Ergonomics & Manual Handling

“Ergonomics & Manual Handling” is a 1-day training
course specifically for those;
people responsible for
performing manual handling
activities and
the personnel who manage
or conduct workplace risk
assessments required by the
Health and Safety Regulations
on Manual Handling
Operations.
Ergonomics & Manual Handling
Introduction

The course includes a thorough description of the
Manual Handling Operations and the Ergonomics
principles that that should be applied to reduce the risk
of manual handling injury..
Introduction
This approach not only
delivers legal compliance, but
will help reduce body-related
sickness and absenteeism,
lower healthcare costs,
insurance premiums and
compensation claims and
improve the productivity of
the workforce.

After completing this course, participants will be able
to;
 Identify potential causes of manual handling back
injuries
 Develop ergonomic solutions that can be applied
to reduce these injuries
 Encourage correct lifting postures, techniques and
principles that minimize injuries to workers
 Use ergonomics principles to re-design manual
handling tasks, work areas and work equipment
 Complete a manual handling checklist to prioritize
levels of risk
Skills and information Participants will learn.

This course is suitable for all participants including;
Who Should Attend
senior managers,
 administrative executives,
 engineers,
facilities professionals,
 managers,
 health and safety professionals,
 line supervisors,
 technicians and
line operators.

Key Elements of Course Outline
Introduction to Ergonomics
Anthropometry and Anatomy
Types and causes of injuries and illnesses
Back/lower limb
Ergonomics principles applied to:
Manual Handling
Work Movement procedures
Work area layout
Seated & Manual Handling workstation jobs
Standing & Manual Handling workstation jobs
The Manual Handling Operations
Correct and Proper Handling & Lifting Techniques
The manual handling risk assessment procedure
Manual Handling Checklists
Instruction and demonstration
Practical exercises
Risk prioritization process
Solution design

Introduction to Ergonomics & Manual Handling
If the workstations are too tall or too low people will
not adapt, they will just be placed into tasks that will
put them under additional stress.
Traditionally equipment
was designed for the
average worker which
meant that it was too low
for half of the population
and too high for the other
half.

Ergonomics is a term that comes from two Greek words
“ergos” and “nomos” which could be literally translated
as the study of work.
Ergonomics is not a new
concept it has been
around for decades…
We often discuss
ergonomics in terms of
fitting the work to the
worker.
Ergonomics

This is opposed to a previous concept were workers
were expected to adapt to existing equipment and
setup.
Ergonomics

Many people have studied the science of ergonomics
and their results can provide us with information that
we can use to design jobs and tasks that will better fit
our workers.
If the design fits the worker
better, it means that it is also
designed to match their
physical abilities better.
This fact should make it
easier for the worker to
perform their job.
Ergonomics

"Manual handling" means using your body to exert
force to handle, support or restrain any object, and
includes not only lifting and carrying but also repetitive
tasks.
A manual handling
task that has the
potential to cause
injury is a "hazardous
manual handling
task".

Manual Handling also involves any transporting or
supporting of a load by one or more employees or
moving a load,….
which by reason of its
characteristics or
unfavorable ergonomic
conditions, involves risk,
particularly of back injury,
to employees.

If not carried out ergonomically, manual handling activities
can lead to serious physical injury – to you and the person
you are moving.
Risks of Hazardous Manual Handling Task
Musculoskeletal
disorders (MSDs)
are the most
common injury
caused by non-
ergonomic manual
handling practices.

Risks of Hazardous Manual Handling Task
Like back pain and upper and lower limb disorders,
including aches, tenderness and stiffness in the legs, hips,
shoulders, neck and joints.
The person being
moved may also suffer
from damage to fragile
skin, cuts, grazes,
bruises, and injuries to
the neck, shoulders
and arms if they are
not handled with care.

Anthropometry and Anatomy
Anthropometry, or anthropometrics; is the study of
human body measurements.
At its most basic,
anthropometrics is
used to help scientists
and anthropologists
understand physical
variations among
humans.

