Lifting Hazards and Some Ideas on How to Reduce Your Risk of Lifting Injury

1. Lifting Hazards and Some Ideas on How to Reduce Your Risk of Lifting Injury

2. By the end of this slideshow you will be able to: Identify the types of lifting that may cause injuries  Review ergonomics principles used in reducing lifting hazards and preventing injuries 

3. Lifting Injuries Aren�t Just Back Injuries Ask: �What other parts of the body do you think could get injured when lifting?� As you click through this slide the percentage of injuries by body part will appear. Talk about how hands and wrists can get injured from the grasping part of lifting. Show participants how the muscles in the forearm are the ones that are used for grasping, and that they attach at the elbow, which is how that joint can get injured. The shoulder gets injured because that�s where the arms attach to the torso, so any load lifted at the hands is supported by the shoulders as well. This joint is especially at risk of injury from lifts done while reaching above the shoulder or away from the body. Due to limitations of the data, these figures don�t include injuries to the hips, knees, ankles, etc., although other studies have shown that these parts of the body can also be injured while lifting. Source of data: SHARP, analysis of State Fund claims. Ask: �What other parts of the body do you think could get injured when lifting?� As you click through this slide the percentage of injuries by body part will appear. Talk about how hands and wrists can get injured from the grasping part of lifting. Show participants how the muscles in the forearm are the ones that are used for grasping, and that they attach at the elbow, which is how that joint can get injured. The shoulder gets injured because that�s where the arms attach to the torso, so any load lifted at the hands is supported by the shoulders as well. This joint is especially at risk of injury from lifts done while reaching above the shoulder or away from the body. Due to limitations of the data, these figures don�t include injuries to the hips, knees, ankles, etc., although other studies have shown that these parts of the body can also be injured while lifting. Source of data: SHARP, analysis of State Fund claims.

4. This is a quote from a 2003 publication by the ASSE on safety and health for young workers.This is a quote from a 2003 publication by the ASSE on safety and health for young workers.

5. Pay special attention to� Heavy lifting Scientific research shows an increase in injuries at certain levels of exposure to heavy, frequent and awkward lifting. The next few slides show examples of these three types of lifting. Emphasize that, as they look at the example tasks, they need to keep in mind that they may not need to make changes to those jobs. This is just the pre-screening part of the process, where they decide if a job may have a potential problem.Scientific research shows an increase in injuries at certain levels of exposure to heavy, frequent and awkward lifting. The next few slides show examples of these three types of lifting. Emphasize that, as they look at the example tasks, they need to keep in mind that they may not need to make changes to those jobs. This is just the pre-screening part of the process, where they decide if a job may have a potential problem.

6. Heavy Lifting The job is adding bags of dry ingredients to a hopper in a manufacturing plant. The class will be analyzing this job later. The job is adding bags of dry ingredients to a hopper in a manufacturing plant. The class will be analyzing this job later.

7. Frequent Lifting This job is palletizing totes of small parts in a warehouse. The class will also analyze this job later.This job is palletizing totes of small parts in a warehouse. The class will also analyze this job later.

8. Awkward Lifting Above the shoulders Below the knees At arms� length This job is lifting 50-pound bags of wet fiberglass in a manufacturing plant. They�ll also get to analyze this job further.This job is lifting 50-pound bags of wet fiberglass in a manufacturing plant. They�ll also get to analyze this job further.

