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2003:090 CIV MASTER'S THESIS The Study of Work-Related Musculoskeletal Disorders Amongst Workers in Brick Making Factory in South Africa Edith Mufamadi Ndivhudzannyi Luleå University of Technology MSc Programmes in Engineering Industrial Ergonomics Department of Human Work Sciences Division of Industrial ergonomics 2003:090 CIV - ISSN: 1402-1617 - ISRN: LTU-EX--03/090--SE

2003:090 CIV MASTER'S THESIS1018292/FULLTEXT01.pdf · 2016. 10. 4. · Edith Mufamadi Ndivhudzannyi Luleå University of Technology MSc Programmes in Engineering Industrial Ergonomics

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Page 1: 2003:090 CIV MASTER'S THESIS1018292/FULLTEXT01.pdf · 2016. 10. 4. · Edith Mufamadi Ndivhudzannyi Luleå University of Technology MSc Programmes in Engineering Industrial Ergonomics

2003:090 CIV

M A S T E R ' S T H E S I S

The Study of Work-Related Musculoskeletal DisordersAmongst Workers in Brick Making Factory

in South Africa

Edith Mufamadi Ndivhudzannyi

Luleå University of Technology

MSc Programmes in Engineering Industrial Ergonomics

Department of Human Work Sciences Division of Industrial ergonomics

2003:090 CIV - ISSN: 1402-1617 - ISRN: LTU-EX--03/090--SE

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THE STUDY OF WORK-RELATED MUSCULOSKELETAL DISORDERS

AMONGST WORKERS IN BRICK MAKING FACTORY IN

SOUTH AFRICA

MUFAMADI NDIVHUDZANNYI EDITH

Division of Industrial Ergonomics

Department of Human Work Sciences

Luleå University of Technology

Sweden

Supervisor/s: Professor H Shahnavaz

B Nyantumbu

February 2003

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ABSTRACT In brick manufacturing industries, studies have been conducted and there has been

a general indication that working with bricks may dispose towards upper limb

disorders. This study investigated work-related musculoskeletal disorders

(WMSDs) in one brick-making factory, concentrating on the sorting section. The

primary objective was to identify specific ergonomic risk factors for WMSDs

among the brick sorters. The Logical Framework Approach method has been used

in the designing of this project because of its simplicity and is objectives oriented,

target group oriented as well as participatory oriented.

Semi-structured interviews were conducted regarding subjective pain/discomfort

on different body regions and psychosocial situations, which brick sorters

perceived as contributing factors to those disorders. Workplace analysis has been

accomplished by observing the employees as they were doing the task. The main

demands of the tasks and the risk factors as to, which may be present, were listed.

Physical exposure to risks for potential WMSDs has been assessed using ovako

working posture analysis method. Lifting indices (LI) based on the 1993 revised

National Institute for Occupational Safety Health lifting (NIOSH) equations were

calculated.

Results of the interviews showed that all of the respondents reported having

experienced pain/discomfort arising from work, with the body parts most

commonly affected being the low back, followed by the wrists/hands, shoulders,

neck and upper back. The respondents consistently identified factors such as

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frequent twisting and bending of the trunk as the leading cause of the

pain/discomfort. These results were supported by the posture analysis results,

which also recommend that the corrective measures for improving the working

postures are needed immediately. NIOSH results showed the recommended

weight limit ranging from (0.50-0.93 kg) substantially less than the weight of

even a single brick (2. 7 kg). The LI ranged from 2.90-5.4, which exceeds 1.0

indicating the job to be stressful. As a result, the study suggests that the job

should be redesigned ergonomically to eliminate the risk factors that may dispose

towards upper limb disorders.

In conclusion, the results of this study point out a number of important factors that

must be addressed in order to reduce WMSDs among brick sorters. These include

the workplace design necessitating frequent bending and twisting of the trunk,

handling techniques, the way work is organized. Other problems such as

inadequate breaks and high speed of work also need to be addressed.

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TABLE OF CONTENTS

ABSTRACT…………………………………………………………….………..2

1. INTRODUCTION……………………………………………………………..9

2. LITERATURE REVIEW……………………………………………………..11

2.1. Reported statistics and costs estimate…………………………………….13

3. POTENTIAL RISK FACTORS………………………………………………14

3.1. Workplace risk factors…………………………………………………….14

3.1.1. Job-related risk factors…………………………………………….15

3.1.2. Awkward postures………………………………………………...16

3.2. Personal factors……………………………………………………………17

3.3. Psychosocial factors……………………………………………………….18

4. PROJECT DESIGN…………………………………………………………...21

5. SPECIFIC OBJECTIVES……………………………………………………..22

6. METHODS……………………………………………………………………22

6.1. Subjects……………………………………………………………………22

6.2. Semi-structured Interviews………………………………………………..22

6.3. Workplace analysis………………………………………………………..24

6.4. Use of the 1993 NIOSH guide…………………………………………….24

6.5. Observational method……………………………………………………..26

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7. RESULTS…………………………………………………………………….27

7.1. Task Description…………………………………………………………27

7.2. Work Organization……………………………………………………….27

7.3. Questionnaire……………………………………………………………..29

7.3.1. Demographic information…………………………………………..29

7.3.2. Self-Reported Discomfort/Pain……………………………………..29

7.3.3. Psychosocial factors…………………………………………………34

7.4. Job Analysis……………………………………………………………..…35

7.5. Postures adopted by workers…………………………………………….36

8. DISCUSSIONS……………………………………………………………….37

9. CONCLUSIONS……………………………………………………………...40

10. RECOMMENDATIONS……………………………………………………40

11. ACKNOWLEDGEMENTS…………………………………………………42

12. REFERENCES………………………………………………………………43

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LIST OF APPENDICES

13. APPENDIX 1:

POBLEM ANALYSIS…………………………………………………………..52

14. APPENDIX 2:

OBJECTIVE ANALYSIS……………………………………………………….53

15. APPENDIX 3:……………………………………………………………….54

THE BASIC ELEMENTS OF THE PROJECT MATRIX

16. APPENDIX 4:

QUESTIONNAIRE……………………………………………………………..57

17. APPENDIX 5:

A modified version of Norwegian translation of the short Swedish version of the

Job content, Questionnaire (In English)…………………………………………61

18. APPENDIX 6:

CHECKLIST……………………………………………………………………..62

19. APPENDIX 7:

Task variables in the sorting/stacking processes………………………………...64

20. APPENDIX 8:

The procedure for calculating RWL and LI in the sorting/stacking processes…..65

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LIST OF FIGURES

Figure 1. A global theory of musculoskeletal injury precipitation………………19

Figure 2. Demand and control model……………………………………………20

Figure 3. Percentage of respondents who complained of pain per body region

during the last 12 months lasting at least 24 hours………………………………30

Figure 4. Percentage of respondents who complained of pain per body region

during the last month lasting at least 24 hours…………………………………...31

Figure 5. Percentage of respondents who complained of pain per body region

during the last 7 days lasting at least 24 hours…………………………………...32

Figure 6. Percentage of respondents who have been prevented from doing normal

activities because of pain per body region……………………………………….33

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LIST OF TABLES

Table 1. The definitions of the multipliers of the revised NIOSH equation and the

