Zainorinali

Anyone Hurt?
Anyone Hurt?

OBJECTIVES
At the end of the session, participants
should be able to:
State the definition of manual handling
List at least 4 accidents that can occur
during manual handling works
State 4 factors that influence manual
handling
Discuss safety measures before and
during manual handling works
3

Objective
State the factors that contribute to MSDs
Explain at least 3 types of work activities
and ergonomic risk factors
Explain at least 3 MSDs and the affected
body parts
Elaborate at least 2 system approaches to
manage MSDs
List at lease 3 early detection methods and
symptoms

SCOPE
Definition

Objective of Ergonomics
Statutory Requirements
Ergonomics Risk Factors

Accident Statistics
Anatomy
Mechanic
Manual handling
Injuries
Consideration
Strategies & Techniques
5

SCOPE
Musculoskeletal Disorders (MSDs)
Factor
Related Disease
Systems approach to manage MSDs
Early detection and reporting of symptoms
Safety measures before and during works
Ergonomics Improvements
Proactive Plan
Job Analysis
Training
Conclusion
6

Positive Values via the

Ergonomic Approach

For the
EMPLOYER

For the
EMPLOYEE

Safety and Health,

Comfortability, Satisfaction

Performance
Quality, Productivity, Flexibility

Reduced worker absenteeism and

turnover, open to changes

EMPLOYEE
welfare

EMPLOYER
welfare

What is Ergonomics?
The term ergonomics is derived from two Greek

words:

ergon, meaning work

nomos, meaning natural laws

Efficient and Safe Arrangement of

Working Conditions
Machines/Equipments
People

What is Ergonomics?
The science and art of Fitting the task to
the employee
The Dual Goals

Minimize

injuries
Improve productivity & quality

Objectives of Ergonomics
To increase levels of work efficiency and

effectiveness or any related activity

undertaken such as through reduction of
mistakes, increase of productivity and
simplification of tasks.
To increase positive human values such as
increased safety, reduced fatigue and stress,
increased work comfortability and increased
quality of work and life in general.
11

Purpose of Ergonomics

Tolerable work system

The aim of the risk assessment process is

to remove a hazard or reduce the level of
its risk by adding precautions or control
measures, as necessary. By doing so, you
have created a safer and healthier
workplace.

Acceptable work
system

Optimal work
system
12

Balance Theory
Human Factor

Work
Environment
Factor

Work Factor
Organisational
Factor
Technology Factor
Each component have +ve & -ve relationship in balance.
Impact on worker performance, stress, job satisfaction
work like a good team player
to maintain harmony and balance
people are comfortable with balance attitudes
13

Approach: Fitting the Worker to the Task, or the Task to

the Worker?
Is it optimal?

Is it well-suited?

Human factors

Human actions

Tasks done by
humans

Work

Select

Redesign

Train

Restructure
Not suitable

Tasks done by
machines

Additions

14

Branches of Ergonomics
ERGONOMICS
Anthropometrics
The study of the human body
and its movement, often
involving research into
measurements relating to
people.
It also involves collecting
statistics or measurement
relevant to the human body,
called Anthropometric Data.
When anthropometric data is
applied to a product, e.g.
measurements of the hand
are used to design the shape
and size of a handle. Hair
Dryer.

Biomechanics

Physiology

Psychology

Mechanics = study the

effect of forces on bodies
during static and dynamic
situations.

the way in which a

living organism or
bodily part functions.

The science that deals

with mental processes
and behavior.

Biomechanics is the
application of mechanical
principles to living
structures either animals
or human being at rest &
during movement.

Physiological
problems occur when
the body is required
to do too much work,
to work awkwardly or
to work under bad
environmental
conditions.

