MANUAL HANDLING - Windley Elygateway.windleyely.com/...Manual_Material_Handling.pdf · Why is manual handling a problem? New Brunswick statistics* reveal the dramatic number of lost-time

Workplace Health, Safety and Compensation Commission of New Brunswick

MANUAL HANDLING

THIS SIDE UP

TABLE OF CONTENTS

INTRODUCTION

Objectives . . . . . . 3

Definition . . . . . . 3

Why is manual handling a problem? . . 4

How to use this document . . . . 4

RISKS IDENTIFICATION

How to use the checklist . . . . 5

Manual handling checklist . . . . 6

SOLUTIONS

How to prevent manual handling injuries . . 7

Potential solutions . . . . . 8

BIBLIOGRAPHY . . . . . . 14

APPENDICES

A: Iceberg theory – Your workplace statistic s

B: Example of manual handling task

– Checklist sample

– Potential solutions

– Implementation

C: WHSCC regional offices

D: Copy of the checklist

Ergonomics Guidelines for Manual Handling

3

Acknowledgment

Special thanks to the Canadian Centre for Occupational Health and Safety andto Worksafe Western Australia for granting permission to use their graphicimages.

Also, we thank all the New Brunswick employers and employees whoprovided feedback during the pilot phase of this document.

Disclaimer

This document represents best practices to prevent manual handlinginjuries and other business losses due to manual handling. Informationcontained in this document may change over time as new research andstudies are done in the field of ergonomics. This document is notdesigned to replace a professional ergonomics analysis.

Workplace Health, Safety and CompensationCommission of New Brunswick

September 1999

INTRODUCTION

As part of its ergonomics strategy, the Workplace Health, Safety andCompensation Commission has developed Ergonomics guidelines formanual handling. This document enables New Brunswick workplaces toidentify the risk of injury associated with manual handling and to movetoward reducing or eliminating these risks.

Objectives

This guide will help you:• develop an understanding of the basic elements of manual handling;

• evaluate and analyze specific tasks that can potentially cause manualhandling injuries;

• develop and implement solutions to reduce the risk of injury.

Definition

Manual handling includes any tasks which require a person to lift, lower,push, pull, hold or carry any object, animal or person.


Introduction 5

lift/lower push carry

pullhold

Please note: thisdocument focuses on

the handling ofobjects, not handling

of persons.

Why is manual handling a problem?

New Brunswick statistics* reveal the dramatic number of lost-time injuries,days lost, and costs as a result of manual handling injuries.

Over one third of injuries are attributable to manual handling whichmakes the prevention of these type of injuries a priority for business, andhealth and safety professionals.

How to use this document

The first part of this document involves using a manual handling checklistto identify the risk of manual handling injuries. This identification processemphasizes lifting/lowering activities by assessing six factors:

• weight;

• posture and layout;

• frequency and duration;

• object characteristics;

• individuals;

• environment.

The second part involves using the potential solutions section to developan action plan to eliminate or reduce the risk of injury. The examplesprovided in the potential solutions correspond with the six factors in themanual handling checklist.


Introduction6

See Appendix B for acomplete example

of a manualhandling task.

Otherclaims

Manualhandling43%

Manualhandling37.1%

Otherclaims

Otherclaims

Manualhandling38.5%

* June 1999

Use Appendix A tocalculate the total

cost of having manualhandling injuries in

your workplace.

Percentage of Days LostPercentage of Lost-time Claims

Total Cost of Lost-time Claims

RISK IDENTIFICATION

How to use the checklist

Step 1

Select a manual handling task that has any of these characteristics:

• high rate of injury;

• workers have concerns about performing the task;

• high score on the comfort survey;

• product damage or defect is common.

Step 2

Advise and involve workers when completing the manual handlingchecklist.

Step 3

Complete the manual handling checklist for the task you have identified.Answer “NA” if the question does not apply to the task. Include allmeaningful comments for each factor.

Each “No” answers indicates a risk of injury or a sub-optimal condition.

Step 4

For each “No” answer, consult the potential solutions for examples of waysto reduce the risk of injury. Use these examples as a starting point forbrainstorming solutions which can be implemented in your workplace.Involve workers in discussions concerning solutions and implementation.


