Materials Handling and Storage October 2016 Pax

SALUS Consultancy Services
ENGR. TITO L. BRIZUELA, JR.

OSH Consultant
Accredited OSH Trainer Specialist
Objective
After the training, participants will be able to demonstrate

with confidence the proper and safe materials handling in
accordance to the Occupational Safety and Health
Standards, thus, completing the job with pride.

MATERIALS HANDLING
Introduction
• Materials handling- refers to any
method for moving materials.
• By people
• By people using machines.
• Industry moves 50 tons of materials
for each ton of product produced.

 Manual handling is a common activity in most workplaces
 It includes lifting, lowering, pulling, pushing, carrying,

moving, holding or restraining an object
 Injuries and musculoskeletal disorders affect the back,

neck, shoulder, arms & hands
 It can be prevented through a systemic approach of

identification, assessment and control of risks associated
with manual handling.
RISK MANAGEMENT ON MANUAL HANDLING
 Required to manage risks under regulations
 Assess the risk
 Take all reasonably practical steps
 Eliminate any risks

 Step 1: Identification of hazard

 Step 2: Assess the risk
 Dependent on severity of risk and

likelihood of hazards
occurring
 severity X likelihood = risk level
 Risk Level = Low, Moderate or High

RISK ASSESSMENT
T Task
I Individual’s capabilities
L Load
E Environment
any other factors?

THE TASK
Holding loads away Strenuous pushing
from body and pulling
Twisting Unpredictable
movement of load
Stooping Repetitive handling
Reaching upwards Insufficient rest or
Large vertical recovery time
movements Workrate imposed by
the process
Long travel distances

INDIVIDUAL CAPABILITY
Physical condition
Illness
Pregnancy
Requires unusual capabilities
Call for special information or training

THE LOAD
Heavy
Bulky or unwieldy
Difficult to grasp
Unstable/unpredictable
Harmful i.e. sharp/hot

THE WORKING ENVIRONMENT
Constraints on posture e.g. lack of space
Poor floors
Variations in levels
Hot/cold/rain/ice/humid conditions
Strong air movement
Poor lighting conditions

OTHER FACTORS
 Is movement hindered by clothing or personal protective
clothing
and people!!
• High Stress
• Poor Diet
• Lack of exercise
• Rushing – pressure of work
• Showing off
• Short cuts

 Step 3: Select Measures to Control and Reduce Risk
Based on hierarchy of hazards control
 1st – Remove the hazard
 2nd – Guard the remaining hazards
 3rd – Mitigate impact of hazard

HAZARDS ASSOCIATED WITH MANUAL HANDLING -
HEAVY
 Lifting over 25kg load can result in back injury
Picture source: http://www.masterlift.ie/images/HealthAndSaftey/HandS.jpg

HEAVY

SHARP
 Potential Cuts on the fingers
HAZARDS ASSOCIATED WITH MANUAL HANDLING –
ODD SHAPES
 Absence of grip to hold the load
 Obstruction of walking view
Picture source: http://make-a-box.com

Picture source: http://www.fork-lift-trucks.info
TOXIC SUBSTANCES
 Skin exposure to chemicals
Picture source: http://discountpowerparts.com
Coolant
Lubricants
Picture source: http://www.vacmagic.com/images/fixture%20macchining%20scene.jpg

TOXIC SUBSTANCES
 Exposure to chemical dust, fumes & vapours
Picture source: http://www.railcamp.com

Picture source: http://www.airborncoatings.com/images/air3.gif

COMMON INJURIES FROM MANUAL
HANDLING
 Neck Strain
Picture source: http://www.abcbodybuilding.com/exercise2/neckspra.jpg

COMMON INJURIES FROM MANUAL HANDLING
 Wrist  Back Sprains

Sprains
Picture source: http://www.drfoot.co.uk/pictures/wrist.jpg Picture source: http://athleticscholarships.net/back%20pain.jpg