Biomechanics deals with

the locomotion system
which is the
musculoskeletal system
(Bones, Joints and
Muscles).
15

Metabolism, breathing, temperature

and heartbeat as work load indicators
Work Load
Assessment

Usage of
Oxygen

Lung
Breathing

Rectal
Temperature

(liter/min)

(liter/min)

(C)

0.25 0.3

6-7

37.5

60 - 70

Low

0.5 - 1

11 - 20

37.5

75 - 100

Moderate

1 - 1.5

20 - 31

37.5-38

100 125

High

1.5 - 2

31 43

38 38.5

125 150

Very high

2 - 2.5

43 56

38.5 39

150 175

Extreme
(sport)

2.4 - 4

60 - 100

> 39

> 175

Very low (resting)

Heartbeat
(beat/min)

16

STATUTORY REQUIREMENTS
Occupational Safety and Health Act 1994
General responsibility of the employer and selfemployed
The making of arrangements for ensuring, so far
as practicable, safety and absence of risks to
health in connection with the use or operation,

handling, storage and transport of plant and

substances. (Section 15 (2)(b))

17

STATUTORY REQUIREMENTS
Factories and Machinery Act 1967

Section 12

No person shall be employed to lift, carry or

move any load so heavy as to be likely to cause
bodily injury to him.

18

Working Conditions
Physical Conditions
Force
Pushing

Working Conditions
Physical Conditions
Lifting
Handling

Working Conditions
Physical Conditions
Lifting
Handling

Ergonomic Risk Factors

22

Ergonomic Risk Factors

Doing repetitive work

Use of excessive force

Improper or static body posture

23

Ergonomic Risk Factors

Work in long duration

Vibration due to hand tools

Contact stress on the blood veins, muscles

and tendons due to contact stress due to
use of hand tools/equipments

24

Working Conditions
Awkward Postures

Working Conditions
Awkward Postures

Working Conditions
Awkward Postures

Working Conditions
Repetitive Motion

Types of activities and

Ergonomic risk factors
No.

Activity and Physical

work situation

Possible ergonomic
risk factors

1.

Use of excessive force to ensure

completion of work process

Force, posture, pressure

2.

Repetition of the same movements

Posture,force,cold temperature,
repetition

3.

Consistent movements without

sufficient resting time

Repetition, force, posture,

pressure, vibration

4.

Work requiring long reach ability

Posture, force

5.

Work surface that is either too high

or too low

Posture, force, pressure

6.

Static position or posture while at

work

Posture, force

29

Types of activities and

Ergonomic risk factors
No.

Activity and Physical

work situation

Possible ergonomic
risk factors

7.

Sitting for long durations

Posture, pressure

8.

Use of hand tools or power tools

Posture, pressure, vibration

9.

Vibrating work surface, machinery

or vehicle

Vibration, force

10.

Movement of heavy loads

Force

11.

Horizontal reach

Repetition, posture

12.

Vertical reach below the knee or

above the shoulder

Posture, pressure

30

Accident Statistics
Largest cause of accidents at work

37% Manual Handling

19% Slips, Trips and Falls
12% Other Causes
20% Struck by an Object
7% Falling from Height
5% Machinery

Accident Statistics
Interpreted another way - the overall figure
of 37% means that:
86000 people are absent daily
26,500,000 working days are lost annually
1000,000,000 is lost in production,
sickness benefit and medical costs
In terms of suffering each injury results in an
average of 20 days off work some never
fully recover. Four out of five people suffer
with back related problems at some time the
risk is greater after the age of 30.

Anatomy
Spine
Three main functions
To protect the spinal cord
To allow movement.
To support the upper body
Complex System
Spinal Cord
Nerves
Ligaments
Muscles & Tendons

Anatomy
Spine - Strong and Flexible
Gentle S bend
Move or lift in wrong way balance can

be disturbed

Problems contributory factors

Poor physical condition
Posture
Lack of exercise
Excess weight
Illness

Disc

Spinal Cord

Vertebrae
33 bones the top 24 are

separated by discs
Each vertebrae has 4 joints
which enables movement
Vertebrae are larger towards
the bottom of the spine

Vertebrae

Anatomy
Discs

Nucleus

Act as shock absorbers

Firmly attached to
vertebrae
Poor blood supply
Annulus stretches and
relaxes during
movement.

