ERGONOMIC

&
MANUAL HANDLING
at the workplace

1
Anyone Hurt?
OBJECTIVES
At the end of the session, participants
should be able to:
• State the definition of manual handling
• List at least 4 accidents that can occur
during manual handling works
• State 4 factors that influence manual
handling
• Discuss safety measures before and
during manual handling works

3
Objective
• State the factors that contribute to MSDs
• Explain at least 3 types of work activities
and ergonomic risk factors
• Explain at least 3 MSDs and the affected
body parts
• Elaborate at least 2 system approaches to
manage MSDs
• List at least 3 early detection methods and
symptoms

4
SCOPE
• Definition
• Objective of Ergonomics
• Statutory Requirements
• Ergonomics Risk Factors
• Accident Statistics
• Anatomy
• Mechanic
• Manual handling
• Injuries
• Consideration
• Strategies & Techniques

5
SCOPE
• Musculoskeletal Disorders (MSDs)
• Factor
• Related Disease
• Systems approach to manage MSDs
• Early detection and reporting of symptoms
• Safety measures before and during works
• Ergonomics Improvements
• Proactive Plan
• Job Analysis
• Training
• Conclusion

6
 Positive Values via the
Ergonomic Approach

For the For the

EMPLOYE EMPLOYE
R E

Safety and Health, Performance –

Comfortability, Satisfaction Quality, Productivity, Flexibility

Reduced worker absenteeism and

turnover, open to changes
EMPLOYEE EMPLOYER
welfare welfare

7
What is Ergonomics?

• The term ‘ergonomics’ is derived from two Greek words:

•
‘ergon’, meaning work
• ‘nomos’, meaning natural laws

• Efficient and Safe Arrangement of Work Rules

• Working Conditions
• Machines/Equipment
• People
What is Ergonomics?
The science and art of “Fitting the
task to the employee”

“The Dual Goals” Minimize injuries

Improve productivity &
quality
Objectives of Ergonomics
To increase levels of work efficiency and
effectiveness or any related activity
undertaken such as through reduction of
mistakes, increase of productivity, and
simplification of tasks.

 To increase positive human values such as

increased safety, reduced fatigue and stress,
increased work comfortability, and increased
quality of work and life in general.
11
 Purpose of Ergonomics
The risk assessment process aims to
remove a hazard or reduce the level of its
Tolerable work system risk by adding precautions or control
measures, as necessary. By doing so, you
have created a safer and healthier
workplace.

Acceptable work
system

Optimal work
system

12
 Balance Theory

Human Factor
Work Environment
Factor
Work Factor
Organizational
Factor
Technology Factor
Each component has a +ve & -ve relationship in
balance. Impact on worker performance, stress, and
job satisfaction Work like a good team player
to maintain harmony and balance
people are comfortable with balanced attitudes.

13
Approach: Fitting the Worker to the Task,
or the Task to the Worker?

Is it optimal?

Is it well-suited?

Human factors Human actions Tasks done by Tasks done by

humans Work machines

Select Redesign
Train Restructure

Not suitable Additions

14
 Branches of Ergonomics
ERGONOMICS
Anthropometrics Biomechanics Physiology Psychology

The study of the human body Mechanics = study the the way in which a The science that deals
and its movement, often effect of forces on bodies living organism or with mental processes
involving research into during static and dynamic bodily part functions. and behavior.
measurements relating to situations.
people. Physiological
Biomechanics is the problems occur when
It also involves collecting application of mechanical the body is required
statistics or measurement principles to living to do too much work,
relevant to the human body, structures either animals to work awkwardly or
called Anthropometric Data. or human being at rest & to work under bad
during movement. environmental
When anthropometric data is conditions.
applied to a product, e.g. Biomechanics deals with
measurements of the hand the locomotion system
are used to design the shape which is the
and size of a handle. Hair musculoskeletal system
Dryer. (Bones, Joints and
Muscles).

