Ergonomic Guidelines
for
Manual Material Handling
MARIO FELETTO - AREA MANAGER
RESEARCH AND EDUCATIN UNIT
CAL/OSHA CONSULTATION SERVICE
SACRAMENTO, CA
&
JAMES J. GALANTE - CHAIRMAN
E.A.S.E. COUNCIL
MATERIAL HANDLING INDUSTRY OF AMERICA
CHARLOTTE, NC
Ergonomic Guidelines for
Manual Material Handling
The Team
•
•
•
•
•
•
•
•
EASE Council - MHIA
Cal/OSHA Consultation Services
NIOSH
University of California, Davis
UC Berkeley Ergonomics Program
Ergonomics Center of North Carolina
Johnson & Johnson
CNA
Ergonomic Guidelines for
Manual Material Handling
MMH Guideline Advantages
z
Focuses On Improvements Not Problems
z
“Best Practices “ Approach
z
Practical & Non-regulatory
MANUAL MATERIAL HANDLING
ART AND SCIENCE
z
The Movement, Storage, Control & Protection of Goods
and Materials
z
Throughout Manufacture, Distribution, Consumption and
Disposal
Why Address
Manual Material Handling ?
MUSCULOSKELETAL DISORDERS
z
PHYSICAL
PROBLEMS
z
CHARACTERISTICS
–
pain, swelling
–
acute or chronic
–
numbness, tingling
–
no early medical findings
–
factors from home / workplace
–
–
ROM and strength
change of skin color
MUSCULOSKELETAL DISORDERS
z
GENERAL
–
SPRAINS & STRAINS
–
MYALGIA
–
TENDINITIS
–
TENOSYNOVITIS
MUSCULOSKELETAL DISORDERS
z
SYNDROMES
– CARPAL TUNNEL
MUSCULOSKELETAL DISORDERS
z
SYNDROMES
– THORACIC OUTLET
MUSCULOSKELETAL DISORDERS
z
BACK PROBLEMS
Disc
Vertebra
Nerve
MUSCULOSKELETAL DISORDERS
z
BACK PROBLEMS
-
DISCS
-
SCIATICA
-
OSTEOARTHRITIS
Tear
Slipped
Degenerated
Why Address
Manual Material Handling ?
z
PHYSICAL DEMANDS
OF WORK
– REPETITION
–
FORCE / WEIGHT
–
AWKWARD POSTURE
–
VIBRATION
z
TOOLS & EQUIPMENT
– POOR GRIPS / HANDLES
– EXCESSIVE
z FORCE / WEIGHT
z VIBRATION
z REPETITION
–
AWKWARD POSTURE
z WRIST / ARM
z UPPER BODY
Why Address
Manual Material Handling ?
z
THE WORK
ENVIRONMENT
z
THE SET UP OF WORK
– ROTATING SHIFT WORK
– COLD
– LACK OF TASK VARIETY
– HOT
– LIGHTING
– EXCESSIVE
z OVERTIME
z WORK PACE / DURATION
– NOISE
– HOUSEKEEPING
– POORLY COMMUNICATED
z EXPECTATIONS
z JOB DEMANDS
Why Address
Manual Material Handling ?
Laborers and Material Movers Suffered the Most Injuries & Illnesses With Days Away From Work
Why Address
Manual Material Handling ?
In all of Private Industry and in Goods Producing & Service Providing Industries,
Overexertion was a leading cause of injuries & illnesses
SOURCE; Bureau of Labor Statistics, U.S. Department of Labor, Survey of Occupational Injuries and Illnesses
Why Address
Manual Material Handling ?
Sprains & Strain, Back Pain, Soreness & Pain , Tendonitis and CTS
Accounted for 53% of All Lost Time Injuries & Illnesses
SOURCE; Bureau of Labor Statistics, U.S. Department of Labor, Survey of Occupational Injuries and Illnesses
Why Address
Manual Material Handling ?
The Back & Upper Extremities Were Involved In Almost 1/2 of All Lost Time Injuries & Illnesses
Why Address
Manual Material Handling ?
Bodily Reaction & Exertion Accounted For Over 40% of All Lost Time Injuries & Illnesses
Why Address
Manual Material Handling ?
