14 Manual Material Handling - storage.googleapis.com · Manual Material Handling 14 Manual Material Handling 14.1 Policy Statement Tim Foster — dba MPC (Maintenance Projects & Construction)

Manual Material Handling

14 Manual Material Handling

14.1 Policy Statement

Tim Foster — dba MPC (Maintenance Projects & Construction) is committed to creating a safe

and healthy work environment.

Lifting, lowering, pushing, pulling and carrying objects by hand can result in adverse health effects ranging from cuts and sore muscles to long-term back pain and serious disability. To

prevent workplace injuries associated with material handling, Tim Foster — dba MPC

(Maintenance Projects & Construction) will implement, as part of its comprehensive Injury and

Illness Prevention Program, a manual material handling safety program to systematically

identify and control hazards in the workplace associated with these kinds of activities.

14.2 Responsibilities

Manual material handling safety is a cooperative effort between Tim Foster — dba MPC

(Maintenance Projects & Construction) and its employees.

14.2.1 Employer Responsibilities

It is the responsibility of Tim Foster— dba MPC (Maintenance Projects & Construction) to:

• Ensure periodic hazard analysis of work areas including lifting hazards;

• Correct identified safety hazards with appropriate engineering and administrative

controls;

• Provide manual material handling and back safety training for personnel;

• Review safe lifting procedures as necessary;

• Ensure all material handling equipment is kept in good repair; and

• Ensure all authorized or qualified personnel have received sufficient training to operate any material handling equipment safely.

14.2.2 Safety Committee Responsibilities

It is the responsibility of the Tim Foster — dba MPC (Maintenance Projects & Construction) safety committee to:

• Assist in identifying hazards associated with manual material handling;

• Assist in providing manual material handling training for personnel;

• Assist in training personnel in the safe operation of material handling equipment; and

• Review safe material handling procedures yearly or as necessary to ensure the safety

and health of personnel.

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14.2.3 Employee Responsibilities

Tim Foster— dba MPC (Maintenance Projects & Construction) employees are expected to:

• Be aware of material handling hazards where they work;

• Follow company safety policy and the instructions of their supervisor;

• Comply with safe operating procedures when lifting, lowering, pushing, pulling and

carrying objects in the workplace;

• Attend and participate in appropriate safety training; and

• Report safety concerns and provide safety recommendations as appropriate.

14.3 Training

Tim Foster — dba MPC (Maintenance Projects & Construction) will train every employee

expected to manually lift or move materials on safe manual material handling and lifting at no

cost to the employee during working hours.

Tim Foster— dba MPC (Maintenance Projects & Construction) will use only training material that

is appropriate in content and vocabulary to educational level, literacy, and language of

employees.

14.3.1 Training Components

Tim Foster will train every employee in the following minimum elements to prevent accidents

and injuries:

• Risk factors associated with manual material handling;

• How to use material handling equipment present in the workplace;

• Housekeeping and staging for material handling safety;

• Safe lifting practices and the benefits of avoiding lifts when possible;

• Lack of evidence to support using back belts as personal protective equipment;

• Stretching, strengthening and the benefits of a healthy lifestyle; and

• How to report an injury.

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14.3.2 Training Records

Training records will include the following information:

• The dates of the training sessions;

• The contents or a summary of the training sessions;

• The names and qualifications of persons conducting the training; and

• The names and job titles of all persons attending the training sessions.

Tim Foster — dba MPC (Maintenance Projects & Construction) will maintain training records for

3 years from the date on which the training occurred.

14.4 Policy

One of the leading causes of occupational injury is lifting heavy objects. Lifting presents two main hazards at once. First, there is the possibility a given lift will injure the lifter's body by

overexertion and strain. Second, a worker who frequently moves heavy objects through the workday faces the possibility of cumulative trauma injury from the stress.

Additionally, lifting and moving materials poses the threat of injury if a worker loses control of an

item, loses balance, or runs into things. Tim Foster — dba MPC (Maintenance Projects &

Construction) seeks to prevent all types of injuries through a combination of controls including

training, work process planning and equipment as appropriate to reduce risks presented by

manual material handling.

14.4.1 Planning

Preventing injuries as the result of manual material handling may require careful planning and

design, and will certainly require training for employees who frequently (or even infrequently)

must lift or carry objects. When performing job hazard assessments, it is vitally important to

consider musculoskeletal injuries and disorders as possible hazards.

Job Hazard Analysis

Every work task at Tim Foster — dba MPC (Maintenance Projects & Construction) that involves

lifting and manual material handling will undergo a job hazard analysis that will consider

workplace ergonomics and the risk of back injury.