Risk Identification 7

A comfort survey is aquestionnaire used to

measure thediscomfort levels in

body parts.


Risk Identification8

NA Yes No

NA Yes No

NA Yes No

NA Yes No

NA Yes No

Manual Handling Checklist

Division/Dept. Workstation

Description of the task evaluated

Completed by Date

1. When standing, is the weight of the object lifted less than 23 kg / 51 lbs?

2. When seated, is the weight of the object handled less than 4.5 kg / 10 lbs?

Comments:

3. Are objects handled between mid-thigh and shoulder height?

4. Are objects within arm's length allowing the worker to reach them withoutbending his/her back?

5. Is the task performed in an open space, allowing worker to move his/herfeet and arms freely?

6. Does the worker move without twisting the trunk during the handlingprocess?

Comments:

7. Does the worker perform the same lifting/lowering motion less than onceevery five minutes?

8. Does the worker use different muscle groups every hour?

9. Does the worker change body positions and movements (go from sitting tostanding or walking) at least once an hour?

Comments:

10. Is the object easy to handle (frontal length ≤ 40 cm / 16 in and height ≤ 30 cm / 12 in), balanced, and stable?

11. Does the object provide good handles and allow a power grip?

Comments:

12. Is the worker trained to perform the task, including safe handling principles?

13. Does the worker's clothing allow safe manual handling?

Comments:

14. Is the floor surface clean, non-slippery and even?

15. Are temperature, humidity, lighting, noise and airflow appropriate for theworker?

Comments:

NA Yes No

We suggest reviewingthe entire document

before using thechecklist.

A blank copy of the checklist is available at the end of this document for reproduction.

WEIGHT

POSTURE AND LAYOUT

FREQUENCY AND DURATION

OBJECT CHARACTERISTICS

INDIVIDUALS

ENVIRONMENT

SOLUTIONS

How to prevent manual handling injuries

Commitment and involvement of the entire workplace, from topmanagement to line workers, are essential elements of a successful injuryprevention program. The best approach to prevent manual handlinginjuries involves the following components.

Education

Education is a key step in preventing injury. The worker should have abasic understanding of ergonomics principles and handling techniques,and should be able to recognize the risk factors and injury symptoms.Workers should make sure that injury symptoms, risk factors, near misses,hazards, incidents, accidents, etc. are reported to their supervisor and/orto the JHSC member so that necessary action can be taken.

Management should have knowledge to assume a leadership role. Thisincludes:

• a visible involvement;

• a policy that places health and safety at the same level ofimportance as production;

• assigning responsibility;

• providing authority and resources to all responsible parties, and;

• ensuring that everyone is accountable for their responsibilities.

Design

The design of the job itself (work/rest schedules, job rotation), the objectbeing handled and the workstation (dimensions/layout) have a directimpact on the risk of injury. In order to prevent injuries, you have toconsider modifying all of these aspects.

There are additional costs incurred in re-designing or modifying a task. Inorder to eliminate these costs, you should design it right the first time orfind creative and innovative solutions to eliminate the risk of injury.Remember, workers are a great source of creativity and innovation!

Also, providing mechanical aids such as conveyors, floor cranes, carts,suspension tools, balancing mechanisms, vacuum hoists, turntables, tilttables, etc. can reduce or eliminate the risk of injury.


Solutions 9

EDUCATION

DESIGN

Potential Solutions

The following sections provide examples of how to reduce or eliminatethe risk of manual handling injuries. They do not encompass all solutions.Any one solution will not eliminate all the risks of injury. Choose thesolution(s) that best applies to your situation and use it as a starting pointto improve your work environment.

Weight

Handling any weight can represent a risk to health and safety. However,the maximum permissible weight lifted/lowered established by the U.S.National Institute of Occupational Safety and Health (NIOSH) under optimalconditions is 23 kg/51 lbs.

Answering “No” to any questions in the checklist decreases the maximumpermissible weight.

