2006 riskanalytics, llc page 1 manual material handling ergonomics training program 2006...
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2006 RiskAnalytics, LLC Page 1
Manual Material Handling Ergonomics Training Program
2006 RiskAnalytics, LLC
2006 RiskAnalytics, LLC
Disclaimer
The information, suggestions and recommendations contained herein are for general informational purposes only. This information has been compiled from sources believed to be reliable. No warranty, guarantee, or representation, either expressed or implied, is made as to the correctness or sufficiency of any representation contained herein. Reliance upon, or compliance with, any of the information, suggestions or recommendations contained herein in no way guarantees the fulfillment of your obligations under your insurance policy or as may otherwise be required by any governmental, national, federal, state, or local laws, rules or regulations. This Information should not be construed as business, risk management or legal advice, or legal opinion.
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Learning Objectives
Describe the concept and purpose of ergonomics
Identify personal, job, and environmental ergonomic risk factors
Discuss ways to prevent musculoskeletal disorders
Discuss the importance of engineering and administrative controls
Describe the steps in implementing an effective ergonomics program
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Introduction The word Ergonomics comes from the Greek words
“Ergos”--(work) and “Nomos”-- (natural law) Ergonomics is an interdisciplinary approach toward
adapting the man-made environment around man, rather than man around the environment
Ergonomics considers the physical and mental capabilities and limits of the worker and how they interact with tools, equipment, work methods, tasks, and the working environment
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Ergonomics Program Goals
Goal: Reduce work-related musculoskeletal disorders (MSDs) by adapting the work to fit the person, instead of forcing the person to adapt to the work
Principle: Human characteristics should be considered at the beginning of the design process
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What are Musculoskeletal Disorders (MSDs)? Illnesses and injuries affecting one or more parts of the
musculoskeletal system They include sprains, strains, inflammation, degeneration,
tears, pinched nerves or blood vessels, bone splintering and stress fractures
Symptoms are discomfort, pain, fatigue, swelling, stiffness or numbness, and tingling
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Why is effective ergonomics so important? Back injuries are the leading cause of disability In 2007, occupational musculoskeletal disorders
comprise 28.9% of all nonfatal injuries and illnesses involving days away from work.
In 2009, there were 195,150 back and spinal cord nonfatal injuries involving days away from work.
Musculoskeletal disorders accounted for 29% of all workplace injuries in 2007
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The Economics of ErgonomicsMSDs Injury: Muscle Strain
Average Direct Cost: $ 5,945
Average Indirect Cost: $11,890
Estimated Total Cost: $17,735
Net profit margin for this company is 4 %
The ADDITIONAL sales necessary to cover Total Costs are: $445,875
MSDs Injury: Carpal Tunnel Syndrome
Average Direct Cost: $ 8,305
Average Indirect Cost: $16,610
Estimated Total Cost: $24,915
The net profit margin 4%
The ADDITIONAL sales necessary to cover Total Costs are: $622,875
MSDs Injury: Cumulative Trauma
Average Direct Cost: $ 9,667
Average Indirect Cost: $19,334
Estimated Total Cost: $29,001
The net profit margin 4%
The ADDITIONAL sales necessary to cover Total Costs are: $725,025
The total additional revenue required to cover the costs of these 3 incidents is estimated to be $1,793,775
The total additional revenue required to cover the costs of these 3 incidents is estimated to be $1,793,775
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The Worker
The EnvironmentThe Job
Ergonomic Risk Factor Interaction
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Ergonomic Risk Factors – PhysicalAwkward Postures
Body postures determine which joints and muscles are used in an activity and the amount of force or stresses generated or tolerated.
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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: 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 – PhysicalVibration
Exposure to local vibration occurs when a specific part of the body comes in contact with a vibrating object, such as a power hand tool
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In control
Out of control!
Ergonomic Risk Factors - PsychologicalPositive Stress vs. Distress
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Ergonomic Risk Factors - Tasks
Lifting/Lowering Pushing/Pulling
Sitting
Twisting
Carrying Holding
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Resting Dynamic Effort Static Effort
Blood Need Blood Flow Blood Need Blood Flow Blood Need Blood Flow
Static vs. Dynamic Muscular Effort Blood Needed vs. Blood Flow
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Spinal Anatomy 101 The spine’s vertebrae are held together by
ligaments
Muscles are attached to the vertebrae by bands of tissue called tendons
Between each vertebra is a cushion known as a disc
Openings in each vertebra line up to form a long, hollow canal
The spinal cord runs through this canal from the base of the brain
Nerves from the spinal cord branch out and leave the spine through spaces between the vertebra
The lower part of the back holds most of the body’s weight
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Spinal Anatomy 101 - Intervertebral DiscsThe vertebrae are separated by Intervertebral discs which act as cushions between the bones.
Each disc is made up of two parts - the hard, tough outer layer called
the Annulus surrounds a mushy, moist center termed the Nucleus.
