osha 3192 grocery store

8/14/2019 OSHA 3192 Grocery Store

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Guidelinesfor RetailGroceryStoresOSHA 3192-05N2004

U.S. Department of Labor

Ergonomicsfor the Prevention of

Musculoskeletal Disorders

www.osha.gov


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Guidelines for Retail Grocery Stores 1


Elaine L. Ch ao, Secretary

Occupational Safety and Health Administration

John L. Henshaw, Assistant Secretary

OSHA 3192-06N

2004

Guidelines for Retail Grocery Stores

Ergonomics for t he Preventionof M usculoskeletal Disorders



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2 Guidelines for Retail Grocery Stores

Executive Summary 3

Introduction 5

A Process for Protecting Workers 7

Provide Management Support 7

Involve Employees 7

Identify Problems 7

Implement Solutions 8

Address Reports of Injuries 8

Figure 1. Checklist for Identifying Potential ErgonomicsRisk Factors by Workplace Activity 9

Figure 2. Checklist for Identifying Potential Job-Specific Ergonomics Concerns 10

Provide Training 11

Evaluate Progress 11

Implementing Solutions 12

Storewide Ergonomic Solutions 13

Front End (Checkout, Bagging and Carryout) 17

Stocking 19

Bakery 21

Meat and Deli 23

Produce 25

Additional Sources of Information 26

References 27

Contents


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OSHAs Ergonomics for the Prevention of Musculoskeletal Disorders: Guidelines for RetailGrocery Stores provide practical recommenda-tions to help grocery store employers and

employees reduce the number and severity of injuries in their workplaces. Many of the work-related injuries and illnesses experienced bygrocery store workers are musculoskeletaldisorders (MSDs), such as back injuries andsprains or strains that may develop from variousfactors, including lifting, repetitive motiondisorders such as carpal tunnel syndrome, orinjuries resulting from overexertion. MSDsmay also be caused partly or wholly by factorsoutside of work.

More remains to be learned about therelationship between workplace activities andthe development of MSDs. However, OSHAbelieves that the experiences of many grocerystores provide a basis for taking action to betterpro tect workers. As the understanding of theseinjuries develops and information and technol-ogy improve, the recommendations made in thisdocument may be modified.

Grocery stores that have implemented injuryprevention efforts have said they have success-fully reduced work-related injuries and workerscompensation costs. Many times, these effortshave reduced injuries and led to increased workerefficiency and lowered operating costs. Forexample, designing checkstands to reduceergonomic risk factors such as twisting or ex-tended reaching can improve cashier effective-ness and productivity (1). The purpose of thesevoluntary guidelines is to build on the progress

Executive Summary

that the grocery store industry has made inaddressing causes of work-related injuries andillnesses.

These guidelines are intended only for retail

grocery stores and combined full-line super-market and discount merchandisers includingwarehouse retail establishments. The discussionis intended primarily for grocery store managersand store employees, but may also be useful forcorporate managers or corporate safetyprofessionals. OSHA did not develop theseguidelines to address warehouses, conveniencestores, or business operations that may belocated within grocery stores, such as banks,post offices, or coffee shops. However, opera-

tions in retail or distribution that involve similartasks or operations as those addressed in theseguidelines may find the information useful.

The information in these guidelines providesgrocery stores with effective approaches, as wellas useful references to be used when determiningthe need for ergonomic solutions. The recom-mendations and information presented here areintended as a general guideline and flexibleframework to be adapted to the needs andresources of each individual store. OSHArecognizes that small employers, in part icular,may not have the need for as comprehensive aprogram as would result from implementation of every action and strategy described in theseguidelines. Additionally, OSHA realizes thatsmall grocery stores may need assistance to im-plement an appropriate ergonomics program.That is why O SHA emphasizes the availability of its free consultation service for smaller employers.


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The heart of these guidelines is the descriptionof various solutions that have been implementedby grocery stores. OSHA recommends thatgrocery stores consider these solutions in the

context of a systematic process that includesthe elements described in the pages that follow.Such a process will make it more likely that thesolutions implemented in a particular workplaceare successful in reducing injuries and are costeffective.

To develop these guidelines, OSHA reviewedexisting ergonomic practices and programs in

These guidelines are advisory in nature and inform ational in content . They are not a new standard orregulation and do not create any new OSHA duties. Under the OSH Act, the extent of an employersobligation to address ergonomic hazards is governed by the general duty clause. 29 U.S.C. 654(a)(1).An employers failure to implement the guidelines is not a violation, or evidence of a violation of thegeneral duty clause. Furthermore, the fact that OSHA has developed this document is not evidence ofan employers obligations under the general duty clause; the fact that a measure is recommended inthis document but not adopted by an employer is not evidence of a violation of the general duty clause.In addition, the recommendations contained herein were developed with the idea that they could beadapted to the needs and resources of each individual place of employment. Thus, implementation ofthe guidelines may differ from site to site depending on the circumstances at each particular site.

the grocery store industry and conducted sitevisits to observe existing programs in action.In addition, the Agency reviewed availablescientific information regarding work activities

that may benefit from ergonomic improvementsand specific solutions. OSHA also conductedone-on-one and group meetings with majorstakeholder groups to gather the best availableinformation on typical workplace activities andon practices, programs and processes that havebeen used successfully in the grocery storeindustry.


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Grocery stores provide a vital service to theAmerican public, and are a major source of employment in the United States. In recentyears, the efforts of grocery store managers and

employees have resulted in fewer occupationalinjuries and illnesses. Even with these efforts,thousands of grocery store workers are stillinjured on the job each year (2).

Many grocery stores have taken actions suchas those recommended in this document to helpreduce exposures to ergonomic risk factors intheir effort to r educe workplace injuries.

Some grocery store work can be physicallydemanding. Many grocery store workers handlethousands of items each day to stock shelves,

check groceries, decorate bakery items, andprepare meat products. These tasks involveseveral ergonomic risk factors. The mostimportant of these include force, repetition,awkward posture, and static postures (4).

