Manual Handling & Lifting Risk Assessments
Manual handling risk is rarely determined by weight alone. The position of the load, the distance from the body, starting and finishing height, frequency, twisting, grip, travel distance, pushing or pulling force and the design of the workplace can all change the physical demand.
Ergo Global assesses manual handling and lifting tasks to identify where risk is being created and what can be changed. Our approach combines observation of real work with appropriate ergonomic assessment methods and practical recommendations.
Tasks We Can Review
lifting and lowering;
carrying;
pushing and pulling;
repetitive material handling;
loading and unloading;
picking and packing;
stock movement;
production-line handling;
laboratory or technical handling tasks;
team handling where relevant.
What We Assess
The ergonomist considers load characteristics, reach, posture, frequency, duration, asymmetry, coupling, workplace layout and how the worker interacts with the task. We also look for opportunities to remove the manual element, use mechanical assistance, improve storage position or redesign the sequence.
Where the task is suitable, the NIOSH Lifting Equation can be used to examine two-handed lifting and the relationship between load, frequency and task geometry. It is one tool among several, not a universal solution for every handling task.
The Assessment Process
Understand the task and handling pattern.
Observe representative work and record key task variables.
Identify posture, load, frequency, reach and environmental factors.
Apply the most suitable assessment method or combination of methods.
Prioritise the main drivers of risk.
Develop control options using the hierarchy of controls where practical.
Document recommendations and determine whether reassessment is required.
Controls Before Training
Training is important, but it should not be used as the only control when the task itself can be improved. Where possible, we first look at whether the lift can be removed, mechanised, shortened, raised, lowered, repositioned or otherwise redesigned. Training then supports the safer system of work rather than asking employees to compensate for poor task design.
NIOSH, REBA and Other Methods
A lifting task may require more than one perspective. The NIOSH method may help quantify lifting demand; REBA may help evaluate whole-body posture; and a broader risk assessment may be needed where the task includes carrying, pushing, pulling or frequent variation.
Manual Handling Within Industrial Ergonomics
Manual handling frequently sits alongside repetitive work, standing, workstation design and material flow. For organisations with several related issues, a broader industrial ergonomics audit may be more efficient than assessing one lift at a time.
What You Receive
task description and observed risk factors;
assessment findings and method outputs where relevant;
prioritised recommendations;
engineering, layout, equipment or work-practice options;
training recommendations where appropriate;
follow-up or reassessment actions.
Discuss a Manual Handling Assessment
Tell us what is being moved, how often, where the task takes place and what concern has been identified. We can scope the most appropriate assessment method and level of review.
