Risk Assessment: A Practical

Guide to Assessing Operational

Risk
Chapter 16:
Ergonomic Risk Assessment
Risk Assessments: Ergonomic Risk Assessment
Objectives
• Introduce Practical Ergonomic Risk Assessment Methods
• Review Fundamental Ergonomic Risk Assessment
Techniques
• Present a Model for Practical Ergonomic Risk Assessment
• Examine the Use of Techniques, their Strengthens and
Limitations
Introduction
Ergonomic risk factors exist in almost all industrial and office work
settings.
Where there are manual tasks, ergonomic risks can generally be found;
however, in many cases they are not recognized or assessed. Such risks
can negatively impact employee safety and health, quality of products
and services, production efficiency, employee morale and overall safety
culture.
The cost of ergonomic risks can be significant.
Ergonomics and Design
Ergonomics - the applied science of designing workplace demands and
environment to accommodate human capabilities and limitation for
well-being and optimum performance.
The concept of designing in safety and ergonomic principles into the
workplace continues to be emphasized and re-enforced by recent
standards such as ANSI Z590.3-2011 and ANSI Z10-2012.
Ergonomic Hazards
Workplace ergonomic hazards can contribute to a number of negative
effects.
The most common and recognized impact is biomechanical and
musculoskeletal stress to the worker.
Workers exposed to ergonomic hazards such as prolonged repetitive
motion, excessive force, awkward or static postures, compression,
vibration and extreme temperature are at risk of developing work
related musculoskeletal disorders (WMSDs).
Ergonomic Hazards
The accumulation of stress (also known as cumulative trauma) to the
soft tissues such as muscles, nerves and blood vessels over time can
cause serious and even permanent damage to the individual.
Ergonomic hazards also contribute to ‘single-event’ incidents such as
soft tissue strains, slips and falls, and ‘struck against’ objects.
These hidden hazards can go unrecognized within the design of work
areas, equipment, tools, or methods eventually causing workers to be
injured from the exposure.
Ergonomic Hazards
Ergonomic hazards also include psychosocial stress or job stress.
Psychosocial stress refers to the interaction of the worker and their
work conditions. The term ‘work organization’ is often associated with
this exposure.
Ergonomic hazards related to system or product usability (poor ‘human
factors engineering’) can contribute to human error.
Ergonomic Risk Factors
Indicators of ergonomic hazards are referred to as ergonomic risk
factors, or stressors.
These risk factors are conditions of a job process, work station, or work
method that contribute to the risk of developing WMSDs, or other
ergonomic hazard.
These include forceful exertions, high repetition and duration, static or
awkward postures, contact stress, vibration, poor lighting, and cold
temperatures.
 Risk Factor Description
Exerting force to complete a motion which requires an
application of considerable contraction forces by the muscles,
Forceful Exertions
causing rapid fatigue. Motions include lifting, lowering, pushing,
pulling, carrying, gripping, pinching, tossing.
Performing repeated identical motions or multiple tasks where
the motions of each task are very similar and involve the same
Repetitive Motions muscles groups and tissues. Repetitive motions include assembly
type tasks, keying, sorting, cutting, and finishing work such as
sanding and buffing, and other similar activities.
Positions of the body (limbs, joints, back) that deviate
significantly from the neutral position while job tasks are being
performed. Muscles do not work as efficiently in awkward
Awkward Postures
postures, and must exert more physical effort to accomplish the
task. Awkward postures include elevated reach, shoulder
abduction, head tilt, deviated wrist, and bent waist.
Physical exertion held in the same posture or position throughout
the exertion causing muscle fatigue. Also referred to as static
Static Postures muscle loading, examples include gripping tools, holding arms
out or up to perform tasks, or standing in one place for prolonged
periods.
Internal and external contact stress occurs from compression of
soft tissues and blood vessels causing blood flow restriction and
damage. Contact stress can occur from leaning on table edges,
Contact Stress gripping handles, contact with hard surfaces, sitting in unpadded
chairs, and internal rubbing of soft tissues against tendons and
bones. Can also result when using a part of the body as a
hammer or striking instrument.
Vibration inhibits the blood supply to the affected body part and
can lead to numbness, tingling, and damage of soft tissues.
Localized vibration occurs when a specific body comes in
contact with a vibrating object such as powered hand tools or
Vibration
equipment. Whole-body vibration occurs when standing or
sitting in a vibrating environment (truck or heavy equipment
operator) and when using heavy vibrating equipment such as a
jackhammer.
Exposure to excessive cold while performing work tasks causing
restricted blood flow and loss of dexterity and sensitivity. The
Cold Temperature
risk of soft tissue damage is increased when exposure to cold is
combined with other risk factors, such as vibration or contact
Ergonomic Risk Factors
Ergonomic risk factors tend to be synergistic in their effect. Individually,
an ergonomic risk factor may not contribute a notable risk, however,
when two or more risk factors are combined, the risk of biomechanical
stress leading to a WMSD can be significantly increased.
Establishing an Ergonomics Assessment
Process
A standardized method of assessing ergonomic risks should be
established, including appropriate ergonomic risk assessment tools,
user training. Process steps include:
• Identify existing jobs/tasks with ergonomic risks
• Assess, prioritize and track ergonomic risk factors
• Select and implement effective control measures
• Prevent new ergonomic risks from being introduced into the
workplace
• Support continuous improvement with team-based problem solving
Assessing Ergonomic Risk
Standard risk assessment techniques are generally not designed to
detect ergonomic risk factors to the level necessary. Tools discussed in
this text such as Job Hazard Analysis (JHA), Preliminary Hazard Analysis
(PHA), Failure Mode and Effects Analysis (FMEA) are used to identify
and evaluate multiple types of hazards and risks on a broader scale.
Ergonomic hazards are sometimes recognized in JHAs, PHAs, and
FMEAs, however, these hazard analysis and risk assessment methods
are unable to pinpoint, analyze and assess detailed ergonomic risk
factors.
For this, a more targeted risk assessment tool is needed.
Assessing Ergonomic Risk
Upon recognizing the potential for an ergonomic hazard, a tool
designed to specifically detect and assess ergonomic risk factors is
required.
Ergonomic risk assessment tools (ERATs), of which there are many, are
used to detect and assess existing risk factors on a micro-level.
The systematic sequence of applying a standard risk assessment
followed by an ergonomic assessment is useful in identifying, assessing,
and controlling ergonomic risks to the degree necessary.
 Assessment Tool Application Body Segment Type Complexity

