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.

2 Consumption and DisposalMANUAL Material HANDLINGMANUAL Material HANDLINGWhy Address Why Address Manual Material handling ? 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 ?

3 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 ? 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 ?

4 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 ? 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 ?

5 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. 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 ?)))

6 Manual Material handling ?Workers' Compensation Data: BY LIFTING (56)STRAIN/INJURY BY MISC. (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 ?)

8 Manual Material handling ?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.))))))))))))))))))))))

10 (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 ? 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 ?))))