15
 Metabolism, breathing, temperature
and heartbeat as work load indicators
Work Load Usage of Lung Rectal Heartbeat
Assessment Oxygen Breathing Temperature (beat/min)
(liter/min) (liter/min) (ºC)

Very low (resting) 0.25 – 0.3 6-7 37.5 60 - 70

Low 0.5 - 1 11 - 20 37.5 75 - 100

Moderate 1 - 1.5 20 - 31 37.5-38 100 – 125

High 1.5 - 2 31 – 43 38 – 38.5 125 – 150

Very high 2 - 2.5 43 – 56 38.5 – 39 150 – 175

Extreme 2.4 - 4 60 - 100 > 39 > 175

(sport)
16
STATUTORY
REQUIREMENTS
Occupational Safety and Health Act 1994

• General responsibility of the employer and

self-employed

• “The making of arrangements for ensuring,

so far as practicable, safety and absence of
risks to health in connection with the use or
operation, handling, storage and transport of
plant and substances”. (Section 15 (2)(b))

17
STATUTORY
REQUIREMENTS
Factories and Machinery Act 1967

• Section 12
“ No person shall be employed to lift, carry
or move any load so heavy as to be likely
to cause bodily injury to him.”

18
Working Conditions

• Physical Conditions
• Force
• Pushing
Working Conditions

• Physical Conditions
• Lifting
• Handling
Working Conditions

• Physical Conditions
• Lifting
• Handling
Ergonomic Risk Factors

22
 Ergonomic Risk Factors

① Doing repetitive work

② Use of excessive force

 Improper or static body posture

23
 Ergonomic Risk Factors
④ Work in long duration

⑤ Vibration due to hand tools

 Contact stress on the blood veins, muscles

and tendons due to contact stress due to
use of hand tools/equipments

24
 Working Conditions

• Awkward Postures
 Working Conditions

• Awkward Postures
 Working Conditions

• Awkward Postures
 Working Conditions

• Repetitive Motion
 Types of activities and
Ergonomic risk factors
No. Activity and Physical Possible ergonomic
work situation risk factors
1. Use of excessive force to ensure Force, posture, pressure
completion of work process

2. Repetition of the same movements Posture,force,cold temperature,

repetition
3. Consistent movements without Repetition, force, posture,
sufficient resting time pressure, vibration

4. Work requiring long reach ability Posture, force

5. Work surface that is either too high Posture, force, pressure

or too low

6. Static position or posture while at Posture, force

work

29
 Types of activities and
Ergonomic risk factors
No. Activity and Physical Possible ergonomic
work situation risk factors
7. Sitting for long durations Posture, pressure

8. Use of hand tools or power tools Posture, pressure, vibration

9. Vibrating work surface, machinery Vibration, force

or vehicle

10. Movement of heavy loads Force

11. Horizontal reach Repetition, posture

12. Vertical reach below the knee or Posture, pressure

above the shoulder

30
 Accident Statistics
Largest cause of accidents at work

37% Manual Handling

19% Slips, Trips and Falls
12% Other Causes
20% Struck by an Object
7% Falling from Height
5% Machinery
 Accident Statistics
Interpreted another way - the
overall figure of 37% means that:
86000 people are absent daily
26,500,000 working days are lost
annually
£1000,000,000 is lost in production,
sickness benefit and medical costs
In terms of suffering each injury results in an
average of 20 days off work – some never
fully recover. Four out of five people suffer
with back related problems at some time – the
risk is greater after the age of 30.
 Anatomy
Spine
Three main functions
• To protect the spinal cord
• To allow movement.
• To support the upper
body

Complex System
• Spinal Cord
• Nerves
• Ligaments
• Muscles & Tendons
 Anatomy
Spine - Strong and Flexible
• Gentle ‘S’ bend
• Move or lift in wrong way
balance can be disturbed

Problems – contributory factors

• Poor physical condition
• Posture
• Lack of exercise
• Excess weight
• Illness
 Disc Spinal Cord

Vertebrae
• 33 bones – the top 24
are separated by discs
• Each vertebrae has 4
joints which enables
movement
• Vertebrae are larger
towards the bottom of
the spine
Vertebrae
 Anatomy