Costs
z
DIRECT
– W.C. (Medical, Indemnity, Loss exposure)
– Lost Productivity
– Errors & Defects
z
INDIRECT (Up to 4X Direct Costs)
– Turnover,
– Absenteeism,
– Re - Training
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Why Address
Manual Material Handling ?
Workers' Compensation Data - 2003
14.00%
12.00%
10.00%
8.00%
% of All Claims
6.00%
% of All Incurred Costs
4.00%
2.00%
0.00%
Pattern of High Losses
Strains, Rep. Motion, Pushing, Pulling, Holding, Twisting, Using Tools/Machines, Carrying, Objects Lifted/Handled
Why Address
Manual Material Handling ?
California W.C. Data - 2003
53% of Insurance Market
% All Claims
Strain/Injury Lifting
11
Strain/Injury Misc.
9
Rep Motion (CRPL Tunnel)
2.5
Injury Pushing/Pulling
3
Injury Holding Carrying
2
Twisting
2
Object Lifting/Handled
3
Strain/Injury by Reaching
1
Totals
34
% All Costs
12
10
3.5
3.5
2
2
1
1
36
Total Incurred Costs ($)
314,484,353
264,614,044
91,683,456
87,505,943
48,248,929
42,645,706
17,821,835
16,859,056
883,863,322
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Why Address
Manual Material Handling ?
Workers' Compensation Data: 2002
14.00%
12.00%
10.00%
8.00%
% of All Claims
6.00%
% of All Incurred Costs
4.00%
2.00%
0.00%
Pattern of High Losses
Strains, Rep. Motion, Pushing, Pulling, Holding, Twisting, Using Tools/Machines, Carrying, Objects Lifted/Handled
Why Address
Manual Material Handling ?
California W.C. Data - 2002
50% of Insurance Market
% All Claims
Strain/Injury Lifting
11
Strain/Injury Misc.
9
Rep Motion (CRPL Tunnel)
2.6
Injury Pushing/Pulling
3
Injury Holding Carrying
2
Twisting
1.5
Object Lifting/Handled
3
Strain/Injury by Reaching
1
Totals
33
% All Costs
12.5
10
3.5
3
2
1. 5
1
1
35
Total Incurred Costs ($)
499,551,388
387,349,560
140,047,697
128,910,435
74,213,592
54,538,089
23,574,020
29,392,193
1,337,576,974
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Why Address
Manual Material Handling ?
Workers' Compensation Data: 2001
14.00%
12.00%
10.00%
8.00%
% of All Claims
6.00%
% of All Incurred Costs
4.00%
2.00%
0.00%
Pattern of High Losses
Strains, Rep. Motion, Pushing, Pulling, Holding, Twisting, Using Tools/Machines, Carrying, Objects Lifted/Handled
Why Address
Manual Material Handling ?
California W.C. Data - 2001
43% of Insurance Market
% All Claims
Strain/Injury Lifting
11
Strain/Injury Misc.
9
Rep Motion (CRPL Tunnel)
3
Injury Pushing/Pulling
3
Injury Holding Carrying
2
Twisting
1.3
Object Lifting/Handled
3
Strain/Injury by Reaching
1
Totals
34
% All Costs
13
11
4.2
3.5
2
1. 3
1
1
36
Total Incurred Costs ($)
558,864,656
445,435,822
180,254,890
152,023,340
78,185,860
55,317,938
23,018,957
29,898,408
1,522,999,871
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Why Address
Manual Material Handling ?
Workers' Compensation Data: 2000
Workers' Compensation Data: 1999
14.00%
14.00%
12.00%
12.00%
10.00%
10.00%
8.00%
% of All Claims
8.00%
% of All Claims
6.00%
% of All Incurred Costs
6.00%
% of All Incurred Costs
4.00%
4.00%
2.00%
2.00%
0.00%
0.00%
ST
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AT
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14.00%
12.00%
12.00%
10.00%
10.00%
4.00%
4.00%
2.00%
2.00%
0.00%
0.00%
O
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14.00%
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Why Address
Manual Material Handling ?
