Ergonomic Guidelines for Manual Material …

1 Ergonomic GuidelinesErgonomic GuidelinesforforManual Material HandlingManual Material HandlingMARIO FELETTO - AREA MANAGERRESEARCH AND EDUCATIN UNITCAL/OSHA CONSULTATION SERVICESACRAMENTO, CA&JAMES J. GALANTE - COUNCILMATERIAL handling INDUSTRY OF AMERICACHARLOTTE, NCErgonomic Guidelines for Ergonomic Guidelines for Manual Material HandlingManual Material HandlingThe Team The Team EASE Council - MHIA Cal/OSHA Consultation Services NIOSH University of California, Davis UC Berkeley Ergonomics Program Ergonomics Center of North Carolina Johnson & Johnson CNAE rgonomic Guidelines for Ergonomic Guidelines for Manual Material HandlingManual Material HandlingMMH Guideline AdvantagesMMH Guideline AdvantageszzFocuses On Improvements Not ProblemsFocuses On Improvements Not Problemszz Best Practices Best Practices ApproachApproachzzPractical & NonPractical & Non--regulatoryregulatoryART AND SCIENCEzThe Movement, Storage, Control & Protection of Goods and Materials zThroughout Manufacture, Distribution, Consumption and DisposalMANUAL Material HANDLINGMANUAL Material HANDLINGWhy Address Why Address Manual Material handling ?

2 Manual Material handling ?MUSCULOSKELETAL DISORDERSMUSCULOSKELETAL DISORDERSzPHYSICAL PROBLEMS pain, swelling numbness, tingling ROM and strength change of skin color zCHARACTERISTICS acute or chronic no early medical findings factors from home / workplaceMUSCULOSKELETAL DISORDERSMUSCULOSKELETAL DISORDERSzGENERAL SPRAINS & STRAINS MYALGIA TENDINITIS TENOSYNOVITISMUSCULOSKELETAL DISORDERSMUSCULOSKELETAL DISORDERSzSYNDROMES CARPAL TUNNELMUSCULOSKELETAL DISORDERSMUSCULOSKELETAL DISORDERSzSYNDROMES THORACIC OUTLETMUSCULOSKELETAL DISORDERS MUSCULOSKELETAL DISORDERS zBACK PROBLEMSV ertebraDiscNerveMUSCULOSKELETAL DISORDERS MUSCULOSKELETAL DISORDERS zBACK PROBLEMS-DISCS -SCIATICA-OSTEOARTHRITISTear Slipped DegeneratedWhy Address Why Address Manual Material handling ? Manual Material handling ?zPHYSICAL DEMANDS OF WORK REPETITION FORCE / WEIGHT AWKWARD POSTURE VIBRATIONzTOOLS & EQUIPMENT POOR GRIPS / HANDLES EXCESSIVE zFORCE / WEIGHTzVIBRATIONzREPETITION AWKWARD POSTUREzWRIST / ARMzUPPER BODY Why Address Why Address Manual Material handling ?

3 Manual Material handling ?zTHE WORK ENVIRONMENT COLD HOT LIGHTING NOISE HOUSEKEEPINGzTHE SET UP OF WORK ROTATING SHIFT WORK LACK OF TASK VARIETY EXCESSIVE zOVERTIMEzWORK PACE / DURATION POORLY COMMUNICATEDzEXPECTATIONSzJOB DEMANDS Why Address Why Address Manual Material handling ? Manual Material handling ?Laborers and Material Movers Suffered the Most Injuries & Illnesses With Days Away From WorkWhy Address Why Address Manual Material handling ? Manual Material handling ?In all of Private Industry and in Goods Producing & Service Providing Industries, Overexertion was a leading cause of injuries & illnesses SOURCE; Bureau of Labor Statistics, Department of Labor, Survey of Occupational Injuries and IllnessesWhy Address Why Address Manual Material handling ? Manual Material handling ?Sprains & Strain, Back Pain, Soreness & Pain , Tendonitis and CTS Accounted for 53% of All Lost Time Injuries & IllnessesSOURCE; Bureau of Labor Statistics, Department of Labor, Survey of Occupational Injuries and IllnessesWhy Address Why Address Manual Material handling ?

