The problem: physical strain in the warehouse is systematically underestimated
Warehouse workers lift, bend and carry, for hours, every day. The consequences show up in the statistics: musculoskeletal disorders (MSDs) account for 19.8 % of all days of sick leave in Germany (AOK Absenteeism Report 2024). In the logistics sector the share is even higher. The loss of gross value added due to incapacity for work amounts to 227 billion euros across Germany, 5.1 % of gross national income.
The good news: ergonomic measures are among the most effective and most economical investments in occupational health and safety.
The biggest ergonomic risk factors in the warehouse
- Manual lifting and carrying: The German Load Handling Ordinance (LasthandhabV) limits permissible loads, in practice it is regularly ignored
- Repetitive movements: Hundreds of identical picks per shift during order picking and packing
- Awkward postures: Bending, overhead work, twisted spine when reaching into low or high rack levels
- Static strain: Long periods of standing without compensating movement
- Inadequate lighting: Increases the risk of accidents and leads to eye fatigue and poor posture
Legal framework: what the employer must provide
- Load Handling Ordinance (LasthandhabV): Requires a risk assessment for the manual handling of loads and the provision of lifting aids
- Occupational Health and Safety Act (ArbSchG) §5: Systematic risk assessment of all workstations
- DGUV Information 208-033: Specific rules for the manual handling of loads in logistics
- DIN EN 12464-1: Workplace lighting, at least 300 lux for warehouse halls, 500 lux for order picking
Solution 1: Height-adjustable packing benches and workstations
Alongside the racking, the packing bench is the most heavily used workstation in the warehouse. A height-adjustable packing bench eliminates the most common poor posture: bending over to pack.
- Electric lift tables: Infinitely adjustable from 650 to 1,050 mm, load capacity 150–500 kg
- Scissor lift tables: Raise heavy pallets to an ergonomic working height (up to 1,000 kg)
- Tilting work surfaces: For visual inspection and order picking without bending over
Rule of thumb: the work surface should be at elbow height minus 5–15 cm.
Solution 2: Ergonomic order picking, the "strike zone"
The ergonomically optimal picking height lies between 600 and 1,500 mm, the so-called "strike zone" or "golden zone". Picks outside this range place a disproportionate strain on the back, shoulders and knees.
Practical measures:
- Store fast movers (A items) in the strike zone
- Heavy items at medium height, light items at the top and bottom
- Goods-to-person systems: the goods come to the employee instead of the other way round
- Pick-by-light and pick-by-voice reduce search movements and picking errors
Solution 3: Industrial trucks and lifting aids
- Order pickers with lifting cab: Raise the employee to the correct picking height
- Vacuum lifters: For boxes and parcels up to 50 kg, reduce the strain of lifting by up to 80 %
- Spring-loaded pallet positioners: The pallet automatically lowers under load, the top layer always remains at an ergonomic picking height
Solution 4: Exoskeletons, the future is here
Exoskeletons are no longer science fiction. They are already in use in German warehouses:
- Passive exoskeletons: Mechanical support via gas pressure springs, reduce back strain by up to 40 %. Lightweight, no power supply required.
- Active exoskeletons: Battery-powered, e.g. Ottobock IX BACK VOLTON, relieves the back by up to 17 kg per lift.
The Fraunhofer IML systematically tests exoskeletons in logistics environments. Companies such as DB Schenker and the medical device manufacturer Medi already use them in regular operations. A warehouse logistics specialist at Medi reports: "I used to work without an exoskeleton. Today I clearly feel the difference, even at home in the evening."
Challenges: the time needed for putting them on and taking them off, sweating during heavy work and acceptance within the team. Long-term studies in industrial use are still pending.
Solution 5: Lighting and floor design
Often overlooked, but highly effective:
- LED high-bay lighting: At least 300 lux (DIN EN 12464-1), 500 lux in picking zones. Modern LED systems also cut energy costs by up to 60 %.
- Anti-fatigue mats: At stationary workstations (packing bench, inspection) they measurably reduce the strain on feet, legs and back during long periods of standing.
- Industrial floors with cushioning: PU-coated floors absorb impacts better than bare concrete.
The business case: numbers that convince
Studies by the Fraunhofer IPA show:
- Productivity increase through ergonomics: up to 25–36 %
- Reduction in absenteeism: 25 % on average, up to 57–73 % with targeted interventions
- Reduction in MSD sick days: up to 75 %
Example calculation: A warehouse operation with 20 employees, an average of 12 MSD sick days per employee per year. Cost per sick day: approx. 500 EUR. Annual MSD costs: 120,000 EUR. With a 50 % reduction through ergonomic measures: 60,000 EUR in savings per year. The investment in height-adjustable packing benches (approx. 2,000 EUR × 5 = 10,000 EUR) and lifting aids (approx. 15,000 EUR) pays for itself in less than 5 months.
Conclusion: ergonomics is not optional but a duty, and it pays off
Ergonomic warehouse design is effective in three ways: it protects the health of employees, increases productivity and reduces costs. Given the shortage of skilled workers in logistics, an ergonomically designed workstation also becomes a competitive advantage in recruitment. The measures range from simple anti-slip mats to exoskeletons, there are effective solutions for every budget.