Manual Material Handling Ergonomics Safety Training

Manual Material Handling
Ergonomics Training Program

2006 RiskAnalytics, LLC
2006 RiskAnalytics,
LLC
Page
1
Disclaimer
The information, suggestions and recommendations contained herein are for
general informational purposes only. This information has been compiled from
sources believed to be reliable. No warranty, guarantee, or representation,
either expressed or implied, is made as to the correctness or sufficiency of
any representation contained herein. Reliance upon, or compliance with, any
of the information, suggestions or recommendations contained herein in no
way guarantees the fulfillment of your obligations under your insurance policy
or as may otherwise be required by any governmental, national, federal, state,
or local laws, rules or regulations. This Information should not be construed as
business, risk management or legal advice, or legal opinion.
Page 2
Learning Objectives
Describe the concept and purpose

of ergonomics
Identify personal, job, and
environmental ergonomic risk
factors
Discuss ways to prevent
musculoskeletal disorders
Discuss the importance of
engineering and administrative
controls
Describe the steps in implementing
an effective ergonomics program
Page 3
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 mental

capabilities and limits of the worker and how they
interact with tools, equipment, work methods, tasks,
and the working environment
D = 24 in
48 lbs
V = 8 in
H = 20 in
Page 4
Ergonomics Program Goals
Goal: Reduce work-related

musculoskeletal disorders
(MSDs) by adapting the work to
fit the person, instead of forcing
the person to adapt to the work
Principle: Human
characteristics should be
considered at the beginning of
the design process
Page 5
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 and
stress fractures
Symptoms are discomfort, pain, fatigue, swelling, stiffness or
numbness, and tingling
Page 6
Why is effective ergonomics so important?
Back injuries are the leading cause of disability

In 2007, occupational musculoskeletal disorders
comprise 28.9% of all nonfatal injuries and illnesses
involving days away from work.
In 2009, there were 195,150 back and spinal cord
nonfatal injuries involving days away from work.
Musculoskeletal disorders accounted for 29% of all
workplace injuries in 2007
Page 7
The Economics of Ergonomics

MSDs 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

The ADDITIONAL sales necessary
to cover Total Costs are:
4%
$445,875
MSDs Injury: Carpal Tunnel Syndrome
$ 8,305
$16,610
$24,915
The net profit margin

4%
$622,875
The total additional

revenue required to
cover the costs of
these 3 incidents is
estimated to be
$1,793,775
MSDs Injury: Cumulative Trauma

$ 9,667
$19,334
$29,001
The net profit margin

4%
$725,025
Page 8
Ergonomic Risk Factor Interaction
The Worker
The Job
The Environment
Page 9
Ergonomic Risk Factors Physical

Awkward Postures
Body postures determine which joints and muscles are
used in an activity and the amount of force or stresses
generated or tolerated.
Page 10

Forceful Exertions
Tasks requiring forceful exertions place higher loads on
the 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 or
recovery
Page 11

Repetitive Motions
Fatigue and muscle-tendon strain can accumulate
if 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 of
time
Page 12

Contact Stresses
Repeated or continuous contact with hard or sharp objects
such as non-rounded desk edges or unpadded, narrow
tool handles
Page 13

Vibration
Exposure to local vibration occurs when a specific
part of the body comes in contact with a vibrating
object, such as a power hand tool
Page 14
Ergonomic Risk Factors - Psychological

Positive Stress vs. Distress
In control
Out of control!
Page 15
Ergonomic Risk Factors - Tasks
Lifting/Lowering
Carrying
Pushing/Pulling
Holding
Twisting
Sitting
Page 16
Static vs. Dynamic Muscular Effort

Blood Needed vs. Blood Flow
Blood Need
Blood Flow
Resting
Blood Need
Blood Flow
Dynamic Effort
Blood Need
Blood Flow
Static Effort
Page 17
Spinal Anatomy 101
The spines vertebrae are held together by

ligaments
Muscles are attached to the vertebrae by bands

of tissue called tendons
Between each vertebra is a cushion known as a

disc
Openings in each vertebra line up to form a long,

hollow canal
The spinal cord runs through this canal from the

base of the brain
Nerves from the spinal cord branch out and

leave the spine through spaces between the
vertebra
The lower part of the back holds most of the

bodys weight
Page 18
Spinal Anatomy 101 - Intervertebral Discs

The vertebrae are separated by Intervertebral discs which act as
cushions between the bones.
Each disc is made up of two parts - the hard, tough outer layer called
the Annulus surrounds a mushy, moist center termed the Nucleus.
Page 19
Physical Stress on Skeletal System

Forces Involved:
Imagine your back as a lever. With the fulcrum in the
center of the lever, how many pounds would it take to lift a
10 pound object?
5 pounds?
10 pounds?
15 pounds?
10 Lbs
Page 20

Forces 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 pound
object with the fulcrum shifted away from the object?
?
10 Lbs
Page 21

Forces Involved:
With the fulcrum shifted away from the object, it takes
more force to lift the object.
The human back operates on a 10:1 lifting ratio, with the
waist acting as the fulcrum.
10 Lbs
Page 22

Forces Involved:
When you add in 105 pounds of the average human upper
torso, lifting a 10 pound object puts 1,150 pounds of
pressure on the human back.
1150 Lbs
105 Lbs
10 Lbs
Page 23