Anthropometry
In the modern era,
anthropometrics have
had more practical
applications, particularly
in the areas of genetic
research and workplace
ergonomics.
Anthropometrics are useful for a wide array of
applications, providing a kind of baseline for human
measurement.

The typical body measurements used in anthropometrics
include height, weight, body mass index (or BMI),
waist-to-hip ratio and body fat percentage.
By studying the
differences in these
measurements
among humans,
researchers can
assess risk factors
for a host of
diseases.

ANTHROPOMETRICS IN ERGONOMIC DESIGN
Ergonomics is the study of people's efficiency in their
working environment. So ergonomic design seeks to
create the most efficient workplace while providing
comfort for the people within it.
For the purposes of ergonomic
design, anthropometrics offers
information about the average
human build to accommodate
the largest set of the population
based on an anthropometric
range.

This gives chair makers data they can use to devise more
comfortable seating, for example.
Desk manufacturers can build
desks that don't force workers
to hunch in uncomfortable
positions, and keyboards can
be designed to reduce the
likelihood of repetitive stress
injuries like carpal tunnel
syndrome.

Anatomy
Anatomy; from the Greek anatomē "dissection” cut up,
cut open“, is the scientific study of the structure
of organisms including their systems, organs and tissues.
It includes the appearance
and position of the various
parts, the materials from
which they are composed,
their locations and their
relationships with other parts.

Anatomy
Anatomy;
The study of human or animal
form, by observation or
examination of the bodily
structure of humans and other
living things, especially as
revealed by dissection and the
separation of parts.

Anatomy
Physical ergonomics is concerned
with human anatomy, and some of
the anthropometric, physiological
and bio mechanical characteristics
as they relate to physical activity.
For example, an anatomist is
concerned with the shape, size,
position, structure, blood supply
and innervations of an organ such
as the liver.

For example, an anatomist is concerned with the shape,
size, position, structure, blood supply and innervations of
an organ such as the liver.
Physical ergonomic
principles have been
widely used in the
design of both
consumer and
industrial products.
Anatomy

Medical conditions are often related to other diseases
and conditions.
These conditions may be
a cause or symptom of
Low Back Pain or be a
condition for which you
may be at increased risk.
Back/lower limb pain

Back/lower limb pain or Sciatica?
Back pain is extremely common. There are many causes
of lower back pain that are not sciatica.
Frequently, low back pain is
caused by back strain of
muscles and ligaments.
The characteristic feature of
sciatica is pain that radiates
down the leg from the low
back, often reaching the
foot.

Back/lower limb pain (Sciatica)
Sciatica is a pain that radiates from the low back down
a lower extremity; it is caused by irritation of the sciatic
nerve.
The sciatic nerve transmits
sensation from the lower
extremities and lumbar
area of the low back. It is
common for people to
recover from sciatica
without a surgical
operation.

Sciatica Symptoms; Low back pain that radiates to the
hip, buttock, and down a lower extremity is the most
common symptom of sciatica.
Sometimes sciatica pain
worsens with bending at the
waist, coughing, sitting, or
sneezing. Sciatica can also
cause tingling, numbness, or
weakness of the leg. Sciatica
symptoms can occur rapidly
and persist for weeks.
Back/lower limb pain (Sciatica)

Sciatica is common as we reach middle age. Pregnancy
can lead to sciatica as a result of direct pressure on
the sciatic nerve by the enlarging uterus.
Other causes of
sciatica are
degenerative
spinal arthritis
and lumbar disk
hernia.
Who Is Likely to Get Sciatica?

Is your Back/lower limb pain Sciatica?
Cause: Herniated Disk.
Disk hernia is a common cause of sciatica. The disk
cushions between the spinal vertebrae weaken and are
more vulnerable to injury as we age.
The weakened disk can
herniate its gel-like
center to cause direct
pressure on the nerves
in the spinal canal that
form the sciatic nerve.

