ERGONOMICS

TRAIN THE TRAINER 2012

MANUAL HANDLING
RISK ASSESSMENT

REVISION 2014-04
AGENDA

Ergonomics terms and definitions

Legal requirements
Manual handling (Practical exercises)
Risk assessment (Practical exercises)
Control measures
Hand injury reduction
 GOAL:
DEVELOP . . .

ERGO EYES
Risk assessment
PLAN AND PREPARE FOR THE ASSESSMENT

Risk assessment principles are

the same as other assessments
PLAN AND PREPARE FOR THE ASSESSMENT

Who makes the assessment?

One person can perform an assessment of
straightforward cases
Assessment team is recommended
Assessors have practical knowledge of the
task to be assessed, the loads to be
handled and the working environment
PLAN AND PREPARE FOR THE ASSESSMENT

Team knowledge:
Requirement of regulations
Handling operations
Human capabilities
Awareness of high risk activities
Practical means of reducing risk
PLAN AND PREPARE FOR THE ASSESSMENT

How will the assessments be

organised?
Departments
Buildings
Process
Operation
Job group
Service provided (maintenance etc)
PLAN AND PREPARE FOR THE ASSESSMENT

Gather information
Accident records
Ill health records
IFE
Operating procedures
Sapa and country guidance
RISK ASSESSMENT

Identify hazards
Evaluate risk
Control
RISK ASSESSMENT

Identify hazards
Evaluate risk
Control
5 STEPS TO RISK ASSESSMENT

1. Identify Hazards

2. Identify People at Risk

3. Evaluate Risk

4. Record

5. Review
POSTURAL HAZARDS

Excessive forces
Sudden unexpected movements
Static, fixed postures
Extremes of joint movement
Overuse (insufficient rest or recover
periods)
RISK FACTORS
Excessive Force:
lifting/lowering;
carrying;
pushing/pulling
(pinch) grip
Awkward Body Postures
Stooping, twisting
Bent wrist; Bent neck; Pinch grip; Forearm rotation
Excessive reaching
Static, fixed postures
Repetition: repeating similar motions with same body part
Contact stress
Vibration
Environment: hot/cold temperatures
HANDLING ACTIVITIES AND RELATED CONCERNS

Lifting from low levels

Lowering (in a controlled manner, not just dropping the load)
Supporting
Carrying
Pushing/Pulling
Overreaching
Twisting
Stooping
Throwing
Team handling
HANDLING ACTIVITIES AND CONCERNS
Lifting from low levels
• Back lift
• Loss of 3 curves in back
• Power comes from the back
• Leg lift
• Knees in end of range
• Stability guaranteed?
• Some loss of curves in back
HANDLING ACTIVITIES AND CONCERNS
Lowering
(in a controlled manner, not just dropping the load)
• Muscles work in a series of jerky movements
• The worst posture tends to happen at the end of the
movement
• The load may trap fingers or strike feet
HANDLING ACTIVITIES AND CONCERNS
Supporting
• Biggest concern is static muscle work
• Changing grip without putting the load down can
lead to sudden movement
• Handler may not know how heavy a load is until it is
passed to him/her
HANDLING ACTIVITIES AND CONCERNS
Carrying
• Are grips/handles appropriate?
• Static muscle work in arms
• Visibility: where are we going?
• Are there any obstacles
• Do we need to move up or down steps?
HANDLING ACTIVITIES AND CONCERNS
Pushing and Pulling
• Possibility to rest mid-operation
• Powering from legs may be difficult when pulling
• Can we see the route ahead when pushing?
• One or two-handed pulling
HANDLING ACTIVITIES AND CONCERNS
Overreaching
• Increased static muscle work at shoulders or lower
back
• Increased effort to maintain stability
• Increased forces through back
• Increased potential for sudden unexpected
movement
HANDLING ACTIVITIES AND CONCERNS
Twisting
• Shoulders and hips are rotated out of alignment
with each other
• Increased forces through thoracic curve of spine
• Typically combined with stooping and
overreaching
• Layout of work area may cause twisting
• Handling while seated often exaggerates twisting
at the spine
HANDLING ACTIVITIES AND CONCERNS
Team Handling
• Team members may get in the way of each others’
sight or movement
• Lack of coordination creates potential for excessive
forces and sudden unexpected movements
• Team carrying may involve walking backwards with
a load
IDENTIFY THE HAZARDS USING STOP