Discs Nucleus
• Act as shock
absorbers
• Firmly attached to
vertebrae
• Poor blood supply
• Annulus stretches
and relaxes during
movement. Disc
Annulus
 Anatomy
Discs
• Repeated stresses
can cause minute
tears and bulging
of the disk.
• Presses on
adjacent nerves
and ligaments –
pins & needles,
pain, numbness
• Commonly called
a slipped disc
 Muscles

• Muscles are bundles of fibre which enable

movement
• Messages from the brain cause them to
contract and relax
• Connected by tendons and when muscles
contract the bones are drawn closer
together
• A damaged muscle is called a strain
 Ligaments & Nerves

Ligaments Nerves
Strong fibrous tissue Millions of fibres
Small degree of transmitting electrical
elasticity impulses
Stooped back posture Vertebrae enclose and
can result in protect
permanent Nerves branch out from the
elongation – spinal cord and pass
weakness and pain between vertebrae
Damaged if stretched Irritated nerves can be felt
too far and torn – right along there length –
called a sprain. called sciatica
 Mechanics
• Balance point is through centre of body when
standing
• A load held in front disturbs the balance -
tension is generated in the back muscles to
compensate
• Forms a lever effect
• Average person holding a 10kg load at arms
length generates a counterbalancing tension
up to 10 times more – to avoid falling over
• High or repetitive levels of tension in the back
can cause damage – called muscle strain
 Mechanics

Centre of Gravity

Centre of Gravity

Lever effect is reduced if load held closer to the body

 UNSAFE ACT

MENGANGKAT OBJEK MELEBIHI 1 / 3 BERAT BADAN

MANUAL HANDLING

Definition:

“Any lifting, lowering, pushing, pulling,

moving, shifting, holding or supporting a
load that is done manually”

43
MANUAL HANDLING

Accidents related to manual handling

works
• Accidentally letting go of load

• Crushed by load

• Fall while carrying load

• Contact with sharp edges of load

44
MANUAL HANDLING
TYPES OF INJURIES

(1) External injuries

• Cuts
• Scratches
• Tears

45
MANUAL HANDLING
TYPES OF INJURIES

(2) Internal injuries

• Muscle or ligament tear
• Damage to joints

– knee, ankle, shoulder, arm

• Slipped disc
• Hernia
• Rheumatism

46
MANUAL HANDLING
CONSIDERATIONS
Factors that need to be considered in
manual handling works include:
1. Size of load
2. Condition of load
3. Physical shape of load
4. Weight load
5. Level of sturdiness
6. External surface of load
7. Position of load

47
MANUAL HANDLING
CONSIDERATIONS

8. Condition of floor surface

9. Head room
10.Temperature
11. Lighting
12. Physical and mental fitness
of worker
13. Lifting equipment
14. Worker clothing
48
MANUAL HANDLING
CONSIDERATIONS

1) Size of load

 Big or small
 Example:
 50 kg cement
 50 kg cotton

 Although they have the same weight,

the size is different

49
MANUAL HANDLING
CONSIDERATIONS

2) Condition of load

• Liquid
• Solid
• Gas

50
MANUAL HANDLING
CONSIDERATIONS

3) Physical Shape of Load

Examples:
• Round
• Square / triangular
• Oval
• Flat
• Long

When lifting, load has to be balanced

51
MANUAL HANDLING
CONSIDERATIONS
4) Weight of load

The weight of the load has to be known

before
handling

• Purpose - to identify
• Method of handling
• Worker capability

52
MANUAL HANDLING
CONSIDERATIONS
5)Level of sturdiness

• The load may change shape upon

handling

• This will cause difficulties in

holding and gripping the load

53
MANUAL HANDLING
CONSIDERATIONS
6) External surface of load

• Rough
• Smooth
• Uneven
Example:
Plastic bag, sack, paper, metals all have
different surfaces