Workers' Compensation Data: 1998
Workers' Compensation Data: 1997
8.00%
% of All Claims
8.00%
% of All Claims
6.00%
% of All Incurred Costs
6.00%
% of All Incurred Costs
Why Address
Manual Material Handling ?
California W.C. Patterns 1997 – 2003
% All Claims
Strain/Injury Lifting
Strain/Injury Misc.
Rep Motion (CRPL Tunnel)
11 - 13
9
2-3
% All Costs
11 - 13
10 – 11
3-5
Injury Pushing/Pulling
Injury Holding Carrying
Object Lifting/Handled
3
1-2
0.1 – 3
3-4
2
0 -1
Strain/Injury by Reaching
1
1
Totals
27 - 34
30 – 37
Total Incurred Costs($)
1,372,900,397
1,097,399,426
411,986,043
368,439,718
200,648,381
64,414,812
76,078,657
3,591,867,434
Ergonomic Guidelines
for Manual Material Handling
Why Develop Guidelines ?
z
What About Ergonomic Regulations ?
– Federal OSHA
– Cal/OSHA
Ergonomic Guidelines
for Manual Material Handling
z
Federal OSHA Ergonomic Standard
– Promulgated November, 2000
– Congress repealed standard March, 2001 as part of
Contract with America, the Congressional Review Act (1995),
z
For the Future
– Same law (i.e. Congressional Review Act) if OSHA promulgates
another standard, the new standard can not be similar to the one
that congress nullified in 2001
Ergonomic Guidelines
for Manual Material Handling
z
Federal OSHA’s Current Strategy - 4 parts
– Develop Industry / Task Specific Voluntary Guidelines
– Enforcement - General Duty Clause (Section 5(a)(1) of OSHA
Act
– National Advisory Committee (convened 2002-3)
– Outreach & Assistance
Ergonomic Guidelines
for Manual Material Handling
z
Industry / Task Specific Voluntary
z
Based On
– Current incidence rates - injuries & illness
– Information on effective / feasible solutions
Ergonomic Guidelines
for Manual Material Handling
z Industry
/ Task Specific Voluntary Guidelines
– Lots of Help - Three Part Recommendations
Management Practices
z Worksite Analysis
z Hazard Control
z
– Meatpacking, Nursing Homes, Grocery, Poultry &
Shipyards
Ergonomic Guidelines
for Manual Material Handling
Industry / Task Specific Voluntary Guidelines
z
Lots of Help - Three Part Recommendations
z
Management Practices
– Providing Management Support, Involving Employees
– Providing Training
– Evaluating Ergonomics Efforts
z
Worksite Analysis
– Identifying Problems
– Checklists
– Addressing Reports of Injuries
Ergonomic Guidelines
for Manual Material Handling
Industry / Task Specific Voluntary Guidelines
z
Lots of Help - Three Part Recommendations
z
Hazard Control
– Implementing Solutions
– Lots of Pictures & Examples of Solutions (Tools, Workstations,
MMH, PPE)
Ergonomic Guidelines
for Manual Material Handling
Industry / Task Specific Voluntary Guidelines
z
Hazard Control
Ergonomic Guidelines
for Manual Material Handling
Industry / Task Specific Voluntary Guidelines
z
Hazard Control
Ergonomic Guidelines
for Manual Material Handling
z
Enforcement
– Focus - industries/employers with know high injury & illness rates
related to ergonomics by:
z National Emphasis Programs
z Local Emphasis Programs
z Enforcement
– Addresses Ergonomic by Issuing:
z Citation under General Duty Clause 5(a)(1)
z Ergonomic Hazard Alert Letters
Ergonomic Guidelines
for Manual Material Handling
z
Enforcement
– National Emphasis Programs
z
Nursing Homes – 2002-3 (1225 Inspections / 157 EHA
Letters)
– Local Emphasis Programs
8 Area Offices (240 EHA Letters)
z Meat processing, Warehousing, Hospitals
z Auto Parts Manufacturing
z
Ergonomic Guidelines
for Manual Material Handling
z
Enforcement
– Ergonomic Hazard Alert (EHA) Letters
Issued When Not Enough Documentation to Write Citation
z 397 Issued (240 to various industries / rest to Nursing Homes)
z Alerts Employers to the Hazards / Suggests Improvements
z Follow-up Case – by -Case
z
