OVERVIEW
A regional distribution warehouse regularly relocated heavy assets such as wrapping machines, conveyor sections, and crated equipment weighing up to 6 tonnes.
These movements were traditionally carried out using pallet trucks, timber bearers, and manual pushing by multiple operatives.
This approach resulted in frequent near misses, inconsistent control of loads, and rising concerns around manual handling injuries.
To address these risks, the site introduced a machine skate and dolly system designed for safe, controlled load movement within warehouse environments.
CHALLENGES
Moving heavy machinery in confined warehouse spaces
High-risk manual handling requiring multiple operatives
Repeated strain injuries linked to pushing and pulling tasks
Poor visibility and coordination during team-based manual moves, increasing the risk of crush injuries and loss of load control
SOLUTION
The upgrade to a machine skate set-up supported compliance with Manual Handling Operations Regulations by removing avoidable hazardous handling, Manpower per move was reduce from five operatives to two, while relocation times improved by approximately 40%.
Machine skates also reduced floor damage and improved confidence among staff when moving heavy equipment.
BENEFITS
Reduced Injury Costs: Avoiding manual handling injuries saved £6,500-£8,000 per incident while significantly reducing musculoskeletal risk.
Faster Moves, Safer Work: Machine skates halved labour needs, reduced move time by 40%, and paid back within one year.