Surroundings
Task
Object
People
eck SURROUNDINGS for: Check TASK for:
Cramped or confined spaces, • Poor/awkward posture
Uneven, unsafe or slippery surfaces • Lifting for too long
Poor housekeeping • Lifting too often
Poor lighting • Carrying too far
Temperature extremes • Carrying up or down stairs or st

STOP
Sprains and Strains
Is the OBJECT: Consider the PEOPLE:
• Too heavy • Hazard Awareness
• Too bulky or awkward • Lifting techniques
• Unbalance or unstable • Attitudes towards lifting
• Difficult to grip • Awareness and use of lifting aids
• Hot cold or contaminated • Warm up before heavy lifting
What are the hazards?
• Surroundings
• Task
• Object
• People
• Force
• Repetition
• Awkward Posture
• Vibration
• Contact Stress
• Cold Temperatures
What are the hazards?
• Surroundings
• Task
• Object
• People
• Force
• Repetition
• Awkward Posture
• Vibration
• Contact Stress
• Cold Temperatures
 What are the hazards?
• Surroundings
• Task
• Object
• People
• Force
• Repetition
• Awkward Posture
• Vibration
• Contact Stress
• Cold Temperatures
What are the hazards?
• Surroundings
• Task
• Object
• People
• Force
• Repetition
• Awkward Posture
• Vibration
• Contact Stress
• Cold Temperatures
What are the hazards?
• Surroundings
• Task
• Object
• People
• Force
• Repetition
• Awkward Posture
• Vibration
• Contact Stress
• Cold Temperatures
What are the hazards?
• Surroundings
• Task
• Object
• People
• Force
• Repetition
• Awkward Posture
• Vibration
• Contact Stress
• Cold Temperatures
What are the hazards?
• Surroundings
• Task
• Object
• People
• Force
• Repetition
• Awkward Posture
• Vibration
• Contact Stress
• Cold Temperatures
What are the hazards?
• Surroundings
• Task
• Object
• People
• Force
• Repetition
• Awkward Posture
• Vibration
• Contact Stress
• Cold Temperatures
MAKING THE ASSESSMENT
Visit the workplace
Observe activity in detail
Take photographs and/or video footage
Discuss activity with employees,
managers, safety representatives
Use checklists to cover all factors of
Task, load, working environment and
individual capability (STOP)
MAKING THE ASSESSMENT USING STOP

Surroundings
Task
Object
People
SURROUNDINGS – TASK – OBJECT – PEOPLE

Poor Housekeeping

Uneven, unsafe or slippery surfaces

SURROUNDINGS – TASK – OBJECT – PEOPLE

Cramped or confined spaces

Poor Lighting

temperature extremes
SURROUNDINGS – TASK – OBJECT – PEOPLE

Poor/awkward posture incl

twisting, turning, bending,
reaching
Force
Repetition
Surroundings – TASK – Object – People

Twisting, Turning, Bending

SURROUNDINGS – TASK – OBJECT – PEOPLE

• Too heavy
• Too bulky or awkward
• Unbalanced or unstable
• Difficult to grip
• Hot cold or contaminated
SURROUNDINGS – TASK – OBJECT – PEOPLE

Hazard Awareness
Lifting techniques
Attitudes towards lifting
Awareness and use of
lifting aids
Fit for the job

ok
STOP: EFFORT RATING
Effort Rating
How difficult is it to carry out the handling activity? Low Moderate High

Use this area to give your judgement on how difficult it is to perform the task, based on the
hazards identified in STOP.
This judgement is not based on how strong the people are, however, on how much physical
effort is required.
Ask yourself: how “ugly” is the task in itself.

Based on physical effort to carry out

handling activity
Subjective measure (by assessor) to allow for
prioritisation
Based on the hazards identified in STOP
STOP: HAZARD RATING
Hazard Rating

Give an overall rating of the hazard considering all elements of

Low Moderate
STOP High

minor = 1
medium = 2
major = 3

Overall rating of the hazard

used for risk rating
RISK ASSESSMENT

Identify hazards
Evaluate risk
Control
FINDA

Frequency with which the task is performed

Intensity, i.e. any kind of pressure under which
the task is performed
Number of people who perform the task at the
facility
Duration of each activity within the task-cycle
Accidents or IFEs reported or statistics of ill
health related to the task
FINDA

Frequency – How often is the operation

performed
Per person, per hour, per shift, per pallet,
etc.
Averages alone are meaningless – give a
range as well as an average, e.g. 3 to 20
times per hour, average 5 times per hour.
FINDA

