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

<strong>Lifting</strong> <strong>Hazards</strong> <strong>and</strong> <strong>Some</strong> <strong>Ideas</strong> onHow to Reduce Your Risk of <strong>Lifting</strong>InjuryLotsapounds

By the end of this lesson you will beable to:• Identify the types of lifting that maycause injuries• Identify the ergonomics principles used inreducing lifting hazards <strong>and</strong> preventinginjuries

<strong>Lifting</strong> Injuries Aren’t Just Back Injuries<strong>Lifting</strong> results in:30% ofShoulderWMSDs43% ofBackWMSDs22% ofElbowWMSDs13% ofH<strong>and</strong>/WristWMSDsWMSD = Work Related Muscular Skeletal Disorder

<strong>Lifting</strong> Injuries Aren’t Just Due to Aging“Overexertion in lifting a heavy objectis the most frequent single type ofinjury for those under 18 resulting inlost work-time.”Source: American Society of SafetyEngineers (ASSE,)

Pay special attention to…Heavy liftingFrequent liftingAwkward lifting

Heavy <strong>Lifting</strong>This job is adding bags of dry ingredients to a hopper in a manufacturing plant.

Frequent <strong>Lifting</strong>This job is palletizing bins of small parts in a warehouse.

Awkward <strong>Lifting</strong>• Above the shoulders• Below the knees• At arms’ lengthThis job is lifting 50-pound bags in amanufacturing plant

Calculator for analyzing liftingoperationsThe use of the following 6 steps will assist you indetermining a safe working weight .We will use factors based on, starting position, repetition, <strong>and</strong>duration of the task to calculate the maximum weight that may be liftedsafely. The purpose of this calculator is to identify the lifting limit <strong>and</strong>ensure your starting weight does not exceed the lifting limit.Step 1Enter the weight of the object lifted. ___________lbs.(We will use the starting weight in step 1 to compare with our answer in step 5)Example – 45 lbs.The above information can be gotten from the following web site -http://ebookbrowse.com/calculator-for-analyzing-lifting-operations-pdf-d314819091

Calculator for analyzing liftingoperationsStep 2Select from the chart on the left,the weight that represents theposition your h<strong>and</strong>s will be in whenyou begin to lift or lower theobjects, i.e. above your head,below your knees , close/awayfrom your body etc.Example - 50

Calculator for analyzing liftingoperationsStep 3Select the number that corresponds to the times the personlifts per minute <strong>and</strong> the total number of hours per day spentlifting.How many hours per dayHow many lifts per minuteUnder 1 hour 1 hr to 2 hrs 2 hrs or more1 lift every 2-5 min 1 0.95 0.851 lift every min 0.95 0.9 0.752-3 lifts every min 0.9 0.85 0.654-5 lifts every min 0.85 0.7 0.456-7 lifts every min 0.75 0.5 0.258-9 lifts every min 0.6 0.35 0.1510+ lifts every min 0.3 0.2 0Example – 2-3 lifts every min for 1-2 hours = .85

Calculator for analyzing liftingoperationsStep 4If your job involves twisting 45 degrees ormore Select 0.85. Otherwise select 1.0Example – Our job involves twisting 45 degreesor more = .85

Calculator for analyzing liftingoperationsStep 5Using the numbers in the exampleswe get, 50 x .85 x .85 = 36lbs.

Calculator for analyzing liftingoperationsStep 6In our example, we started out with a weight of45 lbs. However, our calculations indicated that36 lbs. was the maximum safe lifting limit weshould use. <strong>Lifting</strong> the initial 45 lbs. could resultin an WMSD (Work Related Muscular Skeletal Disorder.)

Principles for reducing heavy lifting• Reduce the weight• Use mechanical assistance• Slide instead of lift• Team lifting

Reducing heavy liftingReduce the weight of the load(plastic pallets)This example shows usinglightweight plastic pallets, whichweigh anywhere from 13 to 30pounds for a st<strong>and</strong>ard 40” x 48”unit (the one in the picture isabout 20 pounds).The traditional wooden 40” x 48”pallets weigh approximately 60pounds.

Reducing heavy liftingSlide instead of liftThis example ismoving heavy dutybatteries from onepallet to another .Large batteries can weigh up to 110pounds (this one weighs about 75pounds). By taking the time to set anotherpallet at the same height as the shelf orbattery to be moved, it can be slid ratherthan lifted.

