MANUAL HANDLING

THIS SIDE UP

Workplace Health, Safety and Compensation Commission of New Brunswick

Ergonomics Guidelines for Manual Handling

TABLE OF CONTENTS
INTRODUCTION
Objectives Definition . . . . . . . . . . . . . . . . 3 3 4 4

Why is manual handling a problem? How to use this document . .

RISKS IDENTIFICATION
How to use the checklist Manual handling checklist . . . . . . . . 5 6

SOLUTIONS
How to prevent manual handling injuries . Potential solutions . . . . . . . . . . . 7 8 14

BIBLIOGRAPHY . APPENDICES

A: Iceberg theory Your workplace statistic s

B: Example of manual handling task Checklist sample Potential solutions Implementation

C: W HSCC regional offices

D: Copy of the checklist

Acknowledgment
Special thanks to the Canadian Centre for Occupational Health and Safety and to Worksafe Western Australia for granting permission to use their graphic images. Also, we thank all the New Brunswick employers and employees who provided feedback during the pilot phase of this document.

Disclaimer
This document represents best practices to prevent manual handling injuries and other business losses due to manual handling. Information contained in this document may change over time as new research and studies are done in the field of ergonomics. This document is not designed to replace a professional ergonomics analysis.

Workplace Health, Safety and Compensation Commission of New Brunswick September 1999

Ergonomics Guidelines for Manual Handling

INTRODUCTION
As part of its ergonomics strategy, the Workplace Health, Safety and Compensation Commission has developed Ergonomics guidelines for manual handling. This document enables New Brunswick workplaces to identify the risk of injury associated with manual handling and to move toward 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 manual handling injuries; develop and implement solutions to reduce the risk of injury. Please note: this document focuses on the handling of objects, not handling of persons.

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

lift/lower

push

carry

hold

pull

Introduction

Ergonomics Guidelines for Manual Handling

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. Percentage of Lost-time Claims
Manual handling 37.1%

Percentage of Days Lost

Other claims

Use Appendix A to calculate the total cost of having manual handling injuries in your workplace.

Other claims

Manual handling 43%

Total Cost of Lost-time Claims

Other claims

Manual handling 38.5%

* June 1999

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

How to use this document

The first part of this document involves using a manual handling checklist to identify the risk of manual handling injuries. This identification process emphasizes lifting/lowering activities by assessing six factors: weight; posture and layout; See Appendix B for a complete example of a manual handling task. frequency and duration; object characteristics; individuals; environment. The second part involves using the potential solutions section to develop an action plan to eliminate or reduce the risk of injury. The examples provided in the potential solutions correspond with the six factors in the manual handling checklist.

Introduction

Ergonomics Guidelines for Manual Handling

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. A comfort survey is a questionnaire used to measure the discomfort levels in body parts.

Step 2
Advise and involve workers when completing the manual handling checklist.

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 all meaningful 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 ways to reduce the risk of injury. Use these examples as a starting point for brainstorming solutions which can be implemented in your workplace. Involve workers in discussions concerning solutions and implementation.

Risk Identification

Ergonomics Guidelines for Manual Handling

Manual Handling Checklist

Division/Dept. Description of the task evaluated Completed by WEIGHT 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: POSTURE AND LAYOUT 3. Are objects handled between mid-thigh and shoulder height? 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: FREQUENCY AND DURATION 7. Does the worker perform the same lifting/lowering motion less than once every five minutes? 8. Does the worker use different muscle groups every hour? 9. Does the worker change body positions and movements (go from sitting to standing or walking) at least once an hour? Comments: OBJECT CHARACTERISTICS 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: INDIVIDUALS 12. Is the worker trained to perform the task, including safe handling principles? 13. Does the worker's clothing allow safe manual handling? Comments: ENVIRONMENT 14. Is the floor surface clean, non-slippery and even? 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 Date NA Yes No Workstation

We suggest reviewing the entire document before using the checklist.

