ERGONOMICS

DESIGN OF MANUAL
HANDLING TASKS
Submitted By,
Ankur Singh
Anjali Agatha Lakra
Apoorva Tiwari
Sumit Anand
Sushvi Priyadarshni
Yamini Mishra
B.F.Tech
Sem-7

INTRODUCTION
Manual handling is a common activity in most
workplaces
It includes lifting, lowering, pulling, pushing, carrying,
moving, holding or restraining an object
Injuries and musculoskeletal disorders affect the back,
neck, shoulder, arms & hands
It can be prevented through a systemic approach of
identification, assessment and control of risks
associated with manual handling.

Example of manual handling

activities

Risk Factors in Manual Handling

Load placed on the discs during

various activities.
Activity

Load on Disc (kg/cm2)

Lying on back

20

Standing

70

Sitting

100

Sitting slumped

180

Walking

85

Coughing, sneezing

110

Laughing

120

Bending forward 20

120

Lifting 20kg, back straight

210

Lifting 20kg, back bent

340

Occupational Diseases in
Singapore

Source: Ministry of Manpower

Various Hazards Associated

with Manual Handling

Hazards Associated with Manual Handling Heavy

Lifting over 25kg load can result in back injury

Picture source: http://www.masterlift.ie/images/HealthAndSaftey/HandS.jpg

Hazards Associated with Manual Handling Heavy

Hazards Associated with Manual Handling Sharp

Potential Cuts on the fingers

Hazards Associated with Manual Handling

Odd Shapes

Absence of grip to hold the load

Obstruction of walking view

Picture source: http://make-a-box.com

Picture source: http://www.fork-lift-trucks.info

Hazards Associated with Manual Handling

Toxic Substances

Skin exposure to chemicals

Picture source: http://discountpowerparts.com

Coolant

Picture source: http://www.vacmagic.com/images/fixture%20macchining%20scene.jpg

Lubricants

Hazards Associated with Manual Handling

Toxic substances

Exposure to chemical dust, fumes & vapours

Picture source: http://www.railcamp.com

Picture source: http://www.airborncoatings.com/images/air3.gif

Health Hazards Resulting From Chemical Handling

Skin dermatitis

Picture source: http://www.ascc.gov.au

Health Hazards Resulting From Chemical Handling

Occupational respiratory & lung diseases

Picture source: http://content.revolutionhealth.com/contentimages/images-image_popup-ww5r370.jpg

Picture source: http://myweb.lsbu.ac.uk/dirt/museum/simon/68-776-gse15.jpg

Health Hazards Resulting From Chemical Handling

Occupational eye diseases

Picture source: http://content.revolutionhealth.com/contentimages/images-image_popup-r7_conjunctivitis.jpg

Musculoskeletal Disorders due to

Manual Handling

Anatomy and biomechanics of manual

handling
When carrying out manual handling tasks, the weight of the
load being lifted is transferred to the spinal column in the
form of compression and shear forces.
The compression and shear are greater when the load is
lifted quickly because higher forces are needed to accelerate
the mass from rest, according to Newtons laws of motion.
The abdominal and thoracic muscles play a major role in
stabilizing the spine when a weight is lifted according to
Morris et al. (1961). In relaxed standing, these muscles
exhibit little activity.

 Spinal

compression

is

increased when loads are

lifted

and

is

increased

even more when they are

lifted quickly and when
the posture is asymmetric.
High load movements and
high

postural

moments

increase the forces even

more.

Compression on intervertebral discs

of the curvature of the column :
Left, posture to avoid
Right, correct posture

Back injuries and lifting and

carrying
The muscles and ligaments of the back can
fail under excessive tension.
The intervertebral disc may herniate as the
nucleus

is

extruded

under

excessive

compression.
The abdominal contents may be extruded
through

the

abdominal

cavity

owing

excessive intra-abdominal pressure.

to

Common Injuries From Manual Handling

Slips, trips and fall

Picture source: http://www.istockphoto.com

Picture source: http://www.greenbergmassarelli.com/Images/slip_fall.jpg

Common Injuries From Manual Handling

Cuts

Picture source : http://krismarkel.com/eclaircie/photos/uncategorized/ouch.JPG

Picture source: http://www.thealmightyguru.com/Boffer/Images/FA-MinorCut.jpg

Common Injuries From Manual Handling

Neck Strain

Picture source: http://www.abcbodybuilding.com/exercise2/neckspra.jpg

Common Injuries From Manual Handling

Wrist Sprains

Picture source: http://www.drfoot.co.uk/pictures/wrist.jpg

Back Sprains

Picture source: http://athleticscholarships.net/back%20pain.jpg

Common Injuries From Manual Handling

Shoulder pain

Upper back pain

Picture source: http://www.gotosee.co.uk

Picture source: http://medicineworld.org

Risk Management on Manual Handling

Identification of hazard.
Assess the risk.
Take all reasonably practical steps.
Eliminate any risks.