9. Analysis tools WISHA Lifting Calculator Other tools: ACGIH Lifting TLV NIOSH Lifting Equation Department of Energy�s �ErgoEaser� ACGIH = American Conference for Governmental Industrial Hygienist TLV = Threshold Limit values NIOSH = National Institute for Occupational Safety and Health Describe the options available for analyzing lifting jobs: The Lifting Calculator was developed by L&I, and is what the class will practice job analysis with, but it isn�t the only option they have for analyzing lifting jobs. The NIOSH Lifting Equation (1991) is one of the most commonly used tools for analyzing lifting jobs. In fact, the Lifting Calculator is based on it. The NIOSH equation requires more precision than the Lifting Calculator, and is a little more complicated to use. The ErgoEaser program is a free download from the Department of Energy�s web site. It�s based on the NIOSH Lifting Equation, but is meant to be a more �user-friendly� version. The ISO standard is the most recent. Part 1 of the standard covers Lifting and Carrying tasks. It has a five-step process for determining if lifting and carrying tasks create hazards, using criteria similar to the NIOSH Lifting Equation. Most of these analysis tools are based on the criteria that NIOSH used to revise their Lifting Equation in 1991. They looked at studies on biomechanics, physiology and psychophysiology, as well as epidemiology and combined the results of these studies to set limits on lifting that are designed to protect 90% of the workforce from injury.Describe the options available for analyzing lifting jobs: The Lifting Calculator was developed by L&I, and is what the class will practice job analysis with, but it isn�t the only option they have for analyzing lifting jobs. The NIOSH Lifting Equation (1991) is one of the most commonly used tools for analyzing lifting jobs. In fact, the Lifting Calculator is based on it. The NIOSH equation requires more precision than the Lifting Calculator, and is a little more complicated to use. The ErgoEaser program is a free download from the Department of Energy�s web site. It�s based on the NIOSH Lifting Equation, but is meant to be a more �user-friendly� version. The ISO standard is the most recent. Part 1 of the standard covers Lifting and Carrying tasks. It has a five-step process for determining if lifting and carrying tasks create hazards, using criteria similar to the NIOSH Lifting Equation. Most of these analysis tools are based on the criteria that NIOSH used to revise their Lifting Equation in 1991. They looked at studies on biomechanics, physiology and psychophysiology, as well as epidemiology and combined the results of these studies to set limits on lifting that are designed to protect 90% of the workforce from injury.

10. Principles for reducing heavy lifting Reduce the weight Increase the weight Use mechanical assistance Slide instead of lift Team lifting List of principles to reduce heavy lifting. Each of the following slides will illustrate these principles. To involve the audience, you can ask them to suggest ways that they might solve the problem before showing the solution examples.List of principles to reduce heavy lifting. Each of the following slides will illustrate these principles. To involve the audience, you can ask them to suggest ways that they might solve the problem before showing the solution examples.

11. Reducing heavy lifting Reduce the weight of the load (plastic pallets) Example of use by an East Coast grocery store chain: Stop & Shop Supermarkets switched to lightweight plastic pallets instead of conventional wooden ones. The difference in weight is impressive � 20 pounds for plastic pallets rather than 60 to 70 pounds for wooden ones. Management justified the switch on the basis of reducing workers compensation costs. According to Stop & Shop, not only were their employees handling less weight, but there were impressive savings in other areas � splinter and puncture wounds decreased as did pallet repair costs. The decision paid off and is working very well for their company. Lewis, D. 1996. �Grocery Industry Grapples With Back Injuries.� Safety + Health. August. Example of use by an East Coast grocery store chain: Stop & Shop Supermarkets switched to lightweight plastic pallets instead of conventional wooden ones. The difference in weight is impressive � 20 pounds for plastic pallets rather than 60 to 70 pounds for wooden ones. Management justified the switch on the basis of reducing workers compensation costs. According to Stop & Shop, not only were their employees handling less weight, but there were impressive savings in other areas � splinter and puncture wounds decreased as did pallet repair costs. The decision paid off and is working very well for their company. Lewis, D. 1996. �Grocery Industry Grapples With Back Injuries.� Safety + Health. August.

12. Reducing heavy lifting Increase the weight of the load (make it so heavy no one would try to lift it) Ask: Why would you want to increase the weight of the load to reduce the hazard? This is actually the solution that the company chose for the analysis job. The picture shows ingredients in a bulk bag. Point out that it weighs 2,000 pounds, so obviously no one would ever think of lifting it by hand. Click again to show the video of the bulk loading system. The costs will come in once the video is done playing. Cost of the bulk loading system - $150,000. Benefits: Reduced raw materials cost when buying in bulk (10�s of thousands of dollars per year) Reduced labor costs (less time required to load one big bag instead of 20, 100-pounders) Greatly reduced risk of injury The company states that the system paid for itself within a few years, not even factoring in the reduced injury costs. Ask: Why would you want to increase the weight of the load to reduce the hazard? This is actually the solution that the company chose for the analysis job. The picture shows ingredients in a bulk bag. Point out that it weighs 2,000 pounds, so obviously no one would ever think of lifting it by hand. Click again to show the video of the bulk loading system. The costs will come in once the video is done playing. Cost of the bulk loading system - $150,000. Benefits: Reduced raw materials cost when buying in bulk (10�s of thousands of dollars per year) Reduced labor costs (less time required to load one big bag instead of 20, 100-pounders) Greatly reduced risk of injury The company states that the system paid for itself within a few years, not even factoring in the reduced injury costs.