variables used for calculations…………………………………………………...25

Table 2. OWAS posture code definitions………………………………………..26

Table 3. An overview of the demographic information of the respondents……..29

Table 4. Description of sorting/stacking tasks and postural analysis……………36

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1. INTRODUCTION

Work-related Musculoskeletal Disorders (WMSDs) have become a major

problem in many industrialized countries (Hagberg et al., 1995). These disorders

have caused a considerable human suffering and are also economically very

costly because of reduced working capacity and lessened production (Luopajarvi,

1990).

Work-related Muscloskeletal Disorders describe a wide range of inflammatory

and degenerative diseases, and disorders that result in pain and functional

impairment (Kilbom et al., 1996) and may affect the body’s soft tissues, including

damage to the tendons, tendon sheaths, muscles and nerves of the hands, wrists,

elbows, shoulders, neck and back (Saldaňa, 1996). Among such disorders, pain in

the neck and shoulders often causes work disability among employees and are

frequently associated with long periods of disability and sick leave (Westerling

and Johsson, 1980).

According to the World Health Organization, WMSDs arise when exposed to

work activities and work conditions that significantly contribute to their

development or exacerbation but not acting as the sole determinant of causation

(World Health Organization, 1985). These disorders have been found to be

associated with numerous occupational ‘risk factors’, including physical work

load factors such as force, posture, manual handling, repetitive work and vibration

(Gerr et al., 1991); psychosocial stressors (Bongers et al., 1993; Bernard et al.,

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1994) and individual factors (Armstrong et al., 1993). Ayoub (1990) explained

that these factors become hazardous due to prolonged repetitive, often in a

forceful and awkward manner, without sufficient rest or recovery.

The present study sought to investigate WMSDs within one brick-making factory

in South Africa. This study has focused on the sorting and stacking section, where

bricks were taken from the conveyor belt and stacked in tight packs, ready for

later transportation. The purpose of this study was to identify the specific risk

factors for WMSDs among the brick sorters. The goal is to reduce Work-related

Musculoskeletal complaints among the employees in brick-making factory.

This brick-making factory was based on the South of Johannesburg in South

Africa. The company manufactures bricks that are defined by their strength,

pleasing aesthetics and durability. Their product range includes, clay face bricks

in many colours and textures, clay pavers, plaster bricks and concrete blocks,

pavers and retaining blocks. It markets its products directly to the building trade

as well as through a national distribution structure.

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2. LITERATURE REVIEW

High incidence rates for WMSDs of the upper extremity have been reported for

workers in office work, manufacturing, and agriculture and numerous materials

handling occupations (Faucet et. al., 2002).

In brick manufacturing industries, studies have been conducted and there has been

a general indication that working with bricks may dispose towards upper limb

disorders. Trevelyen and Haslam (2001) investigated musculoskeletal disorders in

a handmade brick factory, concentrating on the ‘moulding’ department, where

clay is shaped into bricks. Results identified both upper limb and back problems.

Posture and force analysis found poor standing posture and undesirable wrist

positions, accompanied by significant force loadings. An important contributory

factor was considered to be the piecework system.

Basra and Crawford (1995) observed variety of different handling techniques

within the 131 employees in one brick manufacturing plant, of which some of the

techniques were considered potentially harmful although the details of the actual

tasks examined were not given. They identified problems such as poorly designed

workstations, necessitating frequent bending and twisting. Other problems

identified included inadequate rest breaks and effects arising from the employer’s

piecework system.

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A study investigating brick handling among bricklayers found the primary sites

for work-related musculoskeletal complaints, accounting for most reported lost

time and physician visits, to be the back, neck, and shoulder, followed by the

elbow and wrist/hand (Cook et al., 1996). The survey respondents consistently

identified job factors describing awkward postures of the back and shoulders, and

handling bricks and mortar in these awkward postures, as the loading causes of

their WMSDs.

Also dealing with the bricklayers, Heuer et al. (1996) found that musculoskeletal

complaints decreased with length of employment in their study sample. Further

investigation revealed this was most likely due to a ‘healthy worker effect’ where

individuals’ susceptible to musculoskeletal complaints leave the trade, leaving

their more resilient colleagues in the workforce.

A study evaluating lifting tasks during fire brick manufacturing processes,

concentrating on the forming, heating and packing processes by Chung and Kee

(2002) showed that weight of the load significantly influenced the incidence of

back injuries and that workers who reported to have experienced back injuries

were older than those who did not experience them.

Buckle and Stubbs (1990) identified the industrial classification ‘bricks, pottery,

glass, cement’ as having increased risk of inflammation of tendons of the hand,

forearm, or associated tendon sheaths. In the United States, an analysis of data

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held by a major insurance company ranked ‘brick or clay product manufacturing’

sixth out of the 10 highest job classification in terms of percentage claims for

cumulative trauma disorders (Brogmus and Marko, 1991).

Ferreira and Tracy (1991) examined a post-kiln brick sorting activity, with high

levels of reported musculoskeletal complaints, performed differently at two sister

locations. Ferreira and Tracy found that one plant had a high level of back

complaints, while the other had an increased frequency of upper limb disorders.

They concluded differences in task performance between the two plants were

influencing the incidence and pattern of disorders, with a large amount of trunk

bending and twisting required at one plant and repetitive handling of several

bricks at a time at the other plant.

2.1. Reported statistics and costs estimate

The Federal Occupational Safety and Health Administration reported as many as

2% of the entire American workforce suffers WMSDs every year and these

disorders account disproportionately for over 1/3 of all worker compensation

costs for medical care and lost wages (Herman, 2000).

In the United Kingdom, Health and Safety Commission (1998) reported that

WMSDs form the largest category of work-related ill health, which estimates for

1995 suggesting 1.2 million individuals experienced a musculoskeletal condition.