54
MANUAL HANDLING
CONSIDERATIONS
7) Position of load

Position of load that needs to be

handled

• Load is on the floor

• Load is located above head level

55
MANUAL HANDLING
CONSIDERATIONS

8) Condition of floor

• Slippery
• Soft
• Uneven

Stability and condition of the floor is

important for balancing purposes

56
MANUAL HANDLING
CONSIDERATIONS

9) Head room

• Sufficient head room to avoid

bumping head onto surface

• Most manual handling works

involve limited head room

57
MANUAL HANDLING
CONSIDERATIONS

10) Temperature

• Temperature influences the method

and speed of a worker’s movements:

• Cold – muscles are tensed

• Hot – body loses a lot of water

58
MANUAL HANDLING
CONSIDERATIONS

11) Lighting

Dark work environments can lead to

accidents. This is because workers
are not able to decipher the route
and any obstructions on the
floor/along the way

59
MANUAL HANDLING
CONSIDERATIONS

12) Worker physical and mental fitness

• Physical capability
• Age
• Health and fitness level

60
MANUAL HANDLING
CONSIDERATIONS
13) Lifting equipment
Equipment used to assist in manual
handling
activities such as trolleys and pulleys

• Equipment design is suitable to the

activity and load

• Equipment is properly
maintained
61
MANUAL HANDLING
CONSIDERATIONS
14) Worker clothing

• Suitable to individual work task

• Comfortable
• Protects worker from manual handling
hazards – this includes the provision and
use of PPE

62
MANUAL HANDLING STRATEGIES

• Identify load / material to be handled

• Identify the location and destination of
the load
• Assess the potential risks
• Select suitable manual handling method
• Conduct safety assessment before
starting work
• Monitor work activities

63
MANUAL HANDLING
TECHNIQUES

(1) Illustration PM1

• Handling of sack / bag
• Grip / hold from bottom. Grip using palm and fingers
(2) Illustration PM2
(3) Illustration PM3

64
ILLUSTRATION PM1

65
ILLUSTRATION PM2

66
ILLUSTRATION PM3

67
 Musculoskeletal Disorders (MSDs)
A situation arising by excessive use resulting in wear and tear to muscles,
tendons, joints and surrounding tissues
In the long term, may result in incapability to use the related body part

68
 Incapable Level

Incapacity

Disease, injury
Affecting Level

Clear symptoms

Swelling, pain
(affecting performance)
Warning Level

bodily aches, minor pains

uncomfortable, fatigue
(normal)

69
 Factors that contribute
to MSDs

① Speed of work being undertaken

② Use of computers and its accessories in

the office

③ Elderly workforce

70
 List of MSDs related diseases and
affected body parts
Affected
Symptom Source
- of Employees Types of
body part
disease at risk disease
Thumb Pain at the end Twisting and Animal de
of the thumb clenching slaughterers, Quervain’s
housemaids, disease
packagers

Fingers Difficulty to move Repetition using Meat packagers, trigger

fingers, little finger poultry farm finger
interrupted hand workers,
movements electronics
operators

Shoulder Pain, aches Working with Welders, rotator cuff

hands above painters, tendonitis
shoulder level assembly
workers,
operators of
automatic and
powered 71
equipments
 List of MSDs related diseases and
affected body parts

Affected Employees
body part Symptom Source
- of Types of
disease at risk disease
Hand, wrist Pain, swelling, Repetitive hand Poultry farm Tenosynovitis
aches and wrist workers, meat
movement and packagers
excessive use of
force

Fingers, hand Numbness, ticklish, Exposure to Users of saws, Raynaud’s

loss of sense of vibration pneumatic tools syndrome
feel and hand and petrol powered
control equipments

72
 List of MSDs related diseases and
affected body parts

Affected
body part Symptom Source
- of Employees at Types of
disease risk disease
Fingers, wrist Ticklish, Repetitive work Meat and poultry Carpal tunnel
numbness, severe using excessive farm workers, syndrome
pain, loss of sense force, without clothes
of feel at thumb, sufficient rest manufacturers,
middle finger and VDT operators,
part of the ring cashiers
finger