4 Manual Material handling ?The Back & Upper Extremities Were Involved In Almost 1/2 of All Lost Time Injuries & Illnesses Why Address Why Address Manual Material handling ? Manual Material handling ?Bodily Reaction & Exertion Accounted For Over 40% of All Lost Time Injuries & IllnessesCostszDIRECT (Medical, Indemnity, Loss exposure) Lost Productivity Errors & DefectszINDIRECT (Up to 4X Direct Costs) Turnover, Absenteeism, Re -TrainingWhy Address Why Address Manual Material handling ? Manual Material handling ?Why Address Why Address Manual Material handling ? Manual Material handling ?Workers' Compensation Data - BY LIFTING (56)STRAIN/INJURY BY MISC. (60)CUMULATIVE (ALL OTHER) (98)REP MOTION IE CRPL TUNNEL (97)INJURY BY PUSHING/PULLING (57)INJURY BY HOLDING/CARRYING (55 TWISTING (53)INJ URY USING TOOL/MACHINE (59 OBJECT LIFTED OR HANDLED (17)STRAIN/INJURY BY REACHI NG (58 STRAIN/INJURY BY JUMPING (54)CUMULATIVE STRESS (93)CUMULATIVE PRESUMPTION (94)WIELDING OR THROWI NG (61)% of All Claims% of All Incurred CostsPattern of High Losses Strains, Rep.)))

5 Motion, Pushing, Pulling, Holding, Twisting, Using Tools/Machines, Carrying, Objects Lifted/HandledWhy Address Why Address Manual Material handling ? Manual Material handling ?California Data - 2003 53% of Insurance Market% All Claims % All Costs Total Incurred Costs ($)Strain/Injury Lifting 1112314,484,353 Strain/Injury Misc. 910264,614,044 Rep Motion (CRPL Tunnel) 91,683,456 Injury Pushing/Pulling 87,505,943 Injury Holding Carrying 2 2 48,248,929 Twisting2 2 42,645,706 Object Lifting/Handled 3 1 17,821,835 Strain/Injury by Reaching 1 1 16,859,056 Totals 34 36 883,863,322 Why Address Why Address Manual Material handling ? Manual Material handling ?Workers' Compensation Data: BY LIFTING (56)STRAIN/INJURY BY MISC.

6 (60)CUMULATIVE ( AL L OTHER) (98)REP MOTION IE CRPL TUNNEL (97)I NJURY BY PUSHIN G/PULLING (57)INJURY BY HOLDING/CARRYI NG (55)TWISTING (53)I NJURY USING TOO L/MACHINE (59)STRAIN/INJURY BY REACHI NG (58)OBJECT LIFTED OR HANDLED (17)STRAIN/INJURY BY JUMPING (54)CUMULATIVE STRESS (93)CUMULATIVE PRESUMPTION (94)WI ELDING OR THROWING (61)% of All Claims% of All Incurred CostsPattern of High Losses Strains, Rep. Motion, Pushing, Pulling, Holding, Twisting, Using Tools/Machines, Carrying, Objects Lifted/HandledWhy Address Why Address Manual Material handling ? Manual Material handling ?California Data - 200250% of Insurance Market% All Claims % All Costs Total Incurred Costs ($)Strain/Injury Lifting ,551,388 Strain/Injury Misc. 910387,349,560 Rep Motion (CRPL Tunnel) 140,047,697 Injury Pushing/Pulling 33 128,910,435 Injury Holding Carrying 2 2 74,213, 1.

7 5 54,538,089 Object Lifting/Handled 3 1 23,574,020 Strain/Injury by Reaching 1 1 29,392,193 Totals 33 35 1,337,576,974 Why Address Why Address Manual Material handling ? Manual Material handling ?Workers' Compensation Data: BY LIFTING (56)STRAIN/INJURY BY MISC. (60)CUMULATIVE (ALL OTHER) (98)REP MOTION I E CRPL TUNNEL (97)INJURY BY PUSHING/PULLING (57)I NJURY BY HOLDING/CARRYING (55 TWISTI NG (53)INJURY USING TOOL/MACHINE (59)STRAIN/INJURY BY REACHING (58)OBJECT LI FTED OR HANDLED (17)STRAIN/INJURY BY JUMPI NG (54)CUMULATIVE STRESS (93)WI ELDING OR THROWING (61)CUMULATIVE PRESUMPTION (94)% of All Claims% of All Incurred CostsPattern of High Losses Strains, Rep. Motion, Pushing, Pulling, Holding, Twisting, Using Tools/Machines, Carrying, Objects Lifted/HandledWhy Address Why Address Manual Material handling ? Manual Material handling ?)

