Manual Task Risk Checklist

Transcription

1 Manual Task Risk Checklist Machine or Process Name: Assessment Date: Performed by: Folders Stahl TF/TD 78 August 2010 Heidi Turbill (Occupational Therapist) KEY: L = Likelihood C = Consequence COMPANY SIZE: Small (0-1 employees) Medium (16-30 employees) Large (> 30 employees) The aim of this checklist is to document the identified and assessed musculoskeletal risk factors associated with the use of this equipment or process. This information was gathered during a site visit at a large Printing Organisation. Please note that this document is to be used only as a guide and the implementation of a site specific risk management process is recommended. This checklist does not exclude the requirement for additional assessment and testing at your organisation; for example but not limited to chemical, electrical, PPE, guarding and noise. To ensure your site specific risk factors are identified and assessed it is recommended that you complete this checklist at your organisation in consultation with employees who perform the task. Refer to Action Plan Toolkit for additional information. Please note that MSD = Musculoskeletal Disorder. Summary Manual Tasks identified & assessed as having the highest risk: Risk: Risk Matrix Categories: a) Repetitive loading of paper Moderate High Stop work and address risk b) Repetitive unloading of product Moderate Significant Senior executive management attention needed, action plans and management responsibility specified c) Moving of delivery unit / folding unit Moderate Moderate Manage by specific monitoring or response procedures, with management responsibility specified Low Manage by routine procedures Risk control is the process of eliminating or reducing the identified and assessed risk factors. Steps must be taken to reduce the risk level as low as reasonably practicable using the hierarchy of risk control. Refer to the corresponding Proposed Manual Task Control document for suggested controls. Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 1 of 11

2 1. Working Posture 1. Is forceful and / or repetitive work done with the back bent forward, backwards or twisted? Risk of MSD due to employee repetitively bending / twisting back to load paper and transferring bundles of pamphlets to pallet. Forceful work is performed with the back bent to move unit or delivery system, and set up shafts. 2. Is the neck repeatedly or for long periods bent forwards, backwards, sideways or twisted? Risk of MSD due to employee repetitively bending neck to bundle pamphlets at delivery system. 3. Is prolonged or repetitive work performed with one or both arms stretched forwards, above shoulder height, or outwards?. Is work performed reaching behind the body? Risk of MSD due to employee repetitively reaching forward with 1-2 arms during bundling tasks at delivery, loading paper.. Is work performed repeatedly with the forearm twisting, or the wrist bending? Risk of MSD due to employee bending wrists / twisting forearms during bundling tasks at delivery, and when loading paper. 6. Are workers using a wide grip or narrow grip? Risk of MSD to the hand due to employee adopting wide grips to handle bundles of pamphlets, handle paper to load folder. 7. Are awkward postures assumed frequently or over prolonged periods? 8. Are two actions performed at the same time? Risk of MSD to the back and shoulders due to employee reaching to retrieve bundles from delivery, reaching across rollers to change shafts, and pushing units / delivery system into position. 9. Is work performed with sustained squatting or kneeling? Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 2 of 11

3 1. Working Posture (continued) 10. Are workers required to sit or stand continuously for more than 2 hours at a time? Risk of MSD due to employee standing continuously for 2-3 hours up to 7 hours bundling pamphlets. 11. Are workers standing with most of their body weight on one leg? Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 3 of 11

