Guide on Manual Handling Risk

Assessment in the
Manufacturing Sector
Our vision:
A country where worker
safety, health and welfare
and the safe management
of chemicals are central to
successful enterprise
Contents

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

THE BUSINESS CASE FOR MANAGING MANUAL HANDLING IN THE MANUFACTURING SECTOR . . . . .3

WHY IS THERE A NEED TO MANAGE THE HAZARD OF MANUAL HANDLING IN THE WORKPLACE? . . .5

THE MANUAL HANDLING RISK ASSESSMENT PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

MANUAL HANDLING RISK ASSESSMENT CASE STUDIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

APPENDIX 1: MANUAL HANDLING RISK ASSESSMENT WORKSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

APPENDIX 2: EXAMPLES OF RISK FACTORS FOR MANUAL HANDLING OF LOADS . . . . . . . . . . . . . . . . . . . . . . .17

APPENDIX 3: EXAMPLE OF A SAFE SYSTEM OF WORK PLAN (SSWP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Published in 2013 by the Health and Safety Authority, The Metropolitan Building, James Joyce Street, Dublin 1.
Guide on Manual Handling Risk Assessment in the Manufacturing Sector

INTRODUCTION

This guide gives direction and practical information to those that work in the manufacturing sector on
action that can be taken to manage the potential hazard of manual handling in the workplace. This is
necessary in order to work towards preventing musculoskeletal injuries at work and reducing exposure
to high financial costs including compensation claims.

The objectives of providing such information are:

• To raise awareness of the business case for managing the hazard of manual handling

• To explain why the hazard of manual handling needs to be managed in the workplace

• To help employers understand and recognise what the potential risk factors are in relation to manual
handling in their workplace

• To give direction on manual handling risk assessment and how it can be used to highlight potential
hazards and create opportunities for developing better ways of working including use of handling
aids, improved housekeeping or better organisation of work processes resulting in reduced handling
of stock and reduced risk of musculoskeletal injury

• To explain how to complete a manual handling risk assessment process through illustrated case
studies

• To give direction on developing a safe system of work plan

The manufacturing sector covers a wide range of different business types including metalwork,
woodworking, food processing, electronics, plastics and medical device production. The tasks conducted
in the manufacturing sector require people to engage in different types of activity which sometimes may
require manual handling. Not all manual handling is hazardous; however, in some cases the activity will
require a person to engage in a work practice which may involve a significant amount of handling,
including lifting heavy loads or lifting loads above shoulder height. It is important to be aware that
manual handling can be a potential workplace hazard which can result in a person suffering a
musculoskeletal injury such as a back injury and therefore needs to be managed effectively.

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

THE BUSINESS CASE FOR MANAGING MANUAL HANDLING IN THE MANUFACTURING SECTOR

Injuries due to manual handling account for 33% of all accidents reported to the Health and Safety
Authority each year, and nearly 20% of these manual handling accidents take place in the manufacturing
sector. A review of figures in the Health and Safety Authority 2011 Annual Statistics show that 49% of the
manual handling injuries in the manufacturing sector occurred when the person was lifting or carrying a
load.

Figures from the Personal Injuries Assessment Board (PIAB) show that in 2008 €31.36 million was
awarded in respect of 972 employer liability awards. Just over one in five (20.41%) of these awards were to
people working in the manufacturing sector. Further analysis of the data shows that sprains (41.97%) are
the most common injury resulting in a claim. The average employer liability award for 2008 was €32,266.

Musculoskeletal injuries at work are a massive drain on the resources of an employer, including costs such
as sick pay, lost productivity, retraining, legal fees and injury benefit. They represent a significant
opportunity for cost reduction, since they are manageable and preventable.

A study of civil court judgements on cases concerning injury due to manual handling identified the
following key systems failures when making rulings on compensation claims: (Health and Safety Review,
2000)

• No risk assessment of work activities

• Lack of safe system of work plans

• Mechanical aids were not provided and maintained

• Adequate training was not provided

• No evidence of work supervision

The case study below demonstrates how tangible improvements are possible if action is taken to address
systems failures such as those outlined above. The interventions were introduced at a medium-sized Irish
manufacturing company.

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Guide on Manual Handling Risk Assessment in the Manufacturing Sector

Problem identification The production process required a significant level of

manual handling. A number of risk factors resulted
including:
- Repetitive bending during a packing operation
- Large, awkward and heavy parts carried over long
distances
As a result there were a high level of reportable injuries due
to unsafe manual handling practice, and insurance costs
running at €60,000 per year.