In the grocery store industry, the presence of these risk factor s increases the potential forinjuries and illnesses. In these guidelines, OSHAuses the term musculoskeletal disorders (MSDs)to refer to a variety of injuries and illnesses,including:

s Muscle strains and back injuries that occurfrom repeated use or overexertion;s Tendinitis;s Carpal tunnel syndrome;s Rotator cuff injuries (a shoulder problem);s Epicondylitis (an elbow problem); ands Trigger finger that occurs from repeated use

of a single finger.

Just because an employee develops an MSD

does not mean it is work-related. As required byOSHAs recordkeeping ru le (29 CFR 1904),employers should consider an MSD to be work-related if an event or exposure in the work environment either caused or contr ibuted to theMSD, o r significantly aggravated a pre-existingMSD. For example, when an employee developscarpal tunnel syndrome, the employer needs tolook at the hand and forearm activity required

Introduction

The Liberty M utual Insurance Companys WorkplaceSafety Index shows the importance of ergonomicissues.

The Index lists overexertion, bodily reaction, andrepetitive motion as three of the top ten causes ofworkplace injury.

The three injury categories represented 43.8 percentof the total costs of serious workplace injuries in2001.

While the total number of serious workplace injuriesdeclined between 1998 and 2001, the cost grew 13.5percent, or 4 percent after adjusting for inflation (3).

Putting merchandise in the front of a display caseimproves the appearance of merchandise. However,working in the back of a deep display case to face orstock merchandise can be awkward and uncom-fortable, especially when heavy items are involved.

One familiar solution to this problem is display casesthat are stocked from the back. The product, such as

cartons of milk, slides down an inclined shelf so thatits always in front of t he customer. Its also easierfor the employee stocking the shelf.

Recently a market extended this concept to front-loaded cases. The solution was a dummy back forthe case that was placed at the back of t he shelf tolimit the reach. Now the merchandise is at the fron tof the shelf, readily visible to the customer andwithin easy reach for the worker.

At least one vendor has improved this concept by

providing cases with spring-loaded backs. When acustomer removes an item, the back pushes theremaining items to the front, keeping them withineasy reach. The design makes it easier to stock casesby eliminating the need to reach to the back of thecase. The stocker puts the first products in at thefront of the shelf, then pushes it back to make roomfor more items (5).


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Packing produce and other products in ice keepsthem fresh and appealing. It also means handlingice shoveling it, lifting it and shoveling it again.Its heavy work and takes time.

Recently a market devised a method to reduce theamount of time that it takes to put ice on productsand that also cut the amount of handling in half.Originally an employee took a cart to the icemachine, scooped up enough ice to fill a cart,wheeled the cart to the display case, and finallyscooped the ice from the cart into the display case.

The new machine allows gravity flow of ice and hasspace underneath for a cart containing four buckets.The ice falls into the buckets and fills them,eliminating half the shoveling. The buckets areconvenient to handle and can be picked up to pourthe ice into the display case, eliminating the rest ofthe need to shovel. The net result less strenuouswork, more time saved, and an attractive display (5).

for the job and the amount of time spent do ingthe activity. If an employee develops carpaltunnel syndrome, and h is or her job requiresfrequent hand activity, or forceful or sustained

awkward hand motions, then the problem maybe work -related. If the job requires very littlehand or arm activity then the disorder may notbe work-related.

Activities outside of the workplace thatinvolve physical demands may also cause orcontr ibute to MSDs. In addition, developmentof MSDs may be related to genetic causes,gender, age, and other factors. Finally, there isevidence that reports of MSDs may be linked tooccupationally-related psychosocial factors

including job dissatisfaction, monotonous work and limited job contro l (6). However, theseguidelines address only physical factors in theworkplace that are related to the development of MSDs.

Grocery stores that have implemented injuryprevention efforts focusing on musculoskeletaland ergonomic concerns have reported reducedwork-related injuries and associated workerscompensation costs. Fewer injuries can alsoimprove morale, reduce employee turnover,encourage employees to stay longer and dis-courage senior employees from retiring early.Workplace changes based on ergonomicprinciples may also lead to increased pro -ductivity by eliminating unneeded motions,reducing fatigue and increasing worker effi-ciency. Healthier workers, better morale, andhigher productivity can also contribute to bettercustomer service.

These guidelines present recommendations forchanging equipment, workstation design, orwork methods with the goal of reducing work-related MSDs. Many ergonomic changes resultin increased efficiency by reducing the timeneeded to perform a task. Many grocery storesthat have already instituted programs havereported reduced MSDs, reduced workerscompensation costs, and improved efficiency.


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A Process for Protecting Workers

Many of the recommendations below arepractices taken from workplace ergonomicsand safety programs that grocery stores havedeveloped and that OSHA observed while

performing site visits at grocery stores. Theyare intended to provide a flexible framework that a grocery store manager can adapt to anindividua l store. In many grocery stores,ergonomics, other employee safety and healthefforts, workers compensation, an d r isk mana gement ar e integrated into a single pro -gram that is usually administered by the samestaff. O SHA recommends that employersdevelop a process for systematically addressingergonomics issues in their facilities, and incor-

porate this process into an overall program torecognize and p revent occupational safety andhealth hazards.

Store and company management personnelshould consider the general steps discussedbelow wh en establishing and implementing anergonomics program. It should be noted,however, that each store will have differentneeds and limitations that should be consideredwhen identifying and correcting workp laceprob lems. Different stores may implementdifferent types of pro grams and activities andmay assign different staff to accomplish thegoals of the ergonomics program.

Provide Management SupportManagement support for reducing M SDs

and communicating support to employees isvery importan t. You have already demon-strated your interest in reducing MSDs byreading these voluntary guidelines. Manage-ment suppor t impr oves the grocery storesability to m aintain a sustained effort, allocateneeded resources, and follow up on programimplementation . O SHA recommends thatemployers:s Develop clear goals,s Express the companys commitment to

achieving them,

s Assign responsibilities (tra ining, jobanalysis, etc.) to designated staff membersto achieve those goals,

s Ensure that assigned responsibilities arefulfilled, an d

s Provide appropriate resources.

