MANUAL  MATERIALS  HANDLING:  RISK  DRIVEN  OPPORTUNITIES

THE  STATS:  

75%  OF  WORKERS  INVOLVED  IN  MANUAL  MATERIALS  HANDLING  ARE  INJURED

CANADIAN  CENTRE  FOR  OCCUPATIONAL  HEALTH  AND  SAFETY

h=p://www.ccohs.ca/oshanswers/ergonomics/mmh/hlth_haz.html

MANUAL  MATERIAL  HANDLING  CONTRIBUTES  TO  A  LARGE  PERCENTAGE  

OF  MUSCULOSKELETAL  DISORDERS  REPORTED  ANNUALLY  IN  THE  USA.

CalOSHA

68%  OF  VICTORIA’S  WORKERS’  COMP  CLAIMS  

ARE  RELATED  TO  MANUAL  MATERIALS  HANDLING

www.worksafe.vic.gov.au

VICTORIA’S  AVERAGE  WORKER’S  COMPENSATIONS  CLAIM  IS  $55,000.

www.worksafe.vic.gov.au

WHEN  AN  EMPLOYEE  REPORTS  BACK  PAIN,  AN  INVESTIGATION  USUALLY  

FOCUSES  ON  THE  IMMEDIATE  INCIDENT.  HOWEVER,  FATIGUED  MUSCLES  ARE  MORE  SUSCEPTIBLE  TO  INJURY.

Ohio  Bureau  of  Workers’  Compensa[on

IN  SPITE  OF  CONSIDERABLE  SAFETY  PROGRESS,  MANUAL  MATERIALS  

HANDLING  PRESENTS  RISKS  THAT  HAVE  THE  POTENTIAL  TO  IMPACT  A  WIDE  

RANGE  OF  PEOPLE,  POTENTIALLY  FOR  A  LIFETIME.

COMPOUNDING  FACTS

THE  WORKFORCE  IS  AGEING.AROUND  13.5%  ARE  NOW  AGED  65+  

THAT  WILL  RISE  TO  ALMOST  23%  BY  2050  MONASH  UNIVERSITY’S  VERONICA  SHEEN

AS  WE  AGE,  ACTIVITY  DECREASES.HUMAN  RESOURCES  &  SKILLS  DEVELOPMENT  CANADA

ONLY  ABOUT  5  TO  7  PERCENT  OF  THE  (U.S.)  POPULATION  ARE  ACTUALLY  

REGULARLY  ACTIVE.BYU  EXERCISE  SCIENCE  PROFESSOR  LARRY  TUCKER

BUSINESS  RISK  OF  OBESITYMAPLECROFT  GLOBAL  RISK  ANALYTICS

WHERE  AND  WHO?

manufacturer

distribution retailconsumer

automated manual

mechanical

skilled semileast skilled

automated manual

THE  FUTURE  MANUAL  MATERIALS  HANDLING  RISKS  

WILL  BE  COMPOUNDED  BY  AN  INCREASINGLY  UNFIT,  OBESE  AND  

AGEING  POPULATION

CHANGE  IS  DIFFICULT  THESE  RISKS  ARE  AN  OPPORTUNITY  

TO  EFFECT  NEEDED  CHANGE.

CASE  STUDY

A  SIMPLE  CHALLENGE:IMPROVE  THE  MOVEMENT  OF  PACKAGED  AND  CRATED  MILK

FROM  THE  RECEIVING  PALLET  TO  THE  BACK  OF  THE  SHELVES  AND

OPTIMISE  THE  STACKING  PROCESS

THE  STAKEHOLDERS:USER:  MAKE  IT  EASIER

MANAGEMENT:  MAKE  IT  QUICKEROHS:  MAKE  IT  SAFER  

STEP  1:  REINVENT  THE  HAND-­‐TRUCK

HAND-­‐TRUCK  VS  ROTATRUCK

Click here for video element hosted on youtube/rotacaster

ROTATRUCKINNOVATION

HANDTRUCKTRADITION

Reduced effort • Improved Productivity •

Increased safety •

• Used to it• Cheaper hand-truck• Known risk

VS

ROTATRUCKEASE BACK

HANDTRUCKPULL BACK

Easier pull-back effort and no need to stop at waypoints.

Need to park and pull back loads at waypoints increasing strain on musculoskeletal.

✔ ✘

ROTATRUCKLOAD SUPPORT

HANDTRUCKSUPPORT LOAD

Reduced effort as the Rotatruck carries the load, not the operator.

Requires constant operator input to maintain load-balance, exerting strain and effort.

✔ ✘

ROTATRUCKLEVER

HANDTRUCKLIFT

Lever rather than lift up curbs or over obstructions without reversing.

Operator exerts maximum effort to reverse and pull load up and over curb.

✔ ✘

ROTATRUCKBALANCE

HANDTRUCKCARRY

Balance rather than carry the load over soft or uneven terrain.

Operator carries increased share of load to safely move across terrain.✔ ✘

ROTATRUCKTHE SAVINGS

HANDTRUCKTHE COSTS

Heavy user: Couriers, warehouse personnel, food and beverage distribution...Productivity gain: 100+ hours/yrSavings: $2,500

✔ ✘

Moderate user: Large retailers, warehouse personnel, facilities services...Productivity gain: 50+ hours/yrSavings: $1,250Light user: Office, small retail, facilities services...Productivity gain: 25+ hours/yrSavings: $625

Costs per injury? The most common body part affected by MMH is the back, which often suffers strains, sprains, herniated discs, joint inflammation, and dislocation. The average cost of each low back injury is US$24,000, as reported by the National Council on Compensation Insurance. The direct costs can be many times that if the injury is severe or permanent

Loss of productivity? Losing a team member to injury, whether temporary or permanent, replacement labour and the loss of experience increase costs and reduce productivity in real terms.

Insurance rates? Are your insurance costs influenced by claims?

Regulatory risks?Are you taking all available steps to limit safety risk?

INVENT  A  NEW  LATCHING  SYSTEM  TO  TRANSFER  CRATES  

EASILY,  QUICKLY  AND  SAFELY

Click here to video element hosted on youtube/rotacaster

THE  EVIDENCE

  TRADITIONAL         ROTATRUCK

THE  RESULT.WOOLWORTHS  IS  ROLLING  OUT  

THE  PROGRAM  ACROSS  AUSTRALIA.ESTIMATED  ROI  -­‐  90  DAYS.

IN  CONCLUSIONBEING  SAFE  IS  GOOD.

BEING  SAFER  AND  MORE  PRODUCTIVE  IS  GREAT.

BEING  SAFER,  PRODUCTIVE  AND  USER  FRIENDLY

IS  A  WINNER,  FOR  EVERYONE.

EASIER,  QUICKER,  SAFER.