Risk Identification

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

Ergonomics Guidelines for Manual Handling

SOLUTIONS
How to prevent manual handling injuries
Commitment and involvement of the entire workplace, from top management to line workers, are essential elements of a successful injury prevention program. The best approach to prevent manual handling injuries involves the following components.

Education
Education is a key step in preventing injury. The worker should have a basic 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/or to the JHSC member so that necessary action can be taken. Management should have knowledge to assume a leadership role. This includes: a visible involvement; a policy that places health and safety at the same level of importance as production; assigning responsibility; providing authority and resources to all responsible parties, and; ensuring that everyone is accountable for their responsibilities.

EDUCATION

Design
The design of the job itself (work/rest schedules, job rotation), the object being handled and the workstation (dimensions/layout) have a direct impact on the risk of injury. In order to prevent injuries, you have to consider modifying all of these aspects. There are additional costs incurred in re-designing or modifying a task. In order to eliminate these costs, you should design it right the first time or find 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, tilt tables, etc. can reduce or eliminate the risk of injury.

DESIGN

Solutions

Ergonomics Guidelines for Manual Handling

Key questions
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?

Potential Solutions
The following sections provide examples of how to reduce or eliminate the risk of manual handling injuries. They do not encompass all solutions. Any one solution will not eliminate all the risks of injury. Choose the solution(s) that best applies to your situation and use it as a starting point to 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 optimal conditions is 23 kg/51 lbs. Answering No to any questions in the checklist decreases the maximum permissible weight. There are other optimal conditions not included in the manual handling checklist: 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 of the object is less than 25 cm/10 in.

Dividing the weight can sometimes reduce the risk of injury.

Increasing these distances or having unequal weight distribution decreases 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 of objects; 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 standing position; change from lifting to pushing, from carrying to pushing or from pulling to pushing; introduce team lifting.

Store heavier objects at waist level.

10

Solutions

Ergonomics Guidelines for Manual Handling

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 the body).

Key questions
3. Are objects handled between mid-thigh and shoulder height? 4. Are objects within arms 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?

Optimal working heights

Elbow height is measured with upper arms in neutral position

HEAVY WORK between elbow and waist height

LIGHT WORK at approx. elbow height

PRECISION WORK at approx. 5 cm/2 in above elbow height

Optimal working height is based on workers body dimensions.

Optimal working area

Frequently used objects should be place within easy reach in the usual work area.
Solutions

11

Ergonomics Guidelines for Manual Handling

Consider implementing the following solutions to reduce the risk of injury: use proper body mechanics turn by moving the feet rather than twisting the upper body; use storage techniques wall brackets, shelving, gravity feed to reduce holding, carrying, lifting, etc.; minimize the number of times the load is lifted below mid-thigh height; add posture variety by introducing job rotation and/or job enlargement; add posture variety by using a footrest, sit/stand device; provide anti-fatigue matting or shoe inserts for workers who stand for long periods; adjust the height of the workstation to the workers optimal working height. Please refer to the weight section on page 8 for additional solutions.

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

12

Solutions

Ergonomics Guidelines for Manual Handling

Frequency and Duration

Workers should use different muscle groups and vary their posture (sitting, standing, walking) every hour. The physical intensity of the work should also vary, especially for lifting/lowering tasks. Lifting/lowering less than once every five minutes is the best practice. Increasing frequency or duration decreases the maximum permissible weight.
25 20 15 10

Key questions
7. Does the worker perform the same lifting/lowering motion less than once every five minutes? 8. Does the worker use different muscle groups every hour? 9. Does the worker change body positions and movements (go from sitting to standing or walking) at least once an hour?

Duration of 8 hours
5 0

Duration of less than 1 hour

0.2 0.5 1 2 4 6 8 10 12

Number of lifts (per minute)

Consider implementing the following solutions to reduce the risk of injury: 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 or feeder; if frequency is very high, provide mechanical aids or automate task. Please refer to the weight section on page 8 for additional solutions.

A tilt work surface can eliminate reaching and bending.