Reducing heavy liftingTeam liftingTeam lifting works better on larger objects, suchas the wallboard shown here.

Principles for reducing frequent lifting• Use mechanical assistance• Avoid unnecessary lifting• Use mobile storage

Reducing frequent liftingUse mobile storageThe example above is a mobile rack that can hold heavy boxes which require movementfrom one place to another

Principles for reducing duration of lifting• Rotate to other jobs• Use mechanical assistance

Reducing duration of liftingRotate job tasks, i.e. lifting to nonliftingtasks

Principles for reducing awkward lifting-reaching -• Remove obstacles• Slide items closer• Reduce shelf depth• Reduce package size• Use mechanical assistance• Team liftingAlong with object weight, lifting frequency <strong>and</strong> duration, the distance between the h<strong>and</strong>s<strong>and</strong> the low back when lifting is one of the main factors in determining whether a lift is ahazard or not. The longer the reach of a required lift an object, the more of a load itplaces on the low back <strong>and</strong> the greater the risk of injury.

Reducing awkward lifting-reaching -Remove obstaclesThis shows lifting in <strong>and</strong> out of a bin with the side flipped down. Bins with flip-downsides can reduce the reach in many cases, although there may still be some awkwardlifting.

Reducing awkward lifting-reaching -Slide objects closerThis example shows an employee, using an inexpensive, metal hook, made in-house, topull a box close to the edge of the shelf before lifting it. This works well for lighter items.Heavier items would need to be stored lower <strong>and</strong> slid closer using both h<strong>and</strong>s.

Reducing awkward lifting-reaching -Reduce package sizeThe drawings show the difference between lifting a large box with many items in itversus lifting a smaller box with fewer items in it. Not only will this reduce theweight, but it will also reduce the reach necessary to pick up the box.

Reducing awkward lifting-reaching -Team liftingTeam lifting can help to reduce the effort required to pick up a large object. Remember,it’s not as effective as a piece of lifting equipment.

Principles for reducing awkward lifting-bending -• Use mechanical assistance to raise the load• Add h<strong>and</strong>les• Arrange storage• Avoid unnecessary lifting

Reducing awkward lifting-bending -Use mechanical assistance to raise the loadWorkers can bring objects up to abetter height for lifting. The best useis to place the cart at the sameheight as the shelf or table in whichthe object is being transferred to orfrom, <strong>and</strong> then slide it over ratherthan lifting. Carts with rollers orroller balls also help make the slidingtransfer easier.

Reducing awkward lifting-bending -Add h<strong>and</strong>lesThis shows the difference in lifting posturebetween picking up a box from the bottom, <strong>and</strong>picking it up using h<strong>and</strong>les near the top of thebox. In this case, this product is shipped in abox with pre-cut h<strong>and</strong>les. There’s still somebending, but the box is now lifted from abovethe knees, rather than below them.There are a couple of other good ideas in thisphoto as well. The box has been stacked on anempty pallet to raise it up a little (sometimeseven raising something just 6” can make adifference in posture).

Reducing awkward lifting-bending -Rearrange storageThe example shown is where they took a stack of heavy items<strong>and</strong> rearranged them to be placed on shelves between knee <strong>and</strong>shoulder level.

Reducing awkward lifting-bending -Avoid unnecessary liftingThis is an example of a commercial product designed to allow mechanics to hangwheels off the sides of the lift when working on brakes, hubs, etc. This places the wheelsat a better height for lifting, instead of dropping the wheels to the ground. The hangerfolds flat against the lift when not in use.

Principles for reducing awkward lifting– reaching above shoulders -• Arrange storage• Use mechanical assistance• Use a rolling stair or“safety ladder”

Reducing awkward lifting– reaching above shoulders -Arrange storageThis shows arranging storage so that larger, heavier <strong>and</strong> more frequently used boxesare between knee <strong>and</strong> shoulder height. In this case, the height of the shelf for heavyboxes is just above the height of the cart, so they can be slid instead of lifted.