In addition to warning signs presented by employees (e.g. expressions of fatigue, worker

implemented work task modification, absenteeism), a review of written records (e.g. OSHA's Log 300, worker recommendations, worker's compensation claims) will shed light on areas in

the work process where improvements to material handling safety can be implemented. Please

see the chapter on "Job Hazard Analysis" for more.

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14.4.2 Risk Factors

Manual material handling presents a number of workplace hazards. Controls will reflect the range of risk factors for a given lifting task, including personal risk factors, environmental risk factors and the nature of the task itself.

Personal Risk Factors

While lifting and carrying heavy objects and moving heavy material presents a hazard to any worker performing such work, certain worker characteristics may indicate a need for increased mindfulness and consideration of safe manual material handling practices.

History of Back Injury

A history of back injuries may indicate an increased risk of similar injuries. Tim Foster — dba MPC (Maintenance Projects & Construction) expects employees who have had injuries caused by or aggravated by manual material handling and those concerned about reinjuring any body part to bring their concerns to a supervisor and to work with the safety committee and Tim Foster to identify safe work processes and hazard controls to prevent future injuries.

Fitness and Health

Safe manual material handling is a work task made easier by increased personal fitness.

Cardiovascular health, strength and endurance all play a part in reducing physical injuries because of overexertion, strain and cumulative trauma. Additionally, the weight of the lifter

contributes to the muscular exertion required for any given lift.

On the other hand, personal fitness activities and second jobs that demand exertion of the same

muscles and muscles groups as those used regularly at work may reduce opportunities for sufficient rest. Employees are encouraged to balance the physical demands at work with those outside the work environment. Tim Foster — dba MPC (Maintenance Projects & Construction) encourages all employees to identify healthy recreational activities that match their lifestyle and contribute to their overall health and well-being.

Other Factors

There is a range of physical attributes that may affect the likelihood of injuries because of

manual material handling. It is important to recognize that there is a relationship between

physical capacity to perform manual material handling activities and worker characteristics such

as body shape, age or pregnancy of a worker. The physical limitations of every worker must be considered in assigning duties, implementing changes to work processes, selecting equipment and designing the work environment; however, Tim Foster— dba MPC (Maintenance Projects &

Construction) forbids discrimination based on gender, age or similar classifications.

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Figure 1 — Awkward Postures

Environmental Risk Factors

In addition to the personal risk factors related to manual material handling injuries, aspects of the work environment can affect the risk of back injury as well.

Confined & Restrictive Spaces Performing material handling, lifting or any physical activity in a confined space can contribute to musculoskeletal injuries and disorders by requiring workers to constrain their posture and movement in ways that is not ergonomically ideal. Reaching, twisting, and awkward joint angles all contribute to musculoskeletal trauma. Work areas must allow as much freedom of movement as possible.

Certain confined spaces (permit spaces) may legally require special consideration. If the workspace has one or more of the following characteristics, it is a "permit-required confined space" and will conform to permit space regulations as outlined in 29 CFR 1910.146:

• Contains or has a potential to contain a hazardous atmosphere;

• Contains a material that has the potential for engulfing an entrant;

• Has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly converging walls or by a floor which slopes downward and tapers to a smaller cross-section; or

• Contains any other recognized serious safety or health hazard.

Temperature and Weather Extreme temperatures can cause problems for employees. Cold temperatures make the muscles less flexible, resulting in muscle strain and pulls. Hot temperatures lead to dehydration and muscle fatigue.

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In addition to temperature, work done in locations exposed to wind, precipitation and ice can contribute to manual material handling risks. Slipping hazards, reduced traction and slippery grips can lead to injuries and require measures to ensure safety.

Extended Standing

Standing for extended periods can place excessive stress on the back and legs. Solutions

include a footrest or rail, resilient floor mats, height-adjustable chairs or stools, and opportunities for the employee to change position.

Flooring

Hard flooring contributes to discomfort and fatigue for employees who must stand for an extended time. Additionally, sufficient friction between the floor and the feet is an important

element in safe lifting. Tim Foster — dba MPC (Maintenance Projects & Construction) will consider traction when selecting floor coverings. All workers are required to wear work-appropriate shoes.

Other Risk Factors

While personal factors and environmental factors are related to the safety of manual material

handling activities, certain hazards present themselves during MMH and employees should guard against them whenever possible.

According to the National Institute of Occupational Safety and Health, the maximum weight to be lifted by one person with two hands, under ideal conditions, is 51 pounds. However, a number of factors reduce the maximum weight an employee should lift. For a more precise

accounting of acceptable lifting limits, consult the Revised NIOSH Lifting Equation (1994).