Management interventions Management agreed to implement a risk reduction strategy

which included:
- Managers being trained to conduct risk assessments
- The completion of a manual handling risk
assessment of operations
- Changes being made to work practices to reduce the
manual handling risk factors. These improvements
included the introduction of variable height pallet
trucks and hydraulic trollies, the transporting of large
parts on wheels, training of staff and new
housekeeping procedures

Results - No reportable injuries

- Insurance costs reduced to €18,000 per year

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

WHY IS THERE IS A NEED TO MANAGE THE HAZARD OF MANUAL

HANDLING IN THE WORKPLACE?

A work activity that requires repetitive bending and the lifting of heavy
loads could result in compression of the disc, facet joint or ligament
damage. Twisting and bending together is perhaps the greatest stress
on the spine, especially the disc.

It is for reasons such as these that there is a regulation with provisions

governing the management of the hazard of manual handling in the workplace in order to avoid or
reduce the risk of injury, particularly back injury. The Safety, Health and Welfare at Work (General
Application) Regulations 2007 (SI No. 299 of 2007), Chapter 4 of Part 2, outline the requirements that
employers must adhere to in relation to manual handling.

In the first instance manual handling is defined in Regulation 68 of the Safety, Health and Welfare at Work
(General Application) Regulations 2007:

Manual Handling involves any transporting or supporting of a load by one or more employees, and
includes lifting, putting down, pushing, pulling, carrying or moving a load, which by reason of its
characteristics or unfavourable ergonomic conditions, involves risk, particularly of back injury, to
employees.

The regulation applies only to those manual handling operations which involve risk of injury to
employees. The definition of manual handling clarifies that not all manual handling involves a risk of
injury, only handling with particular load characteristics (e.g. loads that are too heavy or too large) or
unfavourable ergonomic conditions (e.g. twisting movement of the trunk). The regulation refers to a
schedule of risk factors (see the Appendices for examples of these risk factors) which take account of
these load characteristics or unfavourable ergonomic conditions. This schedule is an important reference
point when carrying out task-specific manual handling risk assessments.

It is important to have an understanding of the range of work activities that take place in the workplace.
As a first step, a walk-through of the workplace should be carried out and staff consulted to identify work
activities of which manual handling forms a significant part. Most manufacturing sites have three key
stages in their production process:

• Goods inwards

• Production/assembly

• Good outwards/packing

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Guide on Manual Handling Risk Assessment in the Manufacturing Sector

It is useful, through consultation with staff, to get an understanding of the potential risk factors as they
relate to specific tasks. Manual handling tasks that will need to be risk assessed will include one or all of
the following risk factors:

Risk factor (unfavourable ergonomic condition) Picture

The lifting of the load requires repeated manipulation of the

load at a distance from the trunk

The lifting of the load requires repeated bending of the

trunk

The load is very large and difficult to grasp

The handling repeatedly takes place at floor level or above

shoulder height

The physical effort can only be achieved by a twisting of the

trunk

The load is carried over a long distance and there is poor

housekeeping with unsafe access

Note: This is not an exhaustive list of risk factors for manual handling of loads

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

The basic principle of the regulation is that where manual handling activities in the workplace may
involve a risk of injury (particularly to the back) due to exposure to unfavourable ergonomic conditions,
the employer must take measures to avoid or reduce the risk of injury. In other words, the employer needs
to manage the hazard of manual handling through implementation of a manual handling risk assessment
process and implementation of preventative measures based on the outcomes of the risk assessments.
This may include the implementation of safe system of work plans for site-specific tasks, providing
information on the use of mechanical aids, the reorganisation of a work activity to allow loads to be
handled at a safe height or the provision of instruction to workers on how to use handling aids or handle
loads safely.

The manual handling risk assessment process is explained in the next section of this guide.

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Guide on Manual Handling Risk Assessment in the Manufacturing Sector

THE MANUAL HANDLING RISK ASSESSMENT PROCESS

There are different tools for assessing manual handling tasks, including the NIOSH lifting equation and
the Mac Tool. Below is a brief summary of a five-step risk assessment process which can be used to assess
individual manual handling tasks. Examples of completed manual handling risk assessments are detailed
in the next section of this guide.

Step 1 Task description In consultation with staff, collect information on how the task is carried
out. Identify the key stages of the task and summarise all information col-
lected.

Step 2 Collect technical The type of information to collect will include information on the weight
information of the load, physical measurements of the load, postures observed during
the handling activity, the amount of space available, housekeeping, the
duration of the task, the number of handling activities and the employee’s
knowledge of a task.

