1.

0 Experiment No: 04

2.0 Name of the experiment:

Study of manual lifting operation and determination of the recommended weight limit using
NIOSH lifting equation.

3.0 Introduction:
Manual lifting has been recognized as one of the major contributors to injury in most
industries. It is due to lack of attention on safety awareness in the workplace. These injuries
affect employees and also impose heavy costs on employers and society. To reduce this
problem, in 1981, the National Institute of Occupational Safety and Health (NIOSH) had
published working guidelines for manual lifting. A lifting equation was produced in evaluating
the risk related to manual lifting tasks. The guide was revised in 1991 by adding several task
conditions and the equation were also updated. The NIOSH standard has been followed and
practiced worldwide. However, the guide and lifting equation were designed and developed
in the United States. Studies have shown that different populations have different
anthropometric distributions. Three criteria which are physiological, biomechanical and
psychophysical were used in defining the lifting equation and method to analyze the manual
lifting task problem.

4.0 Objectives:
 To study manual lifting operation.
 To determine recommended weight by using the NIOSH lifting equation.
 To ensure workers safety in different lifting related workstation.
5.0 Study related theory:

Recommended weight limit (RWL): The RWL is the principle product of the revised
NIOSH lifting equation. The RWL is defined for a specific set of task condition as the
weight of the load that nearly all healthy workers could perform over a substantial
period of time without an increased risk of developing lifting related LBP. By healthy
workers who are free of adverse health conditions that would increase their risk of
musculoskeletal injury.

The RWL is defined by the following equation:

RWL = LC× HM× VM× DM ×AM× FM× CM

LM = load constant

HM = horizontal multiplier

VM = vertical multiplier

DM = distance multiplier

AM = asymmetric multiplier

FM = frequency multiplier

CM = coupling multiplier

Lifting Index (LI):

The LI is a term that provides a relative estimate of the level of physical stress
associated with a particular manual lifting task. The estimate of the level of physical
stress is define by the relationship of the weight of the load lifted and the
recommended weight limit.

The LI is defined by the following equation:

LI = Load weight/ recommended weight limit RWL =

6.0 Methodology:

Problem description: A punch press operator routinely handles small parts, feeding
them into a press and removing them. A cursory view of this task many overlook the
fact that once per shift the operator must load a heavy reel of supply stock from the
floor onto the machine. The diameter of the reel is 30 inches, the width of the reel
between the worker’s hands is 12 inches, and the reel weight 44 lbs. significant
control of the load is required at the destination of the lift due to the design of the
machine. Also the worker cannot get closer to the roll because the roll is awkward.
 Figure : Loading punch press stock

Data Collection a Calculation:

Data collection Worksheet

Dept.: Manufacturing Job: Punch Press Stock

Object Hand Location Vertical Angle Frequ Time Object

Weight Destination -ency Coupling
(Lbs) (Inches)
Origin Destination Origin Destina Lifts HRS
(Inches) (Inches) -tion /min

L H V H V D A A F C

44 23 15 23 63 48 0 0 0.2 1 fair
(assumed)

This problem is to be solved by following steps:

Step 1: Determine Task Variables Needed: To determine the task variables

needed: Gather information, interview supervisors, group leaders, and workers to
determine the origin (start position) and the destination (ending position) of the lifting
or lowering task, and whether significant control of the object being lifted or lowered
is required at the destination of the lift. Step 2: Measure and Record Task
Variables: The next step is to gather the needed information and perform the
measurements for each lifting task variable, and record the data to be used later to
calculate the RWL and LI for the tasks being evaluated.

Step 3: Enter Data / Calculate RWL and LI: In step 2, we determined and recorded
the lifting task variables in our worksheet. Now the RWL and LI is to be measured.

Origin of Lift:
LC=51 lb = fixed factor

HM = 10/H = 10/ 23 = 0.43

VM = (1–0.0075|V-30|) =1- 0.0075 | 15-30| = 0.89

DM = (0.82+(1.8/D)) =(0.8 +(1.8/48)) = 0.86

AM = (1-(0.0032A)) =1 -0.0032*0 = 1

FM : 1 ( For F= 0.2 lift /min)

CM : 0.95 For fair grip as V < 30 inches

So, RWL = LC * HM* VM *DM *AM*FM*CM

=51*0.43*0.89*0.86*1*1*0.95= 15.95 lbs

And Lifting Index ,LI = Weight / RWL

= 44/15.95 =2.76

Destination of Lift:

LC=51 lbs = fixed factor

HM = 10/H = 10/ 23 = 0.43

VM = (1–0.0075|V-30|) =1- 0.0075 | 63-30| = 0.75

DM = (0.82+(1.8/D)) =(0.8 +(1.8/48)) = 0.86

AM = (1-(0.0032A)) =1 -0.0032*0 = 1

FM : 1 ( For F= 0.2 lift /min)

CM : 1 For fair grip as V >30 inches

So, RWL = LC * HM* VM *DM *AM*FM*CM

=51*0.43*0.75*0.86*1*1*1= 14.14 lbs

And Lifting Index ,LI = Weight / RWL

= 44/14.14 =3.11

7.0 Result:

Origin: The origin of the lift is acceptable and safe since LI<3

Destination: The end of the lift is dangerous since LI>3. This could be point where
serious back injury occur.

8.0 Limitation:

Revised NIOSH does not apply for

1. Lifting with one hand.

2. Lifting/lowering for over 8 hours.
3. Lifting/lowering while seated or kneeling.
4. Lifting/lowering while carrying, pushing or pulling.
5. Lifting/lowering unreasonable foot floor coupling (<0.4 co-efficient of friction
between the sole and the floor).

9.0 Discussion:

Different preferable lifting weight for workers was calculated using NIOSH equation .
The target of this experiment is to find the lifting weight using the NIOSH equation to
facilitate injury free lifting.It was tried to keep the stress of the destination minimal.
The lifting index of origin was below 3, though the lifting index of destination is still
over 3. The final assessment of the study is that for successful outcomes for
reduction in Work related Musculoskeletal Disorders (WMSDs) and LBP, the
equation should be thoroughly considered for manual lifting practices.

10 Conclusion:

The current study shows the implementation of the revised NIOSH lifting equation as
a methodological tool for safety and health to evaluate the lifting task problems for
the workers. The proposed system tool developed ideally associated to evaluate and
validate the lifting model for worker in creating the safe working environment while
complete their tasks and compare to NIOSH Lifting Equation. The designed equation
will help to assist Malaysian people to the acceptable RWL and LI and to prevent the
hazardous problem due to their lifting task. The system tool will propose the
suggestion to reduce the hazard after analyzing each of the lifting tasks to protect
the workers..