Manual Material Handling Ergonomics Safety Training

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2006 RiskAnalytics, LLC Page 1

Manual Material HandlingErgonomics Training Program

2006 RiskAnalytics, LLC


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2006 RiskAnalytics, LLC

Disclaimer

The information, suggestions and recommendations contained herein are forgeneral informational purposes only. This information has been compiled fromsources believed to be reliable. No warranty, guarantee, or representation,either expressed or implied, is made as to the correctness or sufficiency ofany representation contained herein. Reliance upon, or compliance with, anyof the information, suggestions or recommendations contained herein in no

way guarantees the fulfillment of your obligations under your insurance policyor as may otherwise be required by any governmental, national, federal, state,or local laws, rules or regulations. This Information should not be construed asbusiness, risk management or legal advice, or legal opinion.

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Learning Objectives

Describe the concept and purpose

of ergonomics Identify personal, job, and

environmental ergonomic riskfactors

Discuss ways to preventmusculoskeletal disorders

Discuss the importance ofengineering and administrativecontrols

Describe the steps in implementingan effective ergonomics program


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Introduction

The word Ergonomics comes from the Greek words

Ergos

--(work) and

Nomos

-- (natural law)

Ergonomics is an interdisciplinary approach toward

adapting the man-made environment around man,

rather than man around the environment

Ergonomics considers the physical and mentalcapabilities and limits of the worker and how they

interact with tools, equipment, work methods, tasks,

and the working environment

D = 24 in

V = 8 in

48 lbs

H = 20 in


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Ergonomics Program Goals

Goal: Reduce work-relatedmusculoskeletal disorders(MSDs) by adapting the work tofit the person, instead of forcing

the person to adapt to the work Principle: Human

characteristics should beconsidered at the beginning ofthe design process


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What are Musculoskeletal Disorders (MSDs)?

Illnesses and injuries affecting one or more parts of the

musculoskeletal system They include sprains, strains, inflammation, degeneration,

tears, pinched nerves or blood vessels, bone splintering andstress fractures

Symptoms are discomfort, pain, fatigue, swelling, stiffness or

numbness, and tingling



Why is effective ergonomics so important? Back injuries are the leading cause of disability

In 2007, occupational musculoskeletal disorderscomprise 28.9% of all nonfatal injuries and illnessesinvolving days away from work.

In 2009, there were 195,150 back and spinal cordnonfatal injuries involving days away from work.

Musculoskeletal disorders accounted for 29% of allworkplace injuries in 2007



The Economics of ErgonomicsMSDs Injury: Muscle Strain

Average Direct Cost: $ 5,945

Average Indirect Cost: $11,890

Estimated Total Cost: $17,735

Net profit margin for this company is 4 %

The ADDITIONAL sales necessaryto cover Total Costs are: $445,875

MSDs Injury: Carpal Tunnel Syndrome




The net profit margin 4%


MSDs Injury: Cumulative Trauma




The net profit margin 4%


The total additionalrevenue required tocover the costs ofthese 3 incidents isestimated to be$1,793,775


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The Worker

The EnvironmentThe Job

Ergonomic Risk Factor Interaction


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Ergonomic Risk FactorsPhysicalAwkward Postures

Body postures determine which joints and muscles areused in an activity and the amount of force or stressesgenerated or tolerated.


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Ergonomic Risk FactorsPhysicalForceful Exertions

Tasks requiring forceful exertions place higher loads onthe muscles, tendons, ligaments, and joints

Prolonged experiences of this type can give rise not only

to feelings of fatigue but may also lead to musculoskeletal

problems when there is inadequate time for rest orrecovery


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Ergonomic Risk FactorsPhysicalRepetitive Motions

Fatigue and muscle-tendon strain can accumulateif motions are repeated frequently affected by: Duration- Duration refers to the amount of time a

person is continually exposed to a risk factor

Frequency- Frequency refers to how many times a

person repeats a given exertion within a given period oftime


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Ergonomic Risk FactorsPhysicalContact Stresses

Repeated or continuous contact with hard or sharp objectssuch as non-rounded desk edges or unpadded, narrowtool handles


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Ergonomic Risk FactorsPhysicalVibration

Exposure to local vibration occurs when a specificpart of the body comes in contact with a vibratingobject, such as a power hand tool


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In control Out of control!

Ergonomic Risk Factors - PsychologicalPositive Stress vs. Distress


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Ergonomic Risk Factors - Tasks

Lifting/Lowering Pushing/Pulling

Sitting

Twisting

Carrying Holding


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Resting Dynamic Effort Static Effort

Blood Need Blood Flow Blood Need Blood Flow Blood Need Blood Flow

Static vs. Dynamic Muscular EffortBlood Needed vs. Blood Flow


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Spinal Anatomy 101 The spines vertebrae are held together by

ligaments

Muscles are attached to the vertebrae by bandsof tissue called tendons

Between each vertebra is a cushion known as adisc

Openings in each vertebra line up to form a long,

hollow canal

The spinal cord runs through this canal from thebase of the brain

Nerves from the spinal cord branch out andleave the spine through spaces between thevertebra

The lower part of the back holds most of thebodys weight


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Spinal Anatomy 101 - Intervertebral Discs

The vertebrae are separated by Intervertebral discswhich act ascushions between the bones.

Each disc is made up of two parts - the hard, tough outer layer calledthe Annulussurrounds a mushy, moist center termed the Nucleus.


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Physical Stress on Skeletal SystemForces Involved:

5 pounds?

10 pounds?15 pounds?

Imagine your back as a lever. With the fulcrum in thecenter of the lever, how many pounds would it take to lift a10 pound object?

10 Lbs

?


