, breakdowns, unavailability or incompatibility with certain formats are implementation problems requiring correction.
Hypothetical example: boxes in order picking
A warehouse introduces a lifting table to keep boxes at a suitable height. The trial reveals that the incoming trolley cannot bring them close without an awkward manual transfer.
The combined feeding arrangement, table and output are reviewed before implementation. The decision is based on reduced effort throughout the sequence, not merely the table’s ability to lift the intended weight.