In the United States it has been estimated that there are approximately 1.8 million

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disabling work-related injuries per year, 60 000 of which result in permanent

impairment (Frymoyer, 1997). The Bureau of Labor Statistics reported that

musculoskeletal disorders accounted for the majority of the occupational injuries

and illnesses involving lost days (approximately 705, 800 cases or 32% of the

total cases), are specifically resulting from overexertion or repetitive motion

during manual material handling with an estimated total cost of $13 billion per

year (National institute for Occupational Safety and Health, 1997).

3. POTENTIAL RISK FACTORS

A risk factor is defined as an attribute or exposure that increases the probability of

disease or disorder (Last, 1983).

3.1. Workplace risk factors

Workplace risk factors are considered to be the most important cause for the

majority of the musculoskeletal disorders because they are directly related with

the physical hazards to the worker (Waters and Putz-Anderson, 1997). These

factors include: shift work, heavy physical work, heavy manual material handling,

lifting, bending, repetitive work, frequency and duration of a task and dynamic

workload (Ayoub et. al., 1997).

Manual materials handling and lifting are major causes of work-related low back

pains and impairments (Waters et. al., 1993) with other factors such as bent and/or

twisted position (Riihimaki, 1991; Hagberg, 1992).

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Manual material handling is the most frequent (36% of all the claims) and costly

(35% of total cost) category of compensable loss (Leamon and Murphy, 1994;

Murphy et. al., 1996) and is associated with the largest proportion (63-70%) of

compensable low back disability (Snook et. al., 1978; Bigos et. al., 1986; Murphy

and Courtney, 2000).

Repetitive and forceful work activities, awkward or static postures and

mechanical pressure associated with work tasks have been cited as important

etiological factors for WMSDs (Bernard et. al., 1993; Hagberg and Wegman,

1987; Silverstein et. al., 1987).

3.1.1. Job-related risk factors

Ayoub et al., (1997) and Garg (1997) mentioned the more important job-related

risk factors and possible reasons for their association with injury risk associated

with manual material handling of loads.

1) Horizontal and vertical location of the load relative to the worker: with an

increase in horizontal distance the external joint loads will increase and

workers will use a large proportion of their strength capacity. Distance

load to be moved: increased travel distance results in reduced strength and

higher energy expenditures.

2) Frequency and duration of the task: as the frequency of lifting increases,

metabolic demands are higher and the onset of physical fatigue is more

rapid.

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3) Weight and size of the load: the weight of the load can affect the required

strength and postural stress and metabolic demands.

4) Weight and size of the load: the weight of the load can affect the required

strength and postural stress and metabolic demands.

3.1.2. Awkward postures

Awkward posture means a considerable deviation from the neutral position of one

or combination of joints (Pinzke and Kopp, 2001). These postures typically

include reaching behind, twisting, working ahead, wrist bending, kneeling,

stooping, forward and backward bending, and squatting. Such postures are related

to injuries that are incurred during tasks that are static in nature and relatively

long lasting and during tasks that demand exertion of force (Westgaard and Aarås,

1984).

Such strenuous working postures combined with heavy physical workload, they

result in a high frequency of WMSDs (Pinke and Kopp, 2001). It is documented

that there is a relationship between awkward postures and pain, and symptoms

and injuries in the musculoskeletal system (Grandjean and Hünting, 1977). Lifting

with rotated trunk would further increase the risk of back failure (Marras et. al.,

1995).

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Luopajarvi (1990) indicated the most common and well-known risk factors in

different parts of the body:

- In the neck the most work-related disorders and pains seem to be

associated with sustained positions with a bend or twist of over 20

degrees.

- In the shoulders, the disorders are related to repeated elevation of the arms

to more than 30 degrees from the body.

- In the elbows and hands, the reported causes of disorders were

unaccustomed movements, repetitive movements executed with high

speed, extreme positions of wrist and fingers.

3.2. Personal factors

These factors include level of physical fitness, weight, diet, habits, previous

medical record and lifestyle, may also affect the development of musculoskeletal

disorders (Waters and Putz-Andersson, 1997). Ayoub et al., (1997) listed some

more important personal risk factors and possible reasons for their association

with injury risk:

1) Age: muscle strength appears to be greatest in the late 20’s and early 30’s

and declines thereafter.

2) Gender: women on average are weaker than men. Gender differences are

almost entirely explained by differences in muscle size, as estimated by

either the person’s fat-free body weight or cross sectional area dimensions.

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3) Anthropometry: body weight and height have been correlated with

muscle static strength.

3.3. Psychosocial factors

The psychosocial work environment constitutes an important part of an

ergonomics evaluation of a workplace. The term “Psychosocial” is commonly

used in the occupational health arena as the general term to describe a very large

number of factors that fall within three separate domains: (Bongers and de

Winter, 1992)

1) Factors associated with the job and work environment,

2) Factors associated with the extra-work environment, and

3) Characteristics of the individual worker.

Interactions among factors within each of these domains constitute what is

referred to as a “stress process,” the results of which are thought to impact upon

both health status and job performance (Bongers and deWinter 1992).

However, it is speculated that an interaction between the relative weighting of the

variables and the extent to which they have been stressed in any individual

determines the final outcomes as depicted in figure 1.

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Predisposition

Hazards

Vulnerability Stresses

Susceptibility

Response

Tension

Compression

Strain Heightened Probability

Creep

Laxity Progressively Decreasing

Instability Threshold of

Microtrauma Precipitation

Progressively Decreasing

Threshold of Precipitation

Figure 1. A global theory of musculoskeletal injury precipitation (modified from

Kumar, 1991).

Genetic trait

Morphological Characteristics

Psychosocial Profile

Individual

Strain

Structural Biochemical Physiology

Injury Precipitation

Biomechanical Factors

Nociception

Pain

Pain Behaviour

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Increasing evidence suggests that exposure to adverse work organization

characteristics, such as high performance demands coupled with low levels of job

control and low workplace social support, places individuals at increased risk of

stress and illness (Karasek and Theorell 1990: Johnson and Hall, 1988). It has

been indicated that physical work risk factors acting with psychosocial work risk

factors increases the risk of self-reported back disorders (Devereux, 1998; Linton,

1990).

Karasek (1979) derived a composite measure ‘job strain’ which is assumed to be

experienced by workers facing high psychological demands combined with low

control or low decision latitude in meeting those demands (figure 2).