Meaningful efforts b y mana gement a lsoimprove employee participation , wh ich isanother essential element for achievingsuccess.

Involve EmployeesEmployees are a vital source of information

about hazards in their workplace. Employeeshelp identify hazards and solve problems.Their involvement can enhance job satis-faction, motivation, and acceptance of work-place changes. There are many different waysemployers can involve employees in theirergonomics efforts, including the following:s Submit suggestions and concerns;

s Identify and r eport t asks that a re difficult toperform;

s Discuss work methods;

s Provide inpu t in the design of wo rkstations,equipment, procedures and training;

s H elp evaluate equipment;s Respond to surveys and questionnaires;s Report injuries as soon as they occur;s Participate fully in MSD case investigations;

ands Participate in ta sk group s with responsi-

bility for ergonomics.

Identify ProblemsIt is importan t to periodically review you r

job site and the activities of employees toidentify possible ergon omic issues. This cou ldinclude a review of OSHA 300 and 301 injuryand illness information , workers compensa-tion records and employee reports of problems.


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You can also identify ergonomic issues bytalking with employees and walking throu ghthe grocery store to observe employeesperforming their jobs. When reviewing the

various jobs in the grocery store, pay particularattention to the risk factors listed below.s Force the amou nt of physical effort

required to perform a task (such as heavylifting 1, pushing or pu lling), han dle mer-chandise, or maintain control of equipmentor tools;

s Repetition performing the same motion orseries of motions continually or frequentlyfor an extended period of time;

s Awkw ard and static postures assumingpositions that place stress on th e body, suchas pro longed or r epetitive reaching aboveshoulder h eight, k neeling, squatting, leaningover a counter, using a k nife with wristsbent, o r twisting the torso while lifting (4);an d

s Contact stress pressing the body or part of the body (such as the hand) against hard orsharp edges, or using the hand as a hammer.

When there are several risk factor s in a job,there can be a greater risk of injury. H owever,the pr esence of risk factors in a job does notnecessarily mean that employees will developan M SD. Whether certain wor k activities putan employee at risk of injury depends on theduration (how long), frequency (how often),and magnitude (how intense) of the employeesexposure to the risk factors in the activity (6).For example, performing cashier work for anextended period of time without a break hasbeen associated with increased hand and wristproblems (7) and could contribute to back andlower limb pro blems (8).

The grocery store industry has developed anumber of p rotocols and checklists to assess

wor k activities. For example, Figures 1 and 2contain checklists grocery stores may use tohelp ident ify ergonomic concerns. The check-lists include materials developed by the Food

Marketing Institute (4) as well as materialsdeveloped by O SHA.

Implement SolutionsExamples of potential solutions for various

concerns are located in th e ImplementingSolutions section of these guidelines.

Address Reports of InjuriesThe solutions recommended in these guide-

lines are intended to address factors that arebelieved to be associated with M SDs in grocerystores. They are not a guarantee against anyfuture injury occurring. Grocery stores rarelyhave on-site medical staff to care for injured orill employees. Therefore, store managers orother designated individuals shou ld establish aprocedure for receiving reports of injuries andresponding to them appropr iately. Early inter-vention is an effective method of handlingpotential injuries. Employees should repor tinjuries early so that action can be taken to

address any potential job-related issues. Medicaltreatment and possible work restrictions couldbe necessary, but attention should be paid toaddressing root problems early to avoid morecostly actions if injuries are left unaddressed (9,10, 11).

OSHAs injury and illness recording andreporting regulation (29 CFR 1904) requiresemployers to keep records of wor k-relatedinjuries and illnesses. These repo rts can helpthe retail grocery store identify pro blem areas

and evaluate ergonom ic effort s. Federal andstate laws pr ohibit d iscriminating a gainstemployees who report a work-related injury orillness. 29 U.S.C. 660 (c).

1 There are varying op inions regarding the maximu m amou nt of weight an employee should lift. OSHA does notmake a specific recommendation in t hese guidelines regarding th is maxim um amo unt but no tes that employersshould take into account such considerations as the empl oyees physical abiliti es and the num ber of tim es a liftmu st occur. Industry gro ups such as the Grocery M anufactures of America and Food M arketing Instituteencourage the use of containers or packages weighi ng 40 pounds or less. Anoth er industry gr oup, TheInternational Mass Retail Association, suggests 50 pounds as a maxim um weight for l ifting.

(Continued on page 11)


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Figure 1.Checklist for Identifying Potent ial Ergonomics Risk Factors by Workplace Act ivity

If the answer to any of th e following questions is yes , the activity should be fur ther r eviewed.

Force in Liftings Does the lift involve pinching to hold the

object?s Is heavy lifting done with o ne han d?s Are very heavy items lifted without the

assistan ce of a mechanical device?s Are heavy items lifted wh ile bending over,

reaching above shoulder height, ortwisting?

s Are most items lifted rath er than slid overthe scanner?

Force in Pushing, Pulling, Carryings Are dollies, pallet jacks, or other carts

difficult to get started?s Is there debris (e.g., broken pallets) or

uneven surfaces (e.g., cracks in the floor)or d ock plates that could catch th e wheelswhile pushing?

s Is pulling rather th an p ushing rout inelyused to move an object?

s Are heavy objects carried manua lly for a

long distance?

Force t o Use Toolss Do tools require the use of a pinch grip or

single finger to operate?s Are tools too large or too small for the

employees h and s?

Repetit ive Taskss Are multiple scans needed?s Is a quick wrist motion u sed wh ile

scanning?

s Do repetitive motions last for several ho urswithout a break (e.g., slicing deli meats,scanning groceries)?

s Does the job require repeated finger force(e.g., kneading bread, squeezing frosting,using pricing gun)?