13. Reducing heavy lifting Use mechanical assistance

14. Reducing heavy lifting Slide instead of lift This example is moving heavy duty batteries from one pallet to another when picking an order. Large truck and marine batteries can weigh up to 110 pounds (this one weighs about 75 pounds). By taking the time to set the order pallet to the same height as the storage pallet, the battery can be slid rather than lifted. Cost is negligible, just the extra couple of minutes to make the height adjustment. This extra time is not required for every item picked to fill an order, just the heavier ones.This example is moving heavy duty batteries from one pallet to another when picking an order. Large truck and marine batteries can weigh up to 110 pounds (this one weighs about 75 pounds). By taking the time to set the order pallet to the same height as the storage pallet, the battery can be slid rather than lifted. Cost is negligible, just the extra couple of minutes to make the height adjustment. This extra time is not required for every item picked to fill an order, just the heavier ones.

15. Reducing heavy lifting Team lifting Team lifting works better on larger objects, such as the wallboard shown here. With the smaller bags in the analysis job, it would be difficult to coordinate a lift with two people. There is a labor cost involved with team lifting, although in some jobs there is always another person around out of necessity. For the lifting analysis, divide the weight lifted in half when two employees lift together. The risk isn�t always half that of lifting alone, though. It can be difficult to coordinate lifting between two people, especially when maneuvering around objects or going up or down stairs. This is why it�s not a preferred solution.Team lifting works better on larger objects, such as the wallboard shown here. With the smaller bags in the analysis job, it would be difficult to coordinate a lift with two people. There is a labor cost involved with team lifting, although in some jobs there is always another person around out of necessity. For the lifting analysis, divide the weight lifted in half when two employees lift together. The risk isn�t always half that of lifting alone, though. It can be difficult to coordinate lifting between two people, especially when maneuvering around objects or going up or down stairs. This is why it�s not a preferred solution.

16. Principles for reducing frequent lifting Use mechanical assistance Avoid unnecessary lifting Use mobile storage List of principles to reduce frequent lifting (reducing duration of lifting will also be discussed later)List of principles to reduce frequent lifting (reducing duration of lifting will also be discussed later)

17. Reducing frequent lifting Use mechanical assistance The example shown is palletizing using a vacuum lift, from a paper mill that produces bundles of grocery bags. There are two solution photos. The first shows lifting from the conveyor at the end of the packaging line. Click to bring in the next picture, which shows palletizing. The vacuum lift costs around $10,000, but in this case it increases productivity by allowing one employee to palletize on more than one line at a time without getting fatigued. It also allows them to rotate all employees through this job, since physical capacity isn�t a limiting factor. Each of the bundles of grocery bags weighs about 40 pounds, and when the line is running they come one after another. The example shown is palletizing using a vacuum lift, from a paper mill that produces bundles of grocery bags. There are two solution photos. The first shows lifting from the conveyor at the end of the packaging line. Click to bring in the next picture, which shows palletizing. The vacuum lift costs around $10,000, but in this case it increases productivity by allowing one employee to palletize on more than one line at a time without getting fatigued. It also allows them to rotate all employees through this job, since physical capacity isn�t a limiting factor. Each of the bundles of grocery bags weighs about 40 pounds, and when the line is running they come one after another.

