Any major logistics hub, the loading dock, serves as the major bottleneck. It is also the space where the abstract world of supply chain data meets the tangible world of bulky equipment and unforgiving deadlines. A unique psychological phenomenon is created whereby operators feel an overwhelming need to ‘beat the clock. A significant element of this phenomenon is the building-to-vehicle interface, particularly dock shelters. These systems are intended to close the void between the truck and the warehouse, but for the driver or loader, the psychologically challenging task of maneuvering to the back of a cramped, dark shelter can provoke a stress reaction. When workers feel trapped by an incessant queue of trucks, they are most likely to bypass safety measures and, for a few seconds, save time and cultivate a ‘rush culture,’ which is toxic to the health of the facility in the long run.
The Mechanical Pulse: How Equipment Dictates Pace
The equipment’s performance level is mirrored in the level of human activity within a warehouse. In the event the hardware is slow or unpredictable, workers are likely to respond by exerting more effort or taking risks. This phenomenon is most evident in the case of dock levelers which are the most important bridging system for all transitions and therefore most frequently used.
To combat the psychological tendency to hurry, modern dock design attempts to promote a calm and predictable workflow through a number of elements, including the following:
- Visual Command and Control Systems: The facility has integrated an LED ‘traffic light’ system with the position of the levelers so that guesswork is removed for both the drivers and the load team. When a leveler is illuminated with a green light and an active restraining system, the psychological urge to ‘hurry and check’ is removed, and the team is able to adopt a deliberate working pace.
- Automated Cycle Completion: The need for manual control of the levelers means that the operator has to exert a lot of effort to complete the steps, and fatigue is likely to induce the operator to hurry. When such an operator is working with a hydraulic system designed with an ‘auto-return’ feature, the deck will automatically return to the parked position (i.e., the safe position) once the truck leaves. This design reduces the operator’s cognitive load so that an operator’s absent-mindedness during a busy shift does not result in a dangerous gap in the floor.
- Ergonomic Dampening Technology: When the noise and vibration of a forklift crossing a badly calibrated leveler are increased, this worsens both the psychological and physical stress of the workers. The best levelers are custom designed with ‘crowned’ transitions and shock-absorbing mounts to provide a smoother and quieter ride, which directly reduces the employees’ environmental stress.
Creating a “Zone of Calm” with Specialized Doors
The psychological effects of the warehouse’s physical walls also affect workers. A huge, slowly operated door can be a frustrating bottleneck and can create a “run for it” mentality as soon as it is opened. For areas with high traffic, there has been a shift in the type of sectional door design for rapid and high visibility.
A sectional door in Dubai can have integrated vision panels that give employees visibility to outside activities prior to opening. This type of awareness gives operators the opportunity to be ready for incoming vehicles or changing weather without being surprised. “Startle” events have a door open to a person or vehicle on the other side and can increase the overall heart rate of the warehouse and can lead to poor decision-making and increase incidents.
Engineering Safety into the Subconscious
Even with the best safety measures, humans are naturally going to make mistakes at some point, particularly when they grow tired or distracted. This point is where passive safety can function as the final psychological layer at the dock. Instead of relying on the worker to remember a guideline, the construction of the facility utilizes some cues to guide the behavior on the dock.
The goal of the passive safety system with its steel bollards is to encourage safe behavior by establishing boundaries between the safe and the dangerous areas. The effect of these barriers on the behavior around the dock is extensive and can be broken down into a few key areas:
- Defined Visual Pathways and Pedestrian Protection: The heavy-duty bollards make it obvious where the no-go zones are for vehicles. This tells pedestrians where it is safe to be. By separating the human pathways from the forklift lanes, the “constant vigilance” feeling of warehouse workers is significantly reduced. This allows them to concentrate on their assigned duties.
- Structural Confidence for Equipment Operators: It can be frightening to drive a multi-ton forklift near expensive door tracks or cooling units. Operators are able to drive more confidently knowing that there are heavy steel bollards to protect against costly mistakes. More confidence ironically translates to more consistent driving and less erratic movements than a driver that is scared to drive too close to a bollard.
- Impact Dissipation as a Last Resort: When high-quality steel barriers are hit, they are designed to take that impact so the skeleton of the building does not have to. This means more frequent, less expensive repairs for the boardroom, and for the worker, it ensures that a single mistake will not lead to a catastrophic structural failure, allowing them to work in a more relaxed and less frantic environment.
A smart warehouse is one that understands human psychology. By installing good-quality hardware that works with human psychology instead of against it, high throughput is achievable with little to no burnout of the human elements in the system.