Disc
Annulus

Discs
Repeated stresses

Anatomy

can cause minute

tears and bulging of
the disk.
Presses on adjacent
nerves and ligaments
pins & needles,
pain, numbness
Commonly called a
slipped disc

Muscles
Muscles are bundles of fibre which enable
movement
Messages from the brain cause them to contract

and relax
Connected by tendons and when muscles
contract the bones are drawn closer together
A damaged muscle is called a strain

Ligaments & Nerves

Ligaments

Nerves

Strong fibrous tissue

Small degree of
elasticity
Stooped back posture
can result in
permanent
elongation
weakness and pain
Damaged if stretched
too far and torn
called a sprain.

Millions of fibres
transmitting electrical
impulses
Vertebrae enclose and
protect
Nerves branch out from the
spinal cord and pass
between vertebrae
Irritated nerves can be felt
right along there length
called sciatica

Mechanics

Balance point is through centre of body when

standing
A load held in front disturbs the balance - tension is
generated in the back muscles to compensate
Forms a lever effect
Average person holding a 10kg load at arms length
generates a counterbalancing tension up to 10 times
more to avoid falling over
High or repetitive levels of tension in the back can
cause damage called muscle strain

Mechanics

Centre of Gravity

Centre of Gravity

Lever effect is reduced if load held closer to the body

UNSAFE ACT

MENGANGKAT OBJEK MELEBIHI 1 / 3 BERAT BADAN

MANUAL HANDLING
Definition:

Any lifting, lowering, pushing, pulling,

moving, shifting, holding or supporting a load
that is done manually

43

MANUAL HANDLING
Accidents related to manual handling
works
Accidentally letting go of load

Crushed by load
Fall while carrying load
Contact with sharp edges of load
44

MANUAL HANDLING
TYPES OF INJURIES
(1) External injuries

Cuts
Scratches

Tears

45

MANUAL HANDLING
TYPES OF INJURIES
(2) Internal injuries
Muscle or ligament tear
Damage to joints

knee, ankle, shoulder, arm

Slipped disc
Hernia
Rheumatism

46

MANUAL HANDLING
CONSIDERATIONS
Factors that need to be considered in
manual handling works include:

1. Size of load
2. Condition of load

3. Physical shape of load

4. Weight load
5. Level of sturdiness
6. External surface of load
7. Position of load
47

MANUAL HANDLING
CONSIDERATIONS
8. Condition of floor surface
9. Head room
10. Temperature
11. Lighting
12. Physical and mental fitness

of worker
13. Lifting equipment
14. Worker clothing
48

MANUAL HANDLING
CONSIDERATIONS
1) Size of load

Big or small
Example:

50 kg cement
50 kg cotton

Although they have the same weight, the

size is different
49

MANUAL HANDLING
CONSIDERATIONS
2) Condition of load

Liquid
Solid
Gas

50

MANUAL HANDLING
CONSIDERATIONS
3) Physical Shape of Load
Examples:

Round
Square / triangular
Oval
Flat
Long

When lifting, load has to be balanced

51

MANUAL HANDLING
CONSIDERATIONS
4) Weight of load

The weight of the load has to be known before

handling
Purpose - to identify
Method of handling

Worker capability

52

MANUAL HANDLING
CONSIDERATIONS
5)Level of sturdiness

The load may change shape upon

handling
This will cause difficulties in holding
and gripping the load

53

MANUAL HANDLING
CONSIDERATIONS
6) External surface of load

Rough
Smooth
Uneven
Example:
Plastic bag, sack, paper, metals all have different surfaces

