rodney powell - worksafe wa - cost effective solutions to manual handling problems
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Manual Handling
The Cinderella Hazard
Rodney Powell
Senior Scientific Officer (Ergonomics)
rodney.powell@commerce.wa.gov.au
MH Fatalities
1994 WA: 6 x 167 kg sheets of glass
1998 WA: 15 x 29 kg sheets of wire mesh
2002 NSW: 4 - 5 x 60 kg sheets particleboard
2007 WA: 220 kg slab of engineered stone
2007 NSW: 20 x 70 kg sheets of glass
2008 WA: 20 x 46 kg sheets particleboard
Reg 3.4 concerned with allhazards associated with manual handling
From my
perspective:
Sometimes OSH people rely too much
on JSAs
Do accident investigations when a risk
assessment is more appropriate
From my
perspective:
Vocational Rehab. people too much into
“medical model” & focus on RTW mods
rather than what caused injury & not
asking why do it in the first place?
Start
here
I am not endorsing any specific
products.
Photos are shown to give examples only (& maybe provide some inspiration)
OUTLINE
My overview of MT risk assessment
Overview of Risk Controls
How to develop your own solutions
(Participative Ergonomics)
Where to find solutions (Resources)
OUTLINE
My overview of MT risk assessment
Overview of Risk Controls
How to develop your own solutions
(Participative Ergonomics)
Where to find solutions (Resources)
What is “Manual Handling”/a ”Manual Task”?
What is “Manual Handling”/a ”Manual Task”?
Lifting Carrying
Pushing Pulling
Holding Restraining
Holding fixed posture
Holding awkward posture
Repetitive movements
What is “Manual Handling”/a ”Manual Task”?
Lifting Carrying
Pushing Pulling
Holding Restraining
Holding fixed posture
Holding awkward posture
Repetitive movements
Occupation
Duty 1
Task 1
Activity Activity Activity
Task 2
Activity Activity
Duty 2
Task 3
Activity Activity Activity Activity
Weight/
Force
PERSON
Understanding the risk
Weight/
Forcex
Actions &
postures
PERSON
Posture has a major influence on forces exerted on the spine.
The Effects of Body Weight, Posture
& LoadActivity Force
Standing upright 100 %
The Effects of Body Weight, Posture
& LoadActivity Force
Standing upright 100 %
Sitting erect 140 %
Twisting 450 132 %
Bending Forwards 300 171 %
Sitting bending forwards 190%
Standing upright & 10 kg in each hand 142 %
Bending forwards 300 & 10 kg in each hand
279 %
Weight/
Forcex
Actions &
postures
PERSON
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
“Direct Risk Factors”
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
“Direct Risk Factors”
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
“Indirect Risk Factors/Sources of Risk”
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Nature of the Load
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Nature of the Load
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Nature of the LoadWork
Organisation
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Nature of the LoadWork
Organisation
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Nature of the Load
Work Environment
Work
Organisation
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Load Size, Shape & Nature
Work Environment
Work
Organisation
Characteristics of the Employee
Tools & Equipment
Often the risk is a function of a number of tasks with similar postures,
actions or movements
+ +
+
++
Occupation
Duty 1
Task 1
Activity Activity Activity
Task 2
Activity Activity
Duty 2
Task 3
Activity Activity Activity Activity
Task 4
Activity Activity Activity
Duty 3
Task 5
Activity Activity
BAD NEWSOften the injury is cumulative and
there are no big problems
GOOD NEWSThere can be lots of simple solutions
OUTLINE
A quick overview of MT risk assessment
Overview of Risk Controls
How to develop your own solutions
(Participative Ergonomics)
Where to find solutions (Resources)
ELIMINATING
MANUAL HANDLING
TASKS
Implementation Cost: $24.4 Million
Implementation Cost: $24.4 Million
• 24% reduction in back injury claims
• 41% reduction in days lost due to back injury claims
• Payback within 5 years
Canadian Extended
Care Facility
Hoist installation
Cost: $344,000
Paid back in decreased Workers’ Compensation claim costs within 2 ½ years
US study:
6 Nursing Homes introduced hoists, repositioning aids & “no lift” policies
Cost: $158,556
Repaid in 3 years in decreased workers’ comp. costs
Workers’ comp. claims from patient aggression also decreased by 72%
Direct W. Comp premium costs
www.slp.wa.gov.au
Workers’ Compensation Policy Premium Rates 2010/2011
Industry Rate Max. Rate
Bricklaying Services 4.28% 8.56%
Plumbing Services 3.12% 6.24%
Hospitals 1.91% 3.82%
Structural Steel Fabrication 2.96% 5.92%
Nursing Homes 3.55% 7.10%
Meat Processing 4.28% 8.56%
Supermarkets 2.19% 4.38%
Replacement Labour Costs
Based on 2007/2008 MH LTI data:
1 in 26 is off work for 1 day;
1 in 19 is off work for 1 week;
1 in 3 is off work for 1 month;
1 in 4 is off for > 3 months.