Ergonomic Guidelines
for Manual Material Handling
z
Enforcement – General Duty Clause 5(a)(1)
– 5(a)(1) - Employer must “furnish to each employee
employment and place of employment free from recognized
hazards that cause or are likely to cause death or serious
physical harm to employee”
– OSHA Must Show
z
z
z
z
Employer Did Not Keep Workplace Free of Hazards Employees Were
Exposed To
Hazard caused or likely to cause death / serious physical harm
Hazard was recognized
Feasible abatement exists
Ergonomic Guidelines
for Manual Material Handling
z
Enforcement – General Duty Clause 5(a)(1)
z
OSHA Citations 2000 – 2005
z
Total of 17
z
z
z
z
2005 - 0
2004 - 4
2003 - 12
2002 - 1
Ergonomic Guidelines
for Manual Material Handling
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National Advisory Committee ( 2002-4)
z
Advised On:
– Ergonomic Guidelines
– Research - Gaps, Future Needs
– Methods to Provide Outreach / Assistance
Ergonomic Guidelines
for Manual Material Handling
z
Outreach and Assistance
–
–
–
–
–
–
–
–
eTools
Success Stories
Case Studies
Cooperative Programs
Training & Education
Speeches
Industry Developed Guidelines
Additional Information
Ergonomic Guidelines
for Manual Material Handling
California
z
1993 WC REFORMS - AB 110
- CAL /OSHA Must Focus Resources
- Establishments with Highest Incidences of Preventable
Injuries / illness and W.C. Losses
Ergonomic Guidelines
for Manual Material Handling
California Ergonomics Standard
z
z
z
T8CCR 5110
Long History – 1986
Enforced / addressed on a “case by case” basis
– Answer complaints / requests for consultation
z
If facts indicate hazards may be present then:
– inspection /consultation conducted
– information gathered
– standard applied if facts support the case
Ergonomic Guidelines
for Manual Material Handling
California Ergonomics Standard
Scope / Application
z Program to Minimize RMIs
z
– Worksite Evaluation
– Control of Exposures
– Training
z
Satisfaction of Employer’s Obligation
Ergonomic Guidelines
for Manual Material Handling
California Ergonomics Standard
z
(a) Scope & Application
z
RMI to More Than One Employee and
– (1) Work related causation - predominantly caused ( 50% or more
by repetitive work)
- (2) Employees performing job / process / operation of identical
work activity
z same repetitive motion task
z such as / not limited to word processing / assembly /
loading)
Ergonomic Guidelines
for Manual Material Handling
California Ergonomics Standard
z
(a) Scope & Application
z
RMI to More Than One Employee and
- (3) Were Musculoskeletal injuries
- (3) Licensed physician objectively identified / diagnosed
- (4) Reported in last 12 months/not before July 3, 1997
Ergonomic Guidelines
for Manual Material Handling
California Ergonomics Standard
z
(c) Satisfaction of Employer’s Obligation
z
Employers Obligation Satisfied Unless It Is Shown
– measures known but not taken are substantially certain to cause
greater reduction in RMIs
– no additional unreasonable costs from alternative measures
Ergonomic Guidelines
for Manual Material Handling
California Ergonomics Standard
z
z
History- T8CCR 5110 Since Adoption
Inspections Conducted / Citations Issued
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–
–
–
–
–
z
2003
2002
2001
2000
1999
1998
-
6 / 19
10 / 24
14 / 34
16 / 38
18 / 24
6 /5
Totals - 70 Inspections / 144 Citations Issued
Why Develop Guidelines For
Manual Material Handling ?
Summary
Common Type of Operation Worldwide
z Reduce Injuries
z Reduce Costs
z
– Direct
z
z
z
W.C. (Medical, Indemnity, Loss exposure)
Lost Productivity
Errors & Defects
– INDIRECT (Up to 4X Direct Costs)
z
z
z
Turnover
Absenteeism
Re - Training
Why Develop Guidelines For
Manual Material Handling ?
