The Back and 

Material Handling Issues

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 The Spinal Column

Cervical

Thoracic

Lumbar

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 The Basic Structure

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Epidemiology of Back Injuries
Short Term or acute effects:
• Sharp Surfaces
• Dropped Material
• Struck­by Moving Materials
• Mechanical Stress
• Slips and Falls
• “Simpler” Cause and effect relationship

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Epidemiology

Chronic or Long Term Effects
• Back Ache or Pain
• Disc Degeneration
• Cause and effect not 
as simple, more difficult 
to analyze

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Return to Work
• Out more than 6 months only 50% chance 
of returning
• One year only 25%
• Management and Practitioner Training

One study showed that claims dropped from 
200K to 20K per year by providing modified 
work and conservative treat 

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Material Handling

• Lifting/Lowering
• Pushing/Pulling
• Carrying
• Weights and Forces
• Frequency of Activities
• Load Center of Gravity

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Material Handling

QuickTimeª and a
Sorenson Video 3 decompressor
are needed to see this picture.

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Job Risk Factors
• Weight of the Object
• Location (position of load 
w.r.t. worker)
• Frequency of Lifts
• Stability of the Load
• Hand Coupling
• Workplace Geometry 
Twisting/Stooping
• Environmental Factors

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Personal Risk Factors
• Gender
• Age
• Anthropometry
• Lift technique
• Attitude
• Strength
• Training

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Examples of 
Manual Handling Controls
• Avoid extreme range of motion when lifting

• Redesign work station/work area to allow 
freedom of movement

• Provide handles on material handling equipment

• Provide lift­assist devices and tables

• Unit Load Concept
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING
 Job Design
• Can reduce one­third of 
compensable LBP

• Minimize reach and lift 
distances
• Keep off floor
• Work station design

• Frequency
• Relax time standard
• Rotation
• Work­Rest allowances
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING
 Job Design

• Minimize Weight
• Mechanical aids
• Carton capacity
• Balance contents

• Convert
• Carry to push/pull
• Push over pull
• Use large wheels 

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Training
• Focus on awareness and 
avoidance
• Get object as close to body 
as possible
• Planning
• Use of handling aids
• Back Schools
• Strength and fitness 
important  
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING
 NIOSH Lifting Equation
1991 Version

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 NIOSH Lifting Equation

• Objective:  Reduce occurrence of 
lifting­related LBP

• 1981 and 1991 equations

• 1981 limited to sagittal plane

• 1991 includes asymmetry and coupling

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Disqualifiers for Use
• One handed lifts • Wheelbarrows 
• More than 8 hours or shovels
• Seated or kneeling • High speed motion
• Restricted work space • Unreasonable 
foot/floor coupling
• Unstable Objects
• Carrying, pushing or  • Unfavorable 
pulling while lifting environment

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Definition of Terms

• RWL = Recommended  • DM = Distance 
weight limit multiplier
• LC = Load constant • AM = Asymmetric 
• HM = Horizontal  multiplier
multiplier • FM = Frequency 
• VM  = Vertical  multiplier
multiplier • CM = Coupling 
multiplier

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 1991 Equation

 RWL = LC x HM x VM x DM x AM x FM x CM

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 1991 Guide

• Compare RWL to Actual Load (L)

• If Greater than or equal to 1 problem

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Lifting Index

  L
RWL

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 1991 Multipliers
• LC = 51 Pounds

• HM = 10/H

• VM = 1­.0075 x / V­30/

• DM = .82 + (1.8/D)

• AM = 1 – (.0032 x A)

• FM go to Table
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING
 NIOSH Worksheet

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 Lifting Example

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 NIOSH Workshop

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Sorenson Video 3 decompressor
are needed to see this picture.

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 NIOSH Workshop

Start of Lift End of Lift

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 NIOSH 1991 Lifting Calculator
NIOSH Lifting Guidelines -- Job Analysis
Notes Packer

Enter values in Yellow area.

For Composite Lifting Index (CLI) to be computed correctly,

sort tasks in decreasing order based on LI by pressing button.

Sort
CLI = 0.3 Object Wt. Hand Location (inches) Asymmetry Period Freq
Task 1991 Guide 1981 Guide (lbs) Origin Destination (degrees) (hours) (#/min) Handle
No. RWL LI AL MPL L (avg) L (max) H V H V Orig Dest P F C
1 24.3 0.2 29.0 87.0 5.0 18.0 30.0 15.0 40.0 15 0 4.0 0.4 Poor
2 12.2 0.4 13.3 39.9 5.0 18.0 30.0 30.0 15.0 15 0 4.0 0.4 Poor
3 11.0 0.5 11.4 34.1 5.0 18.0 30.0 30.0 52.0 15 0 4.0 0.4 Poor
4 0.0 0.0 0.0 0.0
5 0.0 0.0 0.0 0.0
6 0.0 0.0 0.0 0.0
7 0.0 0.0 0.0 0.0
8 0.0 0.0 0.0 0.0
9 0.0 0.0 0.0 0.0

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 WISHA
Calculator for Analyzing Lifting Operations

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 www.lni.wa.gov/wisha/ergo/calculator/ergo_workshopIE.htm
ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING
 WISHA Workshop

QuickTimeª and a
Sorenson Video 3 decompressor
are needed to see this picture.

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 WISHA
If the job is a hazard

• Reduce weight of load

• Increase weight of load so that it 
requires mechanical assist

• Reduce the capacity of the container

• Etc.

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 References

• Applications guide for the revised NIOSH 
lifting equation – On CD
• Elements of Ergonomic Programs – On CD
• Musculoskeletal Disorders and Workplace 
Factors – On CD
• Work Practices Guide for Manual Lifting
NIOSH 81­122

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING

 What does the worker need to 
know from this presentation?

ERGONOMICS :: TRAIN-THE-TRAINER PROGRAM :: THE BACK & MATERIAL HANDLING