Ergonomics & Manual Handling

“Ergonomics & Manual Handling” is a 1-day training course specifically for those;

people responsible for performing manual handling activities and the personnel who manage or conduct workplace risk assessments required by the Health and Safety Regulations on Manual Handling Operations.

Ergonomics & Manual Handling

Introduction

The course includes a thorough description of the Manual Handling Operations and the Ergonomics principles that that should be applied to reduce the risk of manual handling injury..

Ergonomics & Manual Handling Introduction

This approach not only delivers legal compliance, but will help reduce body-related sickness and absenteeism, lower healthcare costs, insurance premiums and compensation claims and improve the productivity of the workforce.

After completing this course, participants will be able to; Identify potential causes of manual handling back

injuries Develop ergonomic solutions that can be applied

to reduce these injuries Encourage correct lifting postures, techniques and

principles that minimize injuries to workers Use ergonomics principles to re-design manual

handling tasks, work areas and work equipment Complete a manual handling checklist to prioritize

levels of risk


Skills and information Participants will learn.

This course is suitable for all participants including;


Who Should Attend

senior managers, administrative executives, engineers, facilities professionals, managers, health and safety professionals, line supervisors, technicians and line operators.

Key Elements of Course Outline


Introduction to Ergonomics

Anthropometry and Anatomy

Types and causes of injuries and illnesses Back/lower limb

Ergonomics principles applied to: Manual Handling

Work Movement procedures

Work area layout

Seated & Manual Handling workstation jobs

Standing & Manual Handling workstation jobs

The Manual Handling Operations Correct and Proper Handling & Lifting Techniques

The manual handling risk assessment procedure

Manual Handling Checklists Instruction and demonstration

Practical exercises

Risk prioritization process

Solution design

Introduction to Ergonomics & Manual Handling

If the workstations are too tall or too low people will not adapt, they will just be placed into tasks that will put them under additional stress.

Traditionally equipment was designed for the average worker which meant that it was too low for half of the population and too high for the other half.


Ergonomics is a term that comes from two Greek words “ergos” and “nomos” which could be literally translated as the study of work.

Ergonomics is not a new concept it has been around for decades… We often discuss ergonomics in terms of fitting the work to the worker.


Ergonomics

This is opposed to a previous concept were workers were expected to adapt to existing equipment and setup.


Ergonomics

Many people have studied the science of ergonomics and their results can provide us with information that we can use to design jobs and tasks that will better fit our workers.

If the design fits the worker better, it means that it is also designed to match their physical abilities better. This fact should make it

easier for the worker to perform their job.


Ergonomics

"Manual handling" means using your body to exert force to handle, support or restrain any object, and includes not only lifting and carrying but also repetitive tasks.

A manual handlingtask that has the potential to cause injury is a "hazardousmanual handling

task".



Manual Handling also involves any transporting or supporting of a load by one or more employees or moving a load,….

which by reason of its characteristics or unfavorable ergonomic conditions, involves risk, particularly of back injury, to employees.

If not carried out ergonomically, manual handling activities can lead to serious physical injury – to you and the person you are moving.

Risks of Hazardous Manual Handling Task

Musculoskeletal disorders (MSDs) are the most common injury caused by non-ergonomic manual handling practices.


Risks of Hazardous Manual Handling TaskLike back pain and upper and lower limb disorders, including aches, tenderness and stiffness in the legs, hips, shoulders, neck and joints.

The person being moved may also suffer from damage to fragile skin, cuts, grazes, bruises, and injuries to the neck, shoulders and arms if they are not handled with care.


Anthropometry and Anatomy

Anthropometry, or anthropometrics; is the study of human body measurements.

At its most basic, anthropometrics is used to help scientists and anthropologists understand physical variations among humans.


Anthropometry

In the modern era, anthropometrics have had more practical applications, particularly in the areas of genetic research and workplace ergonomics.

Anthropometrics are useful for a wide array of applications, providing a kind of baseline for human measurement.


The typical body measurements used in anthropometricsinclude height, weight, body mass index (or BMI),waist-to-hip ratio and body fat percentage.

By studying the differences in these measurements among humans, researchers can assess risk factors for a host of diseases.



ANTHROPOMETRICS IN ERGONOMIC DESIGNErgonomics is the study of people's efficiency in their working environment. So ergonomic design seeks to create the most efficient workplace while providing comfort for the people within it.

For the purposes of ergonomic design, anthropometrics offers information about the average human build to accommodate the largest set of the population based on an anthropometric range.