Summary
z
Provide Competitive Edge by Improving
- Productivity / Efficiency
–
–
–
Product / Service Quality
Customer Appeal
Management Tools
Why Develop Guidelines For
Manual Material Handling ?
Summary
z
Ergonomic Regulations ?
–
Federal Regulation
z Repealed
z No
Current Regulation
z Future – Can Not Adopt Similar Regulation
z 20 Total OSHA Citations 2000 – 2005
z OSHA Now - Outreach / Guidelines
Why Develop Guidelines For
Manual Material Handling ?
Summary
z
Ergonomic Regulations ?
–
California Regulation
z 70
Inspections / 144 Citations 1998 – 2003
z States
Programmatic Requirements
z Many
Enforcement Issues
Ergonomic Guidelines
for Manual Material Handling
Summary
California Ergonomics Standard
z
Enforcement Issues - (a) Scope & Application
- Standard says “repetitive motion injuries”
z
what about “static posture” or other types of injuries ?
- RMI to More Than One Employee & work related / predominantly
caused ( 50% or more by repetitive work)
z
off the job activities ? Ultimately the doctors opinion / judges decision
Ergonomic Guidelines
for Manual Material Handling
Summary
California Ergonomics Standard
z
Enforcement Issues - (a) Scope & Application
- “identical work activity” ? means the same:
z
“task category” (assembly / loading/ etc.) / risk factors / body parts used
- “objectively identified and diagnosed”
z
z
z
measurable and observable signs & symptoms
“customary protocol” (symptoms / labs / physical exam / work history)
info taken as a whole supports RMI diagnosis
Why Develop Guidelines For
Manual Material Handling ?
Summary
z
Guidelines - Practical, Specific Information on:
– Effective Management Practices
z
Involving Employees
– “Best Practices” Approach - How To
z
z
z
z
Evaluate Worksites
Train Employees
Select & Implement Improvement Options
Ongoing Problem Solving & Follow-up
– Resources & More Help
“BEST PRACTICES”
APPROACH
IMPROVEMENT OPTIONS
IMPROVE THE “FIT”
BETWEEN THE
WORK & EMPLOYEES
A “BEST PRACTICES” APPROACH
Proactive
Proactive
Noticing
Noticing
Potential
PotentialProblems
Problems
No “potential”
problems
identified
Follow-Up
Follow-Up
The
The
Ergonomic
Ergonomic
Cycle
Cycle
Work
Work
Evaluations
Evaluations
Improvements
not
presently needed
Improvement
Improvement
Options
Options&&Training
Training
Ergonomic Guidelines
for Manual Material Handling
What Can These Guidelines Do For You ?
Why Improve Your Workplace ?
How to Improve Your Workplace
- What to Look For
- What Are Ergonomic Improvements ?
- How to Make Changes - “Proactive Problem Solving”
Ergonomic Guidelines
for Manual Material Handling
What Can These Guidelines Do For You ?
“A Best Practices Approach”
- Looking for Clues
- Prioritizing Jobs for Improvements
- Choosing “Effective Improvements”
- Following - Up
The Matrix – Improvement Options for Common
Manual Material Handling Tasks
The Ergonomic
Guidelines for Manual
Material Handling
Mario Feletto
Cal/OSHA Consultation Services
Research & Education Unit
Sacramento, California
James J. Galante
Chairman
EASE Council
Material Handling Industry of America
Charlotte, North Carolina
•Non Profit Trade Association
•Established 1945
•Members include 750+ Manufacturers
EASE Council
Material Handling Industry of America
Charlotte, North Carolina
INTRODUCING …
“The Ergonomic
Guidelines for
Manual Material
Handling ”
What Will the Guidelines Look Like ?
The Layout
I.
Introduction – Process Piece
II.
Matrix: a. What is the worker doing?
b. What is the worker handling?
III.
Templates with Photos & Examples
Equipment Improvement Options & Simple,
Less Expensive Improvement Options
IV.
Resources / Index / Appendices
WHAT IS THE WORKER HANDLING?
What Will the
Guidelines
Look Like ?
