Conclusion
Manual unloading is a workable solution for single SKU containers, if the cartons are not too heavy and the annual volume is limited.
Back to overview
Manual unloading is a labour intensive process that requires workers to lift, carry, and place cartons by hand. It is a workable solution for low volume operations with limited cartons weight.
Single SKU containers (with only one product type) where products need to be stacked on pallets are very suitable to be unloaded manually. A worker unloads the cartons from the container and places them directly on a pallet inside the container at rates of approx. 400 – 500 carton per hour. Another worker supplies empty pallets and removes full pallets from the container with an (electric) pallet jack.
Multi SKU containers
With multi-SKU containers, the cartons also have to be sorted to the right pallet. A (gravity) conveyor might come in handy to transport the cartons to outside the container for further processing. In those cases the unloading worker in the container places the cartons on the conveyor at productivity rates up to 600 – 700 cartons per hour. Other worker(s) outside the container take the cartons from the conveyor and place them on the right pallet. The pallets are typically arranged in a horseshoe configuration around the end of the conveyor. Two workers are required for palletizing up to 4 SKU. Heavily mixed container require even more palletizing workers.
Advantages
- Flexibility: Requires less specialized infrastructure and can be set up in various environments without significant modifications. Easier to set up and get started compared to automated systems which require integration and commissioning.
- Adaptability. Humans can better handle irregularly shaped, loosely packed, or fragile items compared to automated systems. Workers can make quick decisions and adjustments in real-time to address unexpected issues during unloading.
- Low fixed cost: Fixed costs are low since there is no depreciation on expensive machinery or complex systems. In case of flex workers, costs will only be made when there is work to do. This is typically an advantage for seasonal operations.
Disadvantages:
- Working conditions: The process is physically demanding, leading to potential worker fatigue and injury. Workers are at risk of injuries from heavy lifting, repetitive motions, and accidents. Also it can get very hot (summer) or very cold (winter) in the containers.
- Efficiency: Manual unloading is typically slower compared to automated systems. Especially when sorting is involved. Then, workers need to walk a few meters for each carton to place a carton on the right pallet.
- Accuracy: There is a higher likelihood of human error, such as misplacing items, incorrect counts, or mishandling goods. Ensuring consistent quality control can be challenging, impacting the overall reliability of the process.
- Continuity: Finding and retaining enough workers can be difficult, especially in areas with low unemployment or high competition for labour. High turnover rates in manual labour positions can lead to disruptions and increased training costs.
- Fast increasing labour cost: Currently, port workers on the U.S. East Coast earn $35 to $40 per hour, with wages projected to increase to $60 to $65 per hour by 2030.
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