Intensity, i.e. any kind of pressure

under which the task is performed
Refers to pressures and time
constraints, e.g. machine set
times, bonus systems etc
FINDA

Number of people who perform the

operation
At one time
Total number of people who may do the
operation in the department, e.g. 1 of 20
can do the job (but usually the same
person)
FINDA

Duration – the time required to

perform :
One operation
The process/activity before a
change of activity or break
FINDA

Accidents or IFEs reported or

statistics of ill health related to
the task
Previous reported accidents
or incident-free events
EVALUATE THE RISK

Ask employee’s opinion

EVALUATE THE RISK

Exposure Rating

Enter an overall rating of the Exposure considering all

High Medium
elements of FINDA Low

minor = 1; medium = 2 ; high = 3

The exposure rating is often comparative with other assessments.

Overall Risk rating

Enter the risk rating in the adjacent column

Total risk rating is the sum of hazard rating multiplied by exposure rating.
The maximum risk rating can be 9.
Compare the risk rating of this assessment with other assessments to see if it appropriately reflects the risk of
the task
RISK RATINGS
Risk rating = STOP*FINDA
STOP: Low (1), Moderate (2), High (3)
FINDA: Low (1), Medium (2), High (3)

STOP

High (3) 3 6 9

Medium (2) 2 4 6

1 2 3
Low (1)

FINDA Low (1) Medium(2) High (3)

RISK ASSESSMENT

Identify hazards
Evaluate risk
Control
EVALUATE THE RISK

Assessors suggest control actions

Action Requirements

Avoidance Solution:
Recommendations for action
Develop plan for
Immediate action
Medium-term action
Long – term action
Identifying responsible people and time lines.
EVALUATE THE RISK

Risk of injury is usually clear

Actions to reduce risk is the most
important and not the assessment
paper work.
Risk rating can be used for ranking
priority and link to action plans and
investment.
ROLE OF RISK ASSESSOR IN PROPOSING SOLUTIONS

Suggest solutions
Solutions may refer to specific equipment or
interventions.
Assessor may not have the knowledge of the
availability or details of specific equipment or
interventions
In that case, examples of what you may suggest within
your controls:
Consult ergonomist for more detailed assessment
Look into availability of engineering solution to raise
height
CONTROLLING THE RISK WITH STOP

Surroundings
Task
Object
People
eck SURROUNDINGS for: Check TASK for:
Cramped or confined spaces, • Poor/awkward posture
Uneven, unsafe or slippery surfaces • Lifting for too long
Poor housekeeping • Lifting too often
Poor lighting • Carrying too far
Temperature extremes • Carrying up or down stairs or st

STOP
Sprains and Strains
Is the OBJECT: Consider the PEOPLE:
• Too heavy • Hazard Awareness
• Too bulky or awkward • Lifting techniques
• Unbalance or unstable • Attitudes towards lifting
• Difficult to grip • Awareness and use of lifting aids
• Hot cold or contaminated • Warm up before heavy lifting
Reduce Risk using STOP
Surroundings: modify the work environment
• Good Housekeeping: ensure no tripping or
slipping hazards
• Good Lighting ensure people see what they
are doing and where they are going
• Exposure to thermal extremes eliminated
reduced or controlled
• Floor, stairs, changes in level
• Noise, vibration
SURROUNDINGS: SUMMARY

Remove obstructions
Ensure flooring is in good condition
Avoid steps and steep ramps
Prevent extremes of hot and cold
Ensure good lighting
PPE to be suitable and allow free movement
Reduce Risk using STOP
Modify the Task
 Modify handling and handling
procedures of heavy,
awkward or unstable loads!
 Consider weight, size,
stability, hand holds (big bags
to small bags)
 How is the load held
 Lifting and lowering
techniques
 Posture: Reduce Reaching,
Stretching, Twisting
 Reduce carrying distances
 Task duration: consider
rotation for exposure time
reduction
 Team Handling
 Use mechanical aids
LIFTING AIDS

Some of the mechanical aids

you can use to make manual
handling easier include:

• hand trolley;

• wheel barrow;

• winch;

• overhead crane;

• power tools;

