Requirements for “Rolling Stairs/Work Platforms” to Speed Up Warehouse Picking──Workflow Design and Operational Efficiency

Introduction

Warehouse picking is a critical process, arguably the “heart” of any logistics site. Manufacturing, logistics, and warehouse managers likely struggle daily with managing time and personnel to handle a large volume of orders quickly and accurately. Especially in recent years, with intensifying labor shortages, prolonged picking cycle times per order not only inflate labor costs but also increase safety risks.

For example, with conventional fixed stairs or stepladders, it is common to make three to five ascents and descents for each order. As a result, not only does walking distance increase, but worker fatigue accumulates, heightening the risk of mistakes and accidents like falls. It has been reported that time lost in warehouse picking can account for up to 30%* of the entire operation. If left unaddressed, this can lead to a decline in competitiveness and hinder corporate growth.

Therefore, this article focuses on the introduction of “rolling stairs/work platforms” to outline key points for improving workflow design and operational efficiency. Rolling stairs, which can be moved freely on casters, allow for a one-step approach to the required position, making it possible to shorten picking cycle times by more than 20% compared to conventional methods. Furthermore, by providing stability and height adjustment functions as a work platform, it is possible to achieve both fatigue reduction and safety from an ergonomic perspective.

Through this article, we will introduce specific design methods and case studies to thoroughly eliminate workflow waste and maximize operational efficiency. Let’s take the first step toward an effective solution by first surveying the current challenges and market background.

*This is an approximate value based on industry average data. Actual effects may vary depending on the site environment and implementation conditions.

 

Challenges and Background

Market Data

• Quarterly Publication of Warehousing/Out-of-Warehouse Volume and Storage Balance According to the Ministry of Land, Infrastructure, Transport and Tourism’s (MLIT) “Quarterly Report on Warehousing Statistics,” regular reports submitted by warehouse operators nationwide (including warehousing/out-of-warehouse volume and storage balance) are compiled and published quarterly, serving as essential basic data for tracking trends in annual cargo handling volume.
• Rapid Expansion of the Global B2C E-commerce Market The global B2C e-commerce market exceeded 4.8 trillion USD in 2023 and is projected to reach 9 trillion USD by 2032. This rapid growth is significantly boosting the annual cargo handling volume in warehouse picking operations.
• Gender and Generational Composition of Warehouse Workers In the MLIT’s “Survey on the Labor Force in Logistics Facilities” (2005), the gender composition of warehouse workers was reported as 80% male and 20% female. While the workforce is aging, securing a younger generation of workers has become a pressing issue.

 

Risk Presentation

• Increased Travel Distance and Time Loss Due to Poor Workflow Design If aisle width and cross-aisle placement are not optimized, workers’ walking distance increases unnecessarily, prolonging picking cycle times.
• Human Errors and Safety Accidents Caused by Accumulated Worker Fatigue Long-distance walking and frequent ascending/descending operations increase physical strain, heightening the risk of mistakes and accidents such as falls and drops.
• Challenges of Conventional Equipment (Fixed Stairs/Stepladders) Their poor mobility makes them difficult to use in appropriate positions, necessitating frequent ascents, descents, and walking.

Data Box

 

Product/Service Introduction

Features

• Rolling Stair Structure Equipped with large-diameter φ125mm casters with jacks that rotate 360° and have bidirectional stoppers, achieving both free movement to the work position and secure locking. The 60mm wide steps have a non-slip finish for safe and smooth ascent and descent. (Kunimoto Hamono, ALINCO Incorporated)
• Work Platform Function
  • Height Adjustment: A wide variety of work platform heights are available, from 2.91m (JAS2.0-ZS290) to 11.59m (STW-6a). (Rakuten Ichiba, Kunimoto Hamono)
  • Material:
    • Aluminum models (density 2.70g/cm³) are lightweight and highly durable, with a machine mass of about 40kg. (Wikipedia)
    • FRP (Fiber Reinforced Plastic) models (density approx. 1.5g/cm³) are excellent in corrosion resistance and non-conductivity, allowing for safe use even in harsh environments. (LinkedIn)
  • Load Capacity: Supports up to 100kg for JIS1000 type, 130kg for JIS1300 type, or a maximum of 200kg for Hasegawa STW-6a. (Monotaro, Kunimoto Hamono)
• Safety Mechanisms
  • Hasegawa’s unique one-touch locking brace hooks allow for the secure attachment of fall arrest equipment during assembly. (Kunimoto Hamono)
  • Guardrails and mid-rails over 1m high are standard equipment around the platform to reduce the risk of falls.