This gives chair makers data they can use to devise more comfortable seating, for example.

Desk manufacturers can build desks that don't force workers to hunch in uncomfortable positions, and keyboards can be designed to reduce the likelihood of repetitive stress injuries like carpal tunnel syndrome.

Anatomy

Anatomy; from the Greek anatomē "dissection” cut up, cut open“, is the scientific study of the structure of organisms including their systems, organs and tissues.

It includes the appearance and position of the various parts, the materials from which they are composed, their locations and their relationships with other parts.


Anatomy

Anatomy;The study of human or animal form, by observation or examination of the bodily structure of humans and other living things, especially as revealed by dissection and the separation of parts.


Anatomy

Physical ergonomics is concerned with human anatomy, and some of the anthropometric, physiological and bio mechanical characteristics as they relate to physical activity.

For example, an anatomist is concerned with the shape, size, position, structure, blood supply and innervations of an organ such as the liver.



For example, an anatomist is concerned with the shape, size, position, structure, blood supply and innervations of an organ such as the liver.

Physical ergonomicprinciples have been

widely used in the design of both consumer and industrial products.


Anatomy

Medical conditions are often related to other diseases and conditions.

These conditions may be a cause or symptom of Low Back Pain or be a condition for which you may be at increased risk.

Types and causes of injuries and illnesses

Back/lower limb pain

Back/lower limb pain or Sciatica?Back pain is extremely common. There are many causes of lower back pain that are not sciatica.

Frequently, low back pain is caused by back strain of muscles and ligaments.The characteristic feature of

sciatica is pain that radiates down the leg from the low back, often reaching the foot.


Back/lower limb pain (Sciatica)Sciatica is a pain that radiates from the low back down a lower extremity; it is caused by irritation of the sciatic nerve.

The sciatic nerve transmitssensation from the lower

extremities and lumbar area of the low back. It is common for people to recover from sciatica without a surgical operation.


Sciatica Symptoms; Low back pain that radiates to the hip, buttock, and down a lower extremity is the most common symptom of sciatica.

Sometimes sciatica pain worsens with bending at the waist, coughing, sitting, or sneezing. Sciatica can also cause tingling, numbness, or weakness of the leg. Sciatica symptoms can occur rapidly and persist for weeks.

Back/lower limb pain (Sciatica)


Sciatica is common as we reach middle age. Pregnancy can lead to sciatica as a result of direct pressure on the sciatic nerve by the enlarging uterus.

Other causes of sciatica are degenerative spinal arthritis and lumbar disk hernia.

Who Is Likely to Get Sciatica?


Is your Back/lower limb pain Sciatica?

Cause: Herniated Disk. Disk hernia is a common cause of sciatica. The disk cushions between the spinal vertebrae weaken and are more vulnerable to injury as we age.

The weakened disk can herniate its gel-like center to cause direct pressure on the nerves in the spinal canal that form the sciatic nerve.


Diagnosing Sciatica: To detect the cause of sciatica, the doctor will ask about all the symptoms you are experiencing and their location and aggravating or relieving features.

During the examination, you may be asked to do various maneuvers with the lower extremities

Is your Back/lower limb pain Sciatica?


Ergonomics principles applied to: Manual HandlingMINIMIZE SIGNIFICANT BODY MOTIONS

1. Reduce Bending Motions2. Reduce Twisting Motions 3. Reduce Reaching Out Motions

Work Movement procedures REDUCE OBJECT WEIGHTS/FORCES

1. Reduce Lifting and Lowering Forces

Work area layout2. Reduce Pushing and Pulling Forces‘

Seated & Manual Handling workstation jobs3. Reduce carrying forces

Standing & Manual Handling workstation jobs


•Using lift tables, work dispensers and similar mechanical aids. •Raising the work level to an appropriate height. •Raising or Lowering the worker. •Providing all material at work level.

Minimize Significant Body Motions1. Eliminate the need to bend by:

•Keeping materials at work level (e.g., don't lower anything to the floor that must be lifted later).

Ergonomics principals applied to Manual Handling

•Providing all materials and tools in front of the worker.•Using conveyors, chutes, slides, lifts or turntables to change direction of material flow. •Providing adjustable swivel chairs for seated workers. •Providing sufficient workspace for the whole body to turn. •Improving the layout of the work area.