 Shoulder  Upper back

pain pain
Picture source: http://www.gotosee.co.uk
Picture source: http://medicineworld.org

 Slips, trips and fall
Picture source: http://www.istockphoto.com

Picture source: http://www.greenbergmassarelli.com/Images/slip_fall.jpg

 Cuts
Picture source : http://krismarkel.com/eclaircie/photos/uncategorized/ouch.JPG

Picture source: http://www.thealmightyguru.com/Boffer/Images/FA-MinorCut.jpg

HEALTH HAZARDS RESULTING FROM
CHEMICAL HANDLING
 Skin dermatitis
Picture source: http://www.osh.govt.nz

HEALTH HAZARDS RESULTING FROM CHEMICAL
HANDLING
 Skin dermatitis
Picture source: http://www.ascc.gov.au

HEALTH HAZARDS RESULTING FROM
CHEMICAL HANDLING
 Occupational respiratory & lung diseases
Picture source: http://content.revolutionhealth.com/contentimages/images-image_popup-ww5r370.jpg

Picture source: http://myweb.lsbu.ac.uk/dirt/museum/simon/68-776-gse15.jpg

HEALTH HAZARDS RESULTING FROM CHEMICAL
HANDLING
 Occupational eye diseases
Picture source: http://content.revolutionhealth.com/contentimages/images-image_popup-r7_conjunctivitis.jpg

ERGONOMIC
PRINCIPLE
Human capabilities and limitations

must be recognized and respected in the
design of material handling tasks and
equipment to ensure safe and effective
operations.

ERGONOMIC
PRINCIPLE
Definition:
Ergonomics is the science that seeks to adapt

work or working conditions to suit the abilities
of the worker.
ERGONOMIC
PRINCIPLE
KEY POINTS
Equipment should be selected that eliminates repetitive and
strenuous manual labor and which effectively interacts with
human operators and users.
The ergonomic principle embraces both physical and mental tasks.
The material handling workplace and the equipment employed to

assist in that work must be designed so they are safe for people.
FACTS TO BE CONSIDERED:
 Sprains and strains arise from the

incorrect application and/or
prolongation of bodily force.
 Poor posture and excessive
repetition of movement can be
important factors in their onset.

 FACTS TO BE CONSIDERED:
 Many manual handling injuries are

cumulative rather than being truly
attributable to any single handling
incident.
 A full recovery is not always made; the

result can be physical impairment or
permanent disability.

The Regulation establish a clear hierarchy of measures:
 Avoid hazardous manual handling operations

so far as is reasonably practicable – this may
be done by redesigning the task to avoid
moving the load or by automating or
mechanizing the process;
 Make a suitable and sufficient assessment of

any hazardous manual handling operations
that cannot be avoided; and

 Reduce the risk of injury from those
operations so far as is reasonably
practicable –
 particular consideration should be given to

the provision of mechanical assistance but
where this is not reasonably practicable
then other improvements to the task, the
load and the working environment should
be explored.

PROPER MANUAL HANDLING - INDIVIDUAL
ALWAYS KEEP YOUR BACK STRAIGHT WHILE LIFTING
Step 1: Step 2: Step 3: Lift Step 4:

Hold the Keep the the load by Ensure your
load firmly load close pushing up legs are
to you your leg stable before
moving off
KINETIC LIFTING
Summarised by:
Plan the Route

Assess the load
Correct position of feet
Straight back
Correct grip
Lift smoothly

 Lifting aids

 Lifting aids

PROPER MANUAL HANDLING – TEAM
 Team/buddy
lifting
Picture source: www.fork-lift-trucks.info

MATERIAL TO BE HANDLE AND
STORED
• Logs and lumber
• Steel sheet and plates
• Paper pulp and reels
• Coil sheet and reels
• Drums and pallets
• Bagged cereals and other grain
• Container
• Pipes and other long object
• Dangerous goods