Diagnosing Sciatica:
To detect the cause of sciatica, the doctor will ask
about all the symptoms you are experiencing and their
location and aggravating or relieving features.
During the
examination, you may
be asked to do various
maneuvers with the
lower extremities
Is your Back/lower limb pain Sciatica?

Ergonomics principles applied to:
 Manual Handling
MINIMIZE SIGNIFICANT BODY MOTIONS
1. Reduce Bending Motions
2. Reduce Twisting Motions
3. Reduce Reaching Out Motions
 Work Movement procedures
REDUCE OBJECT WEIGHTS/FORCES
1. Reduce Lifting and Lowering Forces
 Work area layout
2. Reduce Pushing and Pulling Forces‘
 Seated & Manual Handling workstation jobs
3. Reduce carrying forces
 Standing & Manual Handling workstation jobs

•Using lift tables, work
dispensers and similar
mechanical aids.
•Raising the work level to an
appropriate height.
•Raising or Lowering the worker.
•Providing all material at work
level.
Minimize Significant Body Motions
1. Eliminate the need to bend by:
•Keeping materials at work level (e.g., don't lower
anything to the floor that must be lifted later).
Ergonomics principals applied to Manual Handling

•Providing all materials and tools in
front of the worker.
•Using conveyors, chutes, slides,
lifts or turntables to change
direction of material flow.
•Providing adjustable swivel chairs
for seated workers.
•Providing sufficient workspace for
the whole body to turn.
•Improving the layout of the work
area.
2.Reduce Twisting Motions
Eliminate the need to twist by:

•Providing tools and machine controls close to
the worker, to eliminate horizontal reaches
over 16 inches.
•Placing materials, workplaces and other heavy
objects as close to the worker as possible.
•Reducing the size of cartons or pallets being
loaded, or allowing the worker to walk around
them; rotate. raise or lower them.
•Reducing the size of the object being
handled.
•Allowing the object to be kept close to the
body (i.e. Scissor Lifts).
3. Reduce Reaching Out Motions
Eliminate the need to reach by:

REDUCE OBJECT WEIGHTS/FORCES
Ergonomics principals applied to Work Movement Procedures

•Using lift tables, lift trucks,
cranes, hoists, balancers,
industrial manipulators,
drum and barrel dumpers,
elevating conveyors, and
similar mechanical aids.
Reduce Lifting and Lowering Forces
A. Eliminate the need to lift or lower manually by:
•Raising the work level. Lowering the operator. Using
gravity dumps and chutes.

But if you really need to lift heavy object from the ground,

B. Reduce the weight of the object by:
•Reducing the size of the object (specify
size to suppliers).
•Reducing the capacity of the
containers.
• Reducing the weight of the container
itself.
•Reducing the load in the containers
(administrative control).
•Reducing the number of objects lifted or lowered at
one time (administrative controls).

C. Increase the weight of the object so that it must
be handled mechanically:
•Use the unit load concept
(such as bins or
containers, preferably with
fold down sides rather
than smaller totes and
boxes).
•Use palletized loads.

D. Reduce the hand distance by:
•Changing the shape of the
object.
•Providing the grips or handles
•Providing better access to
object (i.e. scissor lifts,
turntables or tilters).
•Improving layout of work
area.

•Using powered conveyors.
•Using powered trucks.
•Using powered scissor
lifts or turntables.
Reduce Pushing and Pulling Forces
A. Eliminate the need to push or pull by:

•Reducing the weight of the load.
•Using non-powered conveyors,
air bearings, ball caster tables,
monorails, and similar aids.
•Providing good maintenance of
floor surfaces, hand trucks, etc.
•Treating surfaces to reduce
friction.
•Using powered scissor lifts.
B. Reduce the required force by:
Ergonomics principals applied to Work Area Layout

•Improving
layout of
work area.
•Relocating
production
or
storage area
C. Reduce the distance of push or pull by:
Ergonomics principals applied to Work Area Layout

