Acceptable weights and physiological costs of performing combined manual handling tasks in restricted postures

Eight healthy, male underground coal miners (mean age = 36.9 yrs +/- 4.5 SD) participated in a study examining psychophysically acceptable weights and physiological costs of performing combined lifting and lowering tasks in restricted head-room conditions. Independent variables included posture (stooping or kneeling on two knees), task symmetry (symmetric or asymmetric), and vertical lift distance (35 cm or 60 cm). All tasks were 10 min in duration and were performed under a 1.22 m ceiling to restrict the subject's posture. Subjects were required to raise and lower a lifting box every 10s, and asked to adjust the box weight to the maximum amount they could handle without undue strain or fatigue. During the final 5 min of each test, data were collected to determine the energy expenditure requirements of the task. Results of this study demonstrated that psychophysical lifting capacity averaged 11.3% lower when kneeling as compared to stooping. Subjects selected 3.5% more weight in asymmetric tasks, and lifted 5.0% less weight to the 60 cm shelf compared to the 35 cm shelf. Heart rate was not significantly affected by posture, but was increased an average of 4 beats/min in asymmetric conditions, and by 3.5 beats/min while lifting/lowering to/from the high shelf. Oxygen uptake was increased by 9% when stooped, by 10% when lifting/lowering asymmetrically, and by 8.2% when performing the task to the high shelf. Results of this study indicate that, wherever possible, materials that must be lifted manually in low-seam coal mines be designed in accordance with the decreased lifting capacity exhibited in the kneeling posture.     

Psychophysical modelling for combined manual materials-handling activities

Most psychophysical studies in manual materials handling (MMH)are involved only with single MMH activities, i.e. lifting, lowering, carrying, holding, pushing or pulling. Very little research has been reported on the determination of operator capacities for combinations of MMH activities (e.g. lifting a box, then carrying the box, or carrying a box, then lowering the box). These kinds of combined activities are prevalent in industry and in our daily lives. The objective of this study was to utilize the psychophysical approach to examine the effects of combinations of lifting, carrying and lowering activities. Twelve male students served as subjects for the study. The capacities that were determined as the maximum acceptable workloads for a 1-h work period for four individual MMH activities—lifting from floor to knuckle height (LFK), lifting from knuckle to shoulder height (LKS), lowering from knuckle to floor height (LOW) and carrying for 3·4 m (C) —and three combined MMH activities—LFK + C, LFK + C + LKS and LFK + C + LOW—were determined psychophysically under three frequency conditions: one time maximum, one handling per minute and six handlings per minute. Combined MMH capacities models were developed using the following three methods: a limiting individual MMH capacity, isoinertial 1·83-m maximum strength and fuzzy-set theory. The advantages and disadvantages of different models were discussed.     

Dynamic biomechanical modelling of symmetric and asymmetric lifting tasks in restricted postures

This article describes investigations of dynamic biomechanical stresses associated with lifting in stooping and kneeling postures. Twelve subjects volunteered to participate in two lifting experiments each having two levels of posture (stooped or kneeling), two levels of lifting height (350 or 700 mm), and three levels of weight (15,20, or 25 kg). One study examined sagitally symmetric lifting, the other examined an asymmetric task. In each study, subjects lifted and lowered a box every 10 s for a period of 2 min in each treatment combination. Electromyography (EMG) of eight trunk muscles was collected during a specified lift. The EMG data, normalized to maximum extension and flexion exertions in each posture, was used to predict compression and shear forces at the L3 level of the lumbar spine. A comparison of symmetric and asymmetric lifting indicated that the average lumbar compression was greater in sagittal plane tasks; however, both anterior-posterior and lateral shear forces acting on the lumbar spine were increased with asymmetric lifts. Analysis of muscle recruitment indicated that the demands of lifting asymmetrically are shifted to ancillary muscles possessing smaller cross-sectional areas, which may be at greater risk of injury during manual materials handling (MMH) tasks. Model estimates indicated increased compression when kneeling, but increased shear forces when stooping. Increasing box weight and lifting height both significantly increased compressive and shear loading on the lumbar spine. A multivariate analysis of variance (MANOVA) indicated complex muscle recruitment schemes—each treatment combination elicited a unique pattern of muscle recruitment. The results of this investigation will help to evaluate safe loads for lifting in these restricted postures.     

Manual materials handling capabilities in non-standard postures

Research efforts to establish manual materials handling (MMH) capabilities of individuals and populations have been conducted for many years. Most of the previous efforts have explored ‘standard postures’, utilizing two-handed, symmetric, sagittal plane MMH using unrestricted postures. Recognizing that many industrial MMH activities do not utilize ‘standard postures’, recent research projects have explored psychophysicaly determined MMH capacities in a variety of non-standard postures. Among the non-standard postures examined were: twisting while lifting or lowering, lifting and lowering from lying, sitting, kneeling, and squatting positions, and carrying loads under conditions of constricted ceiling heights. This paper presents the results of a series of previous research efforts at Texas Tech University. The results are presented in the form of population capabilities of both males and females for 99 MMH tasks using ‘non-standard postures’. The data tables contain means and standard deviations of the data, as well as percentile distributions for the subject populations. Sample sizes for the experimental populations ranged from 45 to 50 subjects of each sex in the first three experiments to 20 subjects of each sex in the fourth set of experiments.     

A national cross-sectional study in the Danish wood and furniture industry on working postures and manual materials handling

Musculoskeletal disorders constitute a major problem in the wood and furniture industry and identification of risk factors is needed urgently. Therefore, exposures to different work tasks and variation in the job were recorded based on an observation survey in combination with an interview among 281 employees working in wood working and painting departments. A questionnaire survey confirmed high frequencies of symptoms from the musculoskeletal system: The one-year prevalence of symptoms from the low back was 42% and symptoms from the neck/shoulder was 40%. The exposure was evaluated based on: (1) classification of work tasks, (2) work cycle time, (3) manual materials handling, (4) working postures, and (5) variation in die job. Among the employees 47% performed feeding or clearing of machines, 35% performed wood working or painting materials, and 18% performed various other operations. Among the employees 20% had no variation in their job while 44% had little variation. Manual materials handling of 375 different burdens was observed, which most often occurred during feeding or clearing of machines. The weight of burdens lifted was 0·5-87·0 kg, where 2% had a weight of more than 50 kg. Among the lifting conditions 30% were evaluated as implying a risk of injury. An additional risk factor was the high total tonnage lifted per day, which was estimated to range from 132 kg to 58 800 kg. Working postures implied a risk of injury due to prolonged forward and lateral flexions of the neck, which was seen most frequently during wood working or painting materials. These data substantiate the finding that work tasks mainly during feeding or clearing of machines imply a risk of injury to the low back and a risk of injury to the neck and shoulder area mainly during wood working or painting materials. Optimal strategies for job redesign may be worked out by using these data in order to prevent occupational musculoskeletal disorders.     

Two-dimensional biomechanical model for estimating strength of youth and adolescents for manual material handling tasks

Youth and adolescents are routinely engaged in manual material handling (MMH) tasks that may exceed their strength capability to perform the task and may place them at excessive risk for musculoskeletal disorders. This paper reports on a two-dimensional biomechanical model that was developed to assess MMH tasks performed by youth 3-21 years of age. The model uses age, gender, posture of the youth performing the MMH activity, and weight of the load handled as input, and provides an estimate of the strength demands of the task and spinal disc compression and shear force resulting from the activity as output. The model can be used to assess whether a specific MMH task exceeds the strength demands for youth of certain ages or genders, which of the internal muscle strengths are most affected, and provides information about the estimated spinal disc compression and shear forces on the spine as a result of the specified MMH task. These results would be helpful in deciding whether a task is appropriate for a youth to perform or whether a certain task modification may be sufficient in reducing the physical demands to a level acceptable for a youth of certain age and gender.     

Multiple criteria decision-making for the resolution of conflicting ergonomic knowledge in manual materials handling

The ergonomic design of manual materials handling tasks typically utilizes one or more of three approaches; biomechanical, physiological, and psychophysical. Unfortunately, a comprehensive design is rarely obtained because of the difficulty of resolving the conflicting guidelines and criteria for each of the three approaches. This paper describes a methodology utilizing the multiple criteria decision-making (MCDM) process for resolving this conflict. This approach calculates the ratio of the contribution from each type of stress to an overall stress level as determined by the unacceptability of this stress to the user. An example is presented to demonstrate this technique.     

Developing a verbal protocol method for collecting and analysing reports of workers' thoughts during manual handling tasks

Concurrent and retrospective verbal protocol methods were used to collect thoughts from 18 participants during a manual handling task involving the repeated transfer of loads between locations at two tables. The effectiveness of qualitative and quantitative methods of analysing the reported information was tested in the study. A simple taxonomy was developed to investigate the content of the reports (including reports on postures and loads) and determine how the participants approached the task (whether they made plans, described actions or evaluated their completion of the task). References to posture were obtained in the verbal protocol reports, indicating that the participants had some awareness of their postures during parts of the task. There were similarities in the content of the concurrent and retrospective reports, but there were differences in the amount of detail between the methods and differences in the way the reports were constructed. There could be some scope for developing the quantitative analysis of the frequencies of references to classes of information, though this can only be recommended for concurrent reports on tasks of short duration. The analyses of qualitative data gave a deeper insight into the reports, such as identifying factors that can be important when planning to handle a load, or illustrating how participants can change their focus of attention periodically throughout the task. The relative strengths of the concurrent and retrospective methods are described, along with ideas for improving the quality of information collected in future studies. A number of potential problems with the interpretation of the reported information are explained.     

An on-line microcomputer-based respiratory monitor for manual materials handling

The main objective of the present study is to develop a low cost microcomputer-based respiratory system that is capable of computing the oxygen consumption and minute ventilation of individuals engaged in manual materials handling on an on-line basis. The design, specifications, and merits of the system are given. The software package developed was written in assembly language for the IBM AT personal computer.     

Acceptable workloads for three common mining materials

A series of psychophysical lifting studies was conducted to establish maximum acceptable weights of lift (MAWL) for three supply items commonly handled in underground coal mines (rock dust bags, ventilation stopping blocks, and crib blocks). Each study utilized 12 subjects, all of whom had considerable experience working in underground coal mines. Effects of lifting in four postures (standing, stooping under a 1·5m ceiling, stooping under a l·2m ceiling, and kneeling) were investigated together with four lifting conditions (combinations of lifting symmetry and lifting height). The frequency of lifting was set at four per min, and the task duration was 15?min. Posture significantly affected the MAWL for the rock dust bag (standing MAWL was 7% greater than restricted postures and kneeling MAWL was 6·4% less than stooped); however, posture interacted with lifting conditions for both of the other materials. Physiological costs were found to be significantly greater in the stooped postures compared with kneeling for all materials. Other contrasts (standing versus restricted postures, stooping under 1·5?m ceiling versus stooping under l·2?m ceiling) did not exhibit significantly different levels of energy expenditure. Energy expenditure was significantly affected by vertical lifting height; however, the plane of lifting had little influence on metabolic cost. Recommended acceptable workloads for the three materials are 20·0?kg for the rock dust bag, 16·5?kg for the ventilation stopping block, and 14·7?kg for the crib block. These results suggest that miners are often required to lift supplies that are substantially heavier than psychophysically acceptable lifting limits.     

A comparison of risk assessment of single and combination manual handling tasks: 2. Discomfort,Rating of Perceived Exertion and heart rate measures

Although many manual handling activities involve combinations of pull, lift, carry, lower and push, there are few reports of investigation of how to assess the risk in these combination tasks. Two strategies have been suggested in the literature for estimating the risk in a combination task based on the measures of the separate components of that task. The aim of the study was to compare the risks assessed in single manual handling tasks with those in combination tasks. Ratings of discomfort, exertion and heart rate were collected from nine male and nine female students, performing combination and single tasks. Combination tasks consisted of sequences of pull, lift, carry, lower and push tasks. Combination tasks were performed at 1.min^?1 and 3.min^?1 whilst single tasks (lift, lower, push, pull and carry) were performed at 3.min^?1 and 6.min^?1. The rating of exertion and heart rate for each combination task was compared to the exertion rating and heart rate of the single tasks which comprised the combination task using repeated measures anaylsis of variance with specified contrasts. Similar comparisons for the discomfort data were performed using Friedman and Wilcoxon tests. In at least one of the twelve comparisons performed for each dependent variable, the combination task value was significantly different to each single task value. The differences occurred regardless of whether the most critical single task value or an average of all single task values was used. It was concluded that the risk in combination manual tasks can not be accurately assessed by using estimates from discomfort, exertion ratings and heart rate measures of single tasks.     

A survey of the optimal handle position for boxes with different sizes and manual handling positions

Handles on objects are very important for enhancing the safety and efficiency of manual handling for people who use them. In this study, four different prototype boxes with auxiliary handles were designed to determine the optimal handle position of a box based on the evaluated user preferences and body part discomfort (BPD). Twenty male students participated in the experiment. Likert-5 point summated rating was applied to evaluate user preferences for the provided boxes with handles in upper, middle, and lower positions, in four different sizes and manual handling positions. Ten additional subjects were asked to indicate their BPD on a body chart after performing a similar experiment. The results show that the subjects preferred the upper part of the handle on a small box regardless of handling position; while the mid to upper parts of the handle on a big box were preferred for handling above the waist height. BPD also indicated that an upper handle was less stressful for a relatively smaller box than a big one; and mid to upper handles were less comfortable for a big box. The optimal handle positions depending on box size and handling position were suggested based on the results of the evaluation. It is thus recommended that a box provides a handle according to its relevant position, depending on size and manual handling condition, to reduce the musculoskeletal stress and in turn to increase user satisfaction.     

Minimal acceptable handling time intervals for lifting and lowering tasks

A laboratory study was conducted to determine the minimal acceptable handling time interval (MAHTI) for 4 h of endurance manual materials handling tasks using a psychophysical approach. Nine experienced male subjects were recruited to perform manual materials handling tasks with three load weights (10, 15, and 20 kg) and six ranges (floor to knuckle, FK; knuckle to floor, KF; knuckle to shoulder, KS; shoulder to knuckle, SK; floor to shoulder, FS; shoulder to floor, SF). Subjects were asked to adjust the handling time interval to the minimum that they could perform without becoming strained, uncomfortable, tired, weakened, overheated, or out-of-breath for 4 h of the endurance handling period. The results showed that the heavier load produced a larger MAHTI, and the overall descending sequence of MAHTI values for the six ranges was FS, KS, SF, FK, KF, and SK. The MAHTI for each lifting task was significantly higher than that of its corresponding lowering task (p<0.05). All MAHTI data were further verified by tests run on an additional nine subjects; this showed that the psychophysically determined MAHTIs were appropriate with no apparent underestimation.     

Perception and biomechanics data in a manual handling task: a comparative study

This paper explores the use of subjective perception tasks and its correlations with biomechanical data in the evaluation of manual material handling. Three main dimensions were considered for perception: physical regroups sensations issued from a specific body area; operative regroups feelings related to the execution of the task; and performance regroups feelings that involve a judgement on the execution or reflect overall sensations. The following questions were then explored. To what extent are perception data related to biomechanics data? Do both approaches lead to similar conclusions or interpretations when effect of practice, format and off-centre were tested? How can they complement one another? The task consisted of transferring 50 series of three 15 kg loads in order to verify the impact of free practice, format (box/cylinder) and load centre of gravity position. Eleven subjects rated perception on a CR-10 scale (Borg 1982 Borg, G. A.V. 1982. Psychophysical bases of perceived exertion. Medicine and Science in Sports and Exercise, 14: 377–381. [Crossref], [PubMed], [Web of Science ®] , [Google Scholar]) after each series. The session was completed with an interview on perception. The net resulting moment was systematically found to be the best correlated with data perception. While all physical and performance items corresponded in various ways to biomechanics data, perceptions associated with operative dimension appeared to be less related with biomechanical data. As regards the impact of practice, format and off-centre, both approaches would lead to the same conclusions, except for the effect of the off-centre. Verbal data add rational information about how or why perception can or cannot be reflected in biomechanics data. How both approaches can be matched more closely in manual handling is discussed.     

Evaluation in industry of a draft code of practice for manual handling

This paper reports findings from a study which evaluated the draft New Zealand Code of Practice for Manual Handling. The evaluation assessed the ease of use, applicability and validity of the Code and in particular the associated manual handling hazard assessment tools, within New Zealand industry. The Code was studied in a sample of eight companies from four sectors of industry. Subjective feedback and objective findings indicated that the Code was useful, applicable and informative. The manual handling hazard assessment tools incorporated in the Code could be adequately applied by most users, with risk assessment outcomes largely consistent with the findings of researchers using more specific ergonomics methodologies. However, some changes were recommended to the risk assessment tools to improve usability and validity. The evaluation concluded that both the Code and the tools within it would benefit from simplification, improved typography and layout, and industry-specific information on manual handling hazards.     