MATERIALS HANDLING
EQUIPMENT
• Storage and Handling Equipment
• Pallet racks, carts, shelves, etc
• Engineered System
• Conveyors, handling robots, sortation, etc
• Industrial Trucks
• Operator driven motorize vehicles, forklift
• Bulk Materials Handling
• Equipt use to move and store bulk materials such as ore, liquid
and grains/cereals

LIFTING SAFELY
Ultimate Objective To Relieve Fatigue & Strain
Use correct handling techniques

Ensure good vision
Change position regularly
Avoid over reaching or stretching
Adjust work surface heights
Relax where possible
Use mechanical aids

MECHANICAL HANDLING
• Manual Powered
• Wheeler
• Hand pallet
• drum tilter
• etc.
SALUS Consultancy Services  48

MECHANICAL HANDLING
CLASSIFICATION
• Mechanical Powered
• Lifting Equipment
• Hoist and lift
• Cranes
• Transport Equipment
• Industrial truck
• forklift
• tractor trailer
• dump truck

FORKLIFT
TRUCK
 50
MECHANICAL HANDLING
CLASSIFICATION
Mechanical Powered
• Conveyor
• belt
• pneumatic
• other

BELT CONVEYOR
SYSTEM AT A PACKING
DEPOT
 52
BELT CONVEYOR
SYSTEM IN BAGGAGE
HANDLING

CHAIN CONVEYOR
SYSTEM

BELT CONVEYOR SYSTEM AT A
NEWSPAPER PRINTING PLANT

WALKWAYS

ESCALATORS

USE OF MECHANICAL EQUIPMENT.
• Where mechanical handling equipment is used,

sufficient safe clearances shall be allowed for aisles,
at loading docks, through doorways and wherever
turns or passage must be made.

HAZARDOUS MATERIALS HANDLING,
STORAGE, USE AND DISPOSAL
STORAGE OF SPECIFIC MATERIALS
• Temporary and permanent storage should be

secure, neat and orderly.
• Allow adequate ceiling clearance under the
sprinklers (18-36”).
• Keep all the exits & aisle clear at all times.
• Use bins and racks to facilitate storage & reduce
hazards.

STORAGE OF SPECIFIC MATERIALS CONT’D.
• Segregation and isolation.

• 6 meter Safe Distance.
• Cartons….Lumbers….Bagged
• Materials…. Barrels…. Pipes…. Liquid
Containers…. Paints &thinners…. Gasoline/
diesel…. Oxygen & Acetylene Cylinders.

• Materials should be stored neatly and orderly. A variety of ways
and means could easily be adopted and maintained.
61
• Have at least two exits

• Properly illuminated
• Properly ventilated
• Restricted access

PALLETS

STORAGE RACKS
SALUS
64Consultancy Services
LOCATION OF STORAGE
• Materials not obstruct alarm boxes,
sprinklers system control, First Aid
equipment, etc.
65
HAZARDOUS MATERIALS
• Flammable
• Combustible
• Acid
• Gases
• Oxidizer

FLAMMABLES
• LIQUIDS and GASES that burn readily, such as ethyl ether, gasoline.
• Conditions for burning: just the right amount of flammable and

oxygen; a spark or other source of energy.
TO PROTECT YOURSELF…
• Make sure no flames, sparks, smokes are near flammables.
• Work under lab hood when possible.
• Keep only a small amount of flammables in work area.
• Store (and dispose of) flammables safely.
IN AN EMERGENCY: evacuate area; turn off all flames, sparking

equipment; clean up flammables; ventilate area thoroughly.
STEPS IN SOLVING MATERIALS
HANDLING PROBLEMS
• What are to be moved?