Aw kw ard and Static Posturess Is the back b ent or twisted while lifting or

holding heavy items?s Are objects lifted out of or p ut into cramped

spaces?s Do rou tine tasks involve leaning, bending

forward, kneeling or squatting?s Do routine tasks involve working with the

wrists in a b ent or twisted position?s Are routine tasks done with the hands

below the waist or above the shoulders?s Are routine tasks don e behind (e.g., pushing

items to bagging) or to the sides of thebody?

s Does the job require standing for most of

the shift without anti-fatigue mats?s Do employees work with their arms or

hands in the same position for long periodsof time without changing positions orresting?

Contact Stresss Are there sharp or hard edges with which

the worker may come into contact?s Do employees use their han ds as a hammer

(e.g., closing containers)?s Does the end of th e too l/utensil (knife)

hand le press into th e work ers palm?


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Figure 2.Checklist for Identifying Potential Job-Specific Ergonomics Concerns

If the answer to any of th e following questions is no , the activity may be a potent ial source of ergonomic concern, d epending on th e dura tion, frequency, and magnitude o f the activity.

Cashierings

Are items within easy reach?s Are keyboard supports adjustable?s Can the cashier work with items at about

elbow height?s Can the display be read without twisting?s Are all edges smoothed or rounded so the

cashier does not come into con tact withsharp or hard edges?

s Are objects easily scanned the first time?s Are objects scanned withou t tw isting hand

motions?s Can cashiers scan heavy/bulky/awkward

items without lifting them?s Are the scale, conveyor, and horizontal

scanner plates all the same height?s Is the scanner p late clean and unscratched?s Does the cashier h ave an anti-fatigue mat

and/or footrest?

Bagging and Carry Out

s Can the bagger adjust the height of the bagstand?

s Are all edges smoothed or rounded so thebagger does not come into contact withsharp or hard edges?

s Do b ags have handles?s Can th e bagger put ba gs into cart w ithout

leaning over the checkstand o r tw isting theback?

Produces Are knives kept sharp?s Are worktables, etc. positioned so that the

work can be performed at abo ut elbowheight?

s Are carts used to move heavy items?

Shelf Stocking & Stockroomss

Are step stools/ladders used to reach highshelves?s Is stocking performed with minimal twisting

or bending?s Do totes and boxes have handles?s Are gloves used for handling cold items?s Are box cutter blades sharp?s Are carts used to move heavy items?s Are carts or pallet jacks used to keep lifts at

waist height?

s Are lightweight pallets used?s Are box weights within the lifting ability of

employees?

Bakerys Are counter heights and widths appropriate

for employees?s Are carts used to move heavy items?s Are routine job tasks performed without

holding hands/wrists in a bent o r tw isted

position?s Is work being performed at about elbow

height?

M eat and Deli Related Taskss Are knives kept sharp?s Are counter heights and widths appropriate

for employees?s Are scales, grinders, slicers, etc. p ositioned

so that the work can be performed at about

elbow height?s Are routine job tasks performed without

holding hands/wrists in a bent o r tw istedposition?

s Are box weights within the lifting ability of employees?

s Are tool han dles the right size (not too largeor too small) for the worker?


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Sometimes the muscle soreness employeesexperience when starting or returning to a jobcan be confused with symptoms of M SDinjuries. In most cases muscle soreness from

conditioning lasts only a few days. Temporarymuscle soreness occurs most often with newemployees or workers who are returning to a

job after several weeks away. When thesymptoms linger o r grad ually get wor se, anMSD may be developing.

Provide TrainingTraining is critical for employers and

employees to safely use the solutions identifiedin these guidelines. Training should be

provided in a manner and language that allemployees can understand . There are manyways employers can integrate ergonomicstraining into regular wo rkp lace activities, suchas new employee orientation or at staff,department, or shift meetings. There are alsomany sou rces of training materials, includingOSHA, trade associations, and insurancecompan ies. O SH A recommends training forgrocery store employees tha t pro vides:

s Knowledge of the wor k tasks that ma y lead

to pain or injury;

s Understanding of the proper too ls and work practices for tasks that employees will beperforming;

s The ab ility to r ecognize MSDs and theirearly indications;

s The ad vantages of add ressing earlyindications o f M SDs before serious injuryhas developed; an d

s Awareness of the grocery stores proceduresfor repor ting work -related injuries andillnesses as r equired by O SH As injury andillness recording an d r eporting r egulation(29 CFR 1904).

OSHA also recommends that managementand supervisory staff who coordinate anddirect ergonomics efforts receive training togive them the knowledge to effectively carry

out their responsibilities. These designatedstaff members will benefit fro m inform ationand training that will allow them to:

s Appropriately use checklists and other too lsto analyze tasks in t he grocery store;

s Address problems by selecting properequipment and work practices;

s Identify the potential benefits of specificworkplace changes;

s Help other workers implement solutions;and

s Assess the effectiveness of ergonomicsefforts.

Grocery store employees will also benefitfrom refresher training to address newdevelopments in the workplace and toreinforce knowledge acquired in the initialtraining.

Evaluate ProgressOSHA recommends that grocery stores

evaluate the effectiveness of their ergonomicefforts and follow-up on u nresolved problems.Evaluation and follow-up help sustain

continuous improvement in r educing injuriesand illnesses, tr ack the effectiveness of specificergonomic solutions, identify new pro blems,and show areas where further attention isneeded. Grocery managers can use the samemethods they use to identify ergonomicconcerns (such as OSHA 300 and 301 injuryand illness information , workers compen-sation records, employee interviews, andobservation of workplace conditions) toevaluate progress (10, 11). Employers can

also keep a list of activities and improvementsto track what has been accomplished andpro vide data o n the effectiveness of theinitiatives.

How often an employer evaluates the pro-gram will vary by the size and complexity of thefacility. Management should revise the programin response to identified deficiencies and com-municate the results of the program evaluationand any program revisions to employees.