Modelling of shoulder and torso perception of effort in manual transfer tasks

The aim of the present study was to develop statistical models of perceived effort at the shoulder and torso levels associated with manual load transfer tasks. The motions were directed from a home location toward one of twenty-two target shelves distributed in the right hemisphere. A total of 2149 ratings were obtained from 31 subjects for effort perception at the selected joints, using a ten-point modified Borg scale. Regression models, developed for the perception associated with each body part, included target locations (azimuth, height and distance), posture constraints (standing or sitting), task types (one or two handed transfer conditions), and demographic and anthropometric measures (stature, body weight, gender, and age) as parameters. The models provide a prediction of effort perception with adjusted r-square coefficients of 0.41 and 0.50 for the shoulder and torso, respectively. The results indicate that space and posture interact in a complex way to affect the rating of perceived effort, and are in agreement with the hypothesis that the ‘sense of effort’ is primarily associated with the efference copy of the descending motor command. Since a level of effort is not associated with a unique pattern of motor command, it is proposed that effort perception is likely to result from a summation of the components of the motor command. The models can be applied to optimize the spatial organization of the work environment in an attempt to reduce the risk of musculoskeletal injury.     

Evaluation and assessment of lumbar load during total shifts for occupational manual materials handling jobs within the Dortmund Lumbar Load Study – DOLLY

The load on the lumbar spine during occupational manual materials handling was previously investigated with respect to short activity sections or to specified load-handling types such as lifting or carrying. Within the so-called Dortmund Lumbar Load Study, analysis of the occupationally induced load on the lumbar spine during total working shifts in the field of surface construction, drop forge, industrial meat processing, and refuse collection was performed on the shop-floor. The body postures adopted, the action forces applied at the hands, and the resultant lumbar load for all load-handling tasks were analysed for 2 shifts in each field on the basis of video evaluations. Via a newly developed detailed classification procedure, the spatial position of the body segments as well as amplitude and direction of the action forces were described in a detailed manner. Consecutive biomechanical model calculations lead, for total shifts, to time courses of various measures for the load on the lumbar spine, such as flexion or torsional moments of force as well as compression and shear forces at the lumbosacral disc. In relation to recommended limits for the maximal disc compression provided in the literature, lumbar load is exceeded in numerous situations during a shift, in particular, with regard to persons of higher age. In a “dose model” applied in this study, the cumulative effect of single-task exposures was considered by superproportional weighting of the compressive force with respect to the corresponding duration of a working task.

Relevance to industry

A comprehensive evaluation of lumbar load for complete shifts is presented considering the real shop-floor conditions. Analyses for dustbin removal, surface construction and industrial meat processing have discovered numerous exceedings of lumbar-load limits. Such tasks should not be performed by older persons from the preventive point of view.     

International consensus on manual handling of people in the healthcare sector: Technical report ISO/TR 12296

In 1990 the European Union introduced a directive on manual handling in the health and social care industries. A review of the implementation in 2004 found a wide variation in official national guidance on patient handling. This paper reports the iterative development of a Technical Report (ISO/TR 12296) by the international standards Technical Committee ISO/TC 159, Ergonomics, Subcommittee SC 3, Anthropometry and Biomechanics representing 23 participating and 12 observing countries with expert support from the European Panel on Patient Handling Ergonomics. The process included 6 reviews over 3 years to produce a consensus document as a state of science summary. It has an overarching framework of risk management with sections on risk estimation and evaluation, organisational aspects, aids and equipment, buildings and the environment, staff training and education and intervention evaluation.     

Seated work postures for manual,visual and combined tasks

An awkward and static work posture has been recognized as a risk factor for workrelated musculoskeletal problems. The objective of this study was to investigate some of the factors that can influence the posture adopted during work and in particular aspects of the task and how their influence is affected by work height. Three types of task were studied: a peg-hole assembly task, which was largely manual with very little visual component; a visual character identification task; and a combination of the two. Two levels of difficulty were included in each of the manual and visual elements. Postures of the head/neck, trunk and arm were recorded during performance of these tasks. The results showed that type and difficulty of task do influence the posture adopted, and that some of the postural responses (although complex) are predictable so that poor postures could be improved by adjusting task design in addition to workplace layout.