Posted By Steve Cartwright Any one used the new MAC tool for assessing manual handling operations. Just had a visit from 2 EHO's. They used the MAC tool to assess our manual handling operations. We are now being told that because we put product, which weighs between 1.5kg and 1.8kg onto a pallet which is placed on the floor, this is classed as high risk. The staff are trained in safe manual handling techniques, the staff are rotated and our original risk assessments identified this particular operation as low risk. We have looked at Pallet inverters, lifting tables etc. Not practicable. Anyone got any ideas. Regards Steve Cartwright

Posted By Kieran J Duignan Steve As a safety ergonomist with experience as an expert witness, to me the critical issue is how well you control the risk. In this case, training staff to understand the biomechanics of lifting should mean that they understand how to position their bodyparts in ways that ensure adequate leverage whenever they are lifting. The other controls worth considering are a. introducing staff to techniques of behavioural safety applied to manual handling b. notices to continually remind them to adapt their lifting posture to the physical demands on their backs. In my experience, EHOS are apt to lose sight of the wood for the trees; rather than getting embroiled in a time-and-energy-wasting dispute, surely you're better off devoting your time and energy to optimising safeguards on your staff?

Posted By Adrian Watson Dear Steve, Two things, lifting from waist to floor is considered high risk if it is frequent and involves twisting and turning. Pallet loading would imply a frequent operation... so, how frequent is the task of placing items on a pallet and does it involve twisting and turning? You say that you cannot use Pallet inverters, lifting tables etc. Why not? Could you use a fixed pallet stand so the pallet is placed at knee height. This would reduce the load on the back and allow an increase in productivity. If a fixed stand is not feasable, why not try with a knee high stack of pallets? Remember though, you don't want people lifting above their heads. Regards Adrian Watson PS if you do nothing, regardless of the training, and somebody is injured you will be found liable unless you can prove it was not possible to prevent a risk of injury!