(Continued from page 8)


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The section on ergono mic solutions forgrocery stores describes changes to equipment,work practices, and procedures that canadd ress ergonomic risk factors, help contro lcosts, and reduce employee tur nover. Thesechanges may also increase work er pro ductivityand efficiency because they eliminateunn ecessary movements and reduce heavymanual work. O SH A recommends employersuse engineering and administrative techniques,where feasible, as the pr eferred method o f dealing with ergonomic issues in retail grocerystores. The first solutions described are thosethat are applicable to all or most areas of thegrocery stor e. Then, solution s for specificgrocery store departments are presented,including:s Front end (checkout, bagging and

carryout);s Stocking;

s Bakery;s Meat and deli department; ands Produce department.

OSHA is not providing specific solutions

for every department of every grocery store,but the general recommendations should beuseful. OSHA expects that a grocery storemay need to implement a variety of solutionsto addr ess issues in d ifferent a reas of the store.H owever, O SH A does not expect all of thesolutions to be used in a single grocery store.The solutions are not intended to be anexhaustive list. Grocery store managers areencouraged to develop innovative ergonomicsolutions that are appropriate to their

wor kplace. These are only examples of ergonomic solutions which individual storemanagers should consider as a starting point.Managers are encouraged to look for o therinnovative methods that will meet their storesneeds.

Employers should pay particular attentionto ergonomic issues when redesigning existingstores or designing new ones. At that time,major changes are easier to implement an dergonomic design elements can b e incorpora -ted at little or no additional cost (12).

Implementing Solutions

King Kullen Grocery Company reported that theyinitiated a three-fold approach to effectively managecheckout repetitive motion concerns. First, theyinitiated training for cashiers, store managers andmanagement personnel. They focused training forcheckers on awareness of repetitive motion issues,good work practices, and the value of early injuryreporting.

Second, King Kullen changed the design of th eircheckout stations and scanners. The changes includedusing a combined scanner and scale to reduce liftingand twi sting arm motions, and locating the scannerdirectly in front of the cashier to reduce torso twisting.Finally, King Kullen worked to return injured employeesto work as quickly as possible. Under their program,a nurse contacts injured employees within 48 hours oftheir injury and monitors their care until they returnto work.

According to King Kullen, by putting these changes inplace, they reduced MSD incidents from 21 in 1992 to5 in 1996 (13).


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T his section describes storewide ergonomic principles on safe work practices employees can follow t o reduce their risk of inju ry. Em ployersshould train employees to use these techniquesand design stores to m ake it easy to do so.

Power Grips

A power grip uses the muscles of the hand andforearm effectively, and is less stressful than apinch grasp. Consequently, a one- or two-handedpower grip should be used whenever possible.

A power grip can be described as wrapping allthe fingers and the thumb around the object thatis being gripped. It is sometimes described asmaking a fist around the object being gripped.

The power grip can be used for many items,

including bags, cans and small boxes.

Power Lifts

When the item to be grasped is too heavy or bulky tolift with a one-hand power grip, use the two-handpower grip.

Pinch Grasps

A pinch grasp should never be used when a power gripcan be used instead. However, a pinch grasp isacceptable for small, light items (e.g., a pack of gum,etc.).

1994

1993

1992

Loss Control Savings4% 5% 6% 7% 8% 9% 10% 11%

S T O R E W I D EE R G O N O M I C S O L U T I O N S


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STOREWIDE ERGONOMIC SOLUTIONS

Lifting Safety

Most grocery store jobs involve some lifting. It is important that employers provide employees with help to liftheavy or bulky items. Whether a particular lift will require assistance depends on several factors, including theweight and size of the object, how frequently the object is lifted, how close the object is to the ground, howhigh it must be lifted, how far it must be carried and whether it has handles. Assistance can include a dolly or cart, or help from a co-worker. Employees should be trained in the use of appropriate lifting techniques for different sizes of objects as well as to when it is appropriate to seek assistance.

When holding, lifting or carrying items

q Before lifting boxes and cases, check the weight so you can prepare to lift properly.

q Turn the body as a unit to avoid twisting at the waist.

q Keep the item close to your body.

q Keep your back straight.

q Use your leg muscles to do the lifting.

q Lift smoothly without jerking.

q Get close to where you want to set the item down.


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The Basics of Neutral Working Postures


Recommended Working Postures

Recommended Working Postures describe body positions that are neutral and comfortable to use. Usingpostures other than those recommended will generally waste energy and motion as well as potentially raisethe risk of injury. It

s also important to change position frequently and stretch between tasks. This improvescirculation and lessens fatigue.

Shoulders and Armsq Keep the shoulders relaxed not

shrugged-up or slumped-down.

q Keep your elbows close to your body.q Keep work at about elbow height.

Backq Stand straight avoid situations

that require bending (forward or backward), leaning to the side or twisting.

q A sit/stand stool will allow for changes in posture.

q For work performed while sitting,a back rest will help maintainproper posture.

Head and Neckq Avoid situations that require twisting the neck

or bending it forward, backward or to the side.

Hands and Wristsq Keep the hands straight

and in line with the

forearms avoid twistinghands.q Avoid working with wrists

pressed against sharp or hard edges.

Feet and Legsq Placing a foot on a

footrest or other supportwill promote comfort.

q Provide toe space toallow workers to standcloser to counters. Thiscan reduce reaching.

q Good quality anti-fatiguemats reduce back andleg fatigue.


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Best and Preferred Work Zones

Performing work within the best and preferred work zones shown below facilitates productivity and comfort.Work is safest when lifting and reaching is performed in these zones. Working outside these work zonesresults in non-neutral postures that may increase the risk of injury. It is particularly important to perform heavylifting tasks within the best work zone.

Best Work Zone

q As far forward as your wrist when you holdyour arm slightly bent.

q As wide as the shoulders.

q Upper level at about heart height.

q

Lower level at about waist height.

Preferred Work Zone

q As far forward as your hand when you hold your arm out straight.

q A foot on either side of the shoulders.

q Upper level at shoulder height.

q

Lower level at tip of fingers with handsheld at the side.

