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Ergonomics best practices for factory environments

Author: Liam Neeson
by Liam Neeson
Posted: Sep 02, 2021

Musculoskeletal disorders (MSDs) occur in workers who do heavy lifting, do excessive repetitive work, and handle work-related awkward postures. Work-related MSDs happen because of ergonomic, physical, and psychological factors.

According to The World Health Organization (WHO) and the International Labour Organization (ILO), MSDs cause absence in the workplace and losing a high proportion of productive days. Referred to as a "new epidemic" it creates a burden not only on the health system but also on the businesses and the economic growth.

At present, factories utilise automated equipment to a large extent. Yet, ergonomic risk factors exist because of unavoidable manual activities. Risk factors related to tasks include the complexity of the tasks, workplace geometry, distance moved, frequency, duration, and pace. Risk factors related to the handling of objects include load, load stability, load distribution, and load dimension.

Analysing Work Hazards

A thorough assessment of the worksite will help to evaluate the work environment, tools, and workers. It will help to identify the problems that lead to musculoskeletal disorders.

Every manufacturing factory or industry executes a distinct set of tasks and processes which require customised solutions to reduce MSD related injuries. Upgrading the equipment or modifying the equipment also reduces injuries. Sometimes, changing methods or schedules reduces musculoskeletal injuries. Automating crucial processes in manufacturing industries can also reduce work-related hazards to a greater extent.

Lifting or pulling or moving heavy objects that require excessive force causes musculoskeletal injuries. Repetitive tasks, work leaning or kneeling, or squatting positions continuously, and reaching inside a machine place stress on the body. Prolonged exposure to a chilled environment or continuous hand-arm vibration or vibration of the whole body can also result in musculoskeletal disorders.

Lifting and Moving

End range bending movements in lifting allow the muscles to stretch in full. It results in weakness of the muscles and turns the spine unstable. Additional activation of muscles leads to muscle fatigue and finally results in injury.

Lifting aids help to turn, lift, and place materials in the exact position. And it reduces awkward postures during lifting materials. Next, using lift assist devices in the workplace to lift heavy materials reduces the force on the body of the workers. Using transportation devices such as conveyors, carts, forklifts, and automated guided vehicles instead of manually transporting materials can also help to reduce musculoskeletal disorders and injuries.

Awkward Postures

Awkward positions or postures of the body for extended periods impair the performance and comfort of the muscles; they fail to be in the neutral position. When compared to dynamic postures, static postures increase the load on tendons and muscles. The static posture reduces blood flow to the muscles. It prevents the natural repair and restoration process of the muscles.

Here are some methods that avoid stress and damage to the tissues preventing musculoskeletal injuries. By using extension poles and adjustable height platforms, workers can avoid overreaching.

Using height-adjustable stands prevents bending more to reach the target. The workstations should be designed in such a way to support work processes in the factories. To reduce squatting, stools and knee pads must be used. A sit-stand stool at the factories will help workers not to stand for extended hours.

Pushing and Pulling

In a manufacturing factory, the pushing and pulling of materials and goods will occur commonly. Here are some ways to improve the manual handling of materials with pulling and pushing.

Choose to push rather than pulling because while pushing the stronger leg and back muscles are used. Use casters and carts to move materials from one place to another. The caster wheels must suit the surface or the floor of the factory.

Training on Manual Handling

Conducting regular training for workers on how to handle materials and goods manually will increase awareness of their body and body movements. The training will help workers to know more about work-related injuries. It will also help them avoid injuries by being cautious and move to a safer area during any work-related hazards.

Training helps the workers to understand their responsibility towards protecting their bodies against any musculoskeletal injuries while at work. Once the workers realise the need to understand the risks involved in their work, they will be more alert and report immediately if they find any issues in their working units.

Conclusion

Implementing best ergonomic practices using excellent safety management processes will help to reduce injuries in the workplace. It will not only benefit the organisations, but it will also have a positive impact on the workers.

Following the best ergonomic practices will reduce costs, increase productivity, improve the efficiency of the workers, and better safety measures at the factory. Improving workplace procedures and policies, providing personal protective equipment, mechanical hoists, carts, adjustable tables, redesigned workstations, and better storage of equipment will eliminate workplace hazards and turn the workplace into a safer zone.

About the Author

Liam is a blogger and marketing specialist dedicated to marketing communications in the digital age. He enjoys traveling the world and meeting new people!

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Author: Liam Neeson

Liam Neeson

Member since: Aug 02, 2021
Published articles: 6

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