Step 3 Identify the risk Examples of risk factors include:

factors • Load is too heavy
• Employee is prevented from handling a load at a safe height
• Handling is made with the body in an unstable posture
Each risk factor identified must be supported by evidence. A list of risk
factors or unfavourable ergonomic conditions and load characteristics is
detailed in the Appendices.

Step 4 Identify the This requires consultation with staff and an objective review of the infor-
improvements to mation collected. The improvements put in place should avoid or reduce
be put in place the risk of injury, and may be a combination of the following:
• Use of mechanical aids for all or part of the activity
• Reorganisation of work area or materials
• Where handling will still take place, instruction in safe lift techniques
• Development of a safe system of work plan
• Communication of improvements to staff

Step 5 Review the This could involve simple checks or supervision to ensure that lifting tech-
effectiveness of niques are being conducted in line with the instruction given, or that ap-
the propriate handling aids are being used. Risk assessment should be seen as
improvements a continuous process and a review of risk assessments is important to en-
sure they are kept up to date and revised if necessary.

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

SAFE SYSTEM OF WORK PLAN (SSWP)

The outcomes of each manual handling risk assessment are the improvements that have been identified
in the fourth step of the risk assessment process. A simple way to communicate the improvements or
control measures is to develop a safe system of work plan.

A safe system of work plan is a set of instructions according to which something must be done, which
takes account in advance of the foreseeable manual handling risk factors. The purpose of a safe system of
work plan is to give instruction on the new way of carrying out a particular work activity which avoids or
reduces manual handling and therefore reduces the risk of injury. The safe system of work plan should
take account of the handling required from origin of lift to end point of lift and can include a combination
of the following:

• Use of handling equipment (how is it used) to eliminate or reduce handling

• Reorganisation of work area (what changes are made)

• Instruction and training in safe handling techniques (how is it done)

Ideally safe system of work plans should be incorporated into a manual handling training programme.

While it is important to conduct individual manual handling risk assessments, it is of more importance to
communicate the improvements that are to be implemented. A short safe system of work plan for each
manual handling task assessed is a suitable way to manage risk effectively. The duty to provide safe
systems of work remains the employer’s responsibility. An example of a safe system of work plan is
included in the Appendices.

The case study below illustrates the implications of not conducting a risk assessment of a manual
handling task and not implementing a safe system of work.

CASE STUDY

A High Court Judge rejected allegations of an exaggerated claim by a worker who injured his back while
lifting pallets and awarded the employee €370,000 in damages. The Judge stated that:

• The employee suffered two injuries

• He was required to lift pallets onto a conveyor at an unsafe height

• The company failed to take appropriate measures to avoid the necessity for manual handling

• There were three simple and inexpensive alternatives that the company could have adopted

(Health and Safety Review 2003)

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Guide on Manual Handling Risk Assessment in the Manufacturing Sector

This is one example of the financial implications for an employer and the human cost to the employee of
failing to effectively manage the hazard of manual handling in a workplace.

The case studies in the next section of this guide illustrate some examples of work practices that exist in
the manufacturing sector. They are not intended to represent all types of work practice, but to illustrate
the process of manual handling risk assessment.

MANUAL HANDLING RISK ASSESSMENT CASE STUDIES

This section of the guide aims to demonstrate the application of the five-step manual handling risk
assessment process with the use of case studies specific to the manufacturing sector. This is not an
exhaustive list of work activities that may need to be assessed. The case studies illustrate the importance
of following a logical step-by-step process in order to:

• Fully understand how a work activity is completed

• Be aware of the technical aspects of the activity including weight, posture, environment, etc

• Be able to clearly identify the potential risk factors of the activity

• Be able to make an informed decision based on the facts collected as to the best approach to take to
avoid or reduce the manual handling risk factors within the work activity

The solutions in these case studies are not exhaustive and it may be feasible to develop an alternative
solution for the specific needs of the business which still does not impact negatively on the health of the
staff involved in the handling activity. The handling aids illustrated in the case studies are examples of the
types of handling equipment available on the market. Many handling aids are cost effective as they
provide a solution to a potential manual handling hazard and can improve efficiency and reduce
exposure to compensation claims. It is good practice to consult with relevant staff when sourcing
equipment, to provide appropriate training in the safe use of equipment and to ensure appropriate
maintenance.

FURTHER INFORMATION:

Management of Manual Handling in the Workplace at www.hsa.ie

Manual Handling Risk Assessment Case Studies at www.hsa.ie

Guidance on the Manual Handling of Loads Regulation at www.hsa.ie

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

CASE STUDY 1: PACKING STATION AT GOODS

OUTWARDS

STAGE 1: TASK DESCRIPTION

The employee is working at a packing station which is

at the end of the production process. The employee is
required to transfer boxes weighing 15 kg from the
workbench to the pallet on the floor.