Psychological Demands

LOW HIGH B

Learning Motivation to Develop HIGH New Behaviour Patterns Decision Latitude (Control)

LOW Risk of Psychological Strain and Physical illness

A

Figure 2. Demand and control model. (Karasek, 1979)

Low-strain Active

Passive High-strain

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The Karasek and Theorell (1990) job demands-control-support model predicts

that jobs with high mental demand and high degree of decision latitude or control

and social support (called active jobs) lead to learning, motivation and active

workers. The ways in which high ‘job strain’ can be detrimental to individual

health (e.g. musculoskeletal symptoms, psychological distress) have been

reported in several studies (Johansson, 1995; Karasek and Theorell, 1990).

4. PROJECT DESIGN

This project has been designed using the Logical Framework Approach method.

On the basis of available information from previous researches, the major existing

problems among the brick sorters have been identified and the focal problem (i.e.

work-related musculoskeletal complaints) has been selected for the analysis.

Substantial and direct causes of the focal problem were identified (Appendix 1).

Also the substantial and direct effects of the focal problem were identified. In the

objectives analysis, the problem tree was transformed into a tree of objectives

(future solutions of the problems) and analyzed (Appendix 2). The main project

elements were derived from the objectives tree and transferred into the vertical

column of the project matrix (PM) (Appendix 3)

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5. SPECIFIC OBJECTIVES

i. To determine the prevalence of self-reported musculoskeletal

pain/discomfort among the brick sorters.

ii. To identify the most affected body regions.

iii. To identify specific ergonomic risk factors in the workplace.

iv. To provide the company with advice on how to improve the

work environment.

6. METHODS

6.1. Subjects

Nineteen currently employed male workers performing manual work with

special reference to the process of sorting and stacking of bricks voluntarily

participated in the interviews and signed forms of consent. Each potential

volunteer was informed that participation was on company time at the usual

rate of pay. They were told that their participation in the project was voluntary

and would not influence their employment. The purpose of the study and the

confidentiality of the information provided were also emphasized.

6.2. Semi-structured Interviews

Questionnaires were completed through interviews (Appendix 4). Interviews

were confidential, undertaken in work time but away from the workplace in a

confined office and lasted approximately 15 minutes for each individual.

Frequency and descriptive analysis of data from the questionnaire was

accomplished using Microsoft Excel 2002.

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The interviews were conducted taking into consideration the following

information:

1) Employees’ work such as job title, hours worked, length of time on

present job and employees’ general health as well as some personal

data like age, gender, weight and height.

2) Subjective pain/discomfort on different body regions, which were

measured using a modified version of Nordic Questionnaire by

Kuorinka et al., (1987).

3) Psychosocial work factors, which were measured using a modified

version of Norwegian translation of the short Swedish version of

the Job content, Questionnaire (Theorell et al., 1991) developed

from the job demand-control-social support model by Karasek and

Theorell (1990) (Appendix 5). Questions were selected because

some questions were interrelated and the checklist already covered

some aspects of the work. Questions were structured and

dichotomized alternative “yes” and “no” was used instead of the

three-point scale ranging from 0 (equivalent to “no”, “never” or

“do not agree” for all items) to 1 (equivalent to “yes”, “often” or

“agree” for all items). The advantage was that it was easy for the

employees to answer and also time saving. Taking into

consideration that the interviews were to be conducted during work

time.

.

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6.3. Workplace analysis

Work place analysis has been accomplished by observing the tasks, watching the

employees as they were doing the task. Each task has been described according to

how it was performed. This was to note the main demands of the tasks and list the

risk factors as to which may be present (Appendix 6).

6.4. Use of the 1993 NIOSH equation

The revised National Institute for Occupational Safety and Health (NIOSH) lifting

equation by Waters et al., (1993) was used for the calculation of the

Recommended Weight Limits (RWL) of the loads calculated by the following

equation:

RWL = LC x HM x VM x DM x AM x FM x CM

Measurements of the variables were obtained using NC3 Chrome tape (3m x 13

mm) and asymmetry angles were measured using a Protractor square. Table 1

presents the definitions of the multipliers of the equation and the variables behind

them, as well as the values of the variables kept constant in this study.

The Horizontal location (H) and Vertical location (V) at origin of lift were

assumed to remain unchanged at both the lowest and the highest possible

locations. Both the Horizontal and Vertical location at destination of lifts were

changing variables of which the two extreme lifting positions, the lowest and the

highest possible locations of the hands, were included in the calculations. The

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Frequency Multiplier (FM) was estimated on average of 10 lifts/min and the

average lifting duration per shift of 8 hours. The Coupling Multiplier (CM) was

classified as poor, so the value of the CM was estimated as 0.90.

The procedure for calculating the Lifting Index (LI) was by the formula below:

LI = Object weight

RWL

Table 1. The definitions of the multipliers of the revised NIOSH equation and the

variables used for calculations.

MULTIPLIERS VALUES VARIABLES

Load Constant (LC) 23 23 [ kg ]

Horizontal Multiplier (HM) (25/H) Horizontal location (H) [ cm ]

Vertical Multiplier (VM) 1- (0.003∗ ⎥ V-75⎥ ) Vertical location (V) [cm ]

Distance Multiplier (DM) 0.82 + (4.5/D) Vertical Travel Distance (D) [cm]

Asymmetric Multiplier (AM) 1- (0.0032∗A) Asymmetric Angle (A) [deg]

Frequency Multiplier (FM) FM = 0.13 (F = 10 lifts/min,

T = 8 hrs

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6.5. Observational method

In this study, an instantaneous observation of the posture and posture recording

were made using Ovako working posture analyzing method (OWAS) by Karhu et

al., (1977). Four-digit code representing the back (four choices), three arm

postures, and seven leg postures. The use of strength or the weight of loads

handled was classified by a three-class scale (as shown in table 2). Postures were

recorded for each of the four work phases during the working session. Posture

recordings for each work phase were done within at least 20 to 30 seconds.

OWAS method was manual and the registrations

Table 2. OWAS posture code definitions __________________________________________________________________ Back Arms __________________________________________________________________ 1= straight 1= both arms below shoulder level

2= bent forward or backward 2= one arm at or above shoulder level

3= twisted or bent sideways 3= both arms at or above shoulder level

4= bent and twisted or bent

forward and sideways

__________________________________________________________________ Legs Load/use of force __________________________________________________________________ 1= sitting

2= standing on both legs straight 1= weight or force needed is 10 kg or less

3= standing on one straight leg 2= weight or force needed exceeds 10 kg

4= standing on both knees bent but is less than 20 kg

5= standing on one knee bent 3= weight or force needed exceeds 20 kg

6= kneeling on one or both legs

7= walking or moving

__________________________________________________________________

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7. RESULTS

7.1. Task Description

Bricks were manually sorted right from the conveyor belt to the pallet on the

sides, which were more stable and ready for later transportation. The job was

performed while standing. Methods for handling vary from one worker to the

other. Most sorters often hold two bricks, one in each hand and some with five

bricks at a time (held between the hands). As a result of the requirement of

alternating brick faces in each row, the sorters must pay constant attention to brick

orientation. The sorters appears to have a good knowledge of which bricks were

likely to have defects, so that the inspection become rapid and often it was not

necessary to turn the bricks around.