Solutions

13

Ergonomics Guidelines for Manual Handling

Key questions
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?

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

Neutral wrist posture Localized contact stresses are produced when parts of the body come into contact with hard, sharp objects, resulting in forces transmitted through the skin to underlying structures such as tendons and nerves. Compression can be reduced with soft handle grips that spread the pressure out over a larger area. Pinch grip Power grip

Further analysis is required to assess injury risks when handling animals, persons, tools or hazardous materials.

Please refer to the weight section on page 8 for additional solutions.

Poor

Good

Consider implementing the following solutions to reduce the risk of injury: modify the object change shape, use rigid containers, divide into smaller objects, move center of gravity, and move closer to the lifter; create handles handholds, shock absorbing handles on the object; 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.

Handles designed with finger space

14

Solutions

Ergonomics Guidelines for Manual Handling

Individuals
Regardless of all other factors, workers should always be trained for the specific task assigned. A task may be accomplished in many different ways as the worker naturally attempts to decrease his/her energy expenditure. If the individual is taught the best use of his/her body for a given task, instead of attempting to find it through trial and error, the potential for injury is reduced. Consider implementing the following solutions to reduce the risk of injury: 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 personal protective equipment; provide clear, meaningful instructions for tasks and evaluate worker comprehension.

Key questions
12. Is the worker trained to perform the task, including safe handling principles? 13. Does the workers clothing allow safe manual handling?

Environment
Environmental factors can affect the risk of injury and overall workers well-being. The optimal environmental conditions are: temperature: between 19 21C/66 70F humidity: between 30 50% lighting: greater than 200 LUX/19 foot candle

14. Is the floor surface clean, non-slippery and even? 15. Are temperature, humidity, lighting, noise and airflow appropriate for the worker?

Consider implementing the following solutions to reduce the risk of injury: add lighting to improve workers 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 floor markers or paint, and overhead signs; use mirrors and other visual aids to help workers manoeuvre safely around corners and other obstacles; warm up before performing task, to increase muscle strength and increase blood circulation; if needed, provide personal protective equipment; provide anti-fatigue or anti-vibration matting. Please refer to the weight section on page 8 for additional solutions.

Solutions

15

Ergonomics Guidelines for Manual Handling

BIBLIOGRAPHY
This document is based on information collected from the following sources:
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. N ICHOLSON, AND M.M. AYOUB. A guide to Manual Materials Handling, second edition. Washington: Taylor & Francis Inc., 1997. OCCUPATIONAL HEALTH AND SAFETY AUTHORITY. Code of Practice for Manual Handling (Occupational Overuse Syndrome), Melbourne: Law Press, 1995. DEPARTMENT OF L ABOR. Ergonomics Program for Management Guidelines for Meatpacking 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 Revised NIOSH Lifting Equation, U.S. Department of Health and Human Services - Public Health Services, 1994.

16

Ergonomics Guidelines for Manual Handling

Appendix A
Iceberg theory - your workplace statistics
Any organization which determines the cost of its accidents only in terms of compensation costs is looking at a very small percentage of its identifiable costs. In fact, studies have shown that the costs of workplace injuries are estimated to be anywhere between seven and 50 times the direct costs. By using the following tables with your workplace information, you will appreciate the total cost of accidents.

Iceberg theory
Direct cost of accident per year Building, equipment and product damage, investigation time, and production delays and interruptions Hiring and training of replacement workers, overtime, and wages paid for lost-time from production Total accident costs $1

Your workplace
(a) Start here

$5 minimum value 5 x (a)=

$1 minimum value 1 x (a)= $7 Sum column here

Use the table below to change your Total accident costs into the amount of sales required.