There are other optimal conditions not included in the manual handlingchecklist:

• vertical distance the object travels is less than 25 cm/10 in;

• weight is distributed equally between both hands;

• horizontal distance between the person and the centre of gravity ofthe object is less than 25 cm/10 in.

Increasing these distances or having unequal weight distributiondecreases the maximum permissible weight.

Consider implementing the following solutions to reduce the risk of injury:

• reduce the weight by modifying the size, shape and/or number ofobjects;

• select or design objects which can be held close to the body;

• minimize the traveling distance of the load;

• minimize the total weight handled each day;

• handle objects weighing more than 4.5 kg/10 lbs in a standingposition;

• change from lifting to pushing, from carrying to pushing or frompulling to pushing;

• introduce team lifting.


Solutions10

Key questions1. When standing, is the

weight of the objectlifted less than 23 kg/51 lbs?

2. When seated, is theweight of the objecthandled less than 4.5 kg/10 lbs?

Dividing the weight cansometimes reduce the

risk of injury.

Store heavier objects at waist level.

Posture and Layout

Task(s) should be designed to minimize:

• twisting the trunk or bending to the side;

• reaching below mid-thigh height;

• reaching above shoulder height;

• reaching beyond 50 cm/20 in (horizontal distance in front of thebody).


Solutions 11

Key questions3. Are objects handled

between mid-thighand shoulder height?

4. Are objects withinarm‘s length allowingthe worker to reachthem without bendinghis/her back?

5. Is the task performedin an open space,allowing worker tomove his/her feet andarms freely?

6. Does the workermove without twistingthe trunk during thehandling process?

Elbow height ismeasured with upper

arms in neutralposition

HEAVY WORK

between elbowand waist height

LIGHT WORK

at approx. elbow height

PRECISION WORK

at approx. 5 cm/2 inabove elbow height

Optimal working heights

Optimal working area

Frequently used objects should be place within easy reachin the usual work area.

Optimal working height is based on workers body dimensions.


• use proper body mechanics – turn by moving the feet rather thantwisting the upper body;

• use storage techniques – wall brackets, shelving, gravity feed – toreduce holding, carrying, lifting, etc.;

• minimize the number of times the load is lifted below mid-thighheight;

• add posture variety by introducing job rotation and/or jobenlargement;

• add posture variety by using a footrest, sit/stand device;

• provide anti-fatigue matting or shoe inserts for workers who standfor long periods;

• adjust the height of the workstation to the worker’s optimal workingheight.


Solutions12

A turn table can help bring theload closer to the body.

Please refer to theweight section on

page 8 for additionalsolutions.

Frequency and Duration

Workers should use different muscle groups and vary their posture(sitting, standing, walking) every hour. The physical intensity of the workshould also vary, especially for lifting/lowering tasks. Lifting/lowering lessthan once every five minutes is the best practice.

Increasing frequency or duration decreases the maximum permissibleweight.


• introduce proper task rotation and/or job enlargement;

• introduce short and frequent work-rest cycles;

• introduce task-specific exercises;

• try using large muscle groups instead of small;

• minimize the number of times the load is lifted;

• reduce the pace of the task and/or the pace of the machine orfeeder;

• if frequency is very high, provide mechanical aids or automate task.


Solutions 13

Key questions7. Does the worker

perform the samelifting/loweringmotion less than onceevery five minutes?

8. Does the worker usedifferent musclegroups every hour?

9. Does the workerchange body positionsand movements (gofrom sitting tostanding or walking)at least once an hour?



0

5

10

15

20

25

0.2 1210864210.5

A tilt work surface can eliminatereaching and bending.

Duration of 8 hours

Number of lifts (per minute)

Duration of lessthan 1 hour

Object Characteristics

Object weight, size, shape and material can affect the risk of injury.Providing properly designed handles can increase the handling ability byup to 10 per cent. Handles should be designed to keep wrists in a neutralposture, provide power grip, and minimize contact stresses.

Localized contact stresses are produced when parts of the body come intocontact with hard, sharp objects, resulting in forces transmitted throughthe skin to underlying structures such as tendons and nerves.Compression can be reduced with soft handle grips that spread thepressure out over a larger area.


