Hazardous manual handling solutions in the textile industry

Deep sided stillages, trolleys or tubs are often used to move bobbins, tubes, cones or skeins.

Risks

Sustained or repetitive

• bending the back forwards more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• lifting or lowering, involving either high force or repetitive action
• exerting force while in an awkward posture
• twisting, turning and grabbing actions with the fingers, hands or arms

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

Figure 1 Forward bending and reaching into a stillage.

Risk control measures

Alter the workplace

Place the stillage on a stand to raise and tilt the load.

Figure 2 A stand that raises and tilts the load reduces the need to bend and reach.

Use mechanical aids

Position a spring lift base in the stillage or tub to deliver the bobbins or tubes to the operator at a suitable working height.

Use a stillage tilter to bring items closer to the operator and reduce forward bending, reaching and exertion of force in an awkward posture.

Figure 3 The spring lift insert (shown outside the bin for clarity) raises the tubes up to the operator. This reduces forward bending, reaching and the exertion of force in an awkward posture.

Alter systems of work

Introduce appropriately designed job rotation in combination with other risk control measures to reduce exposure to repetitive wrist and forearm postures.

Many workplaces pack bobbins, tubes, cones, cheeses or other objects into boxes or cartons on the floor.

Risks

Sustained or repetitive

• bending the back forwards more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• twisting, turning and grabbing actions with the fingers, hands or arms
• excessive bending of the wrist
• lifting or lowering
• gripping with the fingers held wide apart
• exerting force while in an awkward posture
• standing with most of the body’s weight on one leg

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• using a pinch-grip or an open-handed grip to handle a heavy or large load
• exerting high force while in an awkward posture

Figure 4 Moving product into a carton pallet often requires bending, twisting and reaching.