Synergist - November 2011

Case Study
Break the Cycle

Get a Grip on Material Handling Problems

Preventing overexertion injuries is a major workplace safety challenge. According to the Bureau of Labor Statistics (BLS), more than one million workers will suffer a back injury over the next year. These types of injuries are predicted to account for one-fifth of all workplace injuries or illnesses and cost billions of dollars in addition to the pain and suffering experienced by employees. The BLS identifies manual material handling (lifting, pushing, pulling, and carrying) as the principal cause of these compensable work-related injuries. Researchers also estimate that 60–86 percent of people with acute low back problems will have a recurrence within a year, and that at least 36 percent will experience two or more recurrences of low back problems during that time.

It is not uncommon for companies to experience persistent MMH problems. Adopting an improvement strategy that uses a define–measure–control approach can stop the cycle of these debilitating disorders. The following case study of customer sales and service representatives (CSSRs) working in uniform and apparel services illustrates that you don’t have to break the bank to address this problem.

BY JOSH KERST

Define

The first step was to clearly define the work conditions that increased the likelihood of MMH injuries for service reps. A cross-functional team defined factors that could contribute to recurring MMH problems and evaluated those assumptions against loss data (injuries, work restrictions, etc.) and feedback about the CSSRs’ daily tasks. This team also identified work conditions of multiple clients in various industries and regions, as well as products that represented the biggest challenges across the entire organization.

Measure

Objective MMH assessment tools were used to quantify the risks. These tools included the NIOSH Lifting Equation; lifting guidelines derived from NIOSH that calculate the recommended weight limit (RWL) based on multiplying a load constant (51 lbs.) by various multipliers; the Snook/Liberty Mutual push/pull/carry

High-Risk MMH Tasks

Manually lifting and carrying overfilled garment/linen bags Table 1. Examples of Critical CSSR Tasks and Priority Controls for Pilot Test Handling large items Entering/exiting vehicle with loads

Controls

Modified garment/linen collec-
tion bag (handles, bag material)
Improved hand cart design
(handles, casters)
Improved vehicle features
(handles, floor coatings)

tables, which provide the female and male population percentages capable of performing MMH tasks without overexertion; and an additional tool that considered guidelines for previously injured workers. This tool resulted from a partnership between the Ohio Bureau of Workers’ Compensation (BWC) and The Ohio State University (OSU). Researchers from OSU worked with BWC personnel and Ohio employers to test MMH limits for employees with previous back injuries, and developed guidelines based on these laboratory studies ( www.ohiobwc.com/employer/programs/ safety/ Ergoliftguide.asp).

When these guidelines were applied to the CSSR lifting tasks, the lifting limits for previously injured workers were 30-50 percent lower than those predicted by traditional assessments. These baseline results influenced the type and magnitude of future workplace control interventions.

Control The team reviewed a list of proposed controls ranging from low-cost items to recommendations that required more capital. Based on control feasibility, expected acceptance by workers, and potential for overall risk reduction, the team created a list of recommendations (see Table 1), which were tested and piloted in three locations.

Results

Improvements were piloted over a six-week period. Follow-up analyses indicated that overall MMH risk was reduced up to 40 percent across the problematic tasks. CSSRs demonstrated excellent retention of skills taught in training and provided positive feedback on the new equipment. Many of the improvements increased operational efficiency. The cost to implement each recommendation was typically under $150—far less than the average direct cost for a back strain ($8,750) or a back injury requiring surgery ($57,500). No repeat injuries have been recorded, and the pilot project is slated to be implemented system-wide over the next 18 months.

Plan the Work, Work the Plan

Systematically addressing recurring MMH problems requires proper planning and carefully selected controls with tested interventions that are guided by an experienced team. The methods, assessment tools, and control measures described here help confirm that any organization can get a handle on preventing repeat injuries—they just have to plan the work, and then work the plan.