What are the implications for your workplace?
Cost: $117,950
Saving: $89,230 pa in annual
plant, labour & maintenance
savings
Cost: 1-2 rows of boxes
Labour Savings:
$22,540 pa
ELIMINATING
MANUAL HANDLING
ACTIVITIES
Occupation
Duty 1
Task 1
Activity Activity Activity
Task 2
Activity Activity
Duty 2
Task 3
Activity Activity Activity Activity
Task 4
Activity Activity Activity
+ how much time do employees spend fetching & looking for tools?
Max. MH Frequency Rate is
about 8
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Load Size, Shape & Nature
Work Environment
Work
Organisation
Characteristics of the Employee
Tools & Equipment
INCREASING THE WEIGHT
OR
SIZE
BEFORE
50 kg bags of
soybean meal
AFTER
850 kg bulk bags
Decreased damage through handling (increased product quality
Less time to unpack (forklift)
BEFORE
AFTER
Cost: $83,500
Labour Saving: $63,000 pa
DECREASING THE WEIGHT
OR
FORCE
UK Building Company:Switched from 50 kg to 25 kg cement bags
Saved ₤ 1,500 per year in reduced wastage
2 side lifts (of a 20 kg total load) can reduce lower back compression by up to 1/3
?? HARMONISATION ??
Changing the way things are stored
Use Levers
18 kg
4.5 kg
Installation of pre-cast concrete steps at the London 2012 Olympic Stadium
Force required: 82 kg
BEFORE
Force required: 82 kg
Force required: 35 kg
AFTER
LIFTING
& HOLDING
AIDS
Manipulators &
Vacuum Lifters
CIBA Specialty
Chemicals of
Kwinana uses one
for bags.
LTI’s dropped from 7
pa before to an
average of 2 pa after
A perfect vacuum
could support 10
tonne/m2
Manipulators &
Vacuum Lifters
Stupid Behaviour
or inadequate MH Aids?
Tool Balancers
Decreased forced by 90%
Doubled productivity
WHEELS
(turning a lift
into a push)
Re-inventing the wheel
is not a bad thing!
Or bigger wheels
+ there are powered tugs
(+ eliminate forklift risk)
TROLLEYS
Photo: SafeWork SAPhoto: DEIR
Photo: WorkSafe Victoria Photos: WorkCover NSW
Worker designed trolley doubled output
Breakage of
bricks
decreased
by 5%
Laying rate
per gang
increased
by 20% to
25%
CONVEYORS,
ROLLERS
&
BALL TRANSFER TABLES
Vertical Blind Maker.Boxes of slats 34 – 68 kg manually slid into bulk racks.Introduced miniature rollers & guides.25 W.C claims per year None in year afterwards
Two Person
Lifts?
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Vacuum Lifters re-visited
(Posture + weight if shared)
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Load Size, Shape & Nature
Work Environment
Work
Organisation
Characteristics of the Employee
Tools & Equipment
Don’t have to bend down as far
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Load Size, Shape & Nature
Work Environment
Work
Organisation
Characteristics of the Employee
Tools & Equipment
Mid-thigh height: 780 mm
Hip height: 945 mm
Elbow height: 1115 mm
Shoulder height: 1450 mm
6% suffered from low back pain at a 4 ½ year follow-up compared to 16% or workers who did not use these controls
BEFORE AFTER
BEFOREAFTER
BEFOREAFTER
London Olympic stadium.
80,000 seats, 4 bolts per seat
Two holes drilled at a time
Less need to carry drills
Reduced noise exposure
BEFORE
Pull along vacuum cleaner with a 23 cm head
AFTER
Self-propelled vacuum cleaner with a 69 cm head.
Threefold saving in time required
BEFORE
Less discomfort &greater accessibility.
