Manual Material Handling OHS-16-A/ R-0

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ADANI GROUP
OHS PROCEDURE FOR

Manual Material Handling

OHS-16-A
DOCUMENT HISTORY:

Rev
Date Key Changes
No.
01/01/2016 0 Issued for implementation

Prepared by:

Ramakant Singh _____________________ 01 / 12 / 2015

Group Safety initiative (Signature) (Date)

Approved by:

Devprakash Joshi _____________________ 01 / 01 / 2016

COO Projects (Signature) (Date)

Adani Group OHS Effective Date: January, 01, 2016

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Procedure Content

Sr. No. Subject Topic Page no.

1.0. PURPOSE & SCOPE 3

2.0. DEFINITIONS/ ABBREVIATIONS 3
3.0. PROCEDURE 3
3.1. General Requirements 3
3.2. Manual Material Handling Risk 3
3.3 Identification and Evaluation of risk 4
3.4 Management of Material Handling Risk 4
4.0. RESPONSIBILITIES 5
4.1 - The Business Site Head 5
4.2 - The Manager/ Head of Departments 6
4.3 - All Employees 6
4.4 - The Site Safety Head 6
4.5 - OHS frame work Element/Component owner 7
4.6 - Group OHS Department 7
5.0. TRAINING 7
6.0. AUDITING 7
7.0. ATTACHMENTS & FORMS 7
 Annexure -A: Site specific Arrangements for manual material
handling
 Annexure- 1: Manual Material Handling task listing and risk 7
evaluation.
 Appendix -1: Manual Material Handling Method guide 8
 Appendix-2: RWL-Ergonomic Equation for Push, Pull, Carry
8.0. CROSS REFERENCE 7

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Manual Material Handling OHS-16-A/ R-0
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MANUAL MATERIAL HANDLING

1. PURPOSE AND SCOPE:

The purpose of this procedure is to provide guidelines for, Identification, Evaluation

and management of manual material handling risk, to reduce and control injuries
and adverse impact on employee health due to improper or repetitive material
handling task.

This procedure applies to Adani Group business locations and activities including
offices within India. Includes manually material handling task, of repetitive nature

2. ABBREVIATION & DEFINITION:

OHS- Occupational Health and Safety

RWL- Recommended Weight Limit, considered safe for average employee group
MSD- Musculoskeletal Disorder
GFR- Gujarat Factory Rules

3. PROCEDURE:

3.1. General Requirements:

a) This procedure covers manual material handling task done by employee and
aims at reduction of ergonomic risk factor and related injury.

b) The other material handling incidental risk and injury and its management
are not covered in this procedure like:
 Fractures and bruises caused by being struck by materials or by being
caught in pinch points, and
 Cuts and bruises caused by falling materials that have been
improperly stored or by incorrectly cutting ties or other securing
devices.

c) The matching of physical task demand with physical ability of worker in

manual material handling becomes essential when weight exceed. Manual
material handling tasks, if not done carefully, can result in injuries to the
back, sprains, and musculoskeletal disorder (MSD) conditions.

d) The Indian factory act Section 34 and rules made by state government (GFR-
62, MHFR 26 and Gujarat BOCW rule 68) restrict to lift, carry or move by
hand or on head the excessive weight by single person as under:

Persons Maximum weight of material,

article, tool or appliance
Adult Male 50 Kilograms
Adult female 30 Kilograms
Adolescent male 30 Kilograms
Adolescent female 20 Kilograms

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3.2. Manual Material Handling Risk:

a) Potential injuries that can occur due to ergonomic risk factor, when
moving materials manually, includes the following:
 Strains and sprains from lifting loads improperly or from carrying
loads that are either too large or too heavy,
b) Particular concern is back and overexertion injuries:
 Back injuries occur when the muscle, ligaments and/or tendons in
the back are damaged due to overstretching or overuse of the
muscles in the back. These injuries can result in strains, sprains and
tears. Herniated disks are also a type of back injury found in
workplace situations. A herniated disk occurs when an injury to the
spine causes the outer layer of the disk resulting in the cushioning
gel to bulge out.
 Overexertion injuries are the result of excessive repetitive handling,
(i.e. lifting, pushing, pulling, holding, turning, carrying or throwing of
an object), and/or the use of excessive force for a single handling.
These injuries involve the nerve, tendons, muscles and supporting
structures of the body.