OSHA Screening General Industry Whole Body Qualitative Low

Tool Repetitive Tasks Checklist
WISHA Checklist General Industry Whole Body Qualitative Low
Repetitive Tasks Checklist
ACGIH TLV for General Industry Trunk Qualitative Moderate
Lifting Lifting Tasks Table
ERAT General Industry Upper Extremities Qualitative Moderate
Repetitive Tasks Spreadsheet
RULA General Industry Upper Extremities Semi-quantitative Moderate
Repetitive Tasks Trunk Worksheet
REBA General Industry Whole Body Semi-quantitative Moderate
Repetitive Tasks Worksheet
Snook Tables General Industry Trunk Semi-quantitative Moderate
Manual Handling Table
ACGIH TLV for Office Settings Upper Extremities Semi-quantitative Moderate
Hand Activity Hand Work Worksheet
NIOSH Revised General Industry Trunk Quantitative Moderate
Lifting Equation Manual Handling Formula
Strain Index General Industry Upper Extremities Quantitative Moderate
Hand Work Worksheet
Energy Expenditure General Industry Upper Extremities Quantitative High
Prediction Program Manual Handling Trunk Software
University of MI
3D Static Strength General Industry Trunk Quantitative High
Prediction Model Manual Handling Lower Extremities Software
University of MI
Ergonomics Improvement Process
Similar to initiatives involving quality, Lean, and operational risk
management systems, the ergonomics process should be managed as
an ongoing, integrated and sustainable process of continuous
improvement.
Ergonomics Improvement Process
Identify Jobs
• To begin, the most obvious place to start is with loss history. Jobs or tasks
that have a history of MSD incidents in both frequency and severity should
be made a priority.
• Often times, information from employees can be most helpful in
identifying high risk jobs. Employee feedback, reported concerns and
discomfort surveys should be used in selecting problem areas.
• Workplace observations by the ergonomics team or other trained
personnel are a good source of information. Modifications made to chairs,
tools and other workplace items are a ‘red flag’ indicating a need further
investigation.
Ergonomics Improvement Process
Assessment Tools
• Qualitative Tools - Qualitative tools are most commonly used and are
good for screening jobs. Most are manual or Excel based.
• Semi-quantitative Tools - Semi-quantitative tools generally require
more expertise in their application. Typically, semi-quantitative tools
are targeted for specific applications and risk factors such as lifting,
hand work, or body region.
• Quantitative Tools - A third group of tools are called quantitative
assessment tools which are typically used to perform more in-depth
analysis. As a result, quantitative tools require a higher degree of
user training, knowledge and skill.
Ergonomics Improvement Process
Assessment Tool Application Body Segment Type Complexity

OSHA Screening General Industry Whole Body Qualitative Low

Tool Repetitive Tasks Checklist
WISHA Checklist General Industry Whole Body Qualitative Low
Repetitive Tasks Checklist
ACGIH TLV for General Industry Trunk Qualitative Moderate
Lifting Lifting Tasks Table
ERAT General Industry Upper Extremities Qualitative Moderate
Repetitive Tasks Spreadsheet
RULA General Industry Upper Extremities Semi-quantitative Moderate
Repetitive Tasks Trunk Worksheet
REBA General Industry Whole Body Semi-quantitative Moderate
Repetitive Tasks Worksheet
Snook Tables General Industry Trunk Semi-quantitative Moderate
Manual Handling Table
ACGIH TLV for Office Settings Upper Extremities Semi-quantitative Moderate
Hand Activity Hand Work Worksheet
NIOSH Revised General Industry Trunk Quantitative Moderate
Lifting Equation Manual Handling Formula
Strain Index General Industry Upper Extremities Quantitative Moderate
Hand Work Worksheet
Energy Expenditure General Industry Upper Extremities Quantitative High
Prediction Program Manual Handling Trunk Software
University of MI
3D Static Strength General Industry Trunk Quantitative High
Prediction Model Manual Handling Lower Extremities Software
University of MI
Ergonomics Improvement Process
Assessment Team
• Ergonomic risk assessments are best performed by a cross-functional
team of trained and qualified members. Such teams should include
users/operators, production, quality, skilled trades, maintenance, and
SH&E professionals.
• Safety committees which have a diverse and experienced group can
be used in this process.
• A qualified ergonomics coordinator that is proficient in workplace
ergonomics and risk assessment to guide the team is essential.
Ergonomics Improvement Process
Performing the Assessment
• Ensure there are adequate resources and time allotted to perform
assessments. Equipment such as digital cameras and measuring
tapes can be useful in gathering and documenting data for analysis.
• Other instruments such as light meters, sound level meters, infrared
thermometers, force gauges, and goniometers may be needed.
• During the assessment, it is advised that the assessor verify that the
selected job is being performed at its typical capacity or rate, and
representative of its normal operation.
Ergonomics Improvement Process
The ergonomic risk assessment process involves three basic steps:
1. Identify and collect data
a. Obtain operator input and involvement
b. Observe task cycles and identify task details
c. Collect digital video and photos of tasks, operator interactions for further analysis
d. Collect data regarding work area, materials, tools, and environment
2. Analyze data
a. Analyze collected data to understand the nature and types of ergonomic risk
b. Use selected ergonomic risk assessment tool inputs to determine level of risks
3. Evaluate
a. Evaluate severity, likelihood, and exposure/duration of each risk
b. Input resulting risk factor in the assessment tool
Ergonomics Improvement Process
Identifying Corrective Measures
• Jobs with high risk scores require immediate corrective measures to reduce
the identified risk factors.
• The ergonomics team should be involved in identifying and developing
effective ergonomics solutions. Brainstorming can be used to identify
potential improvements and controls that will reduce ergonomic risk.
• The team must understand and use the Hierarchy of Controls concept to
select the most effective controls measures. This often requires some use
of cost/benefit analysis and return of investment calculations to select
feasible control measures and help persuade decision makers.
Ergonomics Improvement Process
Implementing Measures
• Before any changes are initiated, affected workers should be made
aware of what will take place, why it is necessary, and when it will
take place.
• Any special training needed by workers to use the controls effectively,
should be provided prior to the implemented changes.
• Workers should be included in the process of selecting ergonomic
interventions to create buy-in and ownership.
Ergonomics Improvement Process
Verify and Refine
• Soon after implementation, the ergonomics team and engineering
personnel should meet with affected operators to verify the measures are
working properly.
• There may be need for fine tuning certain applications, or complete
overhaul in rare cases.
• Operator feedback or concerns about ease of operation, comfort, speed,
etc. should be collected to identify any needed adjustments or corrections.
• After a sufficient break-in period, a more in-depth review of the new
control measures and their effectiveness should be made.
Ergonomics Improvement Process
Communicate Results
• Results from the assessment must be tracked, measured and
communicated for the process to be effective.
• The organization’s ergonomics team should establish short term and
long term metrics that demonstrate the effectiveness of the
ergonomic risk assessment process.
• As with any successful risk assessment model, the ergonomic risk
assessment process should involve stakeholders from beginning to
end. As goals are achieved, the organization should celebrate,
recognize and reinforce involved stakeholders.
Ergonomic Risk Assessment Tool (ERAT) - A
Practical Assessment Tool
One of many quick screening and assessment tools available is the
Ergonomics Risk Assessment Tool (ERAT). ERAT was developed by the
authors (Lyon, Popov), and is based on the draft ANSI Z365 Ergonomics
Checklist that was part of the “Management of Work-Related
Musculoskeletal Disorders Accredited Standards Committee Z365
Working Draft” withdrawn in 2003.
Ergonomic Risk Assessment Tool (ERAT) - A
Practical Assessment Tool
ERAT is limited to the assessment of ergonomic risk factors impacting
the upper extremities, and is appropriate for office work, and assembly
type work environments.
The Initial Assessment (IA Worksheet) is used to develop a baseline risk
score and action level with possible control measures to reduce risk
factor scores.
The Post-Controls Assessment (PCA Worksheet) is used after the Initial
Assessment and implementation of control measures to establish a
current risk factor score.
 Ergonomic Risk Assessment Tool (ERAT) - Initial Assessment Ergonomic Risk Assessment Tool (ERAT) - Post Control Assessment
Job Task: Evaluator: Dept: Date: Job Task: Evaluator: Dept: Date:
Duration of Task Duration of Task
Risk Factor <1 1-4 >4 Score Comments Risk Factor <1 1-4 >4 Score Comments
hour hours hours N/A hour hours hours N/A
Repetition Enter Only One Score Repetition Enter Only One Score
Every few minutes 0 0 1 Every few minutes 0 0 1
Every few seconds 0 1 3 Every few seconds 0 1 3
Lifting Enter Only One Score Lifting Enter Only One Score
5 to 15 lbs. 0 0 1 5 to 15 lbs. 0 0 1
15 to 30 lbs. 1 1 2 15 to 30 lbs. 1 1 2
30 to 50 lbs. 2 2 3 30 to 50 lbs. 2 2 3
Over 50 lbs. 3 3 3 Over 50 lbs. 3 3 3
Push/Pull Force Enter Only One Score Push/Pull Force Enter Only One Score
Easy 0 0 1 Easy 0 0 1
Moderate 0 1 2 Moderate 0 1 2
Heavy 1 2 3 Heavy 1 2 3
Carry > 10 feet Enter Only One Score Carry > 10 feet Enter Only One Score
5 to 15 lbs. 0 0 1 5 to 15 lbs. 0 0 1
15 to 30 lbs. 0 1 2 15 to 30 lbs. 0 1 2
Over 30 lbs. 1 2 3 Over 30 lbs. 1 2 3
Postures Score Each Postures Score Each
Head Tilt 0 1 2 Head Tilt 0 1 2
Shoulder Reaching 0 1 2 Shoulder Reaching 0 1 2
Flying Elbow 0 1 2 Flying Elbow 0 1 2
Bent wrist/pinch grip 0 1 2 Bent wrist/pinch grip 0 1 2
Bend or twist waist 0 1 2 Bend or twist waist 0 1 2
Environmental Score Each Environmental Score Each
Noise 0 1 2 Noise 0 1 2
Lighting/Glare 0 1 2 Lighting/Glare 0 1 2
Impact/compression 0 1 2 Impact/compression 0 1 2
Vibration/power tool 0 1 2 Vibration/power tool 0 1 2
Excessive Pace 0 1 2 Excessive Pace 0 1 2
Extreme Temperature 0 1 2 Extreme Temperature 0 1 2
Action Level Total 0 Action Level Total 0
Action Level 1 Total score of 10 or less - may require further analysis Action Level 1 Total score of 10 or less - may require further analysis
Action Level 2 Total score of 11 - 22 - requires intervention in near future Action Level 2 Total score of 11 - 22 - requires intervention in near future
Action Level 3 Total score of 23 - 36 requires immediate intervention Action Level 3 Total score of 23 - 36 requires immediate intervention
 Hierarchy of Ergonomic Risk Controls
Method Phase/Application Control Examples Effectiveness