7.2. Work Organization

The work was organized in such a way that sorters share the conveyor belt, but

each of them concentrates on his own daily target. Each brick typically weighs 2.7

kg and each worker ensured that he reached his daily target of 10 500 bricks per

day (i.e. 21 pallets/500 bricks each). Some workers concentrated on 2 to 4 pallets

at a time depending on the colours of the bricks. Each sorter ensured that the

bricks were placed correctly; having alternate layers with faces up and faces

down. They work three days in succession and have three days off the next days.

Work hours were normally between 6.00 am and 6.00 pm but all the sorters leave

early if the daily target has been achieved, which encouraged them to work at a

higher speed of work than may be necessary.

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Normally, each sorter has 15 minutes tea breaks in the morning at 9.00 am and

4.00 pm in the afternoon. Also lunch break in the afternoon between 12.00 and

12.30 am of which workers have indicated that they prefer to have only one break

of which the team has to agree upon and that would be their lunch for at least 20

to 30 minutes so that they finish their daily target early. They have also indicated

that when they finish early, they have enough time to rest in order to prepare for

the next day. Therefore, each worker had the passion to work as fast as possible

so that he does not remain alone. Sorters at the first stations tend to handle larger

number of bricks, while those at the later stations have a lighter workload,

therefore they allow for flexibility within the team to rotate, then sorters at first

station have to make 13 pallets and rotate and make another 8 pallets at the later

stations and vice versa.

Then once each sorter finishes his daily target, the supervisor has to check if the

bricks were correctly placed then the worker can be released. If the bricks were

not properly placed, they were told to rearrange the pallet until the supervisor was

satisfied.

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7.3. Questionnaire

7.3.1. Demographic information

The following demographic data was collected from all the 19 male subjects who

participated in the interviews (as shown in table 3). All the subjects used both

hands equally well.

Table 3. An overview of the demographic information of the respondents (n =19).

Mean *S D Range

Age (yrs) 38.7 7.74 28-52

Duration of employment (yrs) 9.4 4.50 2-17

Height (cm) 169.09 6.06 158-183

Weight (kg) 67.75 7.63 51-79

*SD= Standard Deviation

7.3.2. Self-reported discomfort/pain

Workers were asked few questions about perceived pain/discomfort, which lasted,

for at least 24 hrs. Pain was measured at past 12 months, last month and 7 days.

Results are presented in order as mentioned above.

During the last 12 months, 36.8% (7) of the respondents reported pain on low

back and 26.3% (5) on the neck. Of about 21.0% (4) of the employees complained

of upper back problem. And 15.8% (3) of the employees had shoulder and

wrist/hand problems. Concerning elbows and ankles/feet pain, 5.26% (1) of the

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employees complained. No complaints were reported regarding knees and

hips/thighs (figure 3).

05

10152025303540

Neck

Should

ers

Low Back

Upper

Back

Elbows

Wr/h

ands

Ank/fe

et

Body region

Perc

enta

ge

of r

espo

nden

ts (%

)

Figure 3. Percentage of respondents who complained of pain per body region

during the last 12 months lasted at least 24 hours. (n=19)

During the last month, 26.3% (5) of the employees complained of low back pain,

15.8% (3) of the employees complained of the neck, shoulders and wrist/hand

problems. About 10.5% (2) of the employees suffered from upper back pain and

ankles/feet. Of about 5.26% (1) of the employees suffered from elbows,

hips/thighs and knees pain (figure 4).

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0

5

10

15

20

25

30

Neck

Should

ers

Low Back

Upper

Back

Elbows

Wr/h

ands

H/thigh

s

Knees

Ank/fe

et

Body re g ion

Perc

enta

geof

res

pond

ents

(%)

Figure 4. Percentage of respondents who complained of pain per body region

during the last month lasted at least 24 hours. (n=19)

For the last 7 days, 21.0% (4) of the employees had an episode of low back pain.

About 10.5% (2) of the employees suffered from upper back. Of about 5.26% (1)

of the employees had an episode of pain on the neck, shoulders, elbows,

wrist/hand, hips/thighs, knees and ankles/feet (figure 5).

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0

5

10

15

20

25

Neck

Should

ers

Low Back

Upper

Back

Elbows

Wr/h

ands

Ank/fe

et

Body region

Pece

ntag

e of

res

pond

ents

(%)

Figure 5. Percentage of respondents who complained of pain per body region for

the last 7 days lasted at least 24 hours. (n=19)

Workers were also asked if they have been prevented from doing normal activities

because of the pain. 15 of 19 (78.9 %) respondents have been prevented due to

pain from low back. Of about 31.6% (6) of the employees was because of neck

pain. Regarding shoulder pain, 36.8 % (7) of the employees have been prevented.

Of about 26.3% (5) of the employees have been prevented because of upper back

problem. For the elbows, 15.8% (3) and about 47.3% (9) with the wrists/hands of

the employees complained. Also knees and ankles/feet problems were found to be

10.5% (2) and 15.8% (3) of the employees respectively (figure 6).

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0102030405060708090

Neck

Should

ers

Low Back

Upper

Back

Elbows

Wr/h

ands

Knees

Ank/fe

et

B ody re gion

Perc

enta

ge o

f r

espo

nden

ts (%

)

Figure 6. Percentage of respondents who have been prevented from doing normal

activities because of pain per body region. (n=19)

Of all the complaints reported, low back pain constituted the highest number of

percentage. Workers were also asked if they have seen a doctor because of the

pain. About 73.7% (14) indicated that they have seen a doctor because of the

discomfort/pain and only 31.6% (6) of those have stayed away from work.

According to all the respondents the discomfort/pain was caused by the job.

