This refresher covers material handling.

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How materials (such as parts, work pieces or stock) are handled in the

shop matters because many tasks can lead to injuries.

Listed above are 5 examples of worker compensation claims submitted to

a large insurance company between 2010 and 2014. Note the part of the

body injured, how the injury occurred, and the cost of the claim.

Notice that the most expensive claims were related to back injuries.

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A quarter of all claims submitted to the insurance company by 575 metal

fabrication businesses, between 2010 and 2014, were related to

musculoskeletal disorders, of which, one third were back injuries.

The chart on the left shows that the 83% of the back injuries were to the

lower back. The chart on the right shows the medical costs associated

with lower back injuries.

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Here are the numbers used to create the previous graph.

• Notice how expensive the low back and the disc injuries were.

• On average, the disc injuries are the most costly.

• The majority of the injuries are to the low back.

4

When an injury occurs at work, the costs are far greater than the medical

costs incurred.

Costs to the injured employee may include:

- Loss of quality of life

- Increased cost of living – if special accommodations are required

- Future medical issues that may arise

- Loss of earning potential

- Potentially damaged professional reputation

Costs to the business may include:

- Lost productivity

- Employee training and retraining

- New employee hiring

- Change in employee morale

- Damaged business reputation

- Fines imposed by regulatory agencies or costs associated with law

suits

5

Many accidents happen while performing material handling tasks which

include: lifting, carrying, pushing, pulling, and reaching.

Some parts of the body are at increased risk of injury. These are the back,

arms, neck, and knees.

6

An injury does not occur every time a task is carried out. There are several

contributing factors that can lead to an injury. These are called “risk factors”.

Risk Factors include:

• Repetitive motions

• Awkward postures such as reaching above shoulder height, bending,

twisting, or kneeling

• Forceful exertions. The greater the physical effort required to perform

task, the greater the risk.

• Static posture involves maintaining fixed positions for a long period of

time, such as standing at a machine.

The duration and frequency of each factor are critical in determining the actual

risk.

Once the risk factors are identified, we can find solutions to reduce or eliminate

them.

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This chart shows the activities preformed by employees that suffered

back injuries on the job. The activities were identified by the insurance

company for each claim.

Notice that the activities in red have been identified as contributors to

more than three types of back injuries.

8

In many shops, most of the lifting remains an entirely manual task. SMART is

the acronym for the correct lifting technique.

S - Size up the load (determine weight, assess size; shape and stability.

M - Move the load close to your body.

A - Always bend your knees not your back when lifting and lowering an

object. Keep your feet apart to maintain balance.

R - Raise the load with your legs, keeping your back as upright as possible.

Lift smoothly using your leg muscles not your back.

T - Turn your feet in the direction of travel. Do not twist your body when you

are carrying a load.

When you lower the load, follow the lifting process in reverse.

9

The photo on the left illustrates improper lifting technique.

His knees are not bent. This put a lot of strain on the back.

The photo on the right shows the proper way to lift.

His knees are bent and he is using his leg muscles.

The “safe lifting zone” is the distance between your upper thigh and mid-

chest.

Whenever feasible, heavy items should be stored within the “safe lifting

zone”. Moving items within this zone puts the least strain on your back.

Remember that using a back belt does NOT enable you to lift heavier

items!

10

Having a good grip on the object you are about to lift and move is very

important.

Here is an example of a vise handle, that makes it easier to move a vise.

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Get assistance when you need to move objects:

• Anytime your personal health condition warrants it (such as a previous

injury, recovering from surgery, etc.)

• Whenever the object you need to move is heavier than 50 pounds

• When moving large, awkward, or long objects

Remember to coordinate each step of the lift!

Notice that the person on the right in the first photo has his knees locked

and his feet are unstable. He is not using the correct lifting technique.

The 2nd photo shows the proper way to lift – his knees bent and his feet

parallel, creating a stable base.

12

Using a cart, dolly, or hand truck combines manual and mechanical

material handling. You may still have to put the load on and take it off the

cart, but you do not have to carry it. Using this equipment:

• Reduces the amount of lifting necessary

• Allows for good body positioning for weight transfer

• Allows you to work within the “safe lifting zone”

13

Pushing and pulling activities can lead to back injuries. Here are the key

point to keep in mind:

• Pushing puts less strain on your back than pulling.

• When pushing, use both arms.

• If you must pull - avoid sudden stops.

• For both pushing and pulling, maintain an upright posture and stay

close to the load.

14

Mechanical material handling eliminates manual lifting entirely, reducing

the risk of injuries.

Examples of equipment used for mechanical material handling include:

• Forklifts

• Hoists

• Cranes

You must be trained before you can use this type of equipment!

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In Summary:

Risk Factors include – repetitive motions, awkward posture, forceful

exertion and static posture.

The frequency & duration of each risk factor are critical

considerations.

Remember to always use the SMART lifting technique.

Use carts, dollies and hand trucks whenever possible.

Never lift objects heavier than 50 pounds without assistance!

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