Minimize Significant Body Motions2.Reduce Twisting Motions

Eliminate the need to twist by:


•Providing tools and machine controls close to the worker, to eliminate horizontal reaches over 16 inches. •Placing materials, workplaces and other heavy objects as close to the worker as possible. •Reducing the size of cartons or pallets being loaded, or allowing the worker to walk around them; rotate. raise or lower them.•Reducing the size of the object being handled. •Allowing the object to be kept close to the body (i.e. Scissor Lifts).

Minimize Significant Body Motions3. Reduce Reaching Out Motions Eliminate the need to reach by:


REDUCE OBJECT WEIGHTS/FORCES

Ergonomics principals applied to Work Movement Procedures

•Using lift tables, lift trucks, cranes, hoists, balancers, industrial manipulators, drum and barrel dumpers, elevating conveyors, and similar mechanical aids.

Reduce Lifting and Lowering Forces

A. Eliminate the need to lift or lower manually by:

•Raising the work level. Lowering the operator. Using gravity dumps and chutes.



Reduce Lifting and Lowering Forces

But if you really need to lift heavy object from the ground,

Reduce Lifting and Lowering ForcesB. Reduce the weight of the object by:

•Reducing the size of the object (specify size to suppliers).

•Reducing the capacity of the containers.

• Reducing the weight of the container itself.

•Reducing the load in the containers (administrative control).

•Reducing the number of objects lifted or lowered at one time (administrative controls).


Reduce Lifting and Lowering ForcesC. Increase the weight of the object so that it must

be handled mechanically:

•Use the unit load concept (such as bins or containers, preferably with fold down sides rather than smaller totes and boxes).

•Use palletized loads.


Reduce Lifting and Lowering ForcesD. Reduce the hand distance by:

•Changing the shape of the object. •Providing the grips or handles •Providing better access to object (i.e. scissor lifts, turntables or tilters).•Improving layout of work

area.


•Using powered conveyors. •Using powered trucks.•Using powered scissor

lifts or turntables.

Reduce Pushing and Pulling ForcesA. Eliminate the need to push or pull by:


•Reducing the weight of the load. •Using non-powered conveyors, air bearings, ball caster tables, monorails, and similar aids. •Providing good maintenance of floor surfaces, hand trucks, etc. •Treating surfaces to reduce friction. •Using powered scissor lifts.

Reduce Pushing and Pulling ForcesB. Reduce the required force by:

Ergonomics principals applied to Work Area Layout

•Improving layout of work area. •Relocating production or storage area

Reduce Pushing and Pulling ForcesC. Reduce the distance of push or pull by:

Ergonomics principals applied to Work Area Layout

•Use conveyors, air bearings, ball caster tables, monorails, slides, chutes and similar aids. •Use lift trucks, two wheel hand trucks, four wheel hand trucks, dollies and similar aids.

Reduce carrying forces A. Eliminate the need to carry by converting to pushing or pulling.

Ergonomics principals to Seated & Manual Handling Workstation job

•Reducing the size of the object (specify size to suppliers).•Reducing the capacity of containers. •Reducing the weight of the container itself. •Reducing the load in the container (administrative control).•Reducing the number of objects lifted or lowered at one time (administrative control).

Reduce carrying forces B. Reduce the weight of the object by:

Ergonomics principals to Seated & Manual Handling Workstation job

Standing is a natural human posture and by itself poses no particular health hazard. However, working in a standing position for long periods of time and on a regular basis can cause;

Ergonomics principals to Standing & Manual Handling Workstation job

sore feet, swelling of the legs, general muscular fatigue, lower back pain, stiffness in the neck and shoulders, all in a relatively short time.

For the best health and safety outcome, workers should be able to adopt a variety of positions - that is to have the option to sit, stand, move around and vary the nature of work tasks.


It is important for the worker to be able to equally distribute loads on different parts of the body, with no physical strain.

Variety of good posture at workstation.



Reduce the time spent standing or walkingObtain suitable, adjustable

chairsHave more rest breaksAlternate standing and walking

with sittingMake work surfaces height-

adjustable.

The following key advice from the TUC (Britain's peak union council) and the Canadian Centre for Occupational Health and Safety on Standing & Manual Handling Workstation job should be to:

Floor/standing surfaceWooden, cork or rubber-covered floors are far preferable to concrete. If the floor surface is hard, then provide mats for the workers to stand on.


Floor mats must be dense enough to cushion the feet, but not too thick ('anti-fatigue' matting is available). Too much cushioning, from thick foam-rubber mats, for example, can cause fatigue and increase the hazard of tripping.