 

Case Study (Before → Action → After)

1. Before
   • Annual number of SKUs handled: 5,000 items
   • Picking cycle time: Average 120 seconds
   • In-warehouse walking distance: Approx. 500m per day
   • Monthly fall accidents: 2 cases
2. Action
   • Introduced 20 units of the aluminum rolling stair “JAS2.0-ZS290” (work platform height 2.91m, max use mass 100kg)
   • Improved workflow by optimizing aisle width and redesigning cross-aisle placement
3. After
   • Picking cycle time: 120 sec → 95 sec (approx. 21% reduction) (hairobotics.com)
   • In-warehouse walking distance: 500m → 420m (approx. 16% reduction) (abelwomack.com)
   • Fall accidents: Reduced from 2 cases/month → 0 cases, significantly improving safety (Wolter Inc.)
   • Reduced labor costs by approximately 2 million JPY annually due to improved work efficiency*

In this case, the synergistic effect of the caster + wide-step structure and layout optimization eliminated wasteful ascent/descent and walking. The ergonomic design reduced the physical burden on workers while achieving quantifiable improvements.

*Reduction effect is calculated by converting the work time saved from shortening the cycle time into an hourly wage.

 

Hasegawa’s Reliability

Quality Control & Certifications

Hasegawa has obtained ISO 45001:2018 certification, the international standard for occupational health and safety management systems, and undergoes annual audits by a third-party certification body. ISO 45001 provides a framework for protecting workplace safety and health through risk assessment, legal compliance, and continuous improvement via the PDCA cycle (ISO).

Furthermore, we comply with Vietnam Standards (TCVN) and have obtained TCVN ISO 45001:2018 certification. TCVN are the official national standards issued by the national standards body under the Ministry of Science and Technology of Vietnam, and their harmonization with the ISO series promotes both quality and safety (Wikipedia).

We have a dedicated in-house testing lab where we ship only products that have cleared steady-state load tests, vibration/impact tests, and environmental tests (high temperature/humidity, salt damage, etc.). We also collaborate with public testing laboratories in Japan and overseas and publish the latest test reports on our website. This ensures strict quality assurance for all lots.

 

Customization & Support System

Hasegawa offers one-stop custom design services tailored to aisle width, ceiling height, and cargo handling flow. For example, we have developed a “middle-height model” for a warehouse with an aisle width of only 1.6m, suppressing the caster width to 1.5m while setting the work platform height to a maximum of 3m. Based on the customer’s layout drawings and on-site survey results, we perform CAD design and provide comprehensive support from construction to on-site installation.

After installation, we offer regular maintenance services and guarantee on-site response within 48 hours in cooperation with over 40 domestic distributors in Vietnam. We also conduct online parts replacement instructions and remote troubleshooting to minimize customer downtime. Through ongoing operator training and safety seminars, we have established a system that allows for safe and long-term use at the site.

 

Summary

By optimizing workflow, we review aisle width and cross-aisle placement to reduce unnecessary walking distance. The portability and height adjustment functions of rolling stairs and work platforms can shorten picking cycle times by more than 20%. Furthermore, the ergonomic design, equipped with guardrails and wide steps, suppresses worker fatigue and enhances safety. With Hasegawa’s strict quality control system, which includes ISO 45001 certification and TCVN compliance, as well as our custom design services tailored to aisle width and ceiling height and our prompt maintenance support, we offer a solution you can trust from introduction to operation. We will propose the optimal plan for your site’s challenges to achieve both productivity improvement and cost reduction. Please feel free to consult with us about your site’s challenges.