4 2. Repetition and Duration 1. Does the work involve repetitive motions or many similar movements? 2. Does the work require very fast movements? Risk of MSD due to employee repetitively reaching to load paper, retrieving bundles of pamphlets from delivery; repetitively handling bundles to straighten packs and lifting boxes onto pallet. 3. Do elements of this task take more than 2 hours over a whole shift or continually for more than 60 minutes at a time? Risk of MSD due to employee continuously retrieving and bundling pamphlets for the whole shift.. Is a task with the hand / arm repeated every 30 seconds or less? Risk of MSD to the hand / arm due to employee repetitively handling bundles every 30 seconds or less.. Are tasks in job rotation program similar to one another? Site to refer to company job rotation program to assess the level of risk. 6. Are insufficient rest breaks provided? Employees work a standard 7.6 hour shift with a 30 minute meal break. Brief task breaks may be allowed at some sites. Site to refer to company policy to assess the level of risk. 7. Is regular overtime worked in tasks that require heavy manual handling or repetitive work involving the upper limbs? 8. Are there sudden changes in work load, or seasonal changes in volume? Overtime may be worked at some sites. Site to refer to company policy to assess the level of risk. Risk of MSD due to sudden changes in work volumes at the end of the financial year and at Christmas. Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: of 11

5 3. Vibrations 1. Is the worker exposed to whole body vibration for significant portions of the work shift? 2. Is vibration from tools, equipment transmitted to the operator s hand? Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: of 11

6 . Work Area Design 1. Is there insufficient light, poor visibility? Employees report that lighting levels were sufficient in the work area. No formal measurements were taken. 2. Are working heights not adjustable or mismatched to the employee / task? 3. Are there uneven or slippery surfaces? Risk of MSD due to employees working at a fixed height to load and unload paper ( mm).. Can anyone trip, slip or fall due to poor housekeeping? Risk of trip / slip injury if employees are inattentive to pallets and paper stock around the work area Do working heights or reaches cause the worker to bend or reach beyond a comfortable range? Risk of MSD due to employee over reaching to retrieve bundles from delivery unit, when changing shafts, and cleaning during setup. 6. Is there insufficient space for working movements and materials? 7. Is there high or low temperatures Site specific variations - Work may or may not be performed in an air conditioned environment. Work areas may become warm on hot days. Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 6 of 11

7 . Use of Hand Tools 1. Are heavy tools or equipment used repetitively or for prolonged periods? 2. Does the design of the tool handle require the wrist to be bent during use, or require a forceful or wide grip? 3. Are the tool handle dimensions poorly fitted to the hand? 6. Nature of Loads Employees use pallet jacket regularly during a shift but not on a repetitive basis. 1. Are there problems handling a load due to its size or shape? Risk of MSD due to size of paper stacks loaded into infeed (A1 size). Delivery system and units are difficult to push due to large size. 2. Does the load block visibility of employee when moving? 3. Could the handles on containers be better sized or shaped for the weight and size of the load?. Are there problems handling a load due to its condition e.g. hard to grip, fragile, unbalanced, rigid or slippery? Risk of MSD due to employee s vision being blocked when pushing delivery system into place. Risk of injury due to the paper being flimsy and difficult to grip. Delivery system and units are difficult to push due to large size Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 7 of 11

8 7. Load Handling 1. Is forceful handling, such as lifting, lowering, carrying performed? 2. Are there available mechanical aids that are not currently used? 3. Are loads carried with one hand or on one side of body?. Are loads carried over long distances? Risk of MSD due to employee frequently loading stacks of paper onto infeed weighing 10-11kg each; lowering packed boxes onto pallet weighing up to 12kg; lift buckle plates (7-9kg) and handle shafts (6kg).. Are loads stored, or activities performed, which require work below waist height? Risk of MSD due to employee stacking boxes / bundles of pamphlets below waist level, or not adjusting height of scissor lift. 6. Are loads stored, or activities performed, which require work above shoulder height? 7. Are forces such as push or pull performed excessively or repetitively? Risk of MSD due to employee using heavy push / pull forces (~23kg) to move delivery units around 3- times/day. Pallet jacks are used to move product (8-10kg). 8. Are forces applied suddenly in response to unexpected movement? 9. Is the employee required to hold, support or restrain any object, person, animal or tool? 10. Is a team lift required? Risk of MSD due to employee restraining a moving pallet jack, delivery system or folding unit. 11. Are there inadequate numbers of people available to perform the lift? Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 8 of 11