• powered hand truck; and

• fork-lift.
TASK REDESIGN

 Provide a footrest for standing

 alternating feet periodically
 Frequent postural changes
 Avoid bending and twisting
 Get a good grip on objects
 Avoid sudden movements
 Tilt or angle work
 Design for use of both hands
 Avoid hard floors for standing workers
TASK REDESIGN
 Reduce bending by:
 Utilizing lifting devices
 Raising or lowering the work level
 Keeping materials accessible
 Reduce unsafe twisting by:
 Providing sufficient work space
 Improving the layout of the work area
 Reduce reaching by:
 Rearranging work area
 Reducing the size/capacity of the objects
 Keep object close to the body
 Don’t stack objects too high
TASK REDESIGN
 Reduce pushing and pulling forces by:
 Utilizing mechanical devices
 Providing good maintenance of floor surfaces
 Treating surfaces to reduce friction
 Improving the layout of the work area
 Ensure clear visibility

 Reduce carrying forces by:

 Changing the capacity of containers
 Changing the work station layout
Do not Do
Do not Do
Do not Do
WORKPLACE DESIGN

Hand tools
Design of displays
Workstation design
Height
Layout: zone of convenient reach
5S
Visual considerations
Sitting or standing
TASK: SUMMARY
Use a lifting aid
Conveyors
Reduce need to stoop or twist
Avoid lifting from floor level or above shoulder height
Reduce carrying distances
Avoid repetitive handling
Vary the work to give muscle groups a rest
Push rather than pull
Reduce Risk using STOP
Modify the Object

 Make the load:

– Lighter
– Smaller
– Easier to grasp
– More stable
– Less damaging to hold
 Reduce Risk using STOP
Consider the People
Male of Female
Age
Health and General Fitness including warming up
techniques before heavy lifting
Hazard Awareness through training and experience
Lifting aids
Reporting of Injuries and early symptoms

ok
WORKPLACE DESIGN

Designing for people

Within physical and mental
capabilities
Country expectation
EXPECTATION

Colour
Red
Hot, danger, warning, stop
Green
Safe, go
Yellow
Caution,
Blue
Cold, information
EXPECTATION

Shape
Round
Enforcement
Triangle
Caution, attention
Square
Advisory
EXPECTATION

Direction
Clockwise
On, tighten (screws), increases
Anti-clockwise
Off, loosen, decrease
Upwards
Switches on/off, increases
Downwards
Switches off/on, decreases
ANTHROPOMETRY

From the Greek anthropos- "man” and

metron "measure“ giving the
"measurement of man”
Scientists working for private companies
and government agencies conduct
anthropometric studies to determine a
range of sizes for clothing, furniture and
other items.
ANTHROPOMETRIC DATA

Anthropometry - measurement of a
person’s shape and form
height
length
depth
breadth
arc
circumference
reach
ANTHROPOMETRY

The US Military has conducted over 40

anthropometric surveys of U.S. Military
personnel between 1945 and 1988,
including the 1988 Army Anthropometric
Survey of men and women with its 240
measures.
Statistical data from these surveys
encompasses over 75,000 individuals.
TOOL DESIGN
Handles to fit the whole hand
Larger handles need less effort to use
Handle should ideally be soft, textured and non conductive
Can be used in either hand
Design tool for straight wrist operation
Use powered tools whenever possible
Don’t overuse the index finger or thumb
TOOL REDESIGN

Avoid:
rigid, form-fitting handles with grooves for each
finger
tools which require awkward movements
tool handles with sharp corners, edges or pinch
points
hand tools that impose concentrated pressure over
the soft tissues of the hand (i.e. short handles)
PEOPLE: SUMMARY
Pay attention to those who have a physical weakness
Extra attention to pregnant workers
Provide information on tasks to be performed
Provide training:
Manual handling risk factors
How to carry out safe manual handling
Good handling technique
Use of mechanical aids
Keep it practical
CONTROLLING THE RISK
Sapa good practices
Do you have some to share?
Controlling the Risk

Administrative Controls
Work-Rest Schedules
Worker Rotation
Training
Exercise/Rest
Job Changes
ADMINISTRATIVE CONTROLS

Rotate workers on high repetitive tasks

Reduce overtime on high stress jobs
Provide maintenance on powered tools
Provide manual handling training at
induction and on the task
Communicate changes in the
workplace, weights, processes etc
WORK / REST CYCLES

EXERCISE
Warm-up & stretching exercises
Before shift
After breaks
During intense & repetitious hand/wrist/arm work

REST
Mini-breaks during shift
Do not do similar tasks off the job
Utilize large muscle groups
EXERCISES

Assessment organisation
Risk assessment examples
Practical exercises on shop floor