BestWork Zone

PreferredWork Zone

BestWork Zone

PreferredWork Zone


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q Provide footrests for cashiers. Alternately resting

the feet helps to reduce fatigue.

q Provide adequate toe space (at least 4 inches) atthe bottom of the workstation. Toe space allowscashiers to move closer to the checkstand,decreasing reaching requirements.

q Use footrests and anti-fatigue mats in areas whereworkers stand for prolonged periods. Standing onanti-fatigue mats, as compared to bare floors,provides a noticeable improvement in comfort.

q Place the conveyor belt electronic eye close to thescanner, but allow sufficient area between the eyeand the scanner to orient items and to ensure thebelt does not push items into the scanning field.

q Perform work within the preferred work zone.

q Use a powered in-feed conveyor to help cashiersbring the items to their best work zone, rather thanleaning and reaching to get items further up theconveyor.

q Use a sweeper to move items on the conveyor within the checker s reach.

q Locate commonly used items such as the cashdrawer and printer within easy horizontal reach.

q Place in-feed and take-away conveyor belts asclose as possible to the cashier to minimizereaching.

q Consider using checkstands designed with anadjustable sit/stand or lumbar support againstwhich cashiers can lean.

q Remove, round-off, or pad sharp or hard edgeswith which the cashier may come into contact.

F R O N T E N D(C H E C K O U T, B A G G I N G A N D C A R R Y O U T)


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q Set scanners and conveyors at the same height sothat cashiers can slide items across rather than liftthem.

q Establish a regular maintenance schedule for scanners; clean dirty plates and replace scratchedones.

q

Use combined scales/scanners.

q Provide an adjustable-height bag stand. Inbagging areas, the tops of plastic bags should be

just below conveyor height.

q To avoid extended reaches when loading bags intocarts, move carts closer to the employee.

q Use bags with handles. Handles make the bagseasier and less stressful to carry.

q Use carts to carry bags and groceries outside thestore.

q Consider using powered-tugs when retrieving cartsfrom the parking area. Powered tugs facilitatemoving more carts with more efficiency and lesseffort.

q Consider using keyboards to enter the quantity of identical products rather than scanning eachindividual item.

q Use keyboard to enter code if item fails to scanafter second attempt.

q Place keyboards on supports that adjust in height,horizontal distance and tilt to keep work within thepreferred work zone.

q Use front facing checkstands to reduce twistingmotions and extended reaches to the side.

q Adjust the checkstand height to match the cashier swaist height, or use a platform.

q Place cash register displays at or slightly below eyelevel.

q Use scan cards or scan guns for large or bulkyitems to eliminate the need to handle them.


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q Use a step stool to reach items on the top of

pallets or on high shelves.

q Use a kneeler or stool when working at lowshelves for long periods of time. This reducesstress on the knees and legs when squatting andkneeling.

q Rotate stocking tasks to avoid prolonged kneeling,squatting, and overhead reaching.

q Use a cart to move items from the pallet to theshelving or case where they are stocked.

q Keep cart wheels well maintained. Wheels that arein poor repair can be difficult to push. Racks or carts with bad wheels should be removed fromservice until they can be repaired.

q Keep cases close to the body when lifting andcarrying in order to reduce stress to the back.

q Use thermal gloves when stocking frozen foods.Cold temperatures can reduce circulation,causing stress on the hands. If pricing, use aglove with textured fingertips to wipe frost fromfrozen foods.

q Use knee pads when stocking low shelves for longperiods of time. This reduces the stress on theknees and legs when kneeling.

C H E E S E

C H E E S E

C H E E S E

C H E E S E

C H E E S E

C H E E S E

C H E E S E

C H E E S E

C H E E S E

C H E E S E

S T O C K I N G


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q Arrange shelves so that heavy items and fast-moving items are stored within easy reach. Thisreduces the stress on the body caused by bendingor reaching overhead.

q Use the correct safety cutter for the job. Be sureto supply a left-handed cutter if the employee is

left-handed.q Keep safety cutters sharp. Using dull tools

requires more force. Replace cutter blades often.

q Report improperly stacked pallets to the supplier to reduce future problems.

q Ensure that the floor areas are level and free of debris and spills. Report any floor problems thatneed repair immediately.

q Use boxes or totes with hand holds, where suitable.

q Work with suppliers to get lower weight boxes toreduce the weight manually lifted. Industry groupssuch as the Grocery Manufacturers of America andFood Marketing Institute encourage all companiesto use containers and packages that weigh 40pounds or less (14).

q Use carts with larger wheels so they are easier topush. Use carts with raised bottom shelves sothe employee can maintain more neutral bodyposition when lifting or placing cases.

q Ensure that there is adequate room around cartsand pallets for lifting tasks. Workers should be ableto walk around the pallet or cart, rather thanreaching or bending.

q Avoid congestion in grocery store aisles soemployees have adequate room to sort cases,open cases, mark merchandise, and stock shelves.

q Equip stockrooms and central processing areaswith roller bed conveyors and turntables to reducelifting and carrying. Maintain turntables so they

move easily and with little force required by theworker. Maintain rollers to reduce the pushing andpulling forces needed to handle cases.

q If a turntable is not used, place a flat piece of stainless steel over the end section of the roller bed preferably with a non-stick coating to allowcases to be turned easily. The metal surface shouldallow the cases to be pushed onto the roller bedeasily.

q Use a powered hand jack or scissors-lift to raisethe pallet to waist height. This prevents picking upcases with a bent back.

q Work with suppliers to obtain freight with pallet loadheights that are within the reach of workers.


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q Make sure that there is toe-clearance under counters and other work surfaces.

q Put buckets of icing and batter on risers (e.g.,small stands or empty buckets) to raise them tothe best work zone.

q Use smaller containers of flour, sugar,salt and other supplies to reduce the weightsthat must be handled.

q When lifting keep large bags and containers of ingredients close to the body to reduce stress onthe back.

q Use carts or rolling stands to move heavy itemslike tubs of dough or bags of flour.

q Keep wheels on bakery carts well maintained.Wheels that are in poor repair can be difficult topush and should be removed from service untilthey can be repaired.

q Position cake-decorating turntables so thatthe cake is at about elbow height for a morecomfortable working position. Adjustable

height tables are one solution, but you can alsoput a riser under the turntable, use turntableswith different heights, or put in platforms for shorter people to stand on.

q Use small decorating bags whenever possibleto reduce the stress on the worker s hands.The larger the bag, the more force required to

squeeze it.

q Have an adequate number of mixing bowlsavailable to reduce the need to transfer icing or batters that are mixed in the store to other containers.

q Use footrests and anti-fatigue mats in areaswhere workers stand for prolonged periods.

