Rank: Forum user 
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Hi, I am looking for some ergonomic advice re a manual handling operation.
I work for a small operation where as apart of the process we have to dig using shovels an inert crumbly chemical pellet like substance from heavy plastic bunkers into hoppers for further processing. I am trying to carry out an ergonomic/manual handling assessment.
I have obtained the following information;
Bunker contents weigh approx 270kg (265-295kg), which have to be emptied .
Shovel carries approx 6kg of substance .
Approx 48 shovels /bunker used in approx 30mins .
(this shovelling rate can increase from 1 shovel every 43 seconds to one every 17 seconds, covering other operators for breaks , product mix etc) .
Hopper height is approx 1.1m, the operators can build a mound in the hopper to say 1.4m .
Floor of bunker is approx 300mm off floor and sides are approx 600 height .
The weights do exceed the General Risk assessment guidelines HSE INDG143 .
The shovelling techniques vary from short fast bursts (more recovery time between activity) to a more continuous shovelling with less shovel loads and a slower rate (this gives less recovery time) .
Both male and female operatives carry out this function . Height issues? .
There is a history of musculo-skeletal complaints in this area .
I am trying to come up with some factual semi-quantitative or quantitative technique or other to demonstrate and risk assess this activity .
What tools are out there that that would be best to use to risk assess this activity ?
I realize I may be out of my depth but would like to give it a go !
I tried to use Manual Handling Assessment Charts (MAC), but I think these are only good for the pushing/pulling of the bunkers ?
Regards
aiden
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Rank: Super forum user
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Aiden - how are the bunkers filled or are they delivered full?
If they are sack fed, it may be more appropriate to look at emptying the sacks straight in to the hoppers - again looking at mechanical aids.
Any way of raising the bunker to gravity feed the hopper?
Speak to your supplier - they may have information on what their other clients do.
If bunkers are delivered full, is is possible to decant into a sack and fill say 20kg and then fill the hopper that way?
We really need more infiormation to offer a solution.
David
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Rank: Forum user
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Thanks for the reply David, I understand the need for more info, I was trying to keep it brief.
The bunkers really are a way of transmitting the crumbly pellets from one internal process location to another with buffering in between. Conveyors have been looked at in the past ,it would be extremely awkward with the various geographical locations in the plant. The crumbly pellets also need to be kept warm, approx 35c deg. It is a bespoke process, not much assistance elsewhere.If you were doing it now, it would be along the lines you allude to, i.e. raising the bunker
I think the solution is to raise the bunker and gravity feed with possibly plungers or paddles to assist . I would like to get there, however in the meantime I want to see if anyone has come across a technique or technique that could be adapted to RA the shoveling method we are doing preferably with a semi-quantitative or quantitative outcome. This will also assist the case for automation.
regards
aiden
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Rank: Guest
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Aiden
From the problem outline you've presented, the root issue appears to be that the concept of ergonomics you're applying is 30+ years out of date.
Here is a brief outline of the 'ergonomic' approach you asked forthat includes quantitiative methods and specific tools.
1. Conduct a survey of the employees working on this process, asking each person to complete a body map three times a day for at least four different days in the week, indicating where they experience strains, at different levels of intensity; analyse the data according to gender, age and BMI
2. Design and carry out a survey, online or on paper, gathering data from the employees involved about their experiences of strains and on specific options they prefer as possible solutions to any problems
3 Video the operation for at least 90 minutes on 2 separate days; analyse the data (using a program like Adobe Elements) to extract incidents of different postural and biomechanical strains
4. Assemblee the data from the above methods of enquiry and present them to the employees asking for their comments and proposals for improvements; if the number of employees is too large, conduct at least two focus groups for gathering this data
5. Carry out a cost-benefit analysis of two or more alternative solutions, over different timescales and present your guidance to managers including explanations of their responsibilities in relation to all relevant legislation
6. If you don't have the time, energy and knowledge to do the above, carry out a cost-benefit analysis of commissiong a professional ergonomist to do them, and present your guidance to managers including explanations of their responsibilities in relation to all relevant legislation
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Rank: Forum user
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How times have changed, back in the day i use to ,manually load a hopper all day with potatoes for grading and bagging using a Sprong which was bigger than than a snow shovel to speed up the process, no man handling or ergonomics then. If only we knew..............
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Rank: Super forum user
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You are well correct DEC - I remember my shoveling duties as a new start in industry.
But all the best to Aiden in his quest to bring this task into the 21st century.
David
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Rank: Forum user
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Thank you KieranD.
I think you are spot on. The practice is inherently unsafe and must change. Your approach is welcome. I came across such a body map and will include the basis of your suggested approach as part of a case to raise funds to have this totally outdated practice automated at least on a trial in one area for assessment.
Much appreciate your comments.
aiden
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Rank: Guest
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Ergonomics is a multi-disciplinary science which practitioners use to apply methods of psychology (cogntive and occupational), physiology, biomechanics and systems to enable people at work or leisure to combine high performance, usability, safety and heatlh.
If you are interested in applying (modern) ergonomiics, this is a good brief introduction: 'Ergonomics for Beginners. A Quick Reference Guide', J Dul and B Weerdmeester. CRC Press. 2008. Third Edition.
The outline of conttents:
Chapter 1 Introduction
2. Posture and Movement
3. Information and Operation
4. Environmental Factors
5. Work Organisation Jobs and Tasks
6. The Ergonomic Approach
7. Sources of Additional Information
Available through www.amazon.co.uk
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