18. Reducing frequent lifting Use mobile storage Obviously this solution doesn�t apply to the job analyzed, but there are cases where parts are lifted multiple times during manufacturing, and this can help to reduce frequent lifting in those situations. The example is a mobile parts rack from a gas and wood stove manufacturer (Aladdin Hearth Products demonstration project). The metal parts can be fairly heavy (20 to 52 pounds) and go through several finishing and inspection steps before final assembly. By placing them on mobile racks, the parts can be moved from process to process with minimal lifting. These racks were assembled in house using a product called Creform, made by Textube. The kits have plastic coated steel pipes, connectors, hangers, casters, etc., to custom build material handling aids. Cost to put together one of these racks is $250. Obviously this solution doesn�t apply to the job analyzed, but there are cases where parts are lifted multiple times during manufacturing, and this can help to reduce frequent lifting in those situations. The example is a mobile parts rack from a gas and wood stove manufacturer (Aladdin Hearth Products demonstration project). The metal parts can be fairly heavy (20 to 52 pounds) and go through several finishing and inspection steps before final assembly. By placing them on mobile racks, the parts can be moved from process to process with minimal lifting. These racks were assembled in house using a product called Creform, made by Textube. The kits have plastic coated steel pipes, connectors, hangers, casters, etc., to custom build material handling aids. Cost to put together one of these racks is $250.

19. Principles for reducing duration of lifting Rotate to other jobs Use mechanical assistance List of principles to reduce duration of liftingList of principles to reduce duration of lifting

20. Reducing duration of lifting Rotate to non-lifting tasks Rotating workers to other jobs (also job enlargement, adding a variety of tasks to a job) can be one of the easier solutions to implement, although sometimes some additional training is required (especially for things like operating a forklift). To be effective, the rotation should be to work that allows for recovery from lifting. The best type of recovery is light activity, rather than completely sedentary, although some opportunities to sit down are good. This rotation shows going from lifting to operating a forklift to doing paperwork, and then back to lifting. It probably wouldn�t be a good idea to go straight from operating a forklift to lifting, since the whole body vibration associated with forklift driving can cause muscle tightness and fatigue. Providing a period of paperwork in between allows for some additional recovery. Costs: Additional training Slightly reduced productivity while learning new tasks Benefits: Reduced fatigue Ability to fill in for co-workers More job variety means less boredom, higher job satisfactionRotating workers to other jobs (also job enlargement, adding a variety of tasks to a job) can be one of the easier solutions to implement, although sometimes some additional training is required (especially for things like operating a forklift). To be effective, the rotation should be to work that allows for recovery from lifting. The best type of recovery is light activity, rather than completely sedentary, although some opportunities to sit down are good. This rotation shows going from lifting to operating a forklift to doing paperwork, and then back to lifting. It probably wouldn�t be a good idea to go straight from operating a forklift to lifting, since the whole body vibration associated with forklift driving can cause muscle tightness and fatigue. Providing a period of paperwork in between allows for some additional recovery. Costs: Additional training Slightly reduced productivity while learning new tasks Benefits: Reduced fatigue Ability to fill in for co-workers More job variety means less boredom, higher job satisfaction

21. Principles for reducing awkward lifting - reaching - Remove obstacles Slide closer Reduce shelf depth Reduce package size Use mechanical assistance Team lifting List of principles to reduce awkward lifting � reaching Along with object weight, lifting frequency and duration, the distance between the hands and the low back when lifting is one of the main factors in determining whether a lift is a hazard or not. The longer the reach required to lift an object, the more of a load it places on the low back and the greater the risk of injury.List of principles to reduce awkward lifting � reaching Along with object weight, lifting frequency and duration, the distance between the hands and the low back when lifting is one of the main factors in determining whether a lift is a hazard or not. The longer the reach required to lift an object, the more of a load it places on the low back and the greater the risk of injury.