Risk Management on Manual Handling

Step 1: Identification of hazard

Picture source: http://www.safetyworld.com/images/101.gif

Risk Management on Manual Handling

Step 2: Assess the risk

Dependent on severity of risk and likelihood of

hazards
occurring

severity X likelihood = risk level

Risk Level = Low, Moderate or High

Risk Management on Manual Handling

Step 3: Select Measures to Control and Reduce Risk

Based on hierarchy of hazards control

1st Remove the hazard

2nd Guard the remaining hazards

3rd Mitigate impact of hazard

Risk Management on Manual Handling

ELIMINATION
Elimination of any unnecessary
manual handling tasks.
This may include good storage
design to eliminate lifting heavy
items from low down or overhead.

Another way of eliminating unnecessary

manual handling is by avoiding double
handling of items.
Eliamination can be remembered as
Design it out.

SUBSTITUTION
Substitute lighter objects
for heavier ones.
This can be achieved by
reducing the number of
items in a box, breaking
bulk packs down in to
smaller parts before
moving them or
purchasing products in
smaller portions.
It can be remembered as
Use Something Else

ENGINEERING

Engineering is used for installing or applying mechanical aids wherever possible to assist with manual
handling tasks. In the office, mechanical aids can assist with good ergonomics of your workstation.
It can be summed up as Isolation And guarding of machineries /workstation.

ADMINISTRATIVE CONTROLS

Administrative
controls
mean
spreading
the
manual handling tasks
over a larger number of
people or a longer period
of time to reduce the load
on your body. In the
office,
this
includes
regular breaks from sitting
and
good
stretches.
Basically it is Training
and work scheduling of
the
workers/tasks.

PERSONAL PROTECTIVE EQUIPMENT

PPE (Personal protective equipment)-The final step is to complete the
required task safely. Use strong postures that protect your back and
shoulders and allow you to generate the necessary force with your legs
and body weight. When sitting in the office, sit with good posture.
The last resort will be using Protective equipments.

Selection of Personal Protective Equipment (PPE)

for Manual Handling
Are there any sharp or point edges?
Is it enough to prevent injuries or occupational diseases?
Does the PPE fit you correctly?
Does the PPE wear out easily?
Is it based on chemical properties of the substance?
Does it minimize contact with chemicals?
Is it easy to clean and maintain?

Selection of PPE for Manual Handling

Safety boots
Protective gloves
Helmets
Working apron or overalls
Goggles or safety glasses
Face mask or respirators

Picture source: http://www.osha.gov

Selection of PPE for Manual Handling

Safety boots

Picture source: http://www.hse.gov.uk

Picture source: http://www.veganline.com/safety-boot-big.jpg

Selection of PPE for Manual Handling

Protective gloves

Picture source: http://www.hse.gov.uk

Picture source: http://www.dkimages.com

Selection of PPE for Manual Handling

Helmets

Picture source: http://www.hse.gov.uk

Picture source: http://myweb.datahalland.se/w-15080/admin/picture/20050919154156.jpg

Selection of PPE for Manual Handling

Working apron or safety overalls

Picture source: http://www.hse.gov.uk

Picture source: http://www.anzic-int.com
Picture source: http://www.dashackoutdoors.com

Selection of PPE for Manual Handling

Goggles or safety glasses

Picture source: http://www.hse.gov.uk

Picture source: http://teachertech.rice.edu
Picture source: http://www.wintex.ca/english/Images/PPE026b.gif

Selection of PPE for Manual Handling

Face mask or respirator

Picture source: http://www.ammex.com

Picture source: http://www.shingleberrysigns.com
Picture source: http://www.toolrage.com

Selection of PPE for Manual Handling

Back belts to prevent back pain

SAFE MANUAL
HANDLING
TECHNIQUES

Design of lifting tasks

1. Assign the job to more than one person.
2. Use smaller containers.
3. If possible, mechanize the process.
4. Machines, rather than employees, should transfer loads between
surfaces.
5. Change the job from lifting to lowering, from lowering to carrying,
from carrying to pulling, and from pulling to pushing.
6. Use handles, hooks or similar features to enable workers to get a
firm grip on objects to Be lifted.
7. Reduce the weight of containers used to transfer objects.
8. Balance and stabilize the contents of containers to avoid sudden
shifts in load during a lift.
9. Design containers so that they can be held close to the body.
10. Treat work surfaces to allow for ease of movement of containers.