• modify the object – change shape, use rigid containers, divide intosmaller objects, move center of gravity, and move closer to the lifter;

• create handles – handholds, shock absorbing handles – on theobject;

• balance and stabilize the contents of containers;

• assign more people to move object/person;

• use appropriate lifting device;

• use comfortable, safe and well-fitted gloves.


Solutions14

Key questions10. Is the object easy to

handle (frontallength≤ 40 cm/16 inand height ≤30cm/12 in), balancedand stable?

11. Does the objectprovide goodhandles and allow apower grip?

Handles designed withfinger space

Neutral wrist posture

Pinch grip Power grip

Further analysis isrequired to assessinjury risks whenhandling animals,persons, tools or

hazardous materials.

Please refer to theweight section on page 8 for

additional solutions.

Poor Good

Individuals

Regardless of all other factors, workers should always be trained for thespecific task assigned. A task may be accomplished in many differentways as the worker naturally attempts to decrease his/her energyexpenditure. If the individual is taught the ‘best’ use of his/her body for agiven task, instead of attempting to find it through trial and error, thepotential for injury is reduced.


• provide education in safe manual handling principles;

• provide education in proper selection and fit of clothing;

• ensure workers are physically fit to do the task;

• provide education in the proper selection, fit, and use of personalprotective equipment;

• provide clear, meaningful instructions for tasks and evaluate workercomprehension.

Environment

Environmental factors can affect the risk of injury and overall worker’swell-being.

The optimal environmental conditions are:

• temperature: between 19 – 21˚C/66 – 70˚F

• humidity: between 30 – 50%

• lighting: greater than 200 LUX/19 foot candle


• add lighting to improve worker’s ability to see objects;

• use appropriate clothing for cold or hot temperatures;

• keep floor and work surfaces free of clutter;

• ensure good housekeeping in and around work area;

• identify high traffic areas and traffic flow directions, using floormarkers or paint, and overhead signs;

• use mirrors and other visual aids to help workers manoeuvre safelyaround corners and other obstacles;

• warm up before performing task, to increase muscle strength andincrease blood circulation;

• if needed, provide personal protective equipment;

• provide anti-fatigue or anti-vibration matting.


Solutions 15

Key questions12. Is the worker

trained to performthe task, includingsafe handlingprinciples?

13. Does the worker’sclothing allow safemanual handling?

14. Is the floor surfaceclean, non-slipperyand even?

15. Are temperature,humidity, lighting,noise and airflowappropriate for theworker?



BIBLIOGRAPHYThis document is based on information collected from the followingsources:

AUBURN ENGINEERS INC. Design For Ergonomics, Auburn, 1997.

BIRD, Frank E. Jr. and George L.GERMAN. Practical Loss Control Leadership,Revised Edition. Loganville: Det Norske Veritas (U.S.A.) Inc., 1996.

BRIDGER R.S. Introduction to Ergonomics, McGraw-Hill, 1995.

KROEMER, K.H.E. and E. GRANJEAN. Fitting the Task to the Human, fifth edition.Bristol: Taylor & Francis Inc., 1997.

KROEMER, Karl, et al. Ergonomics -How to Design for Ease and Efficiency,Englewood Cliffs: Prentice-Hall, 1994.

MITAL, A., A.S. NICHOLSON, AND M.M. AYOUB. A guide to Manual MaterialsHandling, second edition. Washington: Taylor & Francis Inc., 1997.

OCCUPATIONAL HEALTH AND SAFETY AUTHORITY. Code of Practice for ManualHandling (Occupational Overuse Syndrome), Melbourne: Law Press, 1995.

DEPARTMENT OF LABOR. Ergonomics Program for Management Guidelines forMeatpacking Plants, 1993.

VICTORIAN WORKCOVER AUTHORITY. Regulations and Code of Practice:Manual Handling, Australian Government Publishing Service, 1996.

WATERS, PUTZ-ANDERSON, and GARG. Applications Manual for the RevisedNIOSH Lifting Equation, U.S. Department of Health and Human Services - PublicHealth Services, 1994.