c) Most back injuries can be attributed to one of these six causes:

 �
 � while and lifting and moving
 � ability, Mechanics, Work Habits
 � Repetitive frequency of the task
 �
 � , warmup

3.3. Identification and Evaluation of risk:

a) Each site shall initiate action to identify and prepare list of daily, weekly
or monthly routine operation and maintenance related repetitive type
manual material handling tasks involving the following type of activity
using Annexure-1 Manual Material Handling task listing and risk
evaluation, and update the list when new manual handling task is
introduced or at least once in a year.
I. Lifting, lowering of the martial
II. Hand Carrying, manually moving the object
III. Filling, Emptying or shifting of Containers
IV. Manually scooping pouring or packing/unpacking
V. Assembling & Positioning, pushing, pulling, turning, tilting or
holding
b) All listed manual material handling task or activity will be evaluated for
risk factor of MSD injury using the Annexure-1
c) The identified preliminary high risk manual material handling task must
be managed using following corrective actions in order of priority:

 Elimination or modifying the task.

 Use of mechanical aid and equipment- Engineering control
 Work breaks, team lifting, job rotation, warmup exercise-
Administrative Controls
 Protective equipment against incidental injury - PPE
 Instruction and safe job methods – Training and demonstration

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d) For more guide line on evaluation of risk use NIOSH lifting equation for
Calculating Recommended Weight Limit (RWL) available in Appendix-2.
As RWL- Ergonomic Equation for Push, Pull and Carry.

3.4. Management of Material Handling risk:

a. The identified high risk manual material handling task has to be studied
in detail for present situation condition and shall be applied with
following required changes as applicable to achieve risk reduction which
include:
b. The physical fitness demand: of task based on the frequency, duration
and repetitiveness can be managed by establishing physical fitness and
age group, warm up exercise requirement.
c. The over exertion and repetitive: nature of task result in over use of
muscle, ligament and do not allow muscle and ligament to rest and heal
the damage. this can be managed by administrative measures Like:
Work breaks, employee rotation, team lifting to share load etc.
d. Modifying task or the work area: include material, object, package shape,
size reduction or modifying work area to reduce lifting height, carry
distance etc. to reduce the possibility of muscular sprain, strain and
awkward posture over reach etc.
e. Using Mechanical Aids and equipment assistance: include the use of
suitable hand truck, trolley, cart, forklift reduces the object carrying and
travel distance and the related risk of injury.
f. Elimination of manual handling: can be achieved by implementing
engineering controls like conveyor, lift, chain pulley block etc. or
modifying the process, loading , unloading points.
g. Training and demonstration: safe manual material handling methods
training, warmup Exercise, and dos and don’ts demonstration help to
educate employee to reduce unsafe wrong habits while material handling
and reduce chances of injury.

4. RESPONSIBILITIES:

4.1. The business Site head or his designee is responsible:

a) To ensure implementation of this procedure at site level
b) To allocate and provide required resources to implement procedure.
c) To designate element owner to function on his behalf as per section 4.4
d) To ensure that the annual review are completed at the site for this
procedure and require changes are incorporated in procedure to increase
the effectiveness of hearing conservation program.

4.2. The Managers / Head of Department are Responsible:

a) To maintain list of task involving manual material handling and carry out
risk assessment.
b) To identify and train all required employee for safe material handling
methods.
c) Prioritize and Implement Manual handling risk management methods
based on the risk rating of the task.