Proper Handling Techniques

Proper Handling Techniques

Proper Manual Handling - Individual

Lift S.M.A.R.T

Proper Manual Handling - Individual

Lifting aids

Proper Manual Handling - Individual

Lifting aids

Proper Manual Handling - Individual

Lifting aids

Proper Manual Handling - Team

Team/buddy lifting

Picture source: www.fork-lift-trucks.info

Proper Manual Handling - Team

Team/buddy lifting

Picture source: http://www.atlasstraps.com/example2.gif

Climbing

When climbing with a load,

safe

material

handling

includes maintaining contact

with the ladder or stairs at
three points (two hands and
a foot or both feet and a
hand).

Bulky

loads

would

require a second person or a

mechanical device to assist.

Job Designs to Prevent Manual Handling

Injuries
Team handling for heavy or odd shape loads
Breaks to reduce muscular fatigue
Handlers job rotation between heavy and light activities
Rearrange workplace to reduce twisting, stretching &
stooping

Job Designs to Prevent Manual Handling

Injuries
Keep heavy loads around waist level
Use of mechanical handling aid
Package heavy materials into smaller container

Picture source: http://www.osha.gov

Picture source: CP 92 : 2002

Job Designs to Prevent Manual Handling

Injuries
Provide handles, hand grips or indents for loads
Loads to be free from dust, oil, corrosive deposits, sharp
corners, jagged edges or rough surfaces

Picture source : http://www.saylorsfarm.com

Picture source : http://www.powerwheel-usa.com

Indents & Handles

Job Designs to Prevent Manual Handling

Injuries
Provide secondary containment for chemicals

Picture source : http://www.smithsofthedean.co.uk

Picture source : http://www.fuelproof.co.uk

How To avoid Back Injuries

The back has 4 natural curves. The muscles and joints in the
back receives least strain in the upright posture which
maintains the natural curves. These natural curves should be
maintained in order to prevent back disorders.
When a load has to be manually handled it should be held or
manipulated as close to the body as possible. Twisting, turning,
and bending, of the back should be avoided.

Maximum safe loads for lifting and

lowering
Under the health and
safety
regulations
the
maximum safe loads for an
individual for lifting and
lowering are :
For two people working
together the maximum load
is equal to 2/3 the combined
safe load.

PUSH VS PULL
A variety of techniques
are available to reduce
the likelihood of soft
tissue
Back,

injury.
arm

and

shoulder strain can be

reduced

by

pushing

object vs. pulling them.

Optimal Working Heights

Optimal Working Area

Tasks should be
designed
to
allow
employees
to
work close to
their
neutral
joint
posture.
For the back,
when possible,
should
avoid
frequently
flexing
and
avoid twisting
while
performing
manual

The main risk factors for falls in retail

operations are
Floor surfaces (when dry and when wet)
Footwear (in particular the interaction of footwear and flooring)
Water/objects on floor (water, snow or ice from entrances,
drinking

fountains,

or

leaks

in

ceilings;

clips,

bags

or

packaging/refuse)
Obstructions/poor design (transitions from tiles to carpeted
areas or from one level to another; display pedestals too low
and below the field of view; obstructions that obscure other
hazards)
Distractions (displays designed to attract attention).

Safety measures that could be taken

Extending mats at entrances on rainy days to prevent the
ingress of water.
Placing mats below drinking fountains.
Enforcing a minimum 75 cm distance between display racks.
Reducing the use of electrical extension cords and running
them through covers.
Providing paper towels for employees to clear spillages
Monthly self-inspections using a checklist to assist in the
identification of hazards.

CASE STUDY

Manual Handling tasks

In Apparel industry

Injuries and Illnesses Among

Apparel Workers

70% of Sewing Machine Operators

Using Foot Controls Report Back Pain

35% Report Persistent Low Back Pain

25% Have Suffered a Compensable

Cumulative Trauma Disorder (CTD)
81% of CTDs Were to the Wrist
14% of CTDs to the Elbow
5% of CTDs to the Shoulder
49% of Workers Experience Pain in
the Neck.

Tasks Associated With Injuries and

Illnesses

Hand Sewing and Trimming

are stressful to all upper limbs.

Stitching tasks are associated

with pain in the Shoulders,
Wrists, and Hands.

Ironing by Hand is associated

with Elbow pain.

Garment Assembly tasks are

associated with CTDs of the
Hands and Wrists.

