PErforM manual tasks risk assessment
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This document discusses manual tasks and risk factors for injuries. It provides definitions for hazardous manual tasks and outlines common risk factors like force, awkward postures, vibration, duration, and repetition. Injuries can result from single exposures or repeated exposure over time. The document presents a risk assessment tool called PErforM that evaluates risk factors and controls. It provides an example risk assessment for lifting a heavy lid and the control of installing hinges to reduce force and awkward postures. Finally, it discusses implementing and monitoring controls to ensure risks are effectively reduced.
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PErforM manual tasks risk assessment
- 1. PErforM for work teams Insert presenters names and titles
- 2. Manual tasks Manual tasks risk factors
- 3. DVD- No sprains, big gains
- 4. Meaning of hazardous manual task “Means a task that requires a person to lift, lower, push, pull, carry or otherwise move, hold or restrain any person, animal or thing that involves one or more of the following: (a)repetitive or sustained force (b)high or sudden force (c)repetitive movement (d)sustained or awkward posture (e)exposure to vibration.” [Schedule 19 - Dictionary]
- 5. Manual tasks related injuries • Single, one off exposure: – due to maximum exertion or over load incident – quite rare. • Repeated exposure: – ongoing wear and tear – variety of risk factors – more common. • Combination of both of the above.
- 6. Risk factors: Force • Greater force - greater risk. • Speed and jerk. • Factors that increase effort.
- 7. Risk factors: Working postures • Awkward. • Static.
- 8. Risk factors: Mechanical vibration • Whole body vibration – vibration is transmitted through the whole body • Hand/arm vibration – vibration is transferred to the hand/arm via eg use of a vibrating tool
- 9. Risk factors: Duration • Time taken to perform the task once or repeatedly without a break. • Amount of time exposed to a risk factor. Photos: Daryl Dickenson
- 10. Risk factors: Repetition • Short cycle time < 30 seconds. • Continuously for one hour.
- 11. PErforM risk assessment tool Worksheet 1 - Manual tasks risk assessment form: • Date of assessment and location. • Risk assessors. • Task description.
- 12. Worksheet 2 - Risk factor assessment Risk factors: • exertion • awkward posture • vibration • duration • Repetition. Body map: • body part. PErforM risk assessment tool
- 13. Neck Upper back Elbows Wrists/hands Knees Ankles/feet Shoulders Lower back Hips/thighs Lower legs Body map
- 14. PErforMtask - worksheet 2
- 15. Scenario – lifting lid on pre-heater box Worker exerting force and awkward postures to lift the lid on the pre-heater. Lid was: • catching on the lip of the pre-heater resulting in forceful jerky movements • heavy and awkward to lift.
- 16. Risk assessment - before
- 17. PErforM team control measure • Sun Metals reduced the forceful exertions and awkward postures by repairing the lid so that it no longer caught on the lip of the pre-heater. • By putting a hinge down the middle of the lid it can easily be opened from each side. Pre-heater with lid cut in half and hinges installed. Worker opening pre-heater with lid cut in half and hinges installed.
- 18. Case study - control
- 19. Elimination Engineering Hierarchy of control Elimination Work teams are trained to use control the hierarchy to eliminate or reduce risk
- 21. Administration •J ob rotation • Change of workflow • Task specific training • Preventative maintenance program • Personal protective equipment Team lift
- 22. Risk controls Developing control ideas: • link the control to the risk factor • consult with workers and others • look for different ways • look at similar tasks for ideas • find out what are others are doing • talk to suppliers • trial before implementation.
- 23. Focus controls on sources of risk: • Change design or layout of work areas. • Changing the nature, size, weight or number of persons, animals and things handled. • Systems of work. • Work environment.
- 24. Work area design / layout Good design includes: – suitable working heights – adequate space – frequently used items in easy reach – adjustable to suit all workers.
- 25. Changing the nature, size, weight or number of persons, animals and things handled Consider: – load handling – tools and equipment – maintenance.
- 26. System of work • Guidelines include: – control work load – suitable work pace – task variation – maintenance schedules – match task demands with workers’ capability – training.
- 27. Work environment • Vibration exposure. • Cold conditions. • Heat and humidity. • Windy conditions. • Floors and surfaces. • Lighting.
- 28. • Consider: – short term – medium term – long term. • Maintain ongoing communication and participation between workers, supervisors and managers. Implementing controls
- 29. • To ensure: – controls are working effectively – risk factors have been reduced – another hazard or risk has not been created. Monitor and review
- 30. Practical
- 31. Where to from here? • Ongoing risk assessments. • Communication with managers. • Controls.
