Manual Material Handling
Ergonomics Training Program
 2006 RiskAnalytics, LLC
 2006 RiskAnalytics,
LLC
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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.
 2006 RiskAnalytics, LLC
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Learning Objectives
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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
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Introduction
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The word Ergonomics comes from the Greek words
“Ergos”--(work) and “Nomos”-- (natural law)
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Ergonomics is an interdisciplinary approach toward
adapting the man-made environment around man,
rather than man around the environment
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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
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H = 20 in
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Ergonomics Program Goals
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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
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Principle: Human
characteristics should be
considered at the beginning of
the design process
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What are Musculoskeletal Disorders (MSDs)?
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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
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Why is effective ergonomics so important?
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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
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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
Average Direct Cost:
$ 8,305
Average Indirect Cost:
$16,610
Estimated Total Cost:
$24,915
The net profit margin
The ADDITIONAL sales necessary
to cover Total Costs are:
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
Average Direct Cost:
$ 9,667
Average Indirect Cost:
$19,334
Estimated Total Cost:
$29,001
The net profit margin
The ADDITIONAL sales necessary
to cover Total Costs are:
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4%
$725,025
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Ergonomic Risk Factor Interaction
The Worker
The Job
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The Environment
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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.
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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
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Ergonomic Risk Factors – Physical
Repetitive Motions
Fatigue and muscle-tendon strain can accumulate
if motions are repeated frequently… affected by:
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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
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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
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Ergonomic Risk Factors – Physical
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
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Ergonomic Risk Factors - Psychological
Positive Stress vs. Distress
In control
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Out of control!
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Ergonomic Risk Factors - Tasks
Lifting/Lowering
Carrying
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Pushing/Pulling
Holding
Twisting
Sitting
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Static vs. Dynamic Muscular Effort
Blood Needed vs. Blood Flow
Blood Need
Blood Flow
Resting
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Blood Need
Blood Flow
Dynamic Effort
Blood Need
Blood Flow
Static Effort
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Spinal Anatomy 101
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The spine’s vertebrae are held together by
ligaments
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Muscles are attached to the vertebrae by bands
of tissue called tendons
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Between each vertebra is a cushion known as a
disc
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Openings in each vertebra line up to form a long,
hollow canal
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The spinal cord runs through this canal from the
base of the brain
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Nerves from the spinal cord branch out and
leave the spine through spaces between the
vertebra
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The lower part of the back holds most of the
body’s weight
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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.
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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
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Physical Stress on Skeletal System
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?
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10 Lbs
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Physical Stress on Skeletal System
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
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Physical Stress on Skeletal System
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
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Physical Stress on Skeletal System
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
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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
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Preventing Injuries
Avoid lifting and bending whenever you can
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If you must lift, the best zone for lifting is between your
shoulders and your waist
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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
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Preventing Injuries
Use proper lifting procedure
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Plan your move
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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
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Preventing Injuries
More Lifting Tips
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Transferring weight
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Lifting heavy bags
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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
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Preventing Injuries
Lifting Safety Checklist
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Have you checked the object before you try to lift it?
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Is the load you want to lift packed right?
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Have a tight grip on the object
Is it easy to reach this load?
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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?
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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
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Preventing Injuries
Body Management
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Stretch early and stretch often
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Slow down; don’t overdue it
Take frequent micro breaks
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Sleep on a firm mattress
Get in shape and stay in shape with regular exercise
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Controlling Ergonomic Risk Factors
Recommendations for controlling risk factors include:
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Ask employees in the problem job for
recommendations
Identify, assess and implement feasible controls
Track your progress
Identify and evaluate musculoskeletal hazards
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Hazard Control Strategies
Two Types:
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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
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Hazard Control Strategies
Engineering Controls:
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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
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Hazard Control Strategies
Administrative Controls
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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
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Implementing Control Strategies
Effective control strategies are based on the following
principles:
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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
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Summary
 2006 RiskAnalytics, LLC
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Ergonomics is about fitting the work to the worker
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Lower back problems are the leading cause of disability
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Risk factors exist in the environment, the job or specific
tasks and with the person
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Job related risk factors include awkward posture, forceful
exertions, repetitive motions, and contact stress
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Psychological risk factors include lack of time, unreasonable
workload and poor working relationships
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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
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Ergonomic hazard control strategies include engineering
controls, administrative controls and personal protective
equipment
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