Back Spinal pain, Vibration Bus, lorry, Injury to

numbness at thigh commuter, taxi back/spine
and surrounding drivers, warehouse
areas workers, nurses,
cashiers and
baggage handlers

73
 Types of MSDs

① Tendon related disease

 happens at or close to the joints where there is friction
between the tendons and ligaments and/or bones

 Repeated contact or friction resulting in cut severe of

tendons or swelling at the shield due to over production and
gathering of the cynovial liquid

 Example:
tendonitis, trigger finger,de Quervain’s disease tenosynovitis

74
 Types of MSDs

② Nerve related diseases

 Happens when work is done repetitively, resulting in
exposure of the nerves to pressure from hard or sharp work
surfaces and equipment edges, or even surrounding
bones, ligaments and tendons.

 Effects of numbness and pain will be felt for a period of

time

 Example:
Carpal tunnel syndrome

75
 Types of MSDs

 Neuro-vascular diseases
 Due to the pressure of nerves and veins resulting in
reduced
blood flow to the muscles, tendons and ligaments

 Results in slow recovery of the muscle, and limited

duration of
muscle use

 Example:
Thoracic outlet syndrome and vibration syndrome

76
 Systems approach to
manage MSDs

First Phase – Before Onset

 Conduct comprehensive review of existing and new
job tasks
 Purpose: to identify the ergonomic risk factors that
may result in future MSDs problems
 Giving priority to the critical ergonomic risk factors
and taking necessary action

77
 Systems approach to
manage MSDs

Second Phase - Current

 Identify problems that may arise before serious
implications through the development and
implementation of an early detection system, medical
surveillance, and specific treatments
 The role of a medical practitioner is important to
ensure the success of this system and success in
managing MSDs related diseases

78
 Systems approach to
manage MSDs
Third Phase - After
 Review of the work system through interaction with
workers such as interviews with affected workers and
studying their respective job tasks in comparison with
existing work procedures
 Requires cooperation from various parties; the
respective worker, supervisors, engineers, medical
practitioners in order to develop a strategy for the
prevention and reduction of ergonomic risk factors at
work

79
 The science that deals
the way in which a with mental processes
living organism or MSDs and behavior
bodily part
functions Physiological Psychosocial

 RPE Rated Perceived Exertion

Perceived exertion is how
Fatigue Pressure Individual hard you feel like your  Borg scale
body is working.
factors  Behaviour patterns
the characteristic ways in which
a person or animal acts

Ergonomic risk
Stress factors
 Insufficient  Repetition External factors
oxygen  Force  Work
 Movement  Posture  Technology
 Muscles  Long durations  Environment
 Recovery  Vibration  Organisation
 Pressure

Cumulative
effect

Local Controllable factors

Symptoms 80
 Early detection and reporting of
symptoms
① Continuous pain after weeks of involvement in new
job
② Sudden pain in worker that has been on the same
job for a long time
③ Pain that is getting worse
④ Pain that is centered at certain muscles
⑤ Signs of numbness and aches
⑥ Signs of redness and swelling

81
SAFETY MEASURES
BEFORE HANDLING

• Study whether the weight of the load can

be distributed
• Adjust the shape of a big load for easier
handling
• Adjust the layout of work area or work
station to accommodate manual
handling work
Example:
Provision of a work table of suitable
height for drawing works
82
SAFETY MEASURES
BEFORE HANDLING

• Identify the best method to handle load

- push, pull, lift, support etc…
• Study the proper lifting techniques. Use the
suitable posture and physical capabilities
• Adjust the work method to accommodate
supporting equipments such as wedges,
hooks and crow bars
• Provide training to the worker on respective
job tasks - SOP and other requirements

83
SAFETY MEASURES
DURING HANDLING

• Use the proper methods and

techniques
• Ensure compliance to work plan
• Continuously monitor that proper
methods and techniques are being
practiced by workers

84
 Ergonomics Improvements

• Taking a fresh look at

Workplace
People
Tools

• Engineering Improvements

• Administrative Improvements
 Engineering Improvements

when new facilities, processes, or work procedures

are being planned
• Tools
• Includes
• Equipment
• Rearranging
• Workstations
• Modifying
• Parts
• Redesigning
• Processes
• Replacing
 Engineering Improvements

• Reduce reaching and bending.