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7.3.3. Psychosocial factors

Workers were asked questions regarding their work. All the respondents (19),

described the work as rather ‘very difficult’, ‘monotonous’ and they feel that they

have ‘excessive work’. 18 of 19 (94.7%) employees reported that the working

situation requires that they work ‘very fast’ which forced them to work hard in

order to finish the daily target. About 89.4% (17) of the employees indicated that

they have sufficient time to work whereas only 10.6% showed that the time is not

sufficient, that is why they have to work at high pace. All the employees

emphasized that the job is mentally demanding, since it requires high

concentration, especially that they have to sort different colours at the same time

and they have to ensure that the bricks are correctly placed.

Of about 89.4% (17) of the employees, showed that they are given an opportunity

to voice out their suggestions regarding the work and also that the supervisors are

concerned about their work. Supervisors are responsible of seeing to it that the

work is being performed safely, sometimes advising workers on how to sort well

and also giving good comments if the job has been done perfectly. Of all the

employees, 63.1% (12) indicated that they do not feel like helping their co-

workers, with a reason that, is not possible because they feel that they have a lot

of work to do, whereas only 36.84% (7) of the employees do help friends and

relatives.

With regard to team spirit, 57.9% (11) of the employees explained that they might

like to work in team, because they think that will make the job easier and they can

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be able to plan together how to work. Of about 42.1% (8) of the employees did

not support the teamwork, because they feel that some may tend to relax since

they do not work at the same pace and that may put more workload on some than

others.

7.4. Job Analysis

Horizontal location (H) at origin of lift was estimated to be always 75 cm and H at

destination was estimated to be 50 cm at lowest hand location; 90 cm at highest

hand location. The minimum and maximum Vertical location (V) were also

measured at the origin and destination of lift. V at origin was estimated to be

always 90 cm, whereas V at destination was estimated 22 cm and 115 cm at

lowest and highest hand location respectively. Thereby in the case of lifting at

lowest hand location, Vertical travel distance (D) was 68 cm and 25 cm at the

highest hand location. Asymmetry angle was approximately 650 both at origin

and destination of the lift except for the destination at the lowest hand location of

1000. Frequency Multiplier (FM) was always 0.13, corresponding to the estimated

average of 10 lifts/min and the average lifting duration per shift of 8 hours. The

quality of coupling between hands and bricks was classified as poor, so the value

of the Coupling Multiplier (CM) was 0.90 (see Appendix 7).

The results of NIOSH equations using normally obtained variables are also shown

in Appendix 7. The total variation of RWL was 0.50 – 0.93 kg. The RWL is less

than the weight of even a single brick. The LI was calculated to be 2.90 – 5.4 as

shown in Appendix 8, which exceeds 1.0 indicating the job to be stressful.

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7.5. Postures adopted by workers

The scores for the assessment of postural stress in brick sorters were calculated

and found to be 4 for the sub-tasks like lifting of bricks from the conveyor,

carrying bricks to the pallet as well as packing of bricks in the pallet. The score of

3 was found for the sub-task of rearranging the pallet. The scores were obtained

according to OWAS Worksheet. This score 3 indicates that the postures need

corrective measures as soon as possible whereas the score of 4 indicates that the

corrective measures are needed immediately. The scores assessed by OWAS

method in brick sorters are summarized in table 4.

Table 4. Description of sorting/stacking tasks and postural analysis (Postures

classified according to Karhu et. al., 1977).

*OWAS postures codes

Sub-task description Back Arms Legs Force Score

__________________________________________________________________

Lifting bricks from conveyor belt 4 1 5 1 4

Carrying bricks to the pallet 3 1 5 1 4

Packing bricks in the pallet 4 1 5 1 4

Rearranging the pallet 2 1 5 1 3

__________________________________________________________________

*The OWAS posture codes are explained in table 1. e.g. code 4 means

back bent forward and twisted, 3 means back twisted and 2 means back bent

forward. Arms (1) both arms below shoulder level and legs (5) means Standing on

one knee bent and force (1) means weight or force needed is 10 kg or less.

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8. DISCUSSIONS

Manual materials handling is one of the recognized risk factors for back

problems, with other factors such as bent and/or twisted position (Riihimaki,

1991; Hagberg, 1992). This is specifically evident in industrially developing

countries, where manual materials handling is inherent within industry and where

manual labour involved in physically demanding tasks is a dominant factor (Scott,

1993). In the present study, the job of the brick sorters was described as rather

physically demanding: involving frequent twisting and bending of the trunk. This

type of job was also described as highly repetitive and requires high concentration

as a result of the requirement of alternating brick faces in each row. Therefore,

sorters must pay constant attention to brick orientation and this may impose more

stress and increased mental fatigue.

Brick sorters mainly complained about ‘excessive work’, which encourages them

to work at high pace than is necessary, which appears as a significant source of

stress. Moreover, the workers often explained in the comments that the situations

made them feel frustration and anxiety. It is also seen that workers perceptions

about the job characteristics may differ due to their motivation, emotional state

and work experience level.

However, in this study, pain per body region was measured for the past 12 month,

last month and last 7 days, which lasted for at least 24 hours (Figure, 3, 4, and 5

respectively). The results show that most workers complained of low back pain.

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Fifteen of nineteen employees (78.95%) indicated that they have been prevented

from doing normal activities because of low back pain followed by wrists/hands,

shoulders, neck and upper back. Pain in other body locations accounted for low

rate. (Figure 6) Similar finding was reported by Chung and Kee (2000), indicating

that 78.5% of the workers performing tasks that require trunk twisting were

reported to have experienced low back pain, while 55.6% performing tasks that do

not require trunk twisting were reported to have experienced low back pain. All

the brick sorters have reported having experienced discomfort arising from work.

A study by Ferreira and Tracy (1991) showed that four workers out of seven

(57.1%) at sorting/packing tasks had sick leave due to upper limb disorders. Back

complaints appear more frequently in sorting processes. It is more likely that the

high incidence in packing processes is more influenced by handling techniques,

the way work is organized and the workplace design than by the age of workers.

Work factors contributing to the development of musculoskeletal disorders were

summarized as follows:

The influence of daily target was to reinforce the fast working pace and encourage

the missing of breaks. A further problem was considered to be the job design,

where the brick sorters single main task was the brick sorting process. This may

lead to high proportion of the brick sorters time spent in repetitive activity. The

other problem that was observed was the handling techniques, where most

workers often lift two bricks, one brick in each hand. This type of technique was

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alternated with grasping five bricks between both hands. Also that the present

layout of the workplace requires sorters to turn 1000 as they pack bricks to the

pallet. This involves frequent rotation of the trunk and forward bending. Sorters

have to bend down to the floor as they reach to the bottom of the pallet. These

awkward postures could be minimized by simple alterations of the work

environment.

Other aspects of the workplace design were also identified in this workplace.