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It takes 10 pounds of pressure to lift a 10 pound object.

Will it take more or less force to lift the same 10 poundobject with the fulcrum shifted away from the object?

10 Lbs

?


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With the fulcrum shifted away from the object, it takesmore force to lift the object.

The human back operates on a 10:1 lifting ratio, with thewaist acting as the fulcrum.

10 Lbs


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When you add in 105 pounds of the average human uppertorso, lifting a 10 pound object puts 1,150 pounds ofpressure on the human back.

105 Lbs

1150 Lbs

10 Lbs


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If you were 25 pounds overweight, it would put anadditional 250 pounds of pressure on your back every timeyou bent over.

130 Lbs

1400 Lbs

10 Lbs


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Common Causes of Musculoskeletal Injuries

Heavy Lifting

especially repetitive lifting over a long period of time

Twisting at the waist

while lifting or holding a heavy load

Reaching and lifting

over your head, across a table, or from the floor with straight legs

Working in odd, uncomfortable positions

tasks that require you to bend over for long periods of time

Sitting or standing too long in one positionsitting can be very hard on the lower back

Slips, trips and falls

Preventing Injuries


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Preventing Injuries

Avoid lifting and bending whenever you can

If you must lift, the best zone for lifting is between yourshoulders and your waist

Place objects up off the floor so you wont have to reachdown to get them

Always use a dolly or a forklift if you can

Pushing an object is better than pulling the object

Don't overdo it - if you have to strain to carry the load, it'stoo heavy for you

Make sure you have enough room to lift safely

Look around before you lift and know where you are goingto put down the load

Avoid walking on slippery and uneven surfaces whilecarrying something

Preventing Injuries


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Plan your move Size up the load and make sure your path is clear Get help as needed Use handles or straps Use a dolly or other material handling equipment if possible

Use a wide, balanced stance with one foot slightly ahead of

the other with your heels on the floor Get as close to the load as possible

Use your palms, not just your fingers, to grasp the load

Tighten your stomach muscles as the lift begins

Keep your lower back in its normal arched/curved position Move the feet to turn - Dont twist your back

Lower the load slowly, maintaining the curve in your lowerback

Preventing Injuries

Use proper lifting procedure

Preventing Injuries


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Transferring weight Pull object towards you while transferring your

weight to the lift side

Lift only to the level required

Shift your weight to the other leg while pushing the

object into position. Do not twist

Lifting heavy bags Put one knee down against bag

Pull bag up leg

Rest bag on edge of knee

Stand upright

Pull bag to waist height

Preventing Injuries

More Lifting Tips

Preventing Injuries


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Preventing Injuries

Lifting Safety Checklist Have you checked the object before you try to lift it?

Test every load before you lift by pushing the object lightly with yourhands to see how easily it moves

Remember, a small size does not always mean a light load

Is the load you want to lift packed right? Make sure the weight is balanced and stable so the load does not shift

when moved Loose pieces inside a box can cause accidents if the box becomes

unbalanced Is it easy to grip this load?

Have a tight grip on the object

Is it easy to reach this load? You can be injured if you arch your back when lifting a load over your

head. Avoid lifting overhead

To avoid hurting your back, use a ladder when you're lifting somethingover your head

Preventing Injuries


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Preventing Injuries

Body Management

Stretch early and stretch often Slow down; dont overdue it

Take frequent micro breaks

Sleep on a firm mattress

Get in shape and stay in shape with regular exercise

C t lli E i Ri k F t


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Controlling Ergonomic Risk Factors

Recommendations for controlling risk factors include:

Ask employees in the problem job forrecommendations

Identify, assess and implement feasible controls

Track your progress

Identify and evaluate musculoskeletal hazards

Hazard Control Strategies


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Hazard Control StrategiesTwo Types:

Engineering controls- Eliminates/reduces hazards

existing through equipment redesign, replacement,and/or substitution

Administrative controls- Reduce exposure to thehazard by controlling behaviors through design of work

procedures, schedules, use of personal protectiveequipment



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Hazard Control StrategiesEngineering Controls:

Changing the way materials, parts, and products can

be transported Changing the process or product to reduce worker

exposures to risk factors

Changing workstation layout

Changing the way parts, tools, machinery andmaterials are to be manipulated

Changing tool designs

Changes in materials and fasteners

Changing assembly access and sequence



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Hazard Control StrategiesAdministrativeControls Broadening or varying job content to offset risk factors

such as repetitive motion or awkward posture Adjusting work pace to relieve repetitive motion risks

and give the worker more control of the operationalprocess

Rescheduling work for cooler times of day

Reducing shift length or curtailing the amount ofovertime

Rotating workers through jobs with different physicaldemands to reduce the stress on limbs and body

regions Scheduling more breaks

Implementing Control Strategies


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Implementing Control StrategiesEffective control strategies are based on the following

principles:

Carefully plan the change - make small changes

Conduct limited trials or tests of the selected solutions

Study the effects of the change

Adopt, abandon or revise as needed

Once a change is adopted, implement full-scale

Conduct follow-up evaluation of control strategies

PLAN

DO

STUDY

ACT

Summary


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Summary

Ergonomics is about fitting the work to the worker

Lower back problems are the leading cause of disability

Risk factors exist in the environment, the job or specifictasks and with the person

Job related risk factors include awkward posture, forcefulexertions, repetitive motions, and contact stress

Psychological risk factors include lack of time, unreasonableworkload and poor working relationships

Proper lifting technique includes planning the move, using awide, balanced stance, getting as close to the load aspossible and moving your feet versus twisting the torso

Ergonomic hazard control strategies include engineeringcontrols, administrative controls and personal protectiveequipment

Documents

Manual Material Handling Ergonomics Safety Training