•Use conveyors, air bearings,
ball caster tables, monorails,
slides, chutes and similar aids.
•Use lift trucks, two wheel
hand trucks, four wheel hand
trucks, dollies and similar
aids.
Reduce carrying forces
A. Eliminate the need to carry by converting to pushing
or pulling.
Ergonomics principals to Seated & Manual Handling Workstation
job

•Reducing the size of the object
(specify size to suppliers).
•Reducing the capacity of containers.
•Reducing the weight of the container
itself.
•Reducing the load in the container
•Reducing the number of objects
lifted or lowered at one time
Reduce carrying forces
B. Reduce the weight of the object by:
Ergonomics principals to Seated & Manual Handling Workstation
job

Standing is a natural human posture and by itself poses
no particular health hazard. However, working in a
standing position for long periods of time and on a
regular basis can cause;
Ergonomics principals to Standing & Manual Handling
Workstation job
sore feet,
 swelling of the legs,
 general muscular fatigue,
lower back pain,
 stiffness in the neck and
shoulders, all in a relatively
short time.

For the best health and safety outcome, workers should
be able to adopt a variety of positions - that is to have
the option to sit, stand, move around and vary the
nature of work tasks.
Workstation job
It is important for the
worker to be able to
equally distribute loads
on different parts of the
body, with no physical
strain.

Variety of good posture at workstation.
Workstation job

Workstation job
Reduce the time spent standing
or walking
Obtain suitable, adjustable
chairs
Have more rest breaks
Alternate standing and walking
with sitting
Make work surfaces height-
adjustable.
The following key advice from the TUC (Britain's peak
union council) and the Canadian Centre for Occupational
Health and Safety on Standing & Manual Handling
Workstation job should be to:

Floor/standing surface
Wooden, cork or rubber-covered floors are far preferable
to concrete. If the floor surface is hard, then provide mats
for the workers to stand on.
Workstation job
Floor mats must be dense
enough to cushion the feet, but
not too thick ('anti-fatigue'
matting is available).
Too much cushioning, from thick
foam-rubber mats, for example,
can cause fatigue and increase
the hazard of tripping.

Advice for proper Standing Workstation position:
Workers should always face what they are working on,
with their body close to the work.
Workspace should be adjusted for enough space to
change working position.
Workstation job
Foot rail or portable footrest be provided to shift
their body weight from both legs to one or the
other leg.
A seat whenever possible while working, or at
least during rest breaks.

Comfortable Footwear:
The comfort of the legs, hips and back depends on the
feet and Foot comfort depends largely on footwear.
Workstation job
Shoes need to be wide enough
to leave room to move toes.
Shoes should have arch
supports to prevent flattening
of the feet, and a heel with a
firm grip to prevent slipping.
 The footwear should have
heels that are not flat, but are no
higher than 5 cm (2 inches).

Workstation job
Lace-up shoes are preferable, as
they allow the worker to tighten the
instep of the footwear, ensuring the
foot does not slip inside the shoe or
boot.
If the worker is standing on a metal
or cement floor, the foot should be
cushioned with a shock-absorbing
insole.
Comfortable Footwear:
The comfort of the legs, hips and back depends on the
feet and Foot comfort depends largely on footwear.

Workstation job
Relief stress on a Pedestal Stool
A pedestal stool is an adjustable seat, usually 65-85cm
high, which is tilted forwards between 15 and 30
degrees. Pedestal stools are generally used
in the workplace to vary a standing
work posture, when workers are
required to stand for long periods.
They allow the worker to adopt a
semi-supported posture, to relieve
the stress on the legs.
Do not use a pedestal stool for long periods of time, as it is
only suited to relief stress on long standing activities.

 Correct and Proper Handling & Lifting Techniques
The manual handling risk assessment procedure

Squat down, bending at the hips and knees only. If
needed, put one knee to the floor and your other knee
in front of you, bent at a right angle (half kneeling).
Slowly lift by straightening
your hips and knees (not
your back).
Keep your back straight, and
don't twist as you lift.
 Do not attempt to lift by bending forward.
Never lift a heavy object above shoulder level.

Use your feet to change direction, taking small steps.
Lead with your hips as you change direction.
Keep good posture.
Look straight ahead, and keep
your back straight, your chest
out, and your shoulders back.
This helps keep your upper
back straight while having a
slight arch in your lower back.

Hold the load as close to your body as possible, at the
level of your belly button.
Set down
your load
carefully,
squatting
with the
knees and
hips only

The manual handling risk assessment procedure gives
direction and practical information to those that work in
the manufacturing sector on action that can be taken to
manage the potential hazard of manual handling in the
workplace.
This is necessary to work
towards preventing
musculoskeletal injuries at
work and reducing exposure
to high financial costs
including compensation
claims.

Introduction
The Manual Handling Operations Regulations 1992 (as
amended) requires employers to:
•avoid the need for hazardous
manual handling, as far as
reasonably practicable;
•assess the risk of injury from any
hazardous manual handling that
can’t be avoided; and
•reduce the risk of injury from
hazardous manual handling, as
far as reasonably practicable.
The risk should be reduced to the lowest level ‘reasonably practicable’.
That means reducing the risk until the cost of any further precautions -
time, effort or money - would be far too great in proportion to the benefits.

The basic principle of the regulation is that where manual
handling activities may involve a risk of injury (particularly
to the back) due to unfavorable ergonomic conditions,
the employer
must take
measures to
avoid or reduce
the risk of injury.

The employer
needs to take
measures to
implement
preventative
measures based
on the outcomes
of the risk
assessments.
The employer needs to manage the hazard through
implementation of a manual handling risk assessment
process .

information objectives are;
• To raise awareness of the
business case for the hazard of
manual handling and why it
needs to be managed in the
workplace .
• To understand and recognize
the potential risk factors of
manual handling in their
workplace
• To give direction on manual handling risk assessment to
be used to highlight potential hazards

objectives (continue)
• To develop better ways of
working, including use of handling
aids, improved housekeeping or
better work processes resulting in
reduced handling of stock and
reduced risk of musculoskeletal
injury
•To explain how to complete a manual handling risk
assessment process
•To give direction on developing a safe system of work
plan

Guide on Manual Handling Risk Assessment in the
Manufacturing Sector
It is useful, through consultation with staff, to get an
understanding of the potential risk factors as they
relate to specific tasks.
Manual handling tasks that will need to be risk assessed
will include one or all of the following risk factors:

Note: This is not an exhaustive list of risk factors for manual
handling of loads
Risk factor (unfavorable ergonomic condition) Picture
The lifting of the load requires repeated
bending of the trunk
The lifting of the load requires repeated
manipulation of the load at a distance
from the trunk
The load is very large and difficult to grasp
The Unfavorable Ergonomic Manual Handling Risk Factor

The Unfavorable Ergonomic Manual Handling Risk Factor
Note: This is not an exhaustive list of risk factors for manual
handling of loads
Risk factor (unfavorable ergonomic condition) Picture
The physical effort can only be achieved by a
twisting of the trunk
The load is carried over a long distance and
there is poor housekeeping with unsafe
access
The handling repeatedly takes place at floor
level or above shoulder height

Preventative measures based on the outcomes of the risk
assessments include safe system of work plans for site-
specific tasks, providing;
information on the use of
mechanical aids,
 reorganization of a work
activity to allow loads to be
handled at a safe height or
 the provision of
instruction to workers on;
how to use handling aids or
handle loads safely.

Ergonomic Manual Handling Checklists
 Instruction and
demonstration
 Practical exercises
 Risk prioritization
process
 Solution design
“Tell me and I’ll forget; show me and I may remember;
involve me and I’ll understand.”