Sales required to cover Total accident costs

TOTAL ACCIDENT 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 PROFIT MARGIN 5% 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 10% 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 15% 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 20% 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 25% 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

Appendix A

17

Ergonomics Guidelines for Manual Handling

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 shipping pallet on an irregular basis, as orders are received. This may occur only once per week or as often as six times per day. The task is performed by one of several employees whose other duties involve general warehouse and assembly tasks. It takes approximately 20 minutes to load a pallet. The shipping pallet is on the floor and is surrounded by storage pallets and carts. Components, some relatively light and compact, and others such as the awkward 42 kg/92 lbs springs, are removed from storage pallets or carts and are dragged or carried to the shipping pallet. Each component is then carefully placed in a standard pattern on the shipping pallet. The standard pattern provides stability during transport and consistent presentation of the packages. The workers have had general task training and are experienced in this task, but they have not received specific training in safe manual handling.

Storage Pallets

Shipping Pallet Spring

Cart

18

Appendix B

Ergonomics Guidelines for Manual Handling

II Manual Handling Checklist

Division/Dept. Warehouse Workstation Description of the task evaluated Stacking truck components on a pallet (compiling orders) Completed by John Smith (supervisor), Bill Anderson (worker) WEIGHT Date August 17, 1999 NA Yes No

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

NA Yes No

3. Are objects handled between mid-thigh and shoulder height? 4. Are objects within arms 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: Bending over to floor level to place components on the pallet, other pallets around restrict floor space, must walk around the pallet to properly place the spring.
FREQUENCYAND DURATION 7. Does the worker perform the same lifting/lowering motion less than once every five minutes? 8. Does the worker use different muscle groups every hour? 9. Does the worker change body positions and movements (go from sitting to standing or walking) at least once an hour? Comments: Each pallet takes 20 minutes to stack, task varies with customer demand. On some days, the workload is particularly physically demanding. OBJECT CHARACTERISTICS 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: Springs are awkward, heavy and very difficult to grip. INDIVIDUALS 12. Is the worker trained to perform the task, including safe handling principles? 13. Does the workers clothing allow safe manual handling? Comments: Workers had general task training and are experienced at this task, but have not received specific training in safe handling principles. ENVIRONMENT 14. Is the floor surface clean, non-slippery and even? 15. Are temperature, humidity, lighting, noise and airflow appropriate for the worker? Comments: In cold weather, the metal draws heat from the hands. Gloves offer protection but make gripping more difficult. NA Yes No

NA Yes No

NA Yes No

NA Yes No

19

Ergonomics Guidelines for Manual Handling

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,...), the following 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.

20

Appendix B

Ergonomics Guidelines for Manual Handling

Appendix C: WHSCC Regional Offices

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

Grand Falls Tel: (506) 475-2550 Fax: (506) 475-2568 Toll Free: 1 800 222-9775 Grand Bay/Saint John Tel: (506) 738-4069 Fax: (506) 738-4099 Toll Free: 1 800 282-8080 Bathurst Tel: (506) 547-7300 Fax: (506) 547-7311 Toll Free: 1 800 561-2524 Moncton Tel: (506) 867-0525 Fax: (506) 859-6911 Toll Free: 1 800 222-9775

You can find more information on WHSCCs programs and services on the internet at www.whscc.nb.ca.

Appendix C

21

Ergonomics Guidelines for Manual Handling

Manual Handling Checklist

Division/Dept. Description of the task evaluated Completed by WEIGHT 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: Date NA Yes No Workstation

POSTURE AND LAYOUT 3. Are objects handled between mid-thigh and shoulder height? 4. Are objects within arms 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:

NA Yes No

FREQUENCYAND DURATION 7. Does the worker perform the same lifting/lowering motion less than once every five minutes? 8. Does the worker use different muscle groups every hour? 9. Does the worker change body positions and movements (go from sitting to standing or walking) at least once an hour? Comments:

NA Yes No

OBJECT CHARACTERISTICS 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:

NA Yes No

INDIVIDUALS 12. Is the worker trained to perform the task, including safe handling principles? 13. Does the worker s clothing allow safe manual handling? Comments: ENVIRONMENT 14. Is the floor surface clean, non-slippery and even? 15. Are temperature, humidity, lighting, noise and airflow appropriate for the worker? Comments:

NA Yes No

NA Yes No