From NIOSH perspective, the lifting tasks with LI > 1.0 indicates an increased

risk for lifting-related low back pain for some fraction of the workforce (Waters

et. al., 1993). This study found the recommended weight limit substantially lower

than the weight of even a single brick (2.7-kg) with the lifting indices of more

than one. With the lifting indices of this magnitude, the task is always unsafe and

should be totally redesigned to achieve the LI of 1.0 or less.

In Appendix 8, presenting the procedures of calculating RWL and LI of the

sorting/stacking process. It is seen that the smallest multiplier was 0.13 for the

FM, the second 0.27-0.50 for the HM and the third 0.68-0.79 for the AM of,

which must be given an attention. The employees are given a daily production

order of 12 hours shift, and they normally finish the job within 7-8 h to have a

long break for the rest of the day. Such work practices result in high frequencies.

Therefore is of most important to redesign the workplace, which can be presumed

to be safe for most workers.

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9. CONCLUSIONS

In conclusion, it is likely that the largest number of complaints of work-related

musculoskeletal disorders in sorting/stacking processes is more influenced by the

workplace design necessitating frequent bending and twisting, handling

techniques, the way work is organized. Other problems identified include

inadequate rest breaks and high speed of work.

10. RECOMMENDATIONS

1) Workplace design: positioning the bricks closer to the worker and by

placing the pallet at the right-hand side of the worker in order to reduce

the asymmetric angle.

2) Implement an ongoing training program: to enable each sorter to be aware

of the relevant factors concerning musculoskeletal disorders.

3) Workers should be given education about the types of the work-related

musculoskeletal disorders and causes of these disorders.

4) It is important to address problems related to stress in the workplace as it

may influence the occurrence of the musculoskeletal problems among

employees.

5) Workers should be motivated to adopt working techniques that are

preferable.

6) Encouragement and motivation of all the employees to take rest breaks by

showing its importance.

7) Also by showing the importance of taking physical fitness exercises.

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8) Work organization: review the “daily target”.

9) If it is possible, alternate strain by changing task (job rotation), especially

for those workers who are much more prone to work-related

musculoskeletal disorders.

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11. ACKNOWLEDGEMENTS

Firstly, I thank God Almighty for giving me the strength and wisdom to reach this

point in my academic career.

I gratefully acknowledge the STINT Scholarship (The Swedish Foundation for

International Cooperation in Research and Higher Education) for supporting me

financially throughout the whole study period in Luleå University of Technology

I would also like to express my gratitude to all people who have contributed in

significant ways to this work, in particular my supervisor Professor Houshang

Shahnavaz, the head of the Division of Industrial Ergonomics for his guidance

from the beginning of this programme and during my research. Thanks also

extended to Busisiwe Nyantumbu for supervising this work. Also the support,

encouragement and sacrifices made throughout the whole project. Thanks also go

to Dr. Emma-Christin Lönroth who helped me throughout the whole course.

I would also appreciate the help from Dr. Danuta Kilkowski, the head of

Epidemiology Department at National Centre for Occupational Health,

Johannesburg for making this project successful.

This work would have not been possible without the support and strength that I

have gained from my family, to whom I am very grateful.

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13. APPENDIX 1: PROBLEM ANLYSIS

EFFECTS

CAUSES

Work-related Musculoskeletal Complaints increase amongst workers in Brick

making factory

Inadequate rest pauses

Low payment systems

Monotonous work

Absenteeism increases

Increases costs for productivity

Employees ill health

increases

Decreases productivity

Economic loss for Company

Reduces Working capacity

Insufficient training

Compensation costs increases

Turnover increases

Manual handling of

loads

Awkward working postures

Repetitive work

High job demands

Long working

hours

Low decision latitude

Low social

support

High work pace to meet daily target

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14. APPENDIX 2: OBJECTIVE ANALYSIS

Work-related Musculoskeletal Complaints reduced amongst workers in Brick making

factory

Absenteeism reduced

Costs for productivity decreased

Employees ill health improved

Productivity increased

Economic loss for Company reduced

Working capacity increased

Compensation costs decreased

Turnover reduced

Manual handling of loads is minimized

Poor working postures are limited

Employees are provided with sufficient training

Adequate rest pauses are provided

Pace of work is minimized

Job rotation is introduced

Repetitive actions

minimized

Recommendations for improvement are provided

Low job demands

High social support from co-workers

Workers have control over the job

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15. APPENDIX 3: The Basic Elements of the Project Matrix

Goal:

Work-related musculoskeletal complaints

reduced for employees in brick making factory

in South Africa

Indicators:

- Work-related musculoskeletal complaints reduced

among workers in brick making factory within 12

months after the completion of the project.

- 20% reduction is guaranteed as a result of the

implementation of the recommended measures by

the study.

Assumptions

- Management is assumed to agree

and accept the listed risks factors

in order to improve the working

conditions of their employees.

- The process of working is not

changed for further evaluation.

Purpose:

Specific risks factors for work-related

musculoskeletal disorders identified among the

brick sorters in one brick-making factory in

South Africa.

Indicators:

- Specific risks factors for the selected area (i.e.

sorting /stacking section) listed by the end of

January 2003.

Assumptions

-Outside factors do not influence the

results of the study.

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Outputs:

1) Prevalence of self-reported work-

related musculoskeletal complaints

determined.

2) Most affected body regions identified.

3) Ergonomic risk factors in the

workplace identified.

4) Working postures assessed

5) Results analyzed

6) Written report

7) Recommendations listed

Indicators:

- Among the 19 brick sorters, interviews

regarding subjective pain/discomfort on

different body regions and psychosocial

situations, which brick sorters perceived as

contributing factors to those disorders

conducted by the end of November 2002.

- Workplace analysis: to note the main

demands of the tasks and listing the risk

factors as to which may be present

accomplished by the end of November 2002.

- Assessment of the physical stress by 1993

NIOSH equation completed by the end of

December 2002.

- Among the 19 brick sorters, posture assessed

through instantaneous observation by the end

of December 2002.

- Results analyzed by the end of January 2003.

Assumptions

- The workers who volunteer for

participation will represent the

whole group of brick sorters in this

factory.

- It assumed that workers would not

change the way they perform the

tasks during the observation.

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Written report completed and recommendations

listed by the 15th of February 2003.

Activities:

1) Talk to employees, to understand the

purpose of the study

2) Give voluntary consent form to sign for

participation.

3) Conducting interviews with employees.

4) Observation of the workplace and

measuring the workstation layout

5) Assessing working postures using OWAS.