9 8. Individual Factors 1. Due to the physical demands, are stronger workers assigned to the task? 2. Has there been reported discomfort or pain associated with the task? 3. Do workers report that they believe the task should be performed by more than one person?. Do workers report that the task is physically very strenuous?. Does the worker lack sufficient experience or has not been trained to do the task, or use the equipment safely? Site to refer to company injury statistics and consult with employees to assess the level of risk. Site to refer to company training records to assess the level of risk. 6. Are there any special issues that might affect how the worker performs the task e.g. Age, medical condition / history? Risk of MSD due to employee performing these tasks with a prior history of shoulder, hand and back injury and employees who are of shorter stature Is the worker new to the work or returning from a period of absence or rehabilitation? 8. Does the worker s clothing or PPE interfere with task performance? Site to refer to company leave and workers compensation records to assess the level of risk. 9. Has lack of consideration been given to human error or human behaviour? Risk of MSD due to employee having a tendency to bend / twist when loading infeed and pallets. Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 9 of 11

10 8. Individual Factors (continued) 10. Has there been reported MSD associated with the task? 11. Does the task involve a high level of attention and concentration? 9. Work Organisation Site to refer to company injury statistics to assess the level of risk. 1. Is there insufficient staff to meet deadlines or cope with peaks in demand? Site to refer to company staffing levels and productivity requirements to assess the level of risk. 2. Is the work pace controlled by a machine? Risk of MSD due to employee needing to work at the pace of the machine. 3. Is the work pace controlled by process?. Are there no procedures for reporting unsafe equipment / tasks in place?. Has maintenance on tools and equipment fallen behind schedule? Site to refer to company reporting policies and procedures to assess the level of risk. Site to refer to company maintenance program to assess the level of risk. Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 10 of 11

11 Assessment Details References: Occupational Health, Safety & Welfare Regulations (SA), 2010 National Code of Practice for the Prevention of Musculoskeletal Disorders from Performing Manual Tasks at Work, 2007 Approved Code of Practice for Manual Handling (SA), 1990 AS/NZS ISO 31000:2009 Risk Management Principles and Guidelines, supported by information in: AS/NZS 360:199 Risk Management Examples of Risk Definition and Classification HB 36: 200 Risk Management Guidelines Snook S and Cirello B (1991), The design of Manual Handling Tasks: Revised tables of maximum acceptable weights and forces. Ergonomics Volume 3, Manual Task Risk Assessment completed by: Heidi Turbill (Occupational Therapist), Pinnacle Workplace Consultants Pty Ltd in consultation with Printing Company representatives & Project Steering Committee members. Signed for and on behalf of Pinnacle Workplace Consultants Pty Ltd: Heidi Turbill Sign: Date: June 2011 Reviewed by Project Steering Committee: Janette Pearce Sign: Date: June 2011 Disclaimer Users of this resource agree to be bound by these terms and conditions. Your use of this resource constitutes acceptance of these terms and conditions: 1. The material contained in this resource constitutes general information only and is not tailored to meet the specific needs of individual employees or organisations. Your use of this resource is at your own risk. 2. Employers Mutual, Pinnacle Workplace Consultants Pty Ltd and Printing Industries Association of Australia ( the Parties ) do not purport to exclude any liability arising under statute. The Parties do, however, exclude to the full extent permitted by law all liability for any loss or damage, including but not limited to consequential and incidental damages and however caused (including negligence) that you may incur in relation to your use or reliance on this resource. 3. The Parties also exclude all express or implied warranties, guarantees, conditions, rights and remedies in relation to your use or reliance on this resource to the extent permitted by law.. Notwithstanding that every effort has been made to ensure the accuracy and reliability of this resource at the time of production, this is not guaranteed. Version: 1 Code: PI RA-00 Effective: June 2011 Reviewed: June 2011 Page: 11 of 11