Awkward Postures

When various parts of the body are moved out of straight or neutral position during work, not

only do tasks require more exertion and muscle force to perform, but also pressure on connective tissue, nerves and blood vessels can contribute to acute and cumulative trauma injuries. See Figure 1.

The following are examples of awkward postures:

• Elbows pulled away from the torso such as performing overhead work or reaching in front, to the side, or behind the body;

• Elbows past about 90 degrees for prolonged periods of time;

• Torso bent or twisted to lift an object from low or distant locations;

• Wrist extended, flexed, or bent to the side while using tools or performing connection

tasks;

• Neck bent backward or forward for prolonged periods while working overhead or on low surfaces; and

• Knee or ankle bent to work in a squatting or kneeling position.

Employees should keep the distance between a load and the body as small as possible without compromising an effective grip or forcing an awkward posture. Loads carried further from the

spine are more likely to injure the lifter.


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Best Work Zone

•

Preferred Work Zone


Twisting and Bending the Back

Twisting the torso stretches some sets of muscles while compressing others. This forces smaller, isolated groups of muscles to provide the needed force for the task. Twisting the spine creates non-

symmetrical forces on the back, which can lead to serious injury during lifting.

Supporting a load with the torso bent forward increases both muscle force that must be exerted and compressive force on the spine. Significant force exertion combined with the structural instability

created from twisting increases the opportunity for injury.

Forceful Exertion

Lifting or moving a lot of weight, and speedy or jerky motions demand the application of greater force during movement. Greater

force requires greater exertion and may place undue demands on the musculoskeletal health of workers. Workers should be aware of

the nature of the forces their bodies exert. Employees should handle loads of an appropriate weight and size, and when possible, design

of work processes should discourage exertion.

Further, improperly working equipment such as carts with broken wheels or under-inflated tires, and rough surfaces such as stairs or

bumpy terrain can subject an employee to unnecessary strain.

Equipment maintenance, ramps and appropriate training can help

prevent injury.

The distance between the load and the floor will ideally place the load Figure 2 — Power Zone

between the lifter's knee and shoulders. Appropriate material staging, material handling

equipment and correctly placed handholds can help keep the load within the lifter's "power

zone." See figure 2.

The distance an employee carries a load contributes to the risk. Appropriate staging and

material handling equipment can help transport the load over a distance without requiring excessive effort by workers. Employees should never throw a load or catch a load mid-air.

High Frequency and Long Duration Repetition

When employees hold items for a long period, even if they are light, there is an increased risk for injury from metabolic demands on muscles and continued pressure on connective tissue,

nerves and blood vessels. Further, repeated exertion with insufficient opportunity for

recuperation can lead to musculoskeletal injuries.

Inadequate Handholds

Handholds or handles allow the worker to keep a load close to his or her body, lower the height

of the load and decrease risk of contact stress. They also help ensure a firm grip and help keep

the handler from dropping the load accidentally.

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Figure 3 — Power Grip

Manual Material Handling mm.lw

Handholds should be large enough to accommodate all hands and

should not dig into any part of the hand. Equip loads with suitable top mounted handles if they are to be carried to the side of the body.

14.4.3 Controls

As with any workplace hazard, hazards that emerge from manual

material handling tasks will be subject to a system of controls to encourage safe work practices and prevent injury or illness.

Workplace Design

Workplace design is a vital component of any system of safety

controls. To prevent musculoskeletal injuries and other injuries

associated with manual material handling, special attention needs to be given to receiving

areas, warehouses, stockrooms, closets, other storage areas, and the paths by which material

is conveyed.

Movement of material should flow in one direction as much as possible. Gravity-fed conveyors,

flow racks and similar equipment typically reduce the amount of work that would otherwise have

to be manually performed. The proper use of chutes, conveyers, carrousels and similar

elements decrease material handling hazards.

Staging & Housekeeping

Keep materials off the floor to permit safe movement. Storing heavy materials between shoulder

and knee height reduces strain and effort. Position, package and store materials heavy or bulky

enough to require a team lift in such a way to discourage one-person lifting. Save high shelves for the lightest and least frequently needed material. Staging material close to its final

destination reduces walking distances.