Advice for proper Standing Workstation position:

Workers should always face what they are working on, with their body close to the work.Workspace should be adjusted for enough space to change working position.


Foot rail or portable footrest be provided to shift their body weight from both legs to one or the other leg.A seat whenever possible while working, or at least during rest breaks.

Comfortable Footwear:

The comfort of the legs, hips and back depends on the feet and Foot comfort depends largely on footwear.


Shoes need to be wide enough to leave room to move toes.

Shoes should have arch supports to prevent flattening of the feet, and a heel with a firm grip to prevent slipping.

The footwear should have heels that are not flat, but are no higher than 5 cm (2 inches).


Lace-up shoes are preferable, as they allow the worker to tighten the instep of the footwear, ensuring the foot does not slip inside the shoe or boot.If the worker is standing on a metal or cement floor, the foot should be cushioned with a shock-absorbing insole.

Comfortable Footwear:

The comfort of the legs, hips and back depends on the feet and Foot comfort depends largely on footwear.


Relief stress on a Pedestal StoolA pedestal stool is an adjustable seat, usually 65-85cm high, which is tilted forwards between 15 and 30 degrees. Pedestal stools are generally used

in the workplace to vary a standing work posture, when workers are required to stand for long periods. They allow the worker to adopt a semi-supported posture, to relieve the stress on the legs.

Do not use a pedestal stool for long periods of time, as it is only suited to relief stress on long standing activities.

The Manual Handling Operations


Correct and Proper Handling & Lifting Techniques



Squat down, bending at the hips and knees only. If needed, put one knee to the floor and your other knee in front of you, bent at a right angle (half kneeling).


Slowly lift by straightening your hips and knees (not your back).Keep your back straight, and don't twist as you lift.

Do not attempt to lift by bending forward.Never lift a heavy object above shoulder level.

http://www.webmd.com/pain-management/knee-pain/picture-of-the-knee

http://www.webmd.com/pain-management/knee-pain/rm-quiz-know-your-knees



Use your feet to change direction, taking small steps.Lead with your hips as you change direction.

Keep good posture.Look straight ahead, and keep your back straight, your chest out, and your shoulders back. This helps keep your upper back straight while having a slight arch in your lower back.



Hold the load as close to your body as possible, at the level of your belly button.

Set downyour load carefully, squatting with the knees and hips only


The manual handling risk assessment procedure gives direction and practical information to those that work in the manufacturing sector on action that can be taken to manage the potential hazard of manual handling in the workplace.

This is necessary to work towards preventing musculoskeletal injuries at work and reducing exposure to high financial costs including compensation claims.


IntroductionThe Manual Handling Operations Regulations 1992 (as

amended) requires employers to:

•avoid the need for hazardous

manual handling, as far as

reasonably practicable;

•assess the risk of injury from any

hazardous manual handling that

can’t be avoided; and

•reduce the risk of injury from

hazardous manual handling, as

far as reasonably practicable.

The risk should be reduced to the lowest level ‘reasonably practicable’.

That means reducing the risk until the cost of any further precautions -

time, effort or money - would be far too great in proportion to the benefits.


The basic principle of the regulation is that where manual handling activities may involve a risk of injury (particularly to the back) due to unfavorable ergonomic conditions,

the employer must take measures to avoid or reduce the risk of injury.



The employer needs to take measures to implement preventative measures based on the outcomes of the risk assessments.

The manual handling risk assessment procedure The employer needs to manage the hazard through implementation of a manual handling risk assessmentprocess .


The manual handling risk assessment procedure information objectives are;

• To raise awareness of the business case for the hazard of manual handling and why it needs to be managed in the workplace .• To understand and recognize the potential risk factors of manual handling in their workplace

• To give direction on manual handling risk assessment to be used to highlight potential hazards


The manual handling risk assessment procedure objectives (continue)

• To develop better ways of working, including use of handling aids, improved housekeeping or better work processes resulting in reduced handling of stock and reduced risk of musculoskeletalinjury

•To explain how to complete a manual handling risk assessment process •To give direction on developing a safe system of work plan

Guide on Manual Handling Risk Assessment in the Manufacturing Sector

It is useful, through consultation with staff, to get an understanding of the potential risk factors as they relate to specific tasks.