Prevent entry of hazard into

Conceptual Stage workplace by design through
Avoidance High
Design/Redesign selection of technology and work
methods.

Existing Processes Eliminate hazard by changes in

Elimination High
Redesign design, equipment and methods

Substitute materials, sizes, weights

Moderately
Substitution Existing Processes and other aspects to a lower
High
hazard severity or likelihood

Reduce hazard by changes to

Existing
Engineering workplace, tools, equipment,
Workstations Moderate
Controls fixtures, adjustability, layout,
Redesign
lighting, work environment

Reduce exposure to hazard by

Administrative Practices and changes in work practices, training, Moderately
Controls Procedures job enlargement, job rotation, rest Low
breaks, work pace

Reduce impact of hazard to

Personal
employee by use of protective
Protective Workers Low
equipment and materials such as
Equipment
vibration attenuation gloves
Conclusion
Ergonomic hazards and latent conditions to some degree exist in
almost all work systems and can be missed in standard risk assessment
efforts. Many organizations uncertain of the ergonomic risk levels in
their operation or the impact it has on the business, have a significant
opportunity for improvement. For an organization to improve its ability
to manage ergonomic hazards, an effective ergonomic risk assessment
process is needed to reduce risks to an acceptable level.
For organizations that have yet to implement an ergonomics process, it
is an opportunity for SH&E professionals to help the business decision
makers understand and recognize the value of reducing ergonomic risk,
and guide them in establishing a process. Keeping it simple, yet
effective is a key to success.