Foot Operated Sewing is

associated with pain in the Back.

Problems/Solutions in Spreading Cutting

Section
Problem

Solution

Loading by hand- Bolts of fabric lifted

Limiting the weight of the bolt

by hand are very heavy and create a

Use fork lifters to lift the bolt

substantial risk of low back injury.

Poor Posture during placing the

Use bolt stand to keep the fabric bolt

Spreader bar in fabric bolt

in sloped position

Extreme postures during fabric

Improve shoulder and back posture by

cutting- Excessive reaching with

setting the appropriate height of table

shoulders and back. Poor wrist

and cutter according to worker

postures and Hand or arm vibration

Extend the handle and cut from both

and contact pressure on the hand

sides of the table to reduce excessive

when stapling the pattern to the fabric

reaching.

or perforating the layers of fabric.

Placing spreader bar in the

bolt of fabric

Extreme postures required when

cutting with an electric cutter

Hand-made bolt stand, used to

assist lifting a bolt into a tall
spreader

Automated cutter that would

benefit from controls in a more
accessible location

Contd...
Problem

Solution

Large, heavy scissors are used for

Ergonomically designed scissors and

trimming.

cutting equipment help reduce

Scissor handles are narrow and

contact stresses.

create contact stresses.

They also offer comfortable cutting

Scissors are dull and require

posture and lesser force.

excessive force to operate.

Working in a standing position on a

Use Anti-fatigue mats

regular basis can cause sore feet,

Anti-fatigue mats promote better

swelling of the legs, muscular fatigue,

circulation and reduce fatigue in

low back pain, stiffness in the neck

the lower extremities.

and shoulders, and other health

problems.

Scissors in use.

Workers standing position

Ergonomically designed scissors

Anti fatigue mats

Problems/Solutions in Sewing Section

Problem

Solution

Chairs have no height

adjustable options, back rest and
cushioning.

The chair must be designed

ergonomically. Its essential
features must include back
support, stable legs, height
adjustability as per OSHA

Sewing tables are not easily

adjustable.
Almost all sewing tables are flat.
Flat sewing tables do not
maximize visibility and
compromise the posture of the
upper extremity and neck.
Sewing machine operators have
limited legroom because of
drawers attached to the
underside of the table.

Employees should be able to

work with the elbows down, close
to the body.
Employees should have to reach
no farther than 18 inches to the
front.
Employees should be able to rest
their arms, but not against sharp
edges.
Employees should not have to
twist or bend to pick up or put
down objects.

Stools used by workers.

Sewing table in use

Ergonomic Chairs.

The sewing table designed

ergonomically

Contd
Problem

Solution

With no table height adjustment

Table edges should be padded or

options the worker had to

rounded to enhance the blood

maintain

circulation

awkward postures
Employee had to lean on sharp
edges creating a lot of discomfort
Employees resting forearms or
wrists on sharp edges may cut off
blood circulation, pinch nerves,
and cause injury to the arms or
hands.

Workers arm resting on sharp edges.

Table edges should be padded or

rounded

Reasons for such Ergonomic Issues

The majority of the sewing machine workstations currently in use are
designed without the comfort, health or convenience of the sewing
machine operator in mind .
The sewing machine operators generally work in a seated position at
poorly designed workstations, performing the same operation during
the

entire

course

of

the

workday,

the

risk

of

developing

musculoskeletal disorders is high.

The poor postures resulting from the conditions described above,
combined with highly repetitive, time-pressured work, has resulted in
high rates of work-related musculoskeletal disorders.

Contd
Workers leaning forward
on the machine while
stitching of parts. This
can cause problems in
the
back and neck
regions of the workers.

Absence of backrests in the

chairs
provided
to
the
workers
in
the
sewing
department. This can cause
lower back region difficulties
among the workers.

Contd
Employees resting forearms or
wrists on sharp edges may cut
off blood circulation, pinch
nerves, and cause injury to the
arms or hands.

Doing
the
same
action
repeatedly makes it very much
tiring for the workers, and can
cause fatigue and stiffening in
their fingers.

How it affects?

Tremendous pain in the

lower back region, caused
due to prolonged hours of
sitting
at
the
sewing
machines is felt by the
workers. It even interferes
with the ability to naturally
bend their bodies.

Hands and fingers

of
the
sewing
operators get stiff
due
to
inflammation in the
median
nerve,
caused
by
repetitive actions.

Pain felt in the elbow

joints caused by the
force imparted while
stitching.
The
pressure
of
completing the work
in a limited time
period increases the
stress
on
the
workers.