54

MANUAL HANDLING
CONSIDERATIONS
7) Position of load

Position of load that needs to be handled

Load is on the floor
Load is located above head level

55

MANUAL HANDLING
CONSIDERATIONS
8) Condition of floor

Slippery

Soft
Uneven

Stability and condition of the floor is

important for balancing purposes
56

MANUAL HANDLING
CONSIDERATIONS
9) Head room

Sufficient head room to avoid bumping

head onto surface
Most manual handling works involve
limited head room

57

MANUAL HANDLING
CONSIDERATIONS
10) Temperature

Temperature influences the method and

speed of a workers movements:

Cold muscles are tensed

Hot body loses a lot of water

58

MANUAL HANDLING
CONSIDERATIONS
11) Lighting

Dark work environments can lead to

accidents. This is because workers are
not able to decipher the route and any
obstructions on the floor/along the way

59

MANUAL HANDLING
CONSIDERATIONS
12) Worker physical and mental fitness

Physical capability

Age
Health and fitness level

60

MANUAL HANDLING
CONSIDERATIONS
13) Lifting equipment

Equipment used to assist in manual handling

activities such as trolleys and pulleys
Equipment design is suitable to the activity
and load
Equipment is properly

maintained
61

MANUAL HANDLING
CONSIDERATIONS
14) Worker clothing

Suitable to individual work task

Comfortable
Protects worker from manual handling hazards
this includes the provision and use of PPE

62

MANUAL HANDLING
STRATEGIES
Identify load / material to be handled
Identify the location and destination of the
load
Assess the potential risks
Select suitable manual handling method
Conduct safety assessment before starting
work
Monitor work activities

63

MANUAL HANDLING
TECHNIQUES
(1) Illustration PM1

Handling of sack / bag

Grip / hold from bottom. Grip using palm and

fingers

(2) Illustration PM2

(3) Illustration PM3

64

ILLUSTRATION PM1

65

ILLUSTRATION PM2

66

ILLUSTRATION PM3

67

Musculoskeletal Disorders (MSDs)

A situation arising by excessive use resulting in wear and tear to muscles,
tendons, joints and surrounding tissues
In the long term, may result in incapability to use the related body part

68

Incapable Level

Incapacity

Affecting Level

Disease, injury
Clear symptoms
Swelling, pain
(affecting performance)

Warning Level

bodily aches, minor pains

uncomfortable, fatigue
(normal)
69

Factors that contribute

to MSDs

Speed of work being undertaken

Use of computers and its accessories in

the office
Elderly workforce

70

List of MSDs related diseases and

affected body parts
Affected
body part

Symptom

Source
of
disease

Employees
at risk

Types of
disease

Thumb

Pain at the end

of the thumb

Twisting and
clenching

Animal
slaughterers,
housemaids,
packagers

de
Quervains
disease

Fingers

Difficulty to move
fingers,
interrupted hand
movements

Repetition using
little finger

Meat packagers,
poultry farm
workers,
electronics
operators

trigger
finger

Shoulder

Pain, aches

Working with
hands above
shoulder level

Welders, painters,
assembly workers,
operators of
automatic and
powered
equipments

rotator cuff
tendonitis

71

List of MSDs related diseases and

affected body parts
Affected
body part

Symptom

Source
- of
disease

Employees
at risk

Types of
disease

Hand, wrist

Pain, swelling,
aches

Repetitive hand
and wrist
movement and
excessive use of
force

Poultry farm
workers, meat
packagers

Tenosynovitis

Fingers, hand

Numbness, ticklish,
loss of sense of
feel and hand
control

Exposure to
vibration

Users of saws,
pneumatic tools
and petrol powered
equipments

Raynauds
syndrome

72

List of MSDs related diseases and

affected body parts
Affected
body part

Symptom

Source
- of
disease

Employees
at risk

Types of
disease

Fingers, wrist

Ticklish, numbness,
severe pain, loss of
sense of feel at
thumb, middle
finger and part of
the ring finger