Work time decreasedby 50%
AFTER
BEFORE
Reduced handling. Total removal,repair & reinstallation timereduced by 33%
AFTER
BEFORE AFTER
BEFORE
AFTER
AFTER
68% less time indoors64% less time outdoorsPotential saving on rubber bands $420,000 pa
In the past non-
office workers only
got hand-me-down
chairs
BEFORE
46% of time spent in “hazardous postures”
48% of time spent in “marginally hazardous postures)
AFTER
93% of time spent in “marginally hazardous postures)
Time taken to fill a crate: 41% less
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Load Size, Shape & Nature
Work Environment
Work
Organisation
Characteristics of the Employee
Tools & Equipment
Work Environment Controls
Housekeeping
Common Law Case
Ward v/s Eagle Mining
Employee carrying two “quite heavy” cartons. Could not see hole in paving.
Tripped and fell onto her wrists.
Awarded $431,393 damages
Work Environment Controls
Housekeeping
Layout
UK Case
Product bin heights changed in factory
(Cost: ₤4,000)
Payback in 2 ½ weeks through decreased work time & decreased wastage
Work Environment Controls
Housekeeping
Layout
Plant & vehicles
Impact from stepping down from trucks:
up to 2.16 BW
Jumping down:
up to 7.1 BW
BEFORE
AFTER
Took 10 minutes longer to
load containers (45 mins v. 35 mins)
But containers filled to 95% capacity (v. 89%)
Saving in transport
costs: ₤48,000 p.a.
Weight/
Forcex
Actions &
posturesx
Repetition/
Duration
PERSON
Load Size, Shape & Nature
Work Environment
Work
Organisation
Characteristics of the Employee
Tools & Equipment
Work Organisation Controls
How many times are things handled?
Sometimes it makes more sense to focus on the product rather than the employee
BEFORE
Beer delivered to garage, then transported to rear of shop, then sold at counterSpirit producer sells 6,500
cases of beer per year to staff
AFTER
Customers pay for beer in shop & collect direct from garage
54% decrease in the distance walked
Work Procedure
1. Run to verge & pick up household’s full crate
2. Carry crate to truck & empty it
3. Return crate to verge
4. Run to next house
5. Repeat steps 2-4
Work Procedure – buy 1 extra crate
1. Run to verge with extra crate, drop it & pick up household’s full
crate
2. Carry crate to truck & empty it
3. Run to next house
4. Repeat steps 2-3
Work Organisation Controls
How many times are things handled?
Where are things stored?
Work Organisation Controls
How many times are things handled?
Where are things stored?
41 kg
Work Organisation Controls
How many times are things handled?
Where are things stored?
Work Organisation Controls
How many times are things handled?
Where are things stored?
Work Organisation Controls
How many times are things handled?
Where are things stored?
How well are things maintained?
Work Organisation Controls
How many times are things handled?
Where are things stored?
How well are things maintained?
Can the sequence of work be improved?
Software
How many mouse clicks, tabs etc?
> 6 mouse clicks to save stuff in the correct folder
1 mouse click to save stuff in the correct folder
US Phone Company Directory Assistance
After
US Phone Company Directory Assistance Centres
0.6 second improvement in processing time.
Over 1 year across 5 states this resulted in a saving of $3 million
OUTLINE
A quick overview of MT risk assessment
Estimating the costs of injury
Overview of Risk Controls
How to develop your own solutions
(Participative Ergonomics)
Where to find solutions (Resources)
Advantages of Participative Ergonomics
PRACTICAL
BENEFITS
Reduced injury risk
More cost-effective
solutions
ORGANISTAIONAL BENEFITS
More employee
ownership
Greater perceived
management commitment
Improvements to trust,
communication, support,
Culture (?)
Finish Study at at engineering plant. Did a bunch of improvements. Sick leave fell by 25%
But you need the right training!
Employees need to:
Understand the risks
Motivated & empowered to suggest solutions
If you only train employees how to lift the box, they’ll never think outside it!
In summary
Complete task elimination may be
cost-effective
Or bits of tasks
& don’t forget MH is also
pushing and pulling
& don’t forget levers
Reducing the weight can also
have other benefits
& don’t forget MH is also about
postures
& think outside your industry
Train employees to think outside
the box
OUTLINE
A quick overview of MT risk assessment
Estimating the costs of injury
Overview of Risk Controls
How to develop your own solutions
(Participative Ergonomics)
Where to find solutions (Resources)
www.commerce.wa.gov.au/Worksafe
Industries > Construction > More information
www.osha.gov/SLTC/ergonomics/success_stories.html
http://ergo.berkeley.edu/casestudies/
Copies in the WorkSafe library
QUESTIONS?
rodney.powell@commerce.wa.gov.au
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