STAGE 2: COLLECT ALL TECHNICAL DETAILS

• The boxes weigh 15 kg

• The employee has to lift a number of boxes into position on a pallet

• The employee has to work below knee height when positioning some boxes on the pallet

• The pallet is very close to the employee, which results in the employee engaging in an upper body
twist when transferring the boxes to the pallet

STAGE 3: IDENTIFY THE RISK FACTORS

• The physical effort can involve a twisting movement of the trunk

• The load is positioned in a manner requiring it to be held with a bending of the trunk

• The work environment prevents the handling of loads at a safe height

• The activity requires over-frequent or over-prolonged physical effort involving the spine

STAGE 4: IDENTIFY THE IMPROVEMENTS TO BE PUT IN PLACE

• A high lift or variable height pallet truck is used and can be adjusted to optimum height as the pallet is
being packed

• The staff are trained in the correct use of the pallet truck, including the benefits of setting the
equipment to optimum height

• A job rotation system is introduced so that staff are

not involved in this activity for long periods of
time

• A conveyor table which is adjustable in height is

sourced to allow the boxes to be rolled along the
conveyor

STAGE 5: REVIEW EFFECTIVENESS OF THE SOLUTION

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Guide on Manual Handling Risk Assessment in the Manufacturing Sector

CASE STUDY 2: MAINTENANCE (NON-ROUTINE)

STAGE 1: TASK DESCRIPTION

The employee is completing preventive maintenance

on a production machine. The technician is required to
remove pumps from different machines and bring
them to the workshop for maintenance work. Under
current procedures, the technician brings a low level
trolley to the machine. He then disassembles the part
and lifts it from the machine onto the trolley. He then transfers the part on the trolley to the workshop.
The part is then lifted off the trolley to a workbench for the maintenance work to be completed.

STAGE 2: COLLECT ALL TECHNICAL DETAILS

• The part can weigh in the range of 16–20 kg
• The parts that are removed for maintenance are located at different levels on the machines

• The technician has to work below knee height when positioning the parts onto the trolley and when
transferring the parts to the workbench in the workshop

STAGE 3: IDENTIFY THE RISK FACTORS

• The load is positioned in a manner requiring it to be held with a bending of the trunk
• The work environment prevents the handling of loads at a safe height
• There are excessive lifting distances when lifting from the machine to the trolley

STAGE 4: IDENTIFY THE IMPROVEMENTS TO BE PUT IN PLACE

• A mobile scissors lift table is used and it can be set to the optimum height when transferring the part
from the machine to the lift table. The pump is secured appropriately on the mobile scissors lift

• The staff are trained in the correct use of the lift table and the benefits of setting to optimum height
are included in training

• The technician can adjust the mobile scissors lift to

be flush with the workbench and can then slide the
pump onto the workbench

TAGE 5: REVIEW EFFECTIVENESS OF THE SOLUTION

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

CASE STUDY 3: MANUAL HANDLING DURING THE

PRODUCTION PROCESS

STAGE 1: TASK DESCRIPTION

The employee is required to complete drilling work on
a part. The part has to be drilled in different areas and
this requires the employee to move and adjust the part
a number of times in order to complete the drilling
operations. He lifts the part, places it flat on the floor and completes some drilling. He then has to lift the
metal part and rotate it to another position to complete more drilling operations.

STAGE 2: COLLECT ALL TECHNICAL DETAILS

• The part can weigh up to 30 kg
• The part is large and bulky
• The part has to be manipulated a number of times in order to complete the drilling operations
• The employee engages in a number of awkward postures when rotating the part

STAGE 3: IDENTIFY THE RISK FACTORS

• The load is positioned in a manner requiring it to be held with a bending of the trunk
• The load is positioned requiring it to be manipulated at a distance from the trunk
• The physical effort is made with the body in an unstable posture
• The load is unwieldy and difficult to grasp
• There is excessive lifting distance
• The work environment prevents the handling of loads at a safe height
• There is over-frequent physical effort involving the spine

STAGE 4: IDENTIFY THE IMPROVEMENTS TO BE PUT IN PLACE

• A jig is developed which allows the part to be fixed into position and rotated when carrying out
different drilling operations on the part
• The staff are trained in the correct use of the jig and the benefits of being able to adjust the jig to
allow easier access to the part for drilling
• A trolley is used to transfer parts between workstations
• Housekeeping policy is introduced to ensure that
trolleys are stored in appropriate areas
• The employee can request assistance when
transferring the part onto/off the jig

STAGE 5: REVIEW EFFECTIVENESS OF THE SOLUTION

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Guide on Manual Handling Risk Assessment in the Manufacturing Sector

CASE STUDY 4: MANUAL HANDLING IN GOODS

INWARDS

STAGE 1: TASK DESCRIPTION

The employee is lifting 20 kg boxes into position on the

racking. There are barrels stored on the floor.

STAGE 2: COLLECT ALL TECHNICAL DETAILS

• The barrels weigh 70 kg

• The boxes being loaded onto racking weigh 20 kg

• The loads stored in racking are positioned above shoulder height

STAGE 3: IDENTIFY THE RISK FACTORS

• The box being placed in racking is positioned in a manner requiring it to be manipulated at a distance
from the trunk

• The physical effort when handling the load in racking is made with the body in an unstable posture

• The barrels are too heavy, too large and difficult to grasp

STAGE 4: IDENTIFY THE IMPROVEMENTS TO BE PUT IN PLACE

• The racking is restructured to allow 20 kg loads to be stored at waist height and to allow full pallets to
be loaded directly at ground level in racking

• Through better planning, deliveries are scheduled with a view to reducing congestion

• Areas are marked out to allow for better access and

improved housekeeping

• Barrels are delivered on pallets

• Simple trolleys or sack trucks or dollies are used to

transfer stock

STAGE 5: REVIEW EFFECTIVENESS OF THE SOLUTION

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

APPENDIX 1: MANUAL HANDLING RISK ASSESSMENT WORKSHEET

Step 1: Task description: how is the task carried out?

Step 2: Collect all technical details.

Step 3: Identify the risk factors

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Guide on Manual Handling Risk Assessment in the Manufacturing Sector

Step 4: Identify the improvements to be put in place.

Step 5: Review the effectiveness of the solution.

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

APPENDIX 2: EXAMPLES OF RISK FACTORS FOR MANUAL HANDLING OF LOADS

As part of the five-step manual handling risk assessment process, it will be necessary to identify the risk
factors which are relevant to a particular task. This checklist is a useful aide-memoire to identify risk
factors as part of the risk assessment process. The information collected can then be used to identify what
improvements can be put in place to avoid or reduce manual handling in a task.

RISK FACTORS YES NO COMMENT

Is the load too heavy?
Is the load too large?
Is the load unwieldy or difficult to grasp?
Is the load manipulated at a distance
from the trunk?
Is the load positioned in a manner requir-
ing bending or twisting of the trunk?
Is the physical effort too strenuous?
Is the physical effort only achieved by a
twisting movement of the trunk?
Is the physical effort required likely to re-
sult in a sudden movement of the load?
Is the physical effort made with the body
in an unstable posture?
Is there enough room, particularly
vertically, to carry out the activity?
Is the floor uneven?
Does place of work prevent handling of
the load at a safe height or with good
posture?
Are there variations in the level of the
floor?
Is the floor or footrest unstable?
Does the activity involve over- frequent
or over-prolonged physical effort?
Are there excessive lifting, lowering or
carrying distances?

Note: The guide titled Management of Manual Handling in the Workplace at www.hsa.ie gives more detail on the risk factors above.

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Guide on Manual Handling Risk Assessment in the Manufacturing Sector

APPENDIX 3: EXAMPLE OF A SAFE SYSTEM OF WORK PLAN (SSWP)

SSWP number 1

Title:

Safe system of work plan for the handling of pumps during non-routine maintenance

Scope:

This safe system of work plan summarises the instructions to be followed in order to move pumps safely
during non-routine maintenance.

Key Requirements:

Staff have received appropriate manual handling training and instruction.

There is a mobile scissors lift table in working order and available for use by staff.

Staff are instructed in the safe use of the mobile scissors lift.

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 Guide on Manual Handling Risk Assessment in the Manufacturing Sector

Instructions:

• The employee sources the mobile scissors lift and proceeds to the machine in order to remove a
pump for maintenance.

• The employee moves the mobile scissors lift into position, adjusts the table to the appropriate height
and secures the brake system.

• The employee removes the pump from the machine and ensures that it is secured safely on the
mobile scissors lift. The brake system on the mobile scissors lift is then released.

• The employee proceeds to move the mobile scissors lift to the workshop.

• The employee ensures that the table on the mobile scissors lift is adjusted to be flush with the
workbench, secures the brake system, and the pump is then transferred onto the workbench.

• The employee can then complete the maintenance work required on the pump.

Prepared by: J Smith (Safety Officer)

July 2012

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Notes

Page 20
 A country where
worker safety, health
and welfare and
the safe management
of chemicals are
central to successful
enterprise

ISBN NO. 978-1-84496-171-9 HSA0388