Load Control

One way to reduce risks associated with manual material handling is to reduce the demands

presented by the load itself. Smaller packaging is generally better than larger packaging

because it makes it easier for a worker to keep the load close to the body through the entire lift

and presents less obstruction while carried. On the other hand, while small loads can be as

heavy as large loads, if loads are too light, workers may feel encouraged to carry more than one at a time, increasing risk of injury. Further, packaging heavy items in containers that are too big

to be lifted by one person can encourage the lifter to seek mechanical assistance or assistance from a coworker rather than attempting a hazardous lift on his or her own. Package loads to

prevent shifting or spilling during movement.

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Figure 4 — Safer Lifting

Smart Lifting Practices

While there is no hard and fast safe lifting rule for every object that may be lifted, there are a few principles that may help a person lift and carry more safely. Tim Foster — dba MPC

(Maintenance Projects & Construction) expects every employee to lift and carry material using the following safe lifting procedures:

Plan • The best first step for a lift is to ascertain the object's weight and weight distribution by

testing it with a nudge or a shove. This is especially important for loads with which the lifter is not familiar that do not have the weight printed on the package.

• If the lift will require assistance, select a mechanical device for a safe lift or find a coworker to help. Avoid lifting from the floor if possible. For a team lift, communication is important to ensure coordinated effort. Slide, push or roll the load rather than lifting it when possible and appropriate.

• Track the entire anticipated path of the load from the origin to the place the load will be set down. There must be an absence of hazards along the object's entire path and plenty of space for the object at the destination.

Position

• The lifter must be close to the load with a stable stance and the center of gravity of the load as close to the lifter's spine as possible. This is especially important if the load is unbalanced.

• Use handholds or handles if available. Every load should be grasped with a two-handed "power grip" when possible. See Figure 3.

Pick Up

• Move the load upward with a fluid, natural motion, close to the body through the whole lift. The muscles of the torso should be engaged to stabilize the spine, but the legs and buttocks should do most of the lifting work. Feet should move only to keep the load in line with a straight torso as close to neutral position as possible and to maintain stability through the lift.

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• The load should remain within the "power zone" through the entire lift and while carried if

possible. Distance from the torso increases the load on the back, shoulders and arms

and with it, increases the risk of injury. See Figure 4.

Proceed

• Avoid twisting, bending and reaching while carrying a load. To change direction while

moving with a load, the lifter should lead with a step toward the new direction and pivot

or walk through the turn rather than twisting at the waist.

Put down

• When returning a load to rest, lower it in reverse of how it was lifted. Do not drop, shove or jerk a load when releasing it.

Material Handling Equipment

Selection of material handling equipment relies on the nature of the task. There are many

available assistive technologies, including cranes and hoists for lifting, lowering and

transporting; manipulators for picking and orienting; and work positioners and lift tables for

lifting, lowering and rotating objects. Carts, dollies and trucks help transport loads. Equipment

such as conveyors, totes, flow racks and ball transfers also can reduce physical demands

associated with manual handling tasks. Often combining handling devices to work as a system

provides the best solution to material handling problems. Tim Foster – dba MPC (Maintenance Projects & Construction) will keep material handling equipment in good repair and ensure

employees use it according to the manufacturer's instructions.

The NIOSH recommends the following when selecting and using equipment for use during manual material handling tasks:

• Know your load and buy equipment of appropriate capacity. Remember, lighter-weight

equipment is easier to move.

• Choose equipment appropriate for the material(s) being handled, the layout and design

of your workplace, and the work tasks being performed.

• Consider using powered equipment — rather than non-powered — when pushing and pulling forces are excessive.

• If available, select equipment with vertical handles so workers' hands can be in their

power zone.


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• Choose wheeled equipment that minimizes start forces (inertia) and reduces rolling resistance. The amount of force required to move loads with wheeled equipment depends on a number of factors including the:

o Weight and shape of the load

o Type and condition of the floor surface (e.g., smoothness, density, and other factors)

o Route taken (e.g., slopes, obstacles, and other factors)

o Type of wheels (i.e., the materials they are made of)

o Size of wheels (larger wheels a minimum of 6 inches in diameter move more easily over holes, bumps, and floor irregularities)

o Maintenance of wheels; it is important to clean, lubricate, and/or replace wheels on a regular basis.

• Ground all electrically operated equipment

• Make sure equipment alarms and warning devices are audible and working properly.

• Inspect and maintain equipment according to manufacturers' recommendations.

• Follow all manufacturers' recommendations for proper equipment use.

Gloves Gloves are important to protect the hands from cold, cuts, punctures and possible chemical

agents. Gloves with padded palms and fingers can also protect against contact stress from tools and work surfaces. However, a glove that is too small restricts the hand from opening and may require increased finger force. At the same time, the bulkiness of a glove that is too large can restrict closing of the hand.