Editor's Notes
- Introduce self as facilitator, other staff in the room Emergency procedures
- Insert photo of one of the tasks that your work team do Managing manual tasks risks reduces the injury risks as well as reducing the physical requirements of tasks for all workers. It is therefore important to have an understanding of the risk factors and today we are going to go through these. In future toolbox talks we are going to look at risk assessment and controls using a process called PErforM - we’ll talk about this more in the next session.
- Show the group the DVD.
- The definition includes things like manipulate and throw. The definition covers the wide range of manual tasks not just lifting and carrying. Not all MT are a problem Its only the hazardous ones that you need to control. How do you know if you have a hazardous MT? The risk factors outlined in the regulation identify what is hazardous. Using the whiteboard- Ask the group- What are some hazardous manual task currently being performed at their workplace? Hand out the PErforM tool or have a laminated version to refer to. View the following slides and discuss the risk factors. Consider what score for each of the pictures or videos. Insert video footage or images from your workplace
- How do manual task injuries occur? Basically the musculoskeletal structure can become overloaded and then it fatigues. As with any supportive structure, fatigue can lead to damage and failure or in the case of the human body, a musculoskeletal injury. Occasionally a one off exposure to a severe load can result in a musculoskeletal injury, but more often most musculoskeletal injuries are caused through repeated wear and tear. To identify the manual tasks that are potentially putting ourselves or co-workers at risk, we need to understand manual tasks risk factors. Ask the group to refer to the risk assessment tool for the next few slides. Use the videos/ photos for each risk factor to score on the worksheet 2
- Forceful exertions place high loads on structures such as muscle, discs, ligaments and joints. The greater the force the higher the risk. The force is relative to the body part e.g. the muscles of the hand are smaller and can only tolerate a little force compared to the force the large legs muscles can tolerate. Forceful exertions require muscles to work hard which can cause fatigue in the muscle/s to occur more quickly. Fast movements require: Greater muscle forces, giving the same risk as forceful exertions Do not allow the body to compensate for unexpected changes, such as a tool slipping. Factors which can increase the effort required: Posture Loads – heavy/ bulky, difficult to grip, unpredictable Grips – with poor contact area Vibrating equipment – need to increase the grip to handle this equipment Observation skills - as part of doing a risk assessment you need to use your observation skills to gather information about the task. Highlight that participants probably already have good observation skills but explain that you will now look a the video and discuss what is being observed to indicate a force is being exerted. Note: if video footage demonstrating forceful exertions is available, show footage to the participants. If no footage is available discuss the photo shown on the slide eg tensing of hand, the fact you can see the thumb tendons and the tendons on the back of the hand.
- Working postures Awkward postures are postures where joints are at or near the extreme of their movement, e.g. your head bent to the side so your ear is by your shoulder. Demonstrate Ideally we would work in a neutral posture. A neutral posture for the hand/wrist body part is a handshake position. Have the group stand up and participate- ask the group what postures are “neutral” and compare with extreme “5” scores Review neutral postures for each major joint in the body. (with the aid of the laminated pictures) Certain tasks may require the worker to adopt an awkward posture. This might be due to the design of the tool or object they are handling, or the layout of their task. Awkward postures can cause damage to the muscles and other tissues when in combination with forceful exertion, another awkward posture (or uncomfortable postures) e.g. back bent and twisted, repetitive action or if fixed for a prolonged period. Static or fixed postures such as prolonged sitting or standing can sometimes be more fatiguing than tasks that require moderate movement. Your body has to work hard to hold the posture (leading to quicker muscle fatigue), put greater stress on other tissue and give your body less flexibility to deal with unexpected changes. Can be caused by poorly designed work area, tools, equipment or work practices. Consider pictures above or video if available and discuss which joints are involved, how extreme the postures are and if they a re static or awkward.
- Ask group what sources of vibration they have at their workplaces. Eg, operating a forklift all day on rough surfaces standing on a large machine that vibrates constantly using a jack hammer or grinder. Mechanical Vibration Exposure to continuous or high intensity mechanical vibration is a concern as it increases the strain and wear and tear on the body. Vibration mechanically strains the body; it makes the muscles work harder (and thus fatigue quicker) and reduces the blood flow. Two sources of mechanical vibration include hand/arm or whole body: hand/arm vibration can be caused vibrating hand tools such as grinders, drills and circular saws, particularly if they are not properly maintained or not appropriate for the task. It can result in fatigue, pain, numbness, tingling, decreased sensation in the fingers, hand and arm. whole body vibration commonly results from sitting or standing on work surfaces that vibrate such as forklifts, tractors or platforms. It is associated with general discomfort and lower back pain. Note: Jarring actions on the body such as hammering or jumping out of a vehicle cab are not considered to be vibration. These tasks which cause forces on the body should be considered as a forceful exertion risk factor. AS 2763 may be referred to. Standard states that if the vibration exposure to the worker is in excess of 2.9 meters squared for 4 hours, then the worker would need to have health surveillance. Need to measure the amount of vibration. However as rule of thumb, if after using a power tool for a short time, the finger tips when touched together tingle, it indicates that the nerves and the blood flow has been affected – an indicator of a potential problem. You should then look at controls e.g. select low vibration tools, tools that are insulated, separating the worker from the source.