Leaning on the
machines
while
stitching causes
immense pain in
the spine of the
sewing operators.

Sewing
operators also
face pain in the
neck and at the
shoulders.

Measures that can be taken

Certain infrastructure can be improved keeping in mind the comfort of
the workers and working postures.
They should be given proper training to maintain a healthy working
condition.
Skilled doctors and physiotherapists should be provided for the
assistance of the employees.
Workers should be allowed to take breaks in between their works, and
even change works.
Sewing tables should be provided with adjustable chairs and proper back
rests.
Anti-Fatigue mats must be introduced for workers required to stand for
long hours at a stretch.

Contd

Contd
Ergonomic
Operator Chair

Sewing

Net weight 26 lb 11.8 kg

Seat dimensions 20.5" x 20.5
Back rest dimensions 18.5" x 17.5"
Seat height adjustment 15" x 21
FEATURES
Height adjustment
Contoured cushion
Waterfall seat edge
Tilt and lock mechanism
Back height adjustment

Recommendations for tables

WorkStation Redesign - Sewing

Machines

30 Fixed Tabletop Height

Point of Operation Between 4-7 Above Tabletop
Sewing Machine Tilted 11o Toward Operator
For Jobs of Longer Duration Sewing - Bench Mounted Arm Rests
Adjustable Chair
Adjustable Foot Rest With Movable Machine Control

Work Enhancements

Foam Padded Edges to Sharp Table Edges

Provide Cloth Upholstered Adjustable Chairs
Angle Packing Boxes to Workers With Tilt Equipment
Provide Anti-Fatigue Matting for Standing Workers
Improved Lighting
Require Rest Periods
Job Rotations

Costs of ignoring ergonomics in the

workplace
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Less production output

Increased loss time
Higher medical costs
Increased absenteeism
Higher material costs
Low-quality work
Injuries, sprains, strains
Increased probability of accidents and errors
Increased labour turnover
Less spare capacity to deal with emergencies

Cost Effectiveness Of Ergonomics

Dramatic reductions in workers compensation costs.

This
graph
above
shows
workers compensation cost
data for a division of a major
U.S. manufacturer in cents per
hour
per
employee,
plus
equivalent
data
for
the
industry. The graph shows that
the division had costs that
were initially lower but rising
faster
than
the
industry
average. After the division
started
the
ergonomics
program, its costs dropped
while the rest of the industry
continued to rise. After three
years the savings was $0.25

Cost Effectiveness Of Ergonomics

Improved productivity.It is common for ergonomic

improvements to increase productivity 10 15%.

The example in the

above graph is from
a printing facility
where an ergonomics
task improvement
increased
productivity 30%,
while simultaneously
reducing physical
demands on
employees.

Cost Effectiveness Of Ergonomics

Fewer mistakes and less scrap.

The graph above shows an example where a $400 mechanical device eliminated a
$6000 annual loss in scrap, which was caused by employees simply not being able
to perform a tedious, physically demanding task properly all the time. Thats a
1500% return-on-investment in one year because of good ergonomics.

Cost Effectiveness Of Ergonomics

Identifying waste (and resolving plant conflicts)

The graph is an example from a company that inspects and repairs bags, the
ergonomics evaluation showed that part B was the source of the exertion and fatigue
in the job. Moreover, it was possible to eliminate almost all of part B by purchasing a
pallet lift and stacking the containers directly onto the pallet.

CONCLUSION
Hence by the use of ergonomics, the design of
manual handling tasks can bring about benefits
to the employers as well as the workers
Improved efficiency because of better heights, reaches,
and clearance.
Improved efficiency because of less fatigue
Improved efficiency because of less exertion.
Improved efficiency because of better working posture.

FUNDAMENTAL PRINCIPLES LEARNED SO

FAR
Use proper tools.
Keep repetitive motions to a minimum.
Avoid awkward postures.
Use safe lifting procedures.
Get proper rest.

BIBLIOGRAPHY
https://www3.shu.ac.uk/hwb/placements/physiotherapy/docum
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http://www.worksafenb.ca/docs/manualedist.pdf
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https://osha.europa.eu/en/tools-and-publications/publications/
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http://www.qha.org.au/files/J%20-%20Hazardous%20Manual%2
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BIBLIOGRAPHY
http://www.hse.gov.uk/msd/manualha
ndling.htm
http://www.powershow.com/view/1594
2-N2FjM/Manual_Materials_Handling_
powerpoint_ppt_presentation#.V-TqT
kR940c.gmail
file:///C:/Documents%20and%20Set
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Thank you