22. Reducing awkward lifting - reaching - Remove obstacles

23. Reducing awkward lifting - reaching - Slide objects closer

24. Reducing awkward lifting - reaching - Reduce shelf depth While it�s possible to simply reduce the depth of shelves (you could even put empty boxes in the back to keep the full ones near the front) you also give up some storage space this way, or you have to buy a lot of narrow shelving units. Gravity flow racks can be a good solution, since they allow you to store a lot of boxes on a single deep rack. They use a variety of types of rollers that allow boxes to roll forward as the front box is taken away. They need to be carefully designed so that the boxes towards the back aren�t pressing too heavily on the box in front, making it difficult to take out. The examples shown are designed to fit into existing standard racks, so new gravity flow racks won�t need to be purchased and installed. The costs of these systems range from about $60 per lane to a little over $200 per lane depending on depth and width of lanes.While it�s possible to simply reduce the depth of shelves (you could even put empty boxes in the back to keep the full ones near the front) you also give up some storage space this way, or you have to buy a lot of narrow shelving units. Gravity flow racks can be a good solution, since they allow you to store a lot of boxes on a single deep rack. They use a variety of types of rollers that allow boxes to roll forward as the front box is taken away. They need to be carefully designed so that the boxes towards the back aren�t pressing too heavily on the box in front, making it difficult to take out. The examples shown are designed to fit into existing standard racks, so new gravity flow racks won�t need to be purchased and installed. The costs of these systems range from about $60 per lane to a little over $200 per lane depending on depth and width of lanes.

25. Reducing awkward lifting - reaching - Reduce package size

26. Reducing awkward lifting - reaching - Use mechanical assistance

27. Reducing awkward lifting - reaching - Team lifting

28. Principles for reducing awkward lifting - bending - Use mechanical assistance to raise the load Add handles Arrange storage Avoid unnecessary lifting List of principles to reduce awkward lifting � bending.List of principles to reduce awkward lifting � bending.

29. Reducing awkward lifting - bending - Use mechanical assistance to raise the load

30. Reducing awkward lifting - bending - Add handles

31. Reducing awkward lifting - bending - Rearrange storage The cost of this solution will vary depending on how many items are stored and how much rearranging needs to be done to get them at a good height. This example assumes 30 hours of work (changing rack heights, using forklifts to move pallets) at $20 per hour for a total cost of $600. The cost of this solution will vary depending on how many items are stored and how much rearranging needs to be done to get them at a good height. This example assumes 30 hours of work (changing rack heights, using forklifts to move pallets) at $20 per hour for a total cost of $600.

32. Reducing awkward lifting - bending - Avoid unnecessary lifting Truck and SUV wheels (tire + rim) can weigh over 70 pounds, and would be a hazard if lifted from the floor. The cost of a set of tire hangers is $445.Truck and SUV wheels (tire + rim) can weigh over 70 pounds, and would be a hazard if lifted from the floor. The cost of a set of tire hangers is $445.

33. Principles for reducing awkward lifting � reaching above shoulders - Arrange storage Use mechanical assistance Use a rolling stair or �safety ladder� List of principles to reduce awkward lifting � reaching above the shouldersList of principles to reduce awkward lifting � reaching above the shoulders

34. Reducing awkward lifting � reaching above shoulders - Arrange storage This shows arranging storage so that larger, heavier and more frequently used boxes are between knee and shoulder height. In this case, the height of the shelf for heavy boxes is just above the height of the cart, so they can be slid instead of lifted. This type of �downhill� transfer is the easiest, although if boxes need to go back and forth from the shelf to the cart, they would want to set them as close to the same level as possible. Utility carts like this one are relatively inexpensive, usually less than $120.This shows arranging storage so that larger, heavier and more frequently used boxes are between knee and shoulder height. In this case, the height of the shelf for heavy boxes is just above the height of the cart, so they can be slid instead of lifted. This type of �downhill� transfer is the easiest, although if boxes need to go back and forth from the shelf to the cart, they would want to set them as close to the same level as possible. Utility carts like this one are relatively inexpensive, usually less than $120.

35. Reducing awkward lifting � reaching above shoulders - Use mechanical assistance

36. Reducing awkward lifting � reaching above shoulders - Use mechanical assistance

37. Reducing awkward lifting � reaching above shoulders - Use a rolling stair

38. Principles for reducing awkward lifting � twisting - Use conveyors Provide more space Arrange storage List of principles to reduce awkward lifting - twistingList of principles to reduce awkward lifting - twisting