Manual handling tasks that will need to be risk assessed will include one or all of the following risk factors:

Note: This is not an exhaustive list of risk factors for manual handling of loads

Risk factor (unfavorable ergonomic condition) Picture

The lifting of the load requires repeated bending of the trunk

The lifting of the load requires repeated manipulation of the load at a distance from the trunk

The load is very large and difficult to grasp


The Unfavorable Ergonomic Manual Handling Risk Factor




The physical effort can only be achieved by a twisting of the trunk

The load is carried over a long distance and there is poor housekeeping with unsafe access

The handling repeatedly takes place at floor level or above shoulder height




The lifting of the load requires repeated bending of the trunk

The lifting of the load requires repeated manipulation of the load at a distance from the trunk

The load is very large and difficult to grasp




Preventative measures based on the outcomes of the risk assessments include safe system of work plans for site-specific tasks, providing;

information on the use of mechanical aids, reorganization of a work activity to allow loads to behandled at a safe height or the provision of instruction to workers on; how to use handling aids or handle loads safely.

Ergonomic Manual Handling Checklists

Instruction and

demonstration

Practical exercises

Risk prioritization

process Solution design


“Tell me and I’ll forget; show me and I may remember; involve me and I’ll understand.”

Instruction and demonstration

Must it be moved?Must it be lifted?Can it be moved mechanically?Can the load be reduced?Can assistance be accessed?

Is the load too heavy to lift safely?Is training required?

Control Considerations for Manual Handling


Think before you Lift.Manual handling occurs when you are Lifting, Lowering, Pushing, Pulling, Carrying, Moving, Holding, Restraining…. Any person, animal or thing


Before Lifting• Stop and assess the load and if too heavy seek advice• Consult management or safety officer for advice on how to manage

heavy loads• Plan the lift. i.e. estimate the load and know exactly where it is to be

placed prior to lifting• Avoid reaching out.• Do not reach out to pick up any object• Handle heavy objects close to the body• Keep yourself in good physical shape with proper exercise and diet

• Avoid lifting heavy loads without help and plan the lifttogether

• Can you reduce the load???• Wherever possible use mechanical means, e.g. can you use

a Forklift, winch or crane• Avoid placing objects on ground if they have to be picked up

at a later date

Instruction and demonstration Safe Work Instruction on Manual Handling SW001

•Ergonomic Manual Handling Checklists

When Lifting• Bend your knees, keep a straight back and make use of your legs to lift•Lift slowly and smoothly without jerking and when turning move feet. Do not twist or turn with hips or shoulders•Make sure you have a firm grip •Position the feet evenly on each side of the load•Bend the knees•Keep you back straight and your arms close to the body•Brace the stomach

And remember “Lift using your legs NOT your back”

Instruction and demonstration Safe Work Instruction on Manual Handling SW001

•Ensure objects to be lifted have sufficient space around toenable safe lifting

• Make sure you are capable of lifting and your body is warm and flexible especially when weather is cold

Manual Handling Checklists

Following this lifting technique to ensure a smooth process placing the minimum effort, stress and tension on the body to reduce the likelihood of a cumulative injury.

Manual Handling Practical Exercise -The Six Point Lift

Manual Handling Checklist Example

Item Yes No Required Action Person

Respon-

sible

Comple-

tion

Date

1. Have you identified all manual handling tasks

that may be a risk to health & safety?

List potential manual handling risks

– those that could be a risk. Use

Codes of Practice that can assist

with manual handling

2. Have you assessed the risks from the manual

handling tasks identified in 1 above? (Risk

assessment is included in this topic)

Use the manual handling risk

assessment tool included in this

topic – Risk assessment tool is from

the Victorian Compliance

Code - 2000

3. Have you taken steps to control the risk

associated with the hazards identified in 1

above? Ensure manual handling controls are in

place – use of mechanical aids (cranes, trolleys,

forklifts) should be considered as first priority

Consult with staff to determine the

most suitable control methods. Use

the hierarchy of controls to set

priorities

4. Have workers been trained in correct manual

handling techniques?

Workers should be trained

5. Is there adequate supervision for staff

performing manual handling tasks?

Ensure workers are using

correct manual handling aids and

techniques

Date Assessment Completed ……………………….


Practical Exercise Sign Off Check sheet

Name Signature Name Signature

Staff Sign off -I, the undersigned have read and understood the Manual Handling safety instruction and the general safety controls that are recommended when I am involved in any Manual Handling task.I also understand that I must conduct a risk assessment prior to any Manual Handling activity to ensure I have properly assessed the load and methods of movement.


Risk prioritization process


Solution design

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Healthcare

Ergonomics & Manual Handling