8 California Data - 200143% of Insurance Market% All Claims % All Costs Total Incurred Costs ($)Strain/Injury Lifting 1113558,864,656 Strain/Injury Misc. 911445,435,822 Rep Motion (CRPL Tunnel) 3 180,254,890 Injury Pushing/Pulling 152,023,340 Injury Holding Carrying 2 2 78,185, 1. 3 55,317,938 Object Lifting/Handled 3 1 23,018,957 Strain/Injury by Reaching 1 1 29,898,408 Totals 34 36 1,522,999,871 Why Address Why Address Manual Material handling ? Manual Material handling ?Workers' Compensation Data: BY LIFTING (56S T RA IN /INJUR Y BY MISC. (60 CUMULATIVE (ALL OTHER) (9 8 REP MOTION IE CRPL TU NNEL (97 INJURY BY PU SH IN G/PU LLING (57 INJURY BY HOLD ING/CARRYING (5 TWISTING (53)INJURY USIN G TOO L/MACHINE (5 STRAIN /INJUR Y BY REACHING (5 OBJECT LIFTED OR HANDLED (1 CUMULATIVE STRESS (93 STRAIN /INJUR Y BY JU M PING (5 4 CUMULATIVE PRESUMPTION (94 WIELDING OR THROWING (61% of All Claims% of All Incurred CostsWorkers' Compensation Data: BY LIFTING (56 STRAIN /INJURY BY MISC.))))))))))))))

9 (60 CUMULATIVE (ALL OTHER) (9 8 REP MOTION IE CRPL TUNNEL (97 INJURY BY PUSHING/PULLING (57 INJURY BY HOLDING/CARRYING (55 TWISTING (53)INJURY USING TOOL/M ACHINE (59 STRAIN/INJURY BY REACHING (58CU MULATIVE STRESS (93)STRAIN/I NJ URY BY JU MPING (5 4 OBJECT LIFTED OR HANDLED (17CU MULATIVE PRESUMPTIO N (94 WIELDING OR THROWING (61% of All Claims% of All Incurred CostsWhy Address Why Address Manual Material handling ? Manual Material handling ?Workers' Compensation Data: BY MISC. (60)STRAIN/INJURY BY LIFTIN G (56CU MULATIVE (ALL OTHER) (98 REP MOTION IE CRPL TUNNEL (97 INJURY BY PU SH ING/PULLING (57 INJURY BY HOLDING/CARRYING (55 INJURY USING TOO L/MACHINE (5 9 STRAIN/INJUR Y BY REACHING (58CU MULATIVE STRESS (93)STRAIN /INJUR Y BY JU MPING (54 TWISTING (53)CUMULATIVE PRESUMPTIO N (94 OBJECT LIFTED OR HANDLED (17 WIELDING OR THR OWING (61% of All Claims% of All Incurred CostsWorkers' Compensation Data: BY MISC. (60)STRAIN/INJURY BY LIFTING (56)CUMULATIVE (AL L OTHER) (98)REP MOTION IE CRPL TUNNEL (97)INJURY BY PUSHING/PULLING (57)INJURY BY HOLDING/CARRYING (55 INJURY USING TOOL/MACHINE (59 STRA IN /INJURY BY REACHING (58 CUMULATIVE STRESS (93)STRAIN/INJURY BY JU MPING (54)CUMULATIVE PRESUMPTION (94)OBJECT LIFTED O R HANDL ED (17 TWISTING (53)WIELDING OR THROWING (61)% of All Claims% of All Incurred CostsWhy Address Why Address Manual Material handling ?))))))))))))))))))))))))))

10 Manual Material handling ?California Patterns 1997 2003 %All Claims % All Costs TotalIncurred Costs($)Strain/Injury Lifting 11 - 13 11 - 131,372,900,397 Strain/Injury Misc. 910 111,097,399,426 Rep Motion (CRPL Tunnel) 2 - 3 3 - 5 411,986,043 Injury Pushing/Pulling 33 - 4 368,439,718 Injury Holding Carrying 1 - 2 2 200,648,381 Object Lifting/Handled 3 0 - 1 64,414,812 Strain/Injury by Reaching 1 1 76,078,657 Totals 27 - 34 30 37 3,591,867,434 Ergonomic GuidelinesErgonomic Guidelinesfor Manual Material Handlingfor Manual Material HandlingWhy Develop Guidelines ?zWhat About Ergonomic Regulations ? Federal OSHA Cal/OSHAE rgonomic GuidelinesErgonomic Guidelinesfor Manual Material Handlingfor Manual Material HandlingzFederal OSHA Ergonomic Standard Promulgated November, 2000 Congress repealed standard March, 2001 as part of Contract with America, the Congressional Review Act (1995), zFor the Future Same law ( Congressional Review Act) if OSHA promulgates another standard, the new standard can not be similar to the onethat congress nullified in 2001 Ergonomic GuidelinesErgonomic Guidelinesfor Manual Material Handlingfor Manual Material HandlingzFederal OSHA s Current Strategy - 4 parts Develop Industry / Task Specific Voluntary Guidelines Enforcement - General Duty Clause (Section 5(a)(1) of OSHA Act National Advisory Committee (convened 2002-3))