39. Reducing awkward lifting � twisting - Use conveyors

40. Reducing awkward lifting � twisting - Re-arrange storage

41. How to find ideas Resources: Your employees Your suppliers Your industry association Industry-specific equipment catalogs Product vendors Internet searches These are some tips on where to find more ideas for ways to fix lifting hazards: Employees are one of the best sources of ideas for fixing jobs, since they�re the experts at what they do. They may already have thought of ideas for making things better. Also, if they�re involved in coming up with solutions, they�re more likely to use them. Other sources are suppliers (remember the bags of fiberglass?), industry associations, equipment catalogs that you may already have, suppliers of the materials and equipment that you buy, and the Internet. Be careful when looking for equipment. Just because something is called �ergonomic� doesn�t necessarily mean it will work for your situation.These are some tips on where to find more ideas for ways to fix lifting hazards: Employees are one of the best sources of ideas for fixing jobs, since they�re the experts at what they do. They may already have thought of ideas for making things better. Also, if they�re involved in coming up with solutions, they�re more likely to use them. Other sources are suppliers (remember the bags of fiberglass?), industry associations, equipment catalogs that you may already have, suppliers of the materials and equipment that you buy, and the Internet. Be careful when looking for equipment. Just because something is called �ergonomic� doesn�t necessarily mean it will work for your situation.

42. Ergonomics Ideas Bank There are hundreds of ideas for reducing lifting available in the Ergonomics Ideas Bank. These ideas have been reviewed by a team of ergonomists, so the ideas have some credibility. The picture is linked to the Ideas Bank, so if you�re hooked up to the network, you can do a live demo with the class.There are hundreds of ideas for reducing lifting available in the Ergonomics Ideas Bank. These ideas have been reviewed by a team of ergonomists, so the ideas have some credibility. The picture is linked to the Ideas Bank, so if you�re hooked up to the network, you can do a live demo with the class.

43. Lifting techniques training Teaching lifting techniques to employees Giving training alone is not effective Making changes to jobs and equipment is better Making changes along with training is most effective Training all by itself, without making changes to the workplace, is often not effective in preventing injuries. (see reference below) Often employees are taught �proper lifting techniques� and then sent out to work under conditions that don�t allow them to use these techniques. Training is an important part of implementing changes, though. Showing employees how to use new equipment and explaining why it�s important to use it properly in order to prevent injuries helps to make sure the equipment gets used. The following study provides evidence of the lack of effectiveness of training alone: Daltroy, L.H., et al. (1997). A controlled trial of an educational program to prevent low back injuries. The New England Journal of Medicine, Vol. 337, No. 5, pgs. 322-328. This was a large study involving around 4,000 postal workers. Half received �back school� type training including training on safe lifting and proper postures, while the other half had no training (control group). They followed the workers over a 5-year period, during which the training group had refresher training. When comparing the two groups, they found that the training made no difference in the rate of injury, cost of injury, lost work time, or recurrence of injuries.Training all by itself, without making changes to the workplace, is often not effective in preventing injuries. (see reference below) Often employees are taught �proper lifting techniques� and then sent out to work under conditions that don�t allow them to use these techniques. Training is an important part of implementing changes, though. Showing employees how to use new equipment and explaining why it�s important to use it properly in order to prevent injuries helps to make sure the equipment gets used. The following study provides evidence of the lack of effectiveness of training alone: Daltroy, L.H., et al. (1997). A controlled trial of an educational program to prevent low back injuries. The New England Journal of Medicine, Vol. 337, No. 5, pgs. 322-328. This was a large study involving around 4,000 postal workers. Half received �back school� type training including training on safe lifting and proper postures, while the other half had no training (control group). They followed the workers over a 5-year period, during which the training group had refresher training. When comparing the two groups, they found that the training made no difference in the rate of injury, cost of injury, lost work time, or recurrence of injuries.

44. Lifting techniques training Job-specific, on-site, hands-on training is more effective than classroom Have employees demonstrate proper lifting techniques before �graduating� Being trained where they work, using the objects they typically lift and the equipment they use on the job helps employees to relate to what they�re being taught, rather than showing them a generic lifting video. Make sure that employees have learned what you�re trying to teach them by having each one of them demonstrate the lifting techniques properly before leaving the class. Follow-up with them to make sure they are able to use the techniques on the job.Being trained where they work, using the objects they typically lift and the equipment they use on the job helps employees to relate to what they�re being taught, rather than showing them a generic lifting video. Make sure that employees have learned what you�re trying to teach them by having each one of them demonstrate the lifting techniques properly before leaving the class. Follow-up with them to make sure they are able to use the techniques on the job.

45. Resources

46. You�re done!