Text For Citation: 01 Item/Group: 001 Hazard: ERGONOMIC

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: the employer did not furnish employment and a place of employment which are free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that workers were required or permitted to lift packages which were in excess of the calculated maximum permissible lift, or between the acceptable limit and the Maximum Permissible Lift, resulting in stresses that had caused, were causing, or were likely to cause musculoskeletal injuries. a) Loading dock area: Two employees were required to lift Sauder Entertainment Centers weighing 232 pounds each, from the forks of a lift truck to a pallet resting on the floor. The evaluation of this manual lifting task, which is in excess of the calculated maximum permissible lift, indicated that employees were exposed to a hazard which is causing or is likely to be causing musculoskeletal injuries. The employer did not implement an effective control strategy to reduce or eliminate such injuries. The injury and illness records for 1993 and 1994 documented musculoskeletal injuries. b) Loading dock area: Two employees were required to lift Sauder Entertainment Wall Systems weighing 265 pounds each, from the forks of a lift truck to a pallet resting on the floor. The evaluation of this manual lifting task, which is in excess of the calculated maximum permissible lift, indicated that employees were exposed to a hazard which is causing or is likely to be causing musculoskeletal injuries. The employer did not implement an effective control strategy to reduce or eliminate such injuries. The injury and illness records for 1993 and 1994 documented musculoskeletal injuries. c) Loading dock area: Two employees were required to lift Sauder Dressers weighing 135 pounds each, from the forks of a lift truck to a pallet resting on the floor. The evaluation of this manual lifting task indicated that employees were exposed to a hazard which is causing or is likely to be causing musculoskeletal injuries. The lift falls between the acceptable limit and the Maximum Permissible Lift, and employer did not implement an effective control strategy to reduce or eliminate such injuries. The injury and illness records for 1993 and 1994 documented musculoskeletal injuries. d) Loading dock area: Two employees were required to lift Sauder Double Desks weighing 135 pounds each, from the forks of a lift truck to a pallet resting on the floor. The evaluation of this manual lifting task indicated that employees were exposed to a hazard which is causing or is likely to be causing musculoskeletal injuries. The lift falls between the acceptable limit and the Maximum Permissible Lift, and employer did not implement aneffective control strategy to reduce or eliminate such injuries. The injury and illness records for 1993 and 1994 documented musculoskeletal injuries. e) Loading dock area: Two employees were required to lift Sauder Armoires weighing 117 pounds each, from the forks of a lift truck to a pallet resting on the floor. The evaluation of this manual lifting task indicated that employees were exposed to a hazard which is causing or is likely to be causing musculoskeletal injuries. The lift falls between the acceptable limit and the Maximum Permissible Lift, and employer did not implement an effective control strategy to reduce or eliminate such injuries. The injury and illness records for 1993 and 1994 documented musculoskeletal injuries. Among other methods, one feasible and acceptable abatement method to correct this hazard is the implementation of an ergonomics management program consisting of the following four elements. (1) Worksite analysis to recognize and identify existing manual lifting hazards in the workplace. This analysis should include development and use of an ergonomic checklist and employee questionnaire. Periodic surveys of the worksite shall be conducted at least annually to evaluate work practices and engineering controls. Employee participation in the ergonomic program should be encouraged through a mechanism such as a safety committee. (2) Medical management which includes accurate recordkeeping of manual lifting injuries. The program should address recognition, evaluation, treatment and referral of lifting cases. Systematic worksite review by the medical team should also be included in the program. (3) Training and education for exposed employees, including methods to evaluate the effectiveness of the training. Re-training should be done annually, or as operations change. Training should address hazards associated with the job, the risks of manual material handling, and how to prevent lifting injuries. A supervisor's training program should also be implemented to allow recognition of manual lifting hazards, and to reinforce the employer's ergonomic program. (4) Hazard prevention and control which includes engineering, work practices and administrative controls: (a) Administrative controls are implemented which reduce the duration, frequency, and severity of exposure to manual lifting hazards. These controls may include job rotation, reduction of repetitions, multiple person lifts, and preventative maintenance of related equipment. (b) Work practice controls are implemented which include proper work techniques, new employee conditioning, proper placement of loads, and reduction of weight lifted. Examples of work practice controls applicable to this workplace include: (i) Set a limit on weight of individual lifts to be lifted by one employee; (ii) Splitting of heavy double cases prior to transfer; (iii) Train workers to slide objects from one level to the same level by more extensive use of lift trucks at the points of origination and destination of the loads (iv) Limit height (maximum and minimum) of palletized goods to be stacked manually; (v) Place heavy items on floor with enough clearance so that pallets can be accessed from all sides. (c) Engineering controls are designed by a qualified ergonomist and may include work station redesign, tool and handle redesign, and use of mechanical lifting aids. The goal of this program should be to make the job fit the person. Examples of engineering controls applicable in this workplace include: (i) Use lift table and vacuum assist devices where possible; (ii) Use scissor jacks for heaviest items to be selected (iii) Make more extensive use of the lift trucks in place of manual handling. ABATEMENT SCHEDULE Step 1 - Implementation of an ergonomics program for worksite analysis, medical management, and training and education, as detailed in items 1-3, above. Step 2 - Submit to the Area Director a written, detailed plan of abatement outlining a schedule for the implementation of the administrative, work practice and engineering controls as detailed in items 4(a) - 4(c). ALL PROPOSED CONTROL MEASURES SHALL BE APPROVED FOR EACH PARTICULAR USE BY A PERSON TRAINED IN THE EVALUATION OF WORKPLACE CONDITIONS WHICH CAUSE MUSCULOSKELETAL DISORDERS. SIXTY (60) DAY PROGRESS REPORTS ARE REQUIRED DURING THE ABATEMENT PERIOD. Step 3 - Implementation of administrative, work practice and engineering controls as described in items 4(a) - 4(c), above. STEP 1 - 04/12/95 STEP 2 - 05/12/95 STEP 3 - 06/11/95