Repetitive work
using excessive
force, without
sufficient rest

Meat and poultry

farm workers,
clothes
manufacturers,
VDT operators,
cashiers

Carpal tunnel
syndrome

Back

Spinal pain,
numbness at thigh
and surrounding
areas

Vibration

Bus, lorry,
commuter, taxi
drivers, warehouse
workers, nurses,
cashiers and
baggage handlers

Injury to
back/spine

73

Types of MSDs
Tendon related disease
happens at or close to the joints where there is friction
between the tendons and ligaments and/or bones

Repeated contact or friction resulting in cut severe of

tendons or swelling at the shield due to over production and
gathering of the cynovial liquid

Example:
tendonitis, trigger finger,de Quervains disease tenosynovitis

74

Types of MSDs
Nerve related diseases
Happens when work is done repetitively, resulting in
exposure of the nerves to pressure from hard or sharp work
surfaces and equipment edges, or even surrounding
bones, ligaments and tendons.

Effects of numbness and pain will be felt for a period of time

Example:
Carpal tunnel syndrome

75

Types of MSDs
Neuro-vascular diseases
Due to the pressure of nerves and veins resulting in reduced
blood flow to the muscles, tendons and ligaments

Results in slow recovery of the muscle, and limited duration of

muscle use

Example:
Thoracic outlet syndrome and vibration syndrome

76

Systems approach to
manage MSDs
First Phase Before Onset
Conduct comprehensive review of existing and new
job tasks

Purpose: to identify the ergonomic risk factors that

may result in future MSDs problems
Giving priority to the critical ergonomic risk factors
and taking necessary action

77

Systems approach to
manage MSDs
Second Phase - Current
Identify problems that may arise before serious
implications
through
the
development
and
implementation of an early detection system, medical
surveillance, and specific treatments
The role of a medical practitioner is important to
ensure the success of this system and success in
managing MSDs related diseases

78

Systems approach to
manage MSDs
Third Phase - After
Review of the work system through interaction with
workers such as interviews with affected workers and
studying their respective job tasks in comparison with
existing work procedures
Requires cooperation from various parties; the
respective worker, supervisors, engineers, medical
practitioners in order to develop a strategy for the
prevention and reduction of ergonomic risk factors at
work

79

the way in which a

living organism or
bodily part
Physiological
functions

The science that deals

with mental processes
and behavior

MSDs

Psychosocial

Fatigue

Pressure

Individual
factors

Perceived exertion is how

hard you feel like your
body is working.

RPE Rated Perceived Exertion

Borg scale
Behaviour patterns
the characteristic ways in which
a person or animal acts

Stress
Insufficient
oxygen
Movement
Muscles
Recovery

Ergonomic risk
factors
Repetition

External factors

Force
Posture
Long durations
Vibration
Pressure

Work
Technology
Environment
Organisation

Cumulative
effect

Local

Symptoms

Controllable factors
80

Early detection and reporting of

symptoms
Continuous pain after weeks of involvement in new
job
Sudden pain in worker that has been on the same
job for a long time

Pain that is getting worse

Pain that is centered at certain muscles
Signs of numbness and aches

Signs of redness and swelling

81

SAFETY MEASURES
BEFORE HANDLING
Study whether the weight of the load can be
distributed
Adjust the shape of a big load for easier
handling
Adjust the layout of work area or work station
to accommodate manual handling work

Example:
Provision of a work table of suitable height for
drawing works
82

SAFETY MEASURES
BEFORE HANDLING
Identify the best method to handle load
- push, pull, lift, support etc
Study the proper lifting techniques. Use the
suitable posture and physical capabilities
Adjust the work method to accommodate
supporting equipments such as wedges,

hooks and crow bars

Provide training to the worker on respective
job tasks - SOP and other requirements
83

SAFETY MEASURES
DURING HANDLING
Use the proper methods and

techniques
Ensure compliance to work plan
Continuously monitor that proper
methods and techniques are being
practiced by workers

84

Ergonomics Improvements
Taking a fresh look at
Workplace
People
Tools

Engineering Improvements
Administrative Improvements

Engineering Improvements
when new facilities, processes, or work procedures
are being planned
Includes
Rearranging
Modifying
Redesigning
Replacing

Tools
Equipment

Workstations
Parts
Processes

Engineering Improvements
Reduce reaching and bending.

