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This refresher covers material handling.
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How materials (such as parts, work pieces or stock) are handled in the
shop matters because many tasks can lead to injuries.
Listed above are 5 examples of worker compensation claims submitted to
a large insurance company between 2010 and 2014. Note the part of the
body injured, how the injury occurred, and the cost of the claim.
Notice that the most expensive claims were related to back injuries.
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A quarter of all claims submitted to the insurance company by 575 metal
fabrication businesses, between 2010 and 2014, were related to
musculoskeletal disorders, of which, one third were back injuries.
The chart on the left shows that the 83% of the back injuries were to the
lower back. The chart on the right shows the medical costs associated
with lower back injuries.
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Here are the numbers used to create the previous graph.
• Notice how expensive the low back and the disc injuries were.
• On average, the disc injuries are the most costly.
• The majority of the injuries are to the low back.
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When an injury occurs at work, the costs are far greater than the medical
costs incurred.
Costs to the injured employee may include:
- Loss of quality of life
- Increased cost of living – if special accommodations are required
- Future medical issues that may arise
- Loss of earning potential
- Potentially damaged professional reputation
Costs to the business may include:
- Lost productivity
- Employee training and retraining
- New employee hiring
- Change in employee morale
- Damaged business reputation
- Fines imposed by regulatory agencies or costs associated with law
suits
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Many accidents happen while performing material handling tasks which
include: lifting, carrying, pushing, pulling, and reaching.
Some parts of the body are at increased risk of injury. These are the back,
arms, neck, and knees.
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An injury does not occur every time a task is carried out. There are several
contributing factors that can lead to an injury. These are called “risk factors”.
Risk Factors include:
• Repetitive motions
• Awkward postures such as reaching above shoulder height, bending,
twisting, or kneeling
• Forceful exertions. The greater the physical effort required to perform
task, the greater the risk.
• Static posture involves maintaining fixed positions for a long period of
time, such as standing at a machine.
The duration and frequency of each factor are critical in determining the actual
risk.
Once the risk factors are identified, we can find solutions to reduce or eliminate
them.
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This chart shows the activities preformed by employees that suffered
back injuries on the job. The activities were identified by the insurance
company for each claim.
Notice that the activities in red have been identified as contributors to
more than three types of back injuries.
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In many shops, most of the lifting remains an entirely manual task. SMART is
the acronym for the correct lifting technique.
S - Size up the load (determine weight, assess size; shape and stability.
M - Move the load close to your body.
A - Always bend your knees not your back when lifting and lowering an
object. Keep your feet apart to maintain balance.
R - Raise the load with your legs, keeping your back as upright as possible.
Lift smoothly using your leg muscles not your back.
T - Turn your feet in the direction of travel. Do not twist your body when you
are carrying a load.
When you lower the load, follow the lifting process in reverse.
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The photo on the left illustrates improper lifting technique.
His knees are not bent. This put a lot of strain on the back.
The photo on the right shows the proper way to lift.
His knees are bent and he is using his leg muscles.
The “safe lifting zone” is the distance between your upper thigh and mid-
chest.
Whenever feasible, heavy items should be stored within the “safe lifting
zone”. Moving items within this zone puts the least strain on your back.
Remember that using a back belt does NOT enable you to lift heavier
items!
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Having a good grip on the object you are about to lift and move is very
important.
Here is an example of a vise handle, that makes it easier to move a vise.
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Get assistance when you need to move objects:
• Anytime your personal health condition warrants it (such as a previous
injury, recovering from surgery, etc.)
• Whenever the object you need to move is heavier than 50 pounds
• When moving large, awkward, or long objects
Remember to coordinate each step of the lift!
Notice that the person on the right in the first photo has his knees locked
and his feet are unstable. He is not using the correct lifting technique.
The 2nd photo shows the proper way to lift – his knees bent and his feet
parallel, creating a stable base.
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Using a cart, dolly, or hand truck combines manual and mechanical
material handling. You may still have to put the load on and take it off the
cart, but you do not have to carry it. Using this equipment:
• Reduces the amount of lifting necessary
• Allows for good body positioning for weight transfer
• Allows you to work within the “safe lifting zone”
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Pushing and pulling activities can lead to back injuries. Here are the key
point to keep in mind:
• Pushing puts less strain on your back than pulling.
• When pushing, use both arms.
• If you must pull - avoid sudden stops.
• For both pushing and pulling, maintain an upright posture and stay
close to the load.
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Mechanical material handling eliminates manual lifting entirely, reducing
the risk of injuries.
Examples of equipment used for mechanical material handling include:
• Forklifts
• Hoists
• Cranes
You must be trained before you can use this type of equipment!
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In Summary:
Risk Factors include – repetitive motions, awkward posture, forceful
exertion and static posture.
The frequency & duration of each risk factor are critical
considerations.
Remember to always use the SMART lifting technique.
Use carts, dollies and hand trucks whenever possible.
Never lift objects heavier than 50 pounds without assistance!
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