Inputs:

- Volunteers for participation in the interviews

- Measuring tape

- Statistical software

- Employees are not forced to

participate in the interviews.

- Subjects always available to

provide information throughout

the whole study.

- The language used during

interviews does not influence

information provided by the

employees.

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16. APPENDIX 4: QUESTIONNAIRE: NUMBER: _____ PART I: GENERAL INFORMATION Gender: What year were you born?

Male Female

What is your job title?

How many years and months have Years + Months you been doing your present type of work? On average, how many hours per shift Hours do you work? Minutes How about the rest breaks? kg How much do you weigh? cm How tall are you? Does your work require the use of both hands?

No Yes

Do you have any health problems? No Yes If yes, explain briefly _____________________________________________________ _______________________________________________________________________

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PART II: This part of the survey is designed to determine the musculoskeletal symptoms

among the workers. Note that the questionnaire is to be answered, even if you have

never had trouble in any part of your body.

1. Have you ever been prevented from doing your normal work activities (at home

or away from home) because of musculoskeletal pain/discomfort?

No Yes

2. Where was this pain/discomfort? Please indicate in the diagram (figure 1 below).

Figure 1. Showing the body regions. 3. Did you see a doctor because of your pain? No Yes 4. Did you stay away from work because of the pain? No Yes 5. What caused the pain? _______________________________________________________________________

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6. Have you at any time during the last 12 months had an episode of pain or discomfort

lasting at least 24 hours?

No Yes If yes, identify area on the body (Identify the areas on the figure above, indicate one or

both sides)

_______________________________________________________________________ 7. Have you at any time during the last month had pain or discomfort, which lasted at

least 24 hours?

No Yes If yes, identify area on the body _____________________________________________ 8. Have you ever at any time during the last 7 days had pain or discomfort, which lasted

at least 24 hours?

No Yes If yes, identify area on the body ____________________________________________ PART III: This part of the questionnaire is to measure the psychosocial aspects of the work. 9. Do you think the job is? Very Fast Fast Normal Slow Very Slow Very Easy Easy Normal Difficult Very Difficult 10. Do you think you have excessive work? No Yes

If yes, elaborate _________________________________________________________

11. Do you think you have sufficient time to work? No Yes

If yes, elaborate _________________________________________________________

12. Does the job require creativity? No Yes

If yes, explain __________________________________________________________

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13. Do you have opportunities to learn new things? No Yes If yes, elaborate _________________________________________________________ 14. Are you given opportunity to voice out regarding suggestions on how to improve the

working conditions?

No Yes If yes, explain ___________________________________________________________ 15.Do you assist each other as fellow-workers? No Yes Explain ________________________________________________________________ 16. Is your Supervisor/s concerned about your work? No Yes Explain ________________________________________________________________ 17. Do you prefer working in groups? No Yes Explain ________________________________________________________________ 18. Please describe how satisfied you are with the health service provided by the company? ______________________________________________________________________________________________________________________________________________ 19. Is there something you want me to know about your working situation? ______________________________________________________________________________________________________________________________________________

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17. APPENDIX 5: A modified version of Norwegian translation of the short

Swedish version of the Job content, Questionnaire (In English)

_______________________________________________________________________

Indices Items

Job demands (5 items)

Working fast

Working hard

Excessive work

Insufficient time to work

Conflicting demands

Job control (decision latitude) (6 items) Learn new things

Requires creativity

High skill level

Repetitive work

Tasks variety-how

Tasks variety-what

Social support (6 items)

Atmosphere in the work

environment

Friendly co-workers

Co-workers helpful

Co-workers interested in me

Supervisor concerned

Team spirit

_______________________________________________________________________

Taken from Morken et. al., (2002)

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18. APPENDIX 6: CHECKLIST

The purpose of this checklist is to increase awareness of potential problems associated

with jobs and their tasks for making effective improvement.

Task Details

1. Task name:…………………………………………………..

Area:…………………………………………………………

Assessor:…………………………………………………….

Date of assessment:……….. ……….………

2. Consultation with employees: (Talk to the people who do the task. Get them to mime

the task actions).

3. Observe the tasks: (Watch the employees doing the task. Describe the manual

handling aspects of the task by writing down its steps).

……………………………………………………………………………………………

……………………………………………………………………………………………

……………………………………………………………………………………………

……………………………………………………………………………………………

……………………………………………………………………………………………

Task duration (for how long do they perform the same

task):………………………………………………………………………………………

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Hazard Identification 4. The task - does it involve?

Holding load at a distance from trunk?

Unsatisfactory bodily movement or posture,

Especially twisting the trunk?

Stooping?

Excessive movement of load: especially

Excessive lifting or lowering distances?

Excessive carrying distances?

Risk of sudden movement of load?

Frequent or prolonged physical effort?

Handling that goes on for too long without a break?

5. The load- is it:

Lifted manually? Notice factors of importance as:

Periods of repetitive lifting

Weight of the load?

Awkward grasping of the load?

Awkward location of load at onset or end of lifting?

6. The working environment- is there:

Space too limited for work movements or work materials?

Uneven, slippery, or unstable floors?

Variations in level of floors or work surfaces?

Extremes of temperature, humidity or air movement?

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19. APPENDIX 7: Task Variables in the sorting/stacking processes

____________________________________________________________________________________________________________

Hand location (cm)

Origin Destination

____________________________________________________________________________________________________________

Lowest hand location highest hand location lowest hand location highest hand location

_________________ ________________ _________________ ______________

H V H V H V D H V D

75 90 75 90 50 22 68 90 115 25

____________________________________________________________________________________________________________

Coupling Frequency Duration

Asymmetric angle (lifts/min) (hr)

Origin Destination

_________ __________

650 1000 (lowest hand location) 0.90 0.13 8

____________________________________________________________________________________________________________

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20. APPENDIX 8: The procedure for calculating RWL and LI in the sorting/stacking processes.

____________________________________________________________________________________________________________

LC HM VM DM AM FM CM RWL LI ____________________________________________________________________________________________________________

23 0.333 0.955 0.886 0.792 0.13 0.9 0.60 4.5

at origin of lift at the lowest hand location

23 0.333 0.955 1.00 0.792 0.13 0.9 0.67 4.02

at origin of lift at the highest hand location

23 0.50 1.159 0.886 0.68 0.13 0.9 0.93 2.90

at destination of lift at lowest hand location

23 0.27 0.88 1.00 0.792 0.13 0.9 0.50 5.4

at destination of lift at highest hand location

____________________________________________________________________________________________________________