GuideonManualHandlingRiskAssessmentintheManufacturingSectorOurvision:Acountrywhereworkersafety,healthandwelfareandthesafemanagementofchemicalsarecentraltosuccessfulenterpriseINTRODUCTION.....................................................................................2THEBUSINESSCASEFORMANAGINGMANUALHANDLINGINTHEMANUFACTURINGSECTOR.....3WHYISTHEREANEEDTOMANAGETHEHAZARDOFMANUALHANDLINGINTHEWORKPLACE?...5THEMANUALHANDLINGRISKASSESSMENTPROCESS..............................................8MANUALHANDLINGRISKASSESSMENTCASESTUDIES............................................10APPENDIX1:MANUALHANDLINGRISKASSESSMENTWORKSHEET...................................15APPENDIX2:EXAMPLESOFRISKFACTORSFORMANUALHANDLINGOFLOADS.......................17APPENDIX3:EXAMPLEOFASAFESYSTEMOFWORKPLAN(SSWP)...................................18ContentsPublishedin2013bytheHealthandSafetyAuthority,TheMetropolitanBuilding,JamesJoyceStreet,Dublin1.INTRODUCTIONThisguidegivesdirectionandpracticalinformationtothosethatworkinthemanufacturingsectoronactionthatcanbetakentomanagethepotentialhazardofmanualhandlingintheworkplace.Thisisnecessaryinordertoworktowardspreventingmusculoskeletalinjuriesatworkandreducingexposuretohighfinancialcostsincludingcompensationclaims.Theobjectivesofprovidingsuchinformationare:•Toraiseawarenessofthebusinesscaseformanagingthehazardofmanualhandling•Toexplainwhythehazardofmanualhandlingneedstobemanagedintheworkplace•Tohelpemployersunderstandandrecognisewhatthepotentialriskfactorsareinrelationtomanualhandlingintheirworkplace•Togivedirectiononmanualhandlingriskassessmentandhowitcanbeusedtohighlightpotentialhazardsandcreateopportunitiesfordevelopingbetterwaysofworkingincludinguseofhandlingaids,improvedhousekeepingorbetterorganisationofworkprocessesresultinginreducedhandlingofstockandreducedriskofmusculoskeletalinjury•Toexplainhowtocompleteamanualhandlingriskassessmentprocessthroughillustratedcasestudies•TogivedirectionondevelopingasafesystemofworkplanThemanufacturingsectorcoversawiderangeofdifferentbusinesstypesincludingmetalwork,woodworking,foodprocessing,electronics,plasticsandmedicaldeviceproduction.Thetasksconductedinthemanufacturingsectorrequirepeopletoengageindifferenttypesofactivitywhichsometimesmayrequiremanualhandling.Notallmanualhandlingishazardous;however,insomecasestheactivitywillrequireapersontoengageinaworkpracticewhichmayinvolveasignificantamountofhandling,includingliftingheavyloadsorliftingloadsaboveshoulderheight.Itisimportanttobeawarethatmanualhandlingcanbeapotentialworkplacehazardwhichcanresultinapersonsufferingamusculoskeletalinjurysuchasabackinjuryandthereforeneedstobemanagedeffectively.Page2GuideonManualHandlingRiskAssessmentintheManufacturingSectorTHEBUSINESSCASEFORMANAGINGMANUALHANDLINGINTHEMANUFACTURINGSECTORInjuriesduetomanualhandlingaccountfor33%ofallaccidentsreportedtotheHealthandSafetyAuthorityeachyear,andnearly20%ofthesemanualhandlingaccidentstakeplaceinthemanufacturingsector.AreviewoffiguresintheHealthandSafetyAuthority2011AnnualStatisticsshowthat49%ofthemanualhandlinginjuriesinthemanufacturingsectoroccurredwhenthepersonwasliftingorcarryingaload.FiguresfromthePersonalInjuriesAssessmentBoard(PIAB)showthatin2008€31.36millionwasawardedinrespectof972employerliabilityawards.Justoveroneinfive(20.41%)oftheseawardsweretopeopleworkinginthemanufacturingsecto...