B A K E R Y

These recommendation s are based on information from grocery stores. OSHA recognizes that other bakery operations may be different and th at other solutions may be more appropriate for those operations.


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q Whenever possible, break up continuous activitiessuch as cake decorating and dough handling withless strenuous tasks during the shift.

q Use a short-handled scoop to put icing intodecorating bags. Shorter handles reduce the stressto the wrist.

q Use spatulas, spoons, and other utensils that fit theworker s hand (not too wide or too narrow) and arenot slippery.

q Work from the long side of baking pans to reducereaches when handling dough.

q

Use ambidextrous scoops which allow workers touse either hand to dispense dough or batter.

q Use powered mixers whenever possible to mixcoloring into icing or purchase colored icing. Thisreduces the stress to workers hands and armsfrom manually mixing colors into icing.

q Ensure that the icing is of correct consistency. Icingthat is too thick will be difficult to squeezethrough decorating bags. If icing is mixed in thebakery, add liquid to the recipe or warm the icing toobtain the correct consistency. If icing is purchased

in buckets, store the buckets at room temperatureor warm them before use cold icing is thicker and hard to squeeze through decorating bags.

q Consider using cake decorating methods thatrequire less use of manual frosting bags. Using anair brush or mechanical dispurser whenever possible can reduce the stress on workers

hands.

q Whenever possible work from the long side of thedonut glazing area to reduce reaches and forceson the back. Some glazing stations can be pulledout so that workers can work from the side.

q Use a step stool to reach items on high shelves.

q Look for cases and counter designs that allow theemployee to hand customers their selectionswithout high or long reaches.


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q If overhead storage is necessary, use it for light itemssuch as foam trays.

q Use a step stool to reach items on high shelves.

q Position scales so that they can be used in thebest work zone. Scales that are too high or toolow for a worker can cause employees to work in

awkward positions. If possible, make the scale tableadjustable so that all workers can work in comfortablepostures. Also, position the scale near the lowest partof the counter so that neither the worker nor thecustomer has to reach over tall deli cases for meatpackages.

q Provide a small stool for employees to sit on whencatching and traying meat from the grinder. Squattingand bending at the waist can lead to back and legdiscomfort, especially when grinding for long periodsof time.

q Grind meat into a small lug and move it to a com-fortable work surface for traying. This prevents theawkward back posture that results from catching andtraying the meat immediately as it leaves the grinder.

Many of these solutions may also be useful for the seafood and cheese departments.

q Keep wheels on racks well maintained. Wheelsthat are in poor repair can be difficult to push.Racks with bad wheels should be removedfrom service until they can be repaired.

q Keep all grinders, cutters and other equipmentsharp and in good repair. Dull or improperlyworking equipment requires more force tooperate.

q Provide thermal gloves for use when handlingfrozen items.

q Avoid continuous cutting or grinding. Whenever possible, break up these tasks with other, lessstrenuous tasks throughout the shift.

q Work with suppliers to get meat and other supplies in lower weight boxes to reduce theweight manually handled.

q Keep large boxes and heavy items close to thebody. This helps to reduce stress on the back.

q Use a food processor to prepare ingredients for stuffing and other items.

q Arrange the wrapping station so that labels arewithin easy reach and workers do not have totwist or walk to get to them.

q Remove, round-off, or pad sharp or hard edgeswith which the worker may come into contact.

q Mount controls of the roller bed close to thewrap station so that workers can reach it easily.If there are two wrap stations, there should betwo sets of controls so that neither worker mustpull or lug trays down the conveyor.

q Align the roller bed and the wrap station so thatemployees can slide the trays rather than liftthem to the station.

D E L I

C H E E S

M E A

M E A T & D E L I


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D E L I

C H E E S E

M E A T

q Whenever possible, incorporate adjustable work surfacesinto the department. Examples include cutting tables,scales and deli slicers.

q Look for cases and counters that allow workers to servecustomers without excessive reaches.

q Use anti-fatigue mats, footrests, and sit/stand stoolswhere workers are required to stand for long periodsof time.

q Look for grinders that do not force the worker to bendover to catch meat or to reach too high to dump meatinto the grinder.

q When using tongs select tongs with long handles toreach items in the front of the case.

q Whenever possible, work from the long side of trays toreduce reaches and the resultant high stresseson the back.

q Avoid working with the hands/wrists held in a bent or

twisted position.

q Keep knives sharp. Workers should be trained in the bestknife sharpening methods. Knife sharpening systemsshould be used regularly, and steels and mousetrapsharpeners should be used to keep knives sharpthroughout the shift.

q Try different knives to see if they are more comfortable touse. Some designs work well for specific cutting, trimming,or portioning tasks and should be considered specialpurpose tools.


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q Position scales and wrap stations so that they

can be used in the best work zone. Scalesthat are too high or too low for a worker cancause employees to work in awkward positions.If possible, make the scale and wrap stationtables adjustable so that all workers can workin comfortable postures.

q Keep boxes, melons, bags of potatoes, or other heavy items close to the body whenlifting and carrying. This helps to reducestress on the back.

q Keep heavy items, such as watermelons, inshipping containers and use pallet jacks tomove them.

q Consider using refrigeration rather than ice tocool produce in order to eliminate the need toshovel ice.

q Place heavier or fast-moving items on shelvesthat are in the best work zone.

q Use carts to move heavy items; position cartsalongside displays to minimize reaching andcarrying.

q Keep manual food processing equipment (knives,

slicers, etc.) sharp and in good repair. Equipmentthat is dull or is not working properly may requireexcess force to operate.

q Use a lightweight shorthandled plastic shovel for ice. This tool is less stressful to the body thanheavy shovels. A small shovel allows the worker tomove more ice in less time than a hand scoop.

q Use a portable ice case to transfer ice from theice machine to the produce displays.

P R O D U C E


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The following sources may be useful to thoseseeking further information about ergonomicsand the prevention of work-related musculo-skeletal disorders in grocery stores.

Working Smart in the Retail Environment Ergonom ics Guide , Food Marketing Institute,(202) 452 -8444 . FMI offers (for a fee) severaldifferent guidelines and videos, including thisdocument . This guide instructs cashiers andfront line managers how to enh ance safety,comfort and p rod uctivity. The guide alsoincludes a Working Smart Quick Reference,which summarizes the general and specifictechniques employees shou ld use and a void.(1996, 68 pages)

In Search of Better Checkstands, United Foodand Commercial Workers International Union.This document p rovides detailed informa tionon checkstand design, part icularly the advan-tages of grocery scanners tha t r educe the needfor cashiers to grip and lift grocery itemsacross the scanner.

Easy Ergonomics, A Practical Approach for Imp roving the Workplace ; California

Department of Industrial Relations. Thisdocument is designed to provide generalergonomics advice and is not industry specific.The document provides a simple, han ds-onapproach to ergonomics to help employers,supervisors and workers as they work towardimproving ergonomic cond itions in theirworkplace. (1999, 90 pages)

Elements of Ergonomics Programs , U.S.Department of Health and Human Services National Institute for Occupational Safety andH ealth, (800) 356-4674. The basic elementsof a workplace program aimed at preventingwor k-related m usculoskeletal disorders ar edescribed in this document . It includes a toolbox, which is a collection of techniques,methods, reference materials and sources forother information that can help in programdevelopment.

Ergonomics for Very Small BusinessRetail/ W holesale (Poster) ; California Department of Industrial Relations. A poster with examp lesof safe ergono mic work practices for the very

small retail and wholesale employer.In addition, OSHAs Training Institute in

Arlington Heights, Illinois, offers courses onvarious safety and h ealth top ics, includingergonomics. Courses are also offered throu ghTraining Institute Edu cation Centers locatedthroughout the coun try. For a schedule of courses, conta ct the O SH A Training Institute,2020 South Arlington Heights Road,Arlington H eights, Illinois, 60005, (84 7)297-4810, or visit OSHAs training resourceswebpage.

There are many states and territories thatoperate their own occupational safety andhealth pro grams under a plan appro ved byO SHA. Information is available on O SH Aswebsite on how to contact a state plan directlyfor information a bou t specific state grocerystore initiatives and compliance assistance, ordifferent state standards that may apply togrocery stores.

A free consultation service is available topro vide occupational safety and health

assistance to businesses. O SH A Consultationis fund ed primar ily by federal O SHA butdelivered by th e 50 state governments, theDistrict of Columbia, Guam, Puerto Rico, andthe Virgin Islands. The states offer theexpertise of highly qualified occupationalsafety and health pr ofessiona ls to employerswho request help to establish and maintain asafe and healthful workplace. Developed forsmall and medium-sized employers inhazardous industries or w ith hazardousoperat ions, the service is provided a t no costto the employer and is confidential. Infor-mation on OSHA Consultation can be foundat www.osha.gov or by requesting the book letConsultation Services for the Employer (OSHA 3047) from OSHAs PublicationsOffice at (202) 693-1888.

Additional Sources of Information


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References

(1) Food Mark eting Institute. 199 2. Ergonom ic Improvem ent of ScanningCheckstand Designs . Washington, D.C.

(2) Clarke, Cynthia M ., Workplace injuriesand illnesses in grocery stores, Compensationand Working Conditions , Bureau o f LaborStatistics, December 19, 200 3.

(3) Fall 200 3 Liberty Mutual Workplace SafetyIndex: Identifies the direct costs and leadingcauses of workplace injuries. Liberty MutualInsurance Comp any. September 2003.

(4) Food Mark eting Institute. 199 5. WorkingSmart in the R etail Environment ErgonomicsGuide . Washington, D.C.

(5) E-mail from Supervalu Supermarkets, Inc.to O SH A. 2 003.

(6) Na tional Institute for Occupa tional Safetyand Health (NIOSH). 1997. Musculoskeletal

Disorders (MSDs) and Workplace Factors ACritical Review of Epidemiologic Evidence for Work-Related Musculoskeletal Disorders of the N eck, Upper Extremity and L ow Back.

N ational Institute for O ccupational Safety and Health (N IO SH) Publication #97-141 . (3-18).

(7) Kennedy, S. et al. 1992 . Prevalence of muscle-tendon and nerve compressiondisorders in the hand an d wrist of a wor kingpop ulation of grocery cashiers using laserscanners. Occupa tional and Environ mentalDisease Research Unit, University o f BritishColumbia. March 15.

(8) Ryan, G. Anth ony, The prevalence of musculo-skeletal symptoms in supermark etworkers, Ergonomics , 1989, Vol. 32, N o. 4,359-371.

(9) Cohen, A., C. Gjessing, L. Fine, B.Bernard, and J. McGlothlin . Elements of

Ergonomics Programs . March 1997.National Institute for Occupational Safety andH ealth (NIOSH). Publication # 9 7-117.

(10) Menzel, N . 1994. Workers Comp Management from A to Z . OEM Press.Chapters 11, 12, 19.

(11) Magyar, S. Jr. 1999 . M edical claimmanagement. Professional Safety . March.

(12) Hendrick, H. W. 2003, Determining thecost-benefits of ergonomics projects andfactors that lead to their success, AppliedErgonomics. 34, 419-427.

(13) Allen, E. 199 8. Keeping grocerycheckout lines moving. Risk Management .January.

(14) Grocery Manufacturers of America, FoodMarketing Institute, Food DistributorsInternational. Supply Chain Packaging Voluntary Shipping Container Guidelines for the U.S. G rocery Industry . 1999.


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osha 3192 grocery store

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