Reducing awkward lifting– reaching above shoulders -Use mechanical assistanceThe device shown is a stacker, which is like a h<strong>and</strong> truck with a h<strong>and</strong>-cranked winch tomove the platform up <strong>and</strong> down so that loads can be mechanically raised to the heightthey are shelved or removed from shelves. Stackers are available with lift heights up to12 feet.

Reducing awkward lifting– reaching above shoulders -Use mechanical assistanceThis example shows using a forklift to combine a stack of bins,rather than manually stacking the bins over shoulder height.

Reducing awkward lifting– reaching above shoulders -Use a rolling stairThis example is a cart with a stair attached (or a stair with a cartattached). The advantage is that the steps are always there, so noneed to find a ladder, <strong>and</strong> they can set the load down as they goup <strong>and</strong> down the stairs.

Principles for reducing awkward lifting–twisting -• Use conveyors• Provide more space• Arrange storage

Reducing awkward lifting–twisting -Use conveyorsConveyors are especially useful when changing directions, to help avoidtwisting. This picture shows a gravity conveyor used to unload trucks in ashipping department. It allows the receiver to bring the boxes over to thecomputer to scan in the information <strong>and</strong> inventory the contents. The boxes canthen be slid directly onto carts to be put away. <strong>Lifting</strong> only needs to occur twice,once to take the box from the truck <strong>and</strong> place it on the conveyor, <strong>and</strong> once toput the box away.

Reducing awkward lifting–twisting -Re-arrange storageThis example shows raising the height of the racks toprovide more room to get at products on the lower racks.

<strong>Lifting</strong> techniques trainingTeaching lifting techniques toemployees– Giving training alone isnot effective– Making changes to jobs<strong>and</strong> equipment is better– Making changes alongwith training is mosteffectiveTraining all by itself, withoutmaking changes to theworkplace, is often not effectivein preventing injuries. Oftenemployees are taught “properlifting techniques” <strong>and</strong> then sentout to work under conditions thatdon’t allow them to use thesetechniques. Training is animportant part of implementingchanges. Showing employeeshow to use new equipment <strong>and</strong>explaining why it’s important touse them helps reduce thepossibility of WMSD’s

<strong>Lifting</strong> techniques training• Job-specific, on-site, h<strong>and</strong>sontraining is more effectivethan classroom• Have employees demonstrateproper lifting techniquesbefore “graduating”Being trained where they work, using the objects they typically lift<strong>and</strong> the equipment they use on the job helps employees to relateto what they’re being taught, rather than showing them a genericlifting video. Make sure that employees have learned what you’retrying to teach them by having each one of them demonstrate thelifting techniques properly. Follow-up with them to make sure theyare able to use the techniques on the job.

QUIZ1. Using the lifting calculator… can you safely lift an itemweighing 45 pounds, at waist to shoulder height (out 7”)for 4 to 5 lifts each minute for 1 to 2 hours in duration <strong>and</strong>your not twisting more then 45 degrees?a. Yesb. No2. Job-specific, on-site, h<strong>and</strong>s-on training is more effectivethan classroom.a. Trueb. False3. Name one of the three principles for reducing frequentlifting.____________________

Summary• You have identified the types of lifting that may causeinjuries such as; Heavy lifting, Frequent lifting <strong>and</strong>Awkward lifting. You also learnt some ergonomicsprinciples used in reducing lifting hazards <strong>and</strong> preventinginjuries such as; Reducing the weight you lift to increasingthe weight so that no one will attempt to lift the weight.You also learnt that the use of mechanical assistance cangreatly reduce injuries <strong>and</strong> the use of team lifting worksbetter on larger items.• With the proper use of the lifting techniques you just learntyou can expect to have a productive <strong>and</strong> safe workingenvironment.• Remember, proper lifting not only affects you but thoseworking around you.

QUIZ ANSWERS1. Using the lifting calculator… can you safely lift an itemweighing 45 pounds, at waist to shoulder height (out 7”)for 4 to 5 lifts each minute for 1 to 2 hours in duration <strong>and</strong>your not twisting more then 45 degrees?b. No…The safe weight limit would be 35 lbs.1. Job-specific, on-site, h<strong>and</strong>s-on training is more effectivethan classroom.a. True3. Name one of the three principles for reducing frequentlifting.1. Use mechanical assistance2. Avoid unnecessary lifting3. Use mobile storage