16


Appendix A 17

Appendix A

Iceberg theory - your workplace statistics

Any organization which determines the cost of its accidents only in termsof compensation costs is looking at a very small percentage of itsidentifiable costs. In fact, studies have shown that the costs of workplaceinjuries are estimated to be anywhere between seven and 50 times thedirect costs.

By using the following tables with your workplace information, you willappreciate the total cost of accidents.

Use the table below to change your ‘Total accident costs’ into the amountof sales required.

Iceberg theory

Sales required to cover ‘Total accident costs’

Your workplace

(a)Start here

5 x (a)=

1 x (a)=

Sum column here

Direct cost of accident per year

Building, equipment and product damage,investigation time, and production delays andinterruptions

Hiring and training of replacement workers,overtime, and wages paid for lost-time fromproduction

Total accident costs

$1

$5 minimum value

$1 minimum value

$7

TOTALACCIDENT

COSTS

5,000

10,000

15,000

25,000

50,000

100,000

150,000

200,000

300,000

400,000

500,000

750,000

1,000,000

100,000

200,000

300,000

500,000

1,000,000

2,000,000

3,000,000

4,000,000

6,000,000

8,000,000

10,000,000

15,000,000

20,000,000

50,000

100,000

150,000

250,000

500,000

1,000,000

1,500,000

2,000,000

3,000,000

4,000,000

5,000,000

7,500,000

10,000,000

33,333

66,667

100,000

166,667

333,333

666,667

1,000,000

1,333,333

2,000,000

2,666,667

3,333,333

5,000,000

6,666,667

25,000

50,000

75,000

125,000

250,000

500,000

750,000

1,000,000

1,500,000

2,000,000

2,500,000

3,750,000

5,000,000

20,000

40,000

60,000

100,000

200,000

400,000

600,000

800,000

1,200,000

1,600,000

2,000,000

3,000,000

4,000,000

PROFIT MARGIN

5% 10% 15% 20% 25%


Appendix B18

Appendix B

Example of a manual handling task – Company ABC Inc.

I– Task description: Stacking components on a pallet

A set of heavy vehicle suspension components are stacked on a shippingpallet on an irregular basis, as orders are received. This may occur onlyonce per week or as often as six times per day. The task is performed byone of several employees whose other duties involve general warehouseand assembly tasks. It takes approximately 20 minutes to load a pallet.

The shipping pallet is on the floor and is surrounded by storage palletsand carts. Components, some relatively light and compact, and otherssuch as the awkward 42 kg/92 lbs springs, are removed from storagepallets or carts and are dragged or carried to the shipping pallet. Eachcomponent is then carefully placed in a standard pattern on the shippingpallet. The standard pattern provides stability during transport andconsistent presentation of the packages.

The workers have had general task training and are experienced in thistask, but they have not received specific training in safe manual handling.

Storage Pallets

Shipping Pallet

Cart

Spring


19

II– Manual Handling ChecklistDivision/Dept. Workstation


Completed by DateWEIGHT

1. When standing, is the weight of the object lifted less than 23 kg/51 lbs?

2. When seated, is the weight of the object handled less than 4.5 kg/10 lbs?

Comments:


4. Are objects within arm’s length allowing the worker to reach them without bending his/her back?

5. Is the task performed in an open space, allowing worker to move his/her feet and arms freely?

6. Does the worker move without twisting the trunk during the handling process?

Comments:

FREQUENCYAND DURATION

7. Does the worker perform the same lifting/lowering motion less than once every five minutes?


9. Does the worker change body positions and movements (go from sitting to standing or walking)at least once an hour?

Comments:


10. Is the object easy to handle (frontal length ≤ 40 cm/16 in and height ≤ 30 cm / 12 in), balanced, and stable?


Comments:

INDIVIDUALS


13. Does the worker ’s clothing allow safe manual handling?

Comments:

ENVIRONMENT


15. Are temperature, humidity, lighting, noise and airflow appropriate for the worker?

Comments:

NA Yes No

NA Yes No

NA Yes No

NA Yes No

NA Yes No

NA Yes No

Springs weight is approx. 42 kg/92 lbs, no mechanical aid (forklift) available for heavy components.