Forces Involved:
If you were 25 pounds overweight, it would put an
additional 250 pounds of pressure on your back every time
you bent over.
1400 Lbs
130 Lbs
10 Lbs
Page 24
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 position

sitting can be very hard on the lower back
Slips, trips and falls

Page 25
Preventing Injuries
Avoid lifting and bending whenever you can
If you must lift, the best zone for lifting is between your
shoulders and your waist
Place objects up off the floor so you wont have to reach

down 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's
too heavy for you
Make sure you have enough room to lift safely
Look around before you lift and know where you are going
to put down the load
Avoid walking on slippery and uneven surfaces while
carrying something
Page 26
Preventing Injuries
Use proper lifting procedure
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 lower
back
Page 27
Preventing Injuries
More Lifting Tips
Transferring weight
Lifting heavy bags
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
Put one knee down against bag
Pull bag up leg
Rest bag on edge of knee
Stand upright
Pull bag to waist height
Page 28
Preventing Injuries
Lifting Safety Checklist
Have you checked the object before you try to lift it?
Is the load you want to lift packed right?
Have a tight grip on the object
Is it easy to reach this load?
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?
Test every load before you lift by pushing the object lightly with your
hands to see how easily it moves
Remember, a small size does not always mean a light 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 something
over your head
Page 29
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
Page 30
Controlling Ergonomic Risk Factors

Recommendations for controlling risk factors include:
Ask employees in the problem job for

recommendations
Identify, assess and implement feasible controls
Track your progress
Identify and evaluate musculoskeletal hazards
Page 31
Hazard Control Strategies

Two Types:
Engineering controls - Eliminates/reduces hazards

existing through equipment redesign, replacement,
and/or substitution
Administrative controls - Reduce exposure to the
hazard by controlling behaviors through design of work
procedures, schedules, use of personal protective
equipment
Page 32

Engineering 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 and
materials are to be manipulated
Changing tool designs
Changes in materials and fasteners
Changing assembly access and sequence
Page 33

Administrative Controls
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 operational
process
Rescheduling work for cooler times of day
Reducing shift length or curtailing the amount of
overtime
Rotating workers through jobs with different physical
demands to reduce the stress on limbs and body
regions
Scheduling more breaks
Page 34
Implementing Control Strategies

Effective 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
ACT
STUDY
Page 35
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 specific

tasks and with the person
Job related risk factors include awkward posture, forceful

exertions, repetitive motions, and contact stress
Psychological risk factors include lack of time, unreasonable

workload and poor working relationships
Proper lifting technique includes planning the move, using a

wide, balanced stance, getting as close to the load as
possible and moving your feet versus twisting the torso
Ergonomic hazard control strategies include engineering

controls, administrative controls and personal protective
equipment
Page 36

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Manual Material Handling Ergonomics Safety Training

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Formati disponibili

Manual Material Handling

Ergonomics Training Program

2006 RiskAnalytics, LLC

2006 RiskAnalytics, LLC

Describe the concept and purpose

The word Ergonomics comes from the Greek words

Ergonomics is an interdisciplinary approach toward

Ergonomics considers the physical and mental

2006 RiskAnalytics, LLC

Ergonomics Program Goals

2006 RiskAnalytics, LLC

Goal: Reduce work-related

What are Musculoskeletal Disorders (MSDs)?

2006 RiskAnalytics, LLC

Illnesses and injuries affecting one or more parts of the

Why is effective ergonomics so important?

2006 RiskAnalytics, LLC

Back injuries are the leading cause of disability

The Economics of Ergonomics

Average Indirect Cost:

Estimated Total Cost:

Net profit margin for this company is

MSDs Injury: Carpal Tunnel Syndrome

Average Direct Cost:

Average Indirect Cost:

Estimated Total Cost:

The net profit margin

The total additional

MSDs Injury: Cumulative Trauma

Average Indirect Cost:

Estimated Total Cost:

The net profit margin

Ergonomic Risk Factor Interaction

2006 RiskAnalytics, LLC

Ergonomic Risk Factors Physical

2006 RiskAnalytics, LLC

Ergonomic Risk Factors Physical

2006 RiskAnalytics, LLC

Ergonomic Risk Factors Physical

2006 RiskAnalytics, LLC

Duration - Duration refers to the amount of time a

Ergonomic Risk Factors Physical

2006 RiskAnalytics, LLC

Ergonomic Risk Factors Physical

2006 RiskAnalytics, LLC

Ergonomic Risk Factors - Psychological

2006 RiskAnalytics, LLC

Ergonomic Risk Factors - Tasks

Static vs. Dynamic Muscular Effort

2006 RiskAnalytics, LLC

Spinal Anatomy 101

2006 RiskAnalytics, LLC

The spines vertebrae are held together by

Muscles are attached to the vertebrae by bands

Between each vertebra is a cushion known as a

Openings in each vertebra line up to form a long,

The spinal cord runs through this canal from the

Nerves from the spinal cord branch out and

The lower part of the back holds most of the

Spinal Anatomy 101 - Intervertebral Discs

2006 RiskAnalytics, LLC

Physical Stress on Skeletal System

2006 RiskAnalytics, LLC

Physical Stress on Skeletal System