A Review on Stair Climbing Mini Manual Stacker

Material handling in small warehouses and retail spaces presents unique challenges, especially when navigating stairs and narrow aisles with conventional equipment. This review synthesizes existing research and design approaches relevant to the development of a Stair-Climbing Mini Manual Stacker, a compact, low-cost alternative to forklifts for light to medium-duty loads. Literature on forklift optimization, equipment selection frameworks, 360° fork rotation mechanisms, Tri-Star wheel stairclimbing systems, lightweight structural configurations, and finite element analysis is critically examined to identify design strategies that enhance safety, manoeuvrability, and load-handling efficiency. Comparative analysis highlights the trade-offs between mechanical simplicity, ergonomic operation, material selection, and cost-effectiveness. Special emphasis is placed on integrating manual belt-driven lifting systems with stair-compatible mobility mechanisms to meet the operational constraints of confined spaces. The review underscores that adapting proven mechanical concepts—while optimizing load distribution and structural stability can lead to practical solutions that reduce manual effort, improve operational efficiency, and ensure durability in small-scale logistics. This synthesis provides a foundation for future innovations in affordable, user-friendly, and versatile stair-climbing material handling equipment.