• Direction to be moved?
• Frequency to be moved?
• Volume to be moved?
• With this situation,
• location of the storage
• with respect to its movement:
• Use of special handling equipment

JOB DESIGNS TO PREVENT MANUAL HANDLING
INJURIES
 Keep heavy loads around waist level
 Use of mechanical handling aid
 Package heavy materials into smaller

container
Picture source: CP 92 : 2002
SALUS Consultancy Services Picture source: http://www.osha.gov

JOB DESIGNS TO PREVENT MANUAL HANDLING INJURIES
 Provide handles, hand grips or indents for

loads
 Loads to be free from dust, oil, corrosive

deposits, sharp corners, jagged edges or rough
surfaces
Picture source : http://www.saylorsfarm.com

Picture source : http://www.powerwheel-usa.com
Indents & Handles

THE MATERIAL SAFETY DATA
SHEET
 The MSDS is your guide to

workplace safety.
 This hazard communication

tool gives details on
chemical and physical
dangers, safety procedures,
and emergency response
techniques.

PERSONAL PROTECTIVE
EQUIPMENT
• Safety shoes
• Gloves
• Aprons
• Leggings
• Back belt
 73
SAFE HANDLING PROCEDURE
(SUMMARY)
• Be alert for hazards.

• Follow company safety regulations.
• Take your time and don't take chances.
• Use proper lifting techniques;
• Get help or mechanical assistance
• Wear protective gear.
• Keep an eye on what others are doing.
• Let other workers know what you're doing.
SALUS
74Consultancy Services
END NA PO
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SALUS Consultancy Services

ENGR. TITO L. BRIZUELA, JR.

After the training, participants will be able to demonstrate

SALUS Consultancy Services

SALUS Consultancy Services

 It includes lifting, lowering, pulling, pushing, carrying,

 Injuries and musculoskeletal disorders affect the back,

 It can be prevented through a systemic approach of

 Required to manage risks under regulations

 Assess the risk

 Take all reasonably practical steps

 Eliminate any risks

 Step 1: Identification of hazard

SALUS Consultancy Services

 Step 2: Assess the risk

 Dependent on severity of risk and

 severity X likelihood = risk level

 Risk Level = Low, Moderate or High

SALUS Consultancy Services

any other factors?

SALUS Consultancy Services

SALUS Consultancy Services

SALUS Consultancy Services

SALUS Consultancy Services

SALUS Consultancy Services

SALUS Consultancy Services

 Step 3: Select Measures to Control and Reduce Risk

Based on hierarchy of hazards control

 1st – Remove the hazard

 2nd – Guard the remaining hazards

 3rd – Mitigate impact of hazard

SALUS Consultancy Services

 Lifting over 25kg load can result in back injury

Picture source: http://www.masterlift.ie/images/HealthAndSaftey/HandS.jpg

SALUS Consultancy Services

 Absence of grip to hold the load

 Obstruction of walking view

Picture source: http://make-a-box.com

Picture source: http://www.vacmagic.com/images/fixture%20macchining%20scene.jpg

SALUS Consultancy Services

Picture source: http://www.railcamp.com

SALUS Consultancy Services

Picture source: http://www.abcbodybuilding.com/exercise2/neckspra.jpg

SALUS Consultancy Services

 Wrist  Back Sprains

Picture source: http://www.drfoot.co.uk/pictures/wrist.jpg Picture source: http://athleticscholarships.net/back%20pain.jpg

SALUS Consultancy Services

 Shoulder  Upper back

Picture source: http://www.gotosee.co.uk

Picture source: http://medicineworld.org

SALUS Consultancy Services

 Slips, trips and fall

Picture source: http://www.istockphoto.com

SALUS Consultancy Services

Picture source : http://krismarkel.com/eclaircie/photos/uncategorized/ouch.JPG

SALUS Consultancy Services

Picture source: http://www.osh.govt.nz

Picture source: http://www.ascc.gov.au

SALUS Consultancy Services

Picture source: http://content.revolutionhealth.com/contentimages/images-image_popup-ww5r370.jpg

SALUS Consultancy Services

Picture source: http://content.revolutionhealth.com/contentimages/images-image_popup-r7_conjunctivitis.jpg

SALUS Consultancy Services