 Instruction and demonstration
Must it be moved?
Must it be lifted?
Can it be moved mechanically?
Can the load be reduced?
Can assistance be accessed?
Is the load too heavy to lift safely?
Is training required?
Control Considerations for
Manual Handling
Think before you Lift.
Manual handling occurs when you are Lifting, Lowering,
Pushing, Pulling, Carrying, Moving, Holding, Restraining….
Any person, animal or thing

Before Lifting
• Stop and assess the load and if too heavy seek advice
• Consult management or safety officer for advice on how to manage
heavy loads
• Plan the lift. i.e. estimate the load and know exactly where it is to be
placed prior to lifting
• Avoid reaching out.
• Do not reach out to pick up any object
• Handle heavy objects close to the body
• Keep yourself in good physical shape with proper exercise and diet
• Avoid lifting heavy loads without help and plan the lift
together
• Can you reduce the load???
• Wherever possible use mechanical means, e.g. can you use
a Forklift, winch or crane
• Avoid placing objects on ground if they have to be picked up
at a later date
Safe Work Instruction on Manual Handling SW001

•Ergonomic Manual Handling Checklists
When Lifting
• Bend your knees, keep a straight back and make use of your legs to lift
•Lift slowly and smoothly without jerking and when turning move feet.
Do not twist or turn with hips or shoulders
•Make sure you have a firm grip
•Position the feet evenly on each side of the load
•Bend the knees
•Keep you back straight and your arms close to the body
•Brace the stomach
And remember “Lift using your legs NOT your back”
Safe Work Instruction on Manual Handling SW001
•Ensure objects to be lifted have sufficient space around to
enable safe lifting
• Make sure you are capable of lifting and your body is warm
and flexible especially when weather is cold

Following this lifting technique to ensure a smooth
process placing the minimum effort, stress and tension
on the body to reduce the likelihood of a cumulative
injury.
Manual Handling Practical Exercise -
The Six Point Lift

Manual Handling Checklist Example
Item Yes No Required Action Person
Respon-
sible
Comple-
tion
Date
1. Have you identified all manual handling tasks
that may be a risk to health & safety?
List potential manual handling risks
– those that could be a risk. Use
Codes of Practice that can assist
with manual handling
2. Have you assessed the risks from the manual
handling tasks identified in 1 above? (Risk
assessment is included in this topic)
Use the manual handling risk
assessment tool included in this
topic – Risk assessment tool is from
the Victorian Compliance
Code - 2000
3. Have you taken steps to control the risk
associated with the hazards identified in 1
above? Ensure manual handling controls are in
place – use of mechanical aids (cranes, trolleys,
forklifts) should be considered as first priority
Consult with staff to determine the
most suitable control methods. Use
the hierarchy of controls to set
priorities
4. Have workers been trained in correct manual
handling techniques?
Workers should be trained
5. Is there adequate supervision for staff
performing manual handling tasks?
Ensure workers are using
correct manual handling aids and
techniques
Date Assessment Completed ……………………….

Practical Exercise Sign Off Check sheet
Name Signature Name Signature
Staff Sign off -
I, the undersigned have read and understood the Manual Handling safety instruction
and the general safety controls that are recommended when I am involved in any
Manual Handling task.
I also understand that I must conduct a risk assessment prior to any Manual
Handling activity to ensure I have properly assessed the load and methods of
movement.

 Risk prioritization process

Solution design

• Principal Consultant for Lean Management.
Certified ‘Train the Trainer’ & Kaizen
Specialist with 30 over years working
experience.
Provides Technical Consulting Services on
Lean, Kaizen & 21st Century Manufacturing.
• An Innovative Engineer that innovates by
Recycling & Reusing Idle resources to
promote Green.
• Founder of Tim’s Waterfuel an alternative fuel
supplement using Water to add power &
reduce Co2 emission on automobiles.
• Rode 24 Countries, 18,290km,4 months 11
days 6 3/4 hrs from Malaysia to London on
just a 125 cc.
Timothy Wooi
Senior Consultant
For: Northern Ville Consulting Sdn.Bhd.
info@northernville.com.my
No 8, 2nd Floor, Jalan Mahkota 7/8A,
Pusat Bandar Putra Point, Putra Heights,
47650, Subang Jaya, Selangor Darul Ehsan.
Tel: 03-5191 2688 / 016-238 9686
http://www.northernville.com.my
Fax; 03-5198 0062
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