- Duration is the amount of time exposed to a risk factor e.g. vibration, awkward postures without a break. Long periods of activity without a break increase the strain and wear and tear on the body. Duration may be considered a significant risk factor when a task is performed continuously for one hour or longer. Remember work activities performed before and after a task being assessed may need to be taken into account, particularly if the task has similar physical demands. Discuss video or photo. Now, as a group, we are going to observe a task and assess the risk factors using the PErforM tool
- Repetition also increases the strain and wear and tear on the body. There are even greater risks when repetition is combined with awkward postures and/or forceful exertion and/or fast movement and/or cold conditions. Repetition means making the same type of movements over and over e.g. laying bricks – insert industry relevant example The work cycle is the time taken to perform the task once without interruption. Tasks involving short cycle times of less than 30 seconds and performed for more than one hour are considered to be a risk because the same muscles and other soft tissues are being used continuously. Optional comment: The definition of repetition provided under PErforM is intended for simplicity. If you would like more detail you can refer to the Manual Tasks COP. Discuss video or photo to illustrate repetition.
- We will now go through how to use the risk assessment tool so lets have a look at Worksheet 1 The first part of the PErforM risk assessment process involves thinking about the task that has been identified by the work team and breaking it down to identify any significant risk factors. The risk assessment tool is useful for recording brief notes about the task. Discuss why it is a good idea to have a written record of the assessment eg can refer to it at a later stage, assists with re-evaluation after controls have been implemented, provides evidence that a risk assessment was done. When you are doing the training with the work teams, you and the work team would have identified a task to assess. You would have taken some video of the task being performed so that the team can watch it during the training. It is easier to assess a task using the video rather than trying to assess it on site eg you don’t have all of the distractions that occur in the workplace, you can rewind the video tape and discuss what the group is observing. Go thru form headings in turn - Refer group to the handbook to get an idea of what to put in this section. Also draw their attention to the case studies in Appendix 2 of the handbook. Date and Workplace Risk assessors Task Description: Name of task: Why was this task selected: The tasks should be selected because you think they have problems. To identify these &apos;current problem&apos; tasks look for tasks associated with reports of discomfort, fatigue, injury, poor productivity, awkward/difficult task to perform. You may also select the task if it is one of the primary tasks the work team performs. Location where task occurs: Who performs the task: General description: General description of the task, not the workplace procedure if there is one. It is intended to be a general overview as described by the work team. How do you describe the task? Eg How is the task done, what steps are taken to perform the task, how long does it take, how many times is it done, rest breaks, weight of objects, dimensions. Postures Forceful exertions Repetition and Duration Tools or equipment used Work/task organization and environment Discuss how information can be obtained regarding the above risk factors, tools and equipment, and work organisation and environment eg what questions might be asked or how measurements can be taken as well as observing the tasks and talking to the work team. When observing the task, look for evidence of the direct risk factors (working posture, vibration, repetition and duration, forceful exertions). Consider tool use and differences with workers. Work teams consider pain or discomfort experienced and with what part of the job or task, what aspects of the task they dislike and why, what parts of the task are physically difficult to perform (forceful exertions). More objective information about the task can be gathered by using a stop watch to measure cycle times or how long a task is performed, using a tape measure to measure distance travelled, the height of work surfaces, or the dimensions of objects handled, using scales or supplier information to identify the weight of objects handled. Other questions to ask include what other tasks do workers perform during their shift, breaks taken, have controls for this task been implemented previously - what has worked or not and why, is regular maintenance performed on the tools and equipment?
- Refer to the general headings of Worksheet 2. Worksheet 2 is where you assess the risk. Point out Instructions Risk factors Body map then take each in turn – go to body map slide
- Firstly, think about the parts of the body that are primarily affected when performing the task. Refer participants to the instructions 1 & 2 on worksheet 2 which are: Indicate on the body chart which area(s) of the body you feel is affected by the task. Suggestion: Ask workers which body parts get tired or sore when they perform the task. This will differ between workers. If more than one body part is affected you may shade the different body parts in different colours. If so, use the matching colour when scoring the risk factors( e.g. red for arms on the body and score sheet, blue for low back on the body and score sheet). Additional notes: For the purpose of analysis you may wish to combine different body parts. E.g. combine shoulders and neck; or wrist and elbow. There are no right or wrong answers – workers can assess as many body parts as they believe are affected by the task. Circle the label for the part of the body being assessed on that sheet. Indicate which side of the body part is affected or both.
