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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
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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
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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
Average Direct Cost: $ 8,305
Average Indirect Cost: $16,610
Estimated Total Cost: $24,915
The net profit margin 4%
The ADDITIONAL sales necessaryto cover Total Costs are: $622,875
MSDs Injury: Cumulative Trauma
Average Direct Cost: $ 9,667
Average Indirect Cost: $19,334
Estimated Total Cost: $29,001
The net profit margin 4%
The ADDITIONAL sales necessaryto cover Total Costs are: $725,025
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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Physical Stress on Skeletal SystemForces Involved:
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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Physical Stress on Skeletal SystemForces Involved:
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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Physical Stress on Skeletal SystemForces Involved:
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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Physical Stress on Skeletal SystemForces Involved:
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
Hazard Control Strategies
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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
Hazard Control Strategies
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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