W
H
A
T
I
S
1
Lifting/
Lowering,
Palletizing/
De-Palletizing:
*Material ON
2
Filling / Emptying
Containers:
manually scooping,
pouring or
packing/unpacking
*Material IN
3
Carrying:
manually moving
the objects
4
Assembling &
Positioning:
pushing, pulling,
turning, tilting
or holding
T
H
E
W
O
R
K
E
R
D
O
I
N
G
?
A
B
C
D
E
F
G
H
I
Boxes,
Trays,
Totes,
Crates
Buckets,
bottles,
cans
Drums
Empty
Pallets,
Skids, Large
Containers,
Wire
Baskets
Parts
Rolls,
Coils
Sacks/
Bags
Sheets,
Boards
Tools,
Fixtures,
etc
What Will the Guidelines Look Like ?
What is the worker doing?
What is worker handling?
Lifting/lowering, palletizing/de-palletizing
Boxes, totes, trays crates
Limitations:
Possible Risk Factors:
Awkward Posture
Force on back
Simple, Less Expensive Options:
Equipment Improvement Options:
What Will the Guidelines Look Like ?
What Will the Guidelines Look Like ?
LIFTING
STRETCHING
REACHING
BENDING
STOOPING
and
WALKING
These unnecessary worker activities can result ergonomic problems
Pallets
MANUAL LOADING AND UNLOADING
OF PALLETS CONTINUES TO BE
ONE OF THE MOST COMMON AND
MOST INJURY PRONE TASKS
IN INDUSTRY TODAY
These are automatic load leveling devices that maintain
the top of the load in the 30 to 38” ergonomic window
Sitting or
standing a lift can
eliminate the
back bending to
associated with
pallet
loading/unloading
Portability allows the operator
to bring the machine in close
& eliminate walking around
Notice the bi-directional
work station crane
Balancers can also
be used to unload
pallets and make
positioning goods
at various
locations within a
machine or work
center
these trays of parts become virtually “weightless”
These lightweight
lifts are highly
maneuverable
Lifts and positioners
can also be fitted
with turntables for
“near side” loading
As much as 40% of
the time required
loading a pallet, can
be spent walking
around it!
There are inexpensive machines to transport pallet loads
in and around work stations - even load positioners
This is a really
cheesy job!
This vacuum
lifter makes
easy lifting and
maneuvering of
these heavy
cheese wheels
Containers
Manual loading
and unloading of
wire baskets, containers
and Gaylord's leads to
a high incidence of
lower back injuries
Repetitive bending into containers can
result in a high incidence of back injuries
Bending eliminated!
Parts
picking
at a
hydraulic
press work
station
Imagine the back extension, bending and
reaching required to get to these parts
Parts picking made productive from fixed height tilters
Notice the high hinge causing the
container to elevate as it tilts
Parts picking on assembly line
Manipulators making easy work of handling
cylinder heads in a machining center
Electric
chain
hoist on
articulated
jib crane
Notice the use of gravity roller
conveyor to ease the feeding of parts
Where no
loading dock
exists
Wrong!
Make
that
three
wrongs!
I love this lift!
Right!
This expandable
conveyor is driven
right into the truck
The individual boxes and
cartons are conveyed right
to the worker
Notice how the odd
sizes and shapes are
handled easily by a
single piece of
equipment
Portable lift for vertical positioning
panels in a finishing operation
Lift & Tilt to position electrical panels in this work cell
Notice the
accordion
skirting
to cover
scissors legs
lifters
to
manipulate
the
small stuff
IAD - Intelligent Assist
Devices
Amplifies operator’s power
Unit has an intuitive, humanlike feel
Intuitive
The operator has a sense of control
& feel over the load using normal
arm, wrist and hand movements.
Intelligent
Resolver feedback from the
servomotor allows for future
implementation of programmable
human limits.
This lift and
gravity
conveyor
permits one
person to do
what was a
two man job
Use portable
lifts to level
loads and
eliminate
bending and
reaching
FINIS
Questions?
The Ergonomic
Guidelines for Manual
Material Handling
Mario Feletto - Cal/OSHA
James J. Galante - EASE Council
Ergonomic Guidelines for
Manual Material Handling