It is important to recognize that some gloves can significantly reduce grip and demand more, rather than less, exertion during manual material handling tasks.

Back Belts According to the National Institute for Occupational Safety and Health, there are no definitive

studies to make authoritative, reliable claims on the beneficial or harmful effects of wearing back

belts. The NIOSH does not recommend the use of back belts to prevent injuries among

uninjured workers, but ultimately the use of such devices is a personal choice. Tim Foster — dba MPC (Maintenance Projects & Construction) neither encourages nor discourages the use of back belts, but reminds workers who choose to use a back belt to avoid overconfidence in lifting and always practice safe lifting practices.

Carts, Dollies and Hand Trucks

There are many designs and intended uses for wheeled means of material conveyance. Pallet

jacks, dollies, carts and hand trucks reduce risk when used correctly by permitting workers to move loads over greater distances with less exertion. Such equipment should have handles

positioned around hip height and a low center of gravity to prevent tipping over. Motorized hand

trucks and pallet trucks provide additional power, but may require more training and may

present their own share of hazards.

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Manual Material flandling

Lift Assist Devices and Other Equipment

Scissor lifts, hoists, stackers, tilters and lifters can provide help to lift items. The material handling needs of Tim Foster — dba MPC (Maintenance Projects & Construction) will determine

selection of such equipment.

Conveyers, ball-transfers, chutes and carousels can all be used alone, in conjunction with one

another or in conjunction with devices to roll or lift loads.

Administrative Controls

As with any system designed to reduce safety risks, engineering solutions are always preferred

to prevent injuries. Nevertheless, administrative approaches can complement engineering

solutions to reduce injuries from material handling.

Administrative improvements include changing work practices or the way work is organized.

Administrative improvements require continual monitoring by management and employee

feedback to make sure the improvements are effective.

The purpose of administrative controls is to limit the duration of personal exposure to the risk factors associated with manual material handling tasks. Administrative controls can take many forms, among them are:

• Job rotation (rotating the exposed population into less physically demanding jobs or jobs that do not tax the same muscle groups as the job of concern);

• Job enlargement or enrichment (providing added task variety, adding less taxing aspects

to the job and sharing tasks among several muscle groups);

• Increasing the number of people performing the job (thereby spreading the exposure to a wider population, but reducing individual exposure duration);

• Training in safe handling techniques; and

• Worker selection and placement.

Training Education and training need to be central complements to any ergonomic safety and back

health program. Such training can encourage workers to participate more actively in protecting

themselves against harm and identifying opportunities to create a safer work environment.

Training will be specific to the employee's work and to the hazards present.

Additionally, managers and supervisors will be trained to recognize symptoms of injuries associated with material handling and to encourage employees to come forward if injured on the

job. Early reporting of pain helps minimize the impact of back injuries.

Training also will include information on back anatomy, ways to improve body mechanics for

materials handling and general work tasks, the safe and effective use of MMH devices found in the workplace, and ways to increase back muscle strength.

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Stretching and Strengthening

Strength and endurance reduce the risk of musculoskeletal injury and are likely to shorten recovery in the event of an injury. Regular exercise, several times a week, develops and

maintains strong, flexible muscles. While Tim Foster — dba MPC (Maintenance Projects &

Construction) cannot require healthier lifestyles for employees, training and education coupled

with incentive programs and worker-led fitness activities can all contribute to a workplace culture that values the overall health of employees.

Employees are encouraged to warm up before any physically demanding activity. Stretches that target the muscle groups involved in the activity prepare the muscles by warming the muscles and increasing blood flow.

14.4.4 Program Review

As with any other aspect of Tim Foster — dba MPC (Maintenance Projects & Construction)'s

comprehensive safety and health management program, the safety committee will review all

aspects of the lifting and manual material handling policy yearly, or more frequently, especially in the event of an incident such as an injury or the addition of new tasks or work procedures.

14.5 Forms and Attachments

On the following pages, please find the following document:

• Lifting and Manual Material Handling Training Record Sheet

This form may be reproduced freely by Tim Foster — dba MPC (Maintenance Projects &

Construction) for the purposes of implementing and maintaining an injury and illness prevention

program.

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Lifting and Manual Material Handling Training Record Sheet

Trainer (include qualifications):

Date:

Content of Training:

Attendees

Print Name

Signature

(Retain at least 3 years)

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14 Manual Material Handling - storage.googleapis.com · Manual Material Handling 14 Manual Material Handling 14.1 Policy Statement Tim Foster — dba MPC (Maintenance Projects & Construction)