- Here is an example of a completed risk factor assessment. In this example you can see that there is a high risk for the shoulders and the lower back in regards to force posture and duration and a high risk for the wrists in regards to duration and cycle time. Controls (which will be discussed later in the workshop) should be aimed at reducing these risks. This assessment can be used to re assess the task after controls have been implemented to see if the desired risk reduction has occurred. Some limitations of the PErforM risk assessment PErforM is a simplified manual tasks risk management approach and as such, there are some compromises with the use of PErforM. For example: Complex tasks may require the use of other ergonomic assessment tools, or the engagement of an expert to assist with the assessment and development of controls. The need for greater expertise may also be identified when prioritising control options. The risk assessment tool does not take into account the cumulative effect of the range of manual tasks a worker may perform during their shift. As a result, work teams will need to make some judgements about: which tasks are the hazardous tasks the priority order for their assessment whether the worker is being exposed to similar risk factors throughout the shift despite performing different tasks. If this is the case, consider controls which minimise the cumulative risk.
- We are now going to use the tool to assess this task. This task is carried out at - Sun Metals Corporation Pty. Ltd who are a zinc refinery located in Townsville that employs 310 workers. In 2011, Sun Metals implemented the PErforM program and this is one of the tasks they assessed and controlled. Sun Metals PErforM risk assessment team was made up of workers and managers, including its casting plant team leader, casting operational staff and health and safety advisor. hazardous manual task? The task assessed was lifting the lid on a pre-heater unit, which is a large enclosed box that maintains tools placed inside at about 55 degrees centigrade. This task was being completed regularly each day, with operators required to open the lid of the preheater, to change the tools approximately once per shift. Lifting the lid on the pre-heater was observed as a potential hazardous manual task. Workers advised that the lid was catching on the lip of the pre-heater resulting in forceful jerky movements when trying to lifting the lid, and that the lid was heavy and awkward to lift. ( refer picture) Ask the group – refer to the Risk Assessment tool and consider - What parts of the body might be injured and what were the risk factors? Consider the scores from the group.
- Using the PErforM risk assessment worksheet, Sun Metals work teams identified that opening the lid on the pre-heater exerted high force through the shoulders and back and resulted in moderately uncomfortable awkward postures through the shoulders. Ask the group- Considering the scores – what controls could be made- any ideas
- What was the Sun Metals solution? Sun Metals reduced the forceful exertions and awkward postures by repairing the lid so that it no longer caught on the lip of the pre-heater, and by putting a hinge down the middle of the lid so that it can easily be opened from each side. Outcomes and benefits The repair and modifications to the lid minimised the hazardous manual tasks associated with lifting the lid on the pre-heater unit, and were simple and cost effective to implement. Implementing the PErforM program demonstrated management commitment to addressing work health and safety risks and gave workers ownership of the solution. Worker involvement in identifying the issues and developing the solution was vital in ensuring the best and most sustainable solution was chosen.
- This is the follow up assessment after the control was put in place. Sun Metals Corporation Has saved more than $200,000 in workers&apos; compensation insurance costs and significantly reduced statutory costs over a twelve month period after implementing PErforM. They have assessed over 30 hazardous manual tasks with control put in place to minimise the risk. . In 2010–11, their workers&apos; compensation premium rate was $1.38 and in 2011–12 it dropped to $0.97 - a considerable saving. Similarly, the company&apos;s average statutory cost - the true cost of what was being paid in medical bills after an injury had occurred - reduced by almost 400 per cent in 2011–12, reflecting a significant reduction in incident severity.
- The Manual Tasks regulation requires PCBU&apos;s to work through the hierarchy (S36). Note: The levels on the slide refer to page 21 of new code and page 14 of the How to Manage Work Health and Safety Risks C of P 2011. Engineering controls are preferred over administrative controls because they eliminate or minimise the risk and are permanent. Administrative controls are reliant on human behaviour ie the worker following the correct procedure, they only reduce exposure to the risk, may be forgotten under stressful conditions, and require ongoing supervision.
- Discuss examples here.
