The Back and

Material Handling Issues

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

The Spinal Column

Cervical
Thoracic
Lumbar

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

The Basic Structure

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Epidemiology of Back Injuries

Short Term or acute effects:
Sharp Surfaces
Dropped Material
Struck-by Moving Materials
Mechanical Stress
Slips and Falls
Simpler Cause and effect relationship

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Epidemiology
Chronic or Long Term Effects
Back Ache or Pain
Disc Degeneration
Cause and effect not
as simple, more difficult
to analyze

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Return to Work
Out more than 6 months only 50% chance
of returning
One year only 25%
Management and Practitioner Training

One study showed that claims dropped from

200K to 20K per year by providing modified work
and conservative treat
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Material Handling
Lifting/Lowering
Pushing/Pulling
Carrying
Weights and Forces
Frequency of Activities
Load Center of Gravity

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Material Handling

QuickTime and a
Sorenson Video 3 decompressor
are needed to see this picture.

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Job Risk Factors

Weight of the Object
Location (position of load
w.r.t. worker)
Frequency of Lifts
Stability of the Load
Hand Coupling
Workplace Geometry
Twisting/Stooping
Environmental Factors
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Personal Risk Factors

Gender
Age
Anthropometry
Lift technique
Attitude
Strength
Training

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Examples of
Manual Handling Controls
Avoid extreme range of motion when lifting
Redesign work station/work area to allow freedom of movement
Provide handles on material handling equipment
Provide lift-assist devices and tables
Unit Load Concept
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Job Design
Can reduce one-third of
compensable LBP
Minimize reach and lift
distances
Keep off floor
Work station design
Frequency
Relax time standard
Rotation
Work-Rest allowances
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Job Design
Minimize Weight
Mechanical aids
Carton capacity
Balance contents
Convert
Carry to push/pull
Push over pull
Use large wheels

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Training
Focus on awareness and
avoidance
Get object as close to body
as possible
Planning
Use of handling aids
Back Schools
Strength and fitness
important
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

NIOSH Lifting Equation

1991 Version

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

NIOSH Lifting Equation

Objective: Reduce occurrence of
lifting-related LBP
1981 and 1991 equations
1981 limited to sagittal plane
1991 includes asymmetry and coupling

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Disqualifiers for Use

One handed lifts
More than 8 hours
Seated or kneeling
Restricted work space
Unstable Objects
Carrying, pushing or
pulling while lifting

Wheelbarrows
or shovels
High speed motion
Unreasonable
foot/floor coupling
Unfavorable
environment

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Definition of Terms
RWL = Recommended
weight limit
LC = Load constant
HM = Horizontal
multiplier
VM = Vertical
multiplier

DM = Distance
multiplier
AM = Asymmetric
multiplier
FM = Frequency
multiplier
CM = Coupling
multiplier

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

1991 Equation

RWL = LC x HM x VM x DM x AM x FM x CM

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

1991 Guide
Compare RWL to Actual Load (L)
If Greater than or equal to 1 problem

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Lifting Index

L
RWL

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

1991 Multipliers
LC = 51 Pounds
HM = 10/H
VM = 1-.0075 x / V-30/
DM = .82 + (1.8/D)
AM = 1 (.0032 x A)
FM go to Table
CM go to Table
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

NIOSH Worksheet

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

Lifting Example

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

NIOSH Workshop

QuickTime and a
Sorenson Video 3 decompressor
are needed to see this picture.

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

NIOSH Workshop

Start of Lift

End of Lift

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

NIOSH 1991 Lifting Calculator

NIOSH Lifting Guidelines -- Job Analysis

Notes Packer

Enter values in Yellow area.

For Composite Lifting Index (CLI) to be computed correctly,
sort tasks in decreasing order based on LI by pressing button.

Sort
Task
No.
1
2
3
4
5
6
7
8
9

CLI = 0.3
1991 Guide
RWL
LI
24.3
0.2
12.2
0.4
11.0
0.5
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0

Object Wt.
1981 Guide
(lbs)
AL
MPL L (avg) L (max)
29.0
87.0
5.0
13.3
39.9
5.0
11.4
34.1
5.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0

Hand Location (inches)

Origin
Destination
H
V
H
V
18.0
30.0
15.0
40.0
18.0
30.0
30.0
15.0
18.0
30.0
30.0
52.0

Asymmetry Period Freq

(degrees)
(hours) (#/min) Handle
Orig
Dest
P
F
C
15
0
4.0
0.4
Poor
15
0
4.0
0.4
Poor
15
0
4.0
0.4
Poor

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

WISHA

Calculator for Analyzing Lifting Operations

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

www.lni.wa.gov/wisha/ergo/calculator/ergo_workshopIE.htm
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

WISHA Workshop

QuickTime and a
Sorenson Video 3 decompressor
are needed to see this picture.

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

WISHA
If the job is a hazard
Reduce weight of load
Increase weight of load so that it
requires mechanical assist
Reduce the capacity of the container
Etc.
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

References
Applications guide for the revised NIOSH
lifting equation On CD
Elements of Ergonomic Programs On CD
Musculoskeletal Disorders and Workplace
Factors On CD
Work Practices Guide for Manual Lifting
NIOSH 81-122

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

What does the worker need to

know from this presentation?

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING