Manual material handling environments can be stressful on the bodies of workplace athletes. Help the workplace athletes at your distribution center stay safe, healthy, and productive with these helpful ergonomics and injury prevention resources.
Table of Contents:
Following are the sections of content on this page. Scroll down the page to download resources along the way or click a link below to quickly move to each section.
Understanding Musculoskeletal Disorders (MSDs)
Manual material handling environments put workplace athletes at a higher than average risk for developing MSDs. The physical nature of jobs in this environment can cause “wear and tear” and eventually escalate to an MSD. The first step to prevent this from happening is to gain a clearer understanding of the problem.
The Definition and Causes of Musculoskeletal Disorders
It’s difficult to prevent something if you aren’t clear on what it is and what causes it. Gain a better understanding of MSDs with this in depth Ergonomics Plus article.
MSD Prevention 101 Workshop
For more detail, and a comprehensive overview of how to prevent MSDs, register for our free MSD Prevention 101 Workshop on the Prevention Pro online education platform.
Ergonomics Process
A proactive ergonomics process is a systematic way to identify ergonomic risk factors and put control methods in place to reduce or eliminate the risk. Workplace improvements ensure that job tasks fit within the capabilities and limitations of workplace athletes.
Workplace Ergonomics: Lower Costs and Boost Productivity With a Proactive Ergonomics Improvement Process
New to ergonomics or want to brush up on the basics? Check out the Workplace Ergonomics 101 tutorial from Ergonomics Plus.
How to Get More Support for Your Ergonomics Process
Struggling to get the support you need to implement a best practice ergonomics process? Learn a few practical tips to be more persuasive in your case for ergonomics.
The 10-Step Workplace Ergonomics Checklist
Check all of these items off on the workplace ergonomics checklist and – based on our experience of over two decades providing ergonomics, injury prevention and wellness services – you’ll have the right framework in place to create a successful ergonomics process.
A Guide to Implementing an Ergonomics Process
The American Footwear Apparel Association and Alliance (an OSHA Compliance Program) collaborated on this 101-page PDF file you can use as a reference guide to implementing an ergonomics process.
5 Tips to Engage Team Members in the Ergonomics Process
Your team members out on the shop floor are the real workplace improvement experts. Engage them in the ergonomics process to heighten awareness, generate improvement ideas and build a positive safety culture.
Critical Success Factors for Ergonomics Processes
Treat the ergonomics process as you would a new piece of equipment. Take the time to learn how it works and periodically perform preventative maintenance.
3 Keys to Getting the Most Out of Your Ergonomics Process
Asking your people to do work that is within their body’s capabilities and limitations is part of your company’s commitment to providing a safe place of work. Having an effective ergonomics improvement process will ensure you fulfill this commitment. Follow the three keys above and you’ll be well on your way to fulfilling your commitment to your employees and improving the human performance of your company to achieve your business goals, a win-win scenario.
Reducing the Risk of Manual Materials Handling
Learn more about the risks of manual material handling and the impact an ergonomics process can have in reducing risk and boosting performance.
Ergonomic Risk Assessments
Conducting effective and efficient ergonomic assessments is a core component of the workplace improvement process. You must be capable of identifying the ergonomic risk factors at your distribution center.
Recommended Ergonomic Assessment Tools
Effective ergonomic assessments are an important part of the ergonomics improvement process. Conduct effective and efficient ergonomic assessments using our recommended ergonomic assessment tools.
A Step-by-Step Guide to the WISHA Lifting Calculator
Developed by the Washington State Department of Labor and Industries and based on NIOSH research related to the primary causes of back injuries, this lifting calculator can be used to perform ergonomic risk assessments on a wide variety of manual lifting and lowering tasks, and can be also used as a screening tool to identify lifting tasks which should be analyzed further using the more comprehensive NIOSH Lifting Equation.
Online WISHA Lifting Calculator
Use the online WISHA Lifting Calculator to quickly and easily perform ergonomic assessments using the WISHA lifting assessment tool
A Step-by-Step Guide to the NIOSH Lifting Equation (Single Tasks)
The NIOSH Lifting Equation is a tool used by occupational health and safety professionals to assess the manual material handling risks associated with lifting and lowering tasks in the workplace. This equation considers job task variables to determine safe lifting practices and guidelines.
The primary product of the NIOSH lifting equation is the Recommended Weight Limit (RWL), which defines the maximum acceptable weight (load) that nearly all healthy employees could lift over the course of an 8 hour shift without increasing the risk of musculoskeletal disorders (MSD) to the lower back. In addition, a Lifting Index (LI) is calculated to provide a relative estimate of the level of physical stress and MSD risk associated with the manual lifting tasks evaluated.
Online NIOSH Lifting Equation Calculator
Use the online NIOSH Lifting Equation Calculator to quickly and easily perform ergonomic assessments using the NIOSH Lifting Equation.
A Step-by-Step Guide to the REBA Assessment Tool
This tool uses a systematic process to evaluate whole body postural MSD and ergonomic design risks associated with job tasks. A single page form is used to evaluate required body posture, forceful exertions, type of movement or action, repetition, and coupling. A score is assigned for each of the following body regions: wrists, forearms, elbows, shoulders, neck, trunk, back, legs and knees. After the data for each region is collected and scored, tables on the form are then used to compile the risk factor variables, generating a single score that represents the level of MSD risk.
REBA Worksheet
Use the REBA worksheet to quickly and easily perform ergonomic assessments using the REBA assessment tool.
A Step-by-Step Guide to the RULA Assessment Tool
This diagnostic tool assesses biomechanical and postural load requirements of job tasks/demands on the neck, trunk and upper extremities. A single page form is used to evaluate required body posture, force, and repetition. Based on the evaluations, scores are entered for each body region in section A for the arm and wrist, and section B for the neck and trunk. After the data for each region is collected and scored, tables on the form are then used to compile the risk factor variables, generating a single score that represents the level of MSD risk.
RULA Worksheet
Use the RULA worksheet to quickly and easily perform ergonomic assessments using the RULA assessment tool.
A Step-by-Step Guide to the Snook Tables
The Liberty Mutual MMH Tables (commonly known as Snook Tables) outline design goals for various lifting, lowering, pushing, pulling, and carrying tasks based on research by Dr. Stover Snook and Dr. Vincent Ciriello at the Liberty Mutual Research Institute for Safety. The tables provide weight/force values, for specific types of tasks that are deemed to be acceptable to a defined percentage of the population. This is done by comparing data for each of the specific manual handling tasks against the appropriate table.
Push Calculator | Pull Calculator | Carry Calculator | Lift/Lower Calculator
Use the Snook Tables calculators to quickly and easily perform ergonomic assessment using the Snook Tables assessment tool.
Caution Zone Checklist [PDF]
The Caution Zone Checklist is used as a screening tool. If there are no positive findings identified, the job is regarded to be safe; otherwise a moderate risk is indicated and the job should be evaluated further using the Hazard Zone Checklist.
Hazard Zone Checklist [PDF]
Positive findings with the Hazard Zone Checklist indicate immediate actions should be taken to reduce the risk.
Ergonomic Design Principles and Guidelines
The best time to consider ergonomics is during the design phase of your distribution center, but once you’ve identified existing ergonomic risk factors, you’ll need to make workplace improvements to reduce the risk using solid ergonomic design principles.
Ergonomic Guidelines for Manual Material Handling
This is a comprehensive guide to ergonomic and injury prevention in manual material handling. From learning about the benefits of ergonomics to getting practical tips and takeaways on improving your workplace, this guide is a bookmark-worthy reference guide.
PowerPoint Slides: Guidelines for Manual Material Handling
This PowerPoint presentation from Mario Feletto and James Galante provides a comprehensive view of the art and science of manual material handling — including design guidelines and practical takeaways for your workplace.
Proactive Ergonomics: Design With Ergonomics in Mind
A proactive approach to ergonomics emphasizes primary prevention of MSD through recognizing, anticipating and eliminating risk factors in the design and planning stages of new work processes.
Ergonomic Considerations from Head to Toe
Learn ergonomic design considerations for different parts of the human body. This resource is worth a bookmark, for sure.
Ergonomics and Design Reference Guide
This guide from AllSteel provides a comprehensive overview of ergonomics and design guidelines.
Applying Manual Material Handling Guidelines to Job Tasks
How much can your employees safely lift, push or pull? EHS Today experts review the often conflicting guidelines available and offer simple “rule-of-thumb” procedures to follow.
8 Fundamental Ergonomic Principles for Better Work Performance
This articles contains eight fundamental ergonomic principles to help you identify ergonomic risk factors and maintain your stellar safety record. It might be the most practical article in this list of ergonomics and injury prevention resources.
Ergonomics Cost-Justification
The majority of workplace improvements are low-cost, high-impact. But sometimes larger capital expenditures will need to be cost-justified to gain approval. Don’t let a large capital expenditure stall your projects — cost-justify the solution and prove that the value is there.
Why an Ergonomics Program Makes Good Business Sense
“Ergonomics is a well established applied science that is now over 50 years old. Ergonomics is the ‘science of work’ and is devoted to maximizing human performance without causing injuries or detrimentally affecting performance. Ergonomics is a BENEFIT for companies not a cost.”
Ergonomic Cost Justification Worksheets
Use these ergonomic cost-justification worksheets provided by Cornell University Ergonomics Web to cost-justify ergonomics solutions for your facility.
Cost-Justifying Wellness Programs to Reduce Ergonomic Risk Factors
Certified Professional Ergonomist Ellen Gallo posits that new approaches in addition to ergonomics are needed to break through an injury reduction plateau. “Exploring a link between wellness and ergonomic risk factors is a proactive means to break through the plateau.”
Ergonomics Cost-Benefit Analysis (Washington State Department of Labor and Industries)
To help quantify the value of ergonomics, the Washington State Department of Labor & Industries developed a very useful cost-benefit calculator based on multiple data sources. The calculator allows you to compare up to three ergonomic improvement options, and estimates the benefits and payback periods for each option.
How to Cost-Justify Ergonomic Improvements
For a more detailed guide to using the Washington State Department of Labor & Industries cost-benefit analysis calculator, see our step-by-step guide.
Job Rotation
When engineering control aren’t feasible (or before they’re implemented), job rotation increases the variety of tasks required as the worker takes on more duties, enlarging the physical demands and adding variety to the job.
A Step-by-Step Guide to Job Rotation
Read this step-by-step guide to learn about our consistent and systematic method of developing formal job rotations that are based on the requirements of the jobs being rotated.
5 Common Misconceptions About Job Rotation in the Workplace
Do you hold any of these common misconceptions about job rotation? Read this article to learn the most common misconceptions about job rotation and get the facts.
8 Compelling Reasons to Implement Job Rotation in Your Workplace
If you haven’t implemented job rotation in your workplace, consider these eight compelling reasons to get started today.
Truth vs. Myth: Is Job Rotation an Effective Method of Reducing Injury Risk?
Have you been considering job rotation as part of your MSD prevention strategy? Maybe you’ve pushed for it and gotten some push-back. Or maybe you’re just doing your research and learning more. Either way, the question remains: is job rotation an effective way to reduce injury risk? That question is what is explored in this Truth vs. Myth series article.
Workplace Athlete Health
Workplace athlete health promotion programs take distribution centers to the next level in MSD prevention. MSDs occur at the intersection of two complex systems — the work environment and the human body. The ergonomics process lowers risk in the work environment and workplace athlete health promotion lowers risk by reducing fatigue and improving recovery of the workplace athlete’s musculoskeletal system.
Workplace Athletic Trainers for Workplace Athletes
The employees under your care are no different than professional athletes. They go to work every day, using their physical skills and abilities, their bodies, to earn a wage. They are workplace athletes! It is imperative they remain in peak physical condition to perform as a professional and to be a competitive advantage for their employer.
The Workplace Athlete
Dr. Rozmaryn wrote this research paper based on his personal experiences treating musculoskeletal disorders. His conclusion? That a multi-disciplinary approach to prevention is the most effective way to proactively reduce risk and prevent these injuries. A combination of ergonomics and workplace athlete health promotion is the most effective prevention strategy.
Workplace Safety: Bio-Physics and the Industrial Athlete
Despite your best efforts, employees continue to be injured. What can you do? Treat them as if they are workplace athletes — because they are!
Athletic Trainers Provide High Return on Investment in Today’s Workplace
“With the ever increasing demand on output and return on investment in today’s workplace, employees in the occupational setting remain at risk of acute and overuse, on-the-job injuries. Their work requires special skills often including heavy lifting, carrying, repetitive movement and physical stress. Lost days from work can have a significant impact on a company’s bottom line and on the individual’s own productivity. “Athletic trainers’ expertise in musculoskeletal health makes them a vital part of an occupational health care team whether working as independent contractors or employed through a company, clinic, hospital or other facility,” says NATA President Jim Thornton, MA, ATC, CES.”
Proper Lifting Techniques
According to the Bureau of Labor Statistics (BLS), more than one million workers experience back injuries each year. Help reverse this trend with our workplace athlete handout on proper lifting techniques.
Team Lifting Guidelines
When a load weight exceeds recommended limits, it’s important your workplace athlete ask for help! Help educate them on the benefits of team lifting with our free workplace athlete educational handout.
Preventing Low Back Injuries in the Workplace
Nearly everyone at some point has back pain that interferes with work, routine daily activities, or recreation. Help your workplace athletes experience less back pain with our free workplace athlete educational handout on low back injuries in the workplace.
Total Body Strength Handout
Strength training has been proven to benefit all populations, from young athletes to seniors. Help your workplace athletes develop a total body strength plan with our free workplace athlete educational handout on total body strength.
Preventing Dehydration
Without proper hydration it is difficult for the body to properly recover, resulting in increased risk of an MSD incident. Help your workplace athletes stay hydrated with our free workplace athlete educational handout on preventing hydration.
Rest and Recovery 101
Understanding the significance of adequate recovery and sleep time, and the relationship between rest and overall health and well-being is very important. When we don’t get enough sleep, our body goes into a state of stress. Help your workplace athletes get proper rest and recovery with our free workplace athlete educational handout.
Pre-shift Warm-up Stretching
A pre-shift warm-up stretching program ensures your workplace athletes are ready for work, especially at distribution centers.
Workplace Stretching and Warm-up: Are Your Team Members Ready for Work?
Every single professional athlete goes through a pre-game ritual to get themselves ready for the game to start. The workplace athletes at your company should do the same to prepare themselves for their work day.
The Benefits of a Workplace Readiness System
Making sure your team members are physically ready for work reduces injury risk and promotes a health, safety and team culture.
Flex Time – Zurich
According to this informational handout from Zurich, “Being inflexible about implementing workplace stretching programs can be a costly error—particularly for the manufacturing industry”.
Stretching Program to Decrease Work-Related Injuries in Meat Packing Plant Employees
View an example stretching program plan used to gain support and communicate with people throughout the organization.
The Arguments Against Workplace Stretching (And the Counter-Arguments)
To be perfectly clear, we support workplace stretching programs and regularly implement Work Readiness Systems for clients. We often come across arguments against these programs – these are the typical arguments we hear, and our counter-arguments.
Position Your Workplace Stretching Program for Success With These Six Essential Elements
If you decide to implement a stretching program at your facility, you need to do it right. This is vitally important. A poorly designed program won’t reduce injury risk and it could damage your credibility.
Thank you!
If you’re still reading this, thanks for sticking it out to the end of the post. I know there is an overwhelming amount of information here – you might consider bookmarking this page for future reference. Hope it helps!
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