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Physical Stress on Skeletal System Forces Involved:
5 pounds?10 pounds?15 pounds?
Imagine your back as a lever. With the fulcrum in the center of the lever, how many pounds would it take to lift a 10 pound object?
10 Lbs
?
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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?
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.
105 Lbs
1150 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.
130 Lbs
1400 Lbs
10 Lbs
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Common Causes of Musculoskeletal InjuriesHeavy Lifting
…especially repetitive lifting over a long period of time
Twisting at the waist
…while lifting or holding a heavy load
Reaching and lifting
…over your head, across a table, or from the floor with straight legs
Working in odd, uncomfortable positions
…tasks that require you to bend over for long periods of time
Sitting or standing too long in one position
…sitting can be very hard on the lower back
Slips, trips and falls
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Preventing Injuries
Avoid lifting and bending whenever you can
If you must lift, the best zone for lifting is between your shoulders and your waist
Place objects up off the floor so you won’t have to reach down to get them
Always use a dolly or a forklift if you can Pushing an object is better than pulling the object Don't overdo it - if you have to strain to carry the load, it's too
heavy for you Make sure you have enough room to lift safely Look around before you lift and know where you are going to
put down the load Avoid walking on slippery and uneven surfaces while carrying
something
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Plan your move Size up the load and make sure your path is clear Get help as needed Use handles or straps Use a dolly or other material handling equipment if possible
Use a wide, balanced stance with one foot slightly ahead of the other with your heels on the floor
Get as close to the load as possible Use your palms, not just your fingers, to grasp the load Tighten your stomach muscles as the lift begins Keep your lower back in its normal arched/curved position Move the feet to turn - Don’t twist your back Lower the load slowly, maintaining the curve in your lower
back
Preventing Injuries
Use proper lifting procedure
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Transferring weight Pull object towards you while transferring your
weight to the lift side Lift only to the level required Shift your weight to the other leg while pushing the
object into position. Do not twist
Lifting heavy bags Put one knee down against bag Pull bag up leg Rest bag on edge of knee Stand upright Pull bag to waist height
Preventing Injuries
More Lifting Tips
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Preventing Injuries
Lifting Safety Checklist Have you checked the object before you try to lift it?
Test every load before you lift by pushing the object lightly with your hands to see how easily it moves
Remember, a small size does not always mean a light load Is the load you want to lift packed right?
Make sure the weight is balanced and stable so the load does not shift when moved
Loose pieces inside a box can cause accidents if the box becomes unbalanced
Is it easy to grip this load? Have a tight grip on the object
Is it easy to reach this load? You can be injured if you arch your back when lifting a load over your
head. Avoid lifting overhead To avoid hurting your back, use a ladder when you're lifting something
over your head
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Preventing Injuries
Body Management Stretch early and stretch often Slow down; don’t overdue it Take frequent micro breaks Sleep on a firm mattress Get in shape and stay in shape with regular exercise
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Controlling Ergonomic Risk FactorsRecommendations for controlling risk factors include:
Ask employees in the problem job for recommendations
Identify, assess and implement feasible controls Track your progress Identify and evaluate musculoskeletal hazards
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Hazard Control StrategiesTwo Types: Engineering controls - Eliminates/reduces hazards
existing through equipment redesign, replacement, and/or substitution
Administrative controls - Reduce exposure to the hazard by controlling behaviors through design of work procedures, schedules, use of personal protective equipment
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Hazard Control StrategiesEngineering Controls: Changing the way materials, parts, and products can
be transported Changing the process or product to reduce worker
exposures to risk factors Changing workstation layout Changing the way parts, tools, machinery and
materials are to be manipulated Changing tool designs Changes in materials and fasteners Changing assembly access and sequence
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Hazard Control StrategiesAdministrative Controls Broadening or varying job content to offset risk factors
such as repetitive motion or awkward posture Adjusting work pace to relieve repetitive motion risks
and give the worker more control of the operational process
Rescheduling work for cooler times of day Reducing shift length or curtailing the amount of
overtime Rotating workers through jobs with different physical
demands to reduce the stress on limbs and body regions
Scheduling more breaks
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Implementing Control StrategiesEffective control strategies are based on the following
principles: Carefully plan the change - make small changes Conduct limited trials or tests of the selected solutions Study the effects of the change Adopt, abandon or revise as needed Once a change is adopted, implement full-scale Conduct follow-up evaluation of control strategies
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Summary Ergonomics is about fitting the work to the worker Lower back problems are the leading cause of disability Risk factors exist in the environment, the job or specific
tasks and with the person Job related risk factors include awkward posture, forceful
exertions, repetitive motions, and contact stress Psychological risk factors include lack of time, unreasonable
workload and poor working relationships Proper lifting technique includes planning the move, using a
wide, balanced stance, getting as close to the load as possible and moving your feet versus twisting the torso
Ergonomic hazard control strategies include engineering controls, administrative controls and personal protective equipment