Warehouse

Stacking truck components on a pallet (compiling orders)

John Smith (supervisor), Bill Anderson (worker) August 17, 1999

Bending over to floor level to place components on the pallet, other pallets around restrict floor space, mustwalk around the pallet to properly place the spring.

Each pallet takes 20 minutes to stack, task varies with customer demand.On some days, the workload is particularly physically demanding.

Springs are awkward, heavy and very difficult to grip.

Workers had general task training and are experienced at this task, but havenot received specific training in safe handling principles.

In cold weather, the metal draws heat from the hands. Gloves offer protection but make gripping more difficult.

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

POSTURE AND LAYOUT


Appendix B20

III– Potential Solutions

Brainstorming to reduce risks brought the following potential solutions.

Create or modify the design

• Improve storage methods to more efficiently use racks and clear floor space.• Investigate options for pre-packaging pallets instead of waiting for orders, to even

out the workload.• Modify cart to have a higher base to reduce bending.

Educate the worker

• Train staff in storage and use of mechanical aids.• Train staff in manual handling principles.

Use mechanical aids which fit the worker

• Provide overhead hoist system for moving springs and heavy components.• Place pallet on a stand for stacking at a more suitable work height.• Place pallet on a turntable device.

IV- Implementation

In consultation with all parties (i.e. JHSC, employee, employer,...), thefollowing solutions will be implemented.

Short term (0 - 4 weeks)

• Improve housekeeping (floor space and stock on pallets, clean floor).• Provide initial training to staff in appropriate work practices and use of equipment.• Gather information on options for reducing fluctuations in pallet stacking workload.

Medium term (1 - 4 months)

• Train staff in manual handling principles.• Trial option for reducing workload fluctuations e.g. pre-stacking of some pallets in

quieter periods.• Raise height of cart base at a more suitable level.• Investigate hoist system, and mechanism for grasping the springs during lift by the

hoist.

Long term (4 - 8 months)

• Install hoist system for heavy springs develop work procedures• Construct/purchase fixed-height pallet stands to improve work height.• Provide employees with further training on new procedures.


Appendix C 21

Appendix C: WHSCC Regional Offices

Grand FallsTel: (506) 475-2550

Fax: (506) 475-2568

Toll Free: 1 800 222-9775

Grand Bay/Saint JohnTel: (506) 738-4069

Fax: (506) 738-4099

Toll Free: 1 800 282-8080

BathurstTel: (506) 547-7300

Fax: (506) 547-7311

Toll Free: 1 800 561-2524

MonctonTel: (506) 867-0525

Fax: (506) 859-6911

Toll Free: 1 800 222-9775

You can find more information on WHSCC’s programs and services on theinternet at www.whscc.nb.ca.

For more information, contact the ergonomics consultant in your region:


Manual Handling ChecklistDivision/Dept. Workstation


Completed by DateWEIGHT

1. When standing, is the weight of the object lifted less than 23 kg/51 lbs?

2. When seated, is the weight of the object handled less than 4.5 kg/10 lbs?

Comments:


4. Are objects within arm’s length allowing the worker to reach them without bending his/her back?

5. Is the task performed in an open space, allowing worker to move his/her feet and arms freely?

6. Does the worker move without twisting the trunk during the handling process?

Comments:

FREQUENCYAND DURATION

7. Does the worker perform the same lifting/lowering motion less than once every five minutes?


9. Does the worker change body positions and movements (go from sitting to standing or walking) at least oncean hour?

Comments:


10. Is the object easy to handle (frontal length ≤ 40 cm/16 in and height ≤ 30 cm / 12 in), balanced, and stable?


Comments:

INDIVIDUALS


13. Does the worker ’s clothing allow safe manual handling?

Comments:

ENVIRONMENT


15. Are temperature, humidity, lighting, noise and airflow appropriate for the worker?

Comments:

NA Yes No

NA Yes No

NA Yes No

NA Yes No

NA Yes No

NA Yes NoPOSTURE AND LAYOUT

Documents

MANUAL HANDLING - Windley Elygateway.windleyely.com/...Manual_Material_Handling.pdf · Why is manual handling a problem? New Brunswick statistics* reveal the dramatic number of lost-time