2006 RiskAnalytics, LLC Page 1 Manual Material Handling Ergonomics Training Program 2006 RiskAnalytics, LLC

2006 RiskAnalytics, LLC Page 1

Manual Material Handling Ergonomics Training Program

2006 RiskAnalytics, LLC

2006 RiskAnalytics, LLC

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.

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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


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


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


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


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


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 necessary to cover Total Costs are: $445,875

MSDs Injury: Carpal Tunnel Syndrome




The net profit margin 4%


MSDs Injury: Cumulative Trauma




The net profit margin 4%


The total additional revenue required to cover the costs of these 3 incidents is estimated to be $1,793,775

The total additional revenue required to cover the costs of these 3 incidents is estimated to be $1,793,775


The Worker

The EnvironmentThe Job

Ergonomic Risk Factor Interaction


Ergonomic Risk Factors – PhysicalAwkward Postures

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


Ergonomic Risk Factors – Physical 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


Ergonomic Risk Factors – Physical 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


Ergonomic Risk Factors – Physical Contact Stresses

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


Ergonomic Risk Factors – PhysicalVibration

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


In control

Out of control!

Ergonomic Risk Factors - PsychologicalPositive Stress vs. Distress


Ergonomic Risk Factors - Tasks

Lifting/Lowering Pushing/Pulling

Sitting

Twisting

Carrying Holding


Resting Dynamic Effort Static Effort

Blood Need Blood Flow Blood Need Blood Flow Blood Need Blood Flow

Static vs. Dynamic Muscular Effort Blood Needed vs. Blood Flow


Spinal Anatomy 101 The spine’s 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 body’s weight


Spinal Anatomy 101 - Intervertebral DiscsThe 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.


Physical Stress on Skeletal System Forces Involved:

5 pounds?10 pounds?15 pounds?

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?

10 Lbs

?



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

?



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



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.

105 Lbs

1150 Lbs

10 Lbs



If you were 25 pounds overweight, it would put an additional 250 pounds of pressure on your back every time you bent over.

130 Lbs

1400 Lbs

10 Lbs


Common Causes of Musculoskeletal InjuriesHeavy 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


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 won’t 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


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 - Don’t twist your back Lower the load slowly, maintaining the curve in your lower

back

Preventing Injuries

Use proper lifting procedure


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

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 your hands 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 something

over your head


Preventing Injuries

Body Management Stretch early and stretch often Slow down; don’t overdue it Take frequent micro breaks Sleep on a firm mattress Get in shape and stay in shape with regular exercise


Controlling Ergonomic Risk FactorsRecommendations 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


Hazard Control StrategiesTwo 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


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 and

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


Hazard Control StrategiesAdministrative 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


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


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

Documents

2006 RiskAnalytics, LLC Page 1 Manual Material Handling Ergonomics Training Program 2006 RiskAnalytics, LLC