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4.3. The site Safety Head is responsible:

a) To assist Site Head in Implementation of this procedure.

b) Verify and audit the procedure implementation and record keeping
requirement annually using program evaluation scorecard. Annexure -1 of
procedure OHS-20-program evaluation element.
c) Review and suggest the improvement required in procedure based on the
observation record and other data.

4.4. Respective OHS frame work Element/Component owner is responsible:

a) To follow up with respective person responsible for implementation of the

respective procedure step of this procedure.
b) Maintain the record of information received for implementation and
compile the information for site.
c) To carry out quarterly self-assessment of the Element/Component using
Annexure -1 program evaluation score card of OHS-20 Program evaluation
procedure.
d) Coordinate and Prepare action plan to implement this procedure.
e) Report the action plan, resource requirement and status of this procedure
to the Site Head.
f) Maintain Annexure –A and review and update as and when changes in
information occur, or at the minimum once in a year.
g) Keep record of site specific improvement, arrangements, deviations and
exclusions done to implement this procedure in Annexure-A.
h) Send information to Group Safety related to best practice and major
deviation recorded in Annexure-A annually or when required for annual
review.

5. TRAINING:

Refer training procedure OHS -05 for training matrix for training need and available
training topics.

For employee engaged in Routine manual handling shall undergo the training
course:

Manual Material Handling: AG-OHS-T-059

6. AUDITING:

This procedure, program shall be reviewed annually. The review shall be

documented shall reflect changes/updates based on audit findings, gaps, trends,
regulatory changes etc.

7. ATTACHMENTS & FORMS:

Annexure -A : Site specific Arrangements for Manual Material Handling

Annexure -1 : Manual Material Handling task listing and risk evaluation.

Appendix -1 : Manual Material Handling Method guide

Appendix-2 : RWL-Ergonomic Equation for Push, Pull, Carry

8. CROSS REFERENCES:

OHS-05 : Induction and Training site training Matrix.

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OHS-02A : Hazard Reporting

OHS-20 : Program Evaluation

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Annexure-A

Site specific Arrangements for Manual Material Handling

(To be filled in, updated once in a year by Element Owner, and kept along with
procedure)

Part-A

Name of Business Site &

1
Location:

2 Name of Site Head:

Name of Site Safety Head /

3
Representative:
Name of OHS Element /
4
Component Owner:
Manual Material Handling List
5 updated on Date: ____/____/________

6. List of Manual Material Handling Task considered for Risk reduction:

Sr.
Name of the Task Risk Reduction action agreed and Initiated
No

Part-B
Site Specific improvement
A record (describe)
Site Specific Changes-
B Deviation, Exclusion record
(describe)

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Annexure-1

Manual Material Handling task Listing and Risk Evaluation

Annexure-1 Manual
Material Handling Task Listing and Risk Evaluation..xlsx

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Manual Material Handling
Appendix -1
Manual Material Handling Method guide
1. Plan ahead before lifting.
Know what you're doing and where you're
going to help prevent you from making
awkward movements or turning awkwardly
while holding heavy object. Clear a path, and
if lifting something with another person, make
sure both of you agree on the plan.
3. Bend at the Knees:
Squat down bending at the knees (not your
waist). Tuck your chin while keeping your
back as vertical as possible.
5. Lift with Your Legs:
Begin slowly lifting with your LEGS by
straightening them. Never twist your body
during this step. Keeping back straight.
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OHS-16-A/ R-0
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2. Stand Close to the Load:
Stand close to the load with your feet spread
apart about shoulder width. Place one foot
slightly in front of the other for balance.
4. Control the Load:
Get a firm grasp of the object before
beginning the lift.
6. Keep Load Close to Body:
Once the lift is complete, keep the object as
close to the body as possible. As the load's
center of gravity moves away from the body,
there is a dramatic increase in stress to the
lumbar region of the back.
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Appendix-2
RWL-Ergonomics Equations for–Push- Pull- Carry

RWL Ergo
Equations_push_pull-carry.xlsx

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