Reduce the stress on your back and shoulders.

Reduce the effort and force needed to perform work

tasks.

Engineering Improvements
Improve your grip, Use a tool.

Reduce contact pressure on your shoulders and hands.

Use powered and non-powered equipment.

Engineering Improvements
Mechanical handling equipment

Engineering Improvements
Mechanical handling equipment

Engineering Improvements
Modify the load
repackage to reduce weight

Engineering Improvements
Modify the load improve grip
provide hand holds

Administrative
Improvements
Alternate heavy tasks with light tasks.

Provide variety in jobs.

Adjust work schedules, work pace,

work practices.

Administrative
Improvements
Provide recovery time

Rotate workers through jobs that use different

muscles, body parts, or postures.

Administrative
Improvements
Ideas for Improving work practices

Job Rotation

Identifying Problem Jobs

Time Spent on particular task

Administrative Improvements

Administrative Improvements
Modify workplace layout

Administrative Improvements
Modify workplace layout

A Proactive Plan
Identify Problems
Set priorities

Looking Around
Talking to Employees

Four steps to a Proactive Action Plan.

1. Look for clues
2. Prioritize job for improvements.

3. Make improvements.
4. Follow up.

Job Analysis

7 Steps

Determination of measurement criteria and

work target
Compilation of history of targeted job task
Identification of ergonomic risk factors

Discovery of preventive measures

104

Job Analysis

Selection of preventive measures

Implementation of preventive measures

Monitoring of preventive measures

105

Characteristics of
Sitting Works
Precise hand movements
High body stability
Use of exact and sensitive foot control

All work components and equipment within

seating range
Handling of heavy loads
Static posture for long durations
106

Characteristics of
Standing Works
Frequent handling of heavy loads
Frequent stretching and movements
require use of energy

that

Work mobility
frequent forceful exertion that requires high
energy

107

Characteristics of
Sit/Stand Works
Provision of high chairs as the worker is
required to alternate sitting and standing and
change of postures
Mobility of the chair
Provision of footrest to reduce swelling and
fatigue of the leg and foot

108

Relationship of Posture and Pressure

on the Backbone

Skill Solutions Sdn Bhd

109

Choices of Work Postures

for Selected Job Tasks
Type of Job Task

Work Posture
First Choice

Second Choice

Lifting above 5kg

standing

sit/stand

Work below elbow height

standing

sit/stand

Horizontal reach requiring body support

standing

sit/stand

Light assembly work with repetitive

movements

sitting

sit/stand

Precise works

sitting

sit/stand

Examination and monitoring using eyes

sitting

sit/stand

sit/stand

standing

Frequent movements

110

Determination of
Working Height

Elbow height

Precise
works

Light works
Skill Solutions Sdn Bhd

Heavy works
111

Normal and Maximum Range

Maximum range

Normal range

112

Training

A pivotal role in ergonomic improvement

Use several types of visual aids

Pictures, charts, Videos
Group discussions,
Encourage to Ask Questions

Hands-on practice with

New tools
Equipment
Work procedures

KUIZ KENALPASTI HAZARD ERGONOMIK

115
Copyright 2006 NIOSH Malaysia. All rights reserved. No part of this text shall be reproduced without written consent of NIOSH Malaysia

CONCLUSION
Manual handling can cause internal and external
injuries to the worker
Various statutory requirements outline
provisions related to manual handling
Manual handling programme has to take into
consideration various factors such as size, shape
and weight of load to be handled
Safety measures have to be followed before and
during handling to avoid unwanted incidences
116