- Suggested Activity- refer back to whiteboard examples the group identified as hazardous manual tasks in their workplace and ask what controls are currently in place to manage the risk. Discuss where they belong in the hierarchy
- How do you develop control ideas? Brainstorm – look for all possible control options to reduce the risks for this task. Make a rule with the work team that we can work outside the square, any idea is ok. Don’t dismiss ideas at this stage. Develop ideas for controls by: look at what is causing the risk and change these factors Talk to workers and others who may can contribute eg engineers Be creative - think of different or new ways of doing the task look at similar tasks and see how they are done, if they have a solution/control Find out what other workplaces are doing by talking to work teams, supervisors or work colleagues/acquaintances who may do similar work Talk to suppliers, find out what is available or raise your problem with them. They may be able to suggest something or come up with a new product. Always trial controls before implementation
- When a manual task risk factor has been identified, it is important to identify what is causing it. In order to eliminate or minimize the risks, controls should be aimed at: Change design or layout of work areas Changing the nature, size, weight or number of persons, animals and things handled Systems of work Work environment These are the things that are causing the manual tasks risk factors. If you fix these things you will take away the problems that are affecting the body.
- Throughout the following slides it is good to have industry specific examples of suggested controls. You may wish to insert different examples/photos to reflect your workplace/industry. Work Area Design Work area is where the job is based and includes work bench, seating, layout of workstation. A well designed work area: reduces exertion e.g. reduces reach distance reduces awkward postures e.g. reduces bending, twisting, fixed postures Reduces whole body vibration Guidelines for work area design include: Provide suitable working heights matched to the task demands e.g. adjust work bench height to reduce back and neck bending (if working height is too low) or shoulder and arms raising (if too high) Provide adequate space to minimise awkward postures Effective placement of all components of the task to minimise reach and access Provide for adjustability to accommodate a wide variety of physical size, shapes and dimensions i.e. suitable for people of different heights and sizes. Provide appropriate seating suited to the individual and the task. Storage areas are often an area that is easy to improve the design of , reducing manual task risk factors.
- Consider size of loads when handling. Making it smaller may reduce the exertion or making It larger to become managed by mechanical means Reduce the size or capacity of containers Consider Tool Design A well designed tool: reduces exertion e.g. reduces effort to grip or balance tool reduces hand arm vibration reduces awkward postures e.g. reduces bending of wrist Maintenance on tools and equipment may reduce unnecessary exertion or excessive vibration
- Good work organisation allows for: provision of postural variety, flexible tasks and times minimised time pressures and stress consultative processes Consider: Control the work loads. Minimise peaks in workload through appropriate staffing levels, preparing work in off peak periods or rearrangement of material flow. Set suitable work pace. Ensure reasonable/adequate work rates particularly with risk factors at an unsafe level. Provide task variation. This allows for postural variety. Develop maintenance schedules. Maintenance on equipment can reduce the effort required and may prevent awkward postures. Match task demands with workers’ physical and functional capacity. See that the job is suitable for the worker e.g. returning from long absence, injury or pregnancy. Training. It is important workers are training in the correct work practices and training is updated when the job changes.
- The work environment can be a source of risk for MSD when performing manual tasks. Consider: the impact whole body or hand arm vibration have on the worker. Improving vehicle suspension, road maintenance, vehicle speed , substitute alternate manufacturing methods or processes to eliminate the need for vibrating equipment- are some areas that can be addressed to reduce risk Select lighting to suit the task performed- prevent awkward or sustained postures that may arise from low or excessive lighting levels -Control the exposure of cold to you workers by regular rest breaks in a warm place, appropriate clothing and footwear – example in picture – working in refrigerators -Consider impact of heat and humidity- providing a cool, well ventilated area for breaks , drinking water, work schedules, ventilation and cooling systems.\ -Consider co-ordinating tasks during low wind conditions -Keep work areas clean and tidy and free of clutter- Housekeeping -
- Implementation of control measures An action plan of what needs to be done; and who is going to do it; and by when: will assist the work place to track progress and allocate responsibilities. Consider control options for the: Short term Medium term Long term Ensure workers and supervisors are kept informed about what is happening.
- Monitoring solutions It is important to monitor and review to ensure that: the control is reducing the risk factors - re-evaluate using worksheet another risk factor isn’t introduced another hazard has not been created It is important that the PErforM process is ongoing to ensure that the controls implemented are working. Work teams should be getting together on a regular basis, where they have the opportunity to go through this stage (and others) of the risk management process. As the coordinator/trainer, you are a vital part of driving this ongoing commitment to PErforM
- Practical
- Discuss how PErforM risk assessments will be conducted (e.g. which work teams, who will coordinate it, when will they be done e.g. 1 per month / toolbox talk etc).