This case study focuses on the implications of manual material handling within warehouse operations. A significant portion of warehouse-related costs is associated with internal material flows, where manual material handling primarily generates costs in terms of labor as well as the operation and maintenance of equipment such as forklifts. When such processes are automated, the need for manual labor is reduced, while the cost structure related to systems and technical equipment changes. By examining the proportion of working time spent on forklift operations, combined with the collection of cost data related to forklift usage, it becomes possible to estimate the potential cost savings that could be achieved by reducing or eliminating these activities.

The study is theoretically grounded in Lean, PDCA, inventory management, and material handling principles in order to investigate whether manual material handling should be reduced or eliminated. To determine the amount of time devoted to material handling activities, a work sampling study is conducted, where observations and data collection form the basis for estimating both time consumption and associated costs.

The results of the study indicate that manual material handling generates significant costs for the operation. Consequently, the findings may serve as decision support for future investment and automation calculations.