• Reduce the stress on your back and shoulders.

• Reduce the effort and force needed to perform work

tasks.
 Engineering Improvements
• Improve your grip, Use a tool.

• Reduce contact pressure on your shoulders and hands.

• Use powered and non-powered equipment.

Engineering Improvements
Mechanical handling
equipment
Engineering Improvements
Mechanical handling
equipment
 Engineering Improvements

Modify the load

repackage to reduce weight
Engineering Improvements
Modify the load – improve
grip
provide hand holds
Administrative Improvements
• Alternate heavy tasks with light tasks.

• Provide variety in jobs.

• Adjust work schedules, work pace,

work practices.
Administrative Improvements
• Provide recovery time

• Rotate workers through jobs that use different muscles, body

parts, or postures.
Administrative Improvements
 Ideas for Improving work practices

 Job Rotation

 Identifying Problem Jobs

 Time Spent on particular task

Administrative Improvements
Administrative Improvements

Modify workplace layout

Administrative Improvements

Modify workplace layout

A Proactive Plan

• Identify Problems

• Set priorities

• Looking Around

• Talking to Employees
Four steps to a Proactive Action Plan.

1. Look for clues

2. Prioritize job for improvements.

3. Make improvements.

4. Follow up.
 Job Analysis 7 Steps

① Determination of measurement criteria and

work target

② Compilation of history of targeted job task

③ Identification of ergonomic risk factors

④ Discovery of preventive measures

104
 Job Analysis

⑤ Selection of preventive measures

⑥ Implementation of preventive measures

⑦ Monitoring of preventive measures

105
 Characteristics of
Sitting Works
① Precise hand movements
② High body stability
③ Use of exact and sensitive foot control
④ All work components and equipment within
seating range
⑤ Handling of heavy loads
⑥ Static posture for long durations
106
 Characteristics of
Standing Works

① Frequent handling of heavy loads

② Frequent stretching and movements that
require use of energy
③ Work mobility
④ frequent forceful exertion that requires high
energy

107
 Characteristics of
Sit/Stand Works

① Provision of high chairs as the worker is

required to alternate sitting and standing and
change of postures
② Mobility of the chair
③ Provision of footrest to reduce swelling and
fatigue of the leg and foot

108
Relationship of Posture and Pressure
on the Backbone

Skill Solutions Sdn Bhd 109

 Choices of Work Postures
for Selected Job Tasks
Type of Job Task Work Posture

First Choice Second Choice

Lifting above 5kg standing sit/stand

Work below elbow height standing sit/stand

Horizontal reach requiring body support standing sit/stand

Light assembly work with repetitive sitting sit/stand

movements
Precise works sitting sit/stand

Examination and monitoring using eyes sitting sit/stand

Frequent movements sit/stand standing

110
 Determination of
Working Height

Elbow height
Precise Light works Heavy
works works
Skill Solutions Sdn Bhd 111
Normal and Maximum Range

Maximum range

Normal range

112
Training

 A pivotal role in ergonomic improvement

 Use several types of visual aids

 Pictures, charts, Videos
 Group discussions,
 Encourage to Ask Questions

 Hands-on practice with

 New tools
 Equipment
 Work procedures
KUIZ KENALPASTI HAZARD ERGONOMIK

115
Copyright © 2006 NIOSH Malaysia. All rights reserved. No part of this text shall be reproduced without written consent of
NIOSH Malaysia
CONCLUSION

• Manual handling can cause internal and

external injuries to the worker
• Various statutory requirements outline
provisions related to manual handling
• Manual handling programme has to take
into consideration various factors such as
size, shape and weight of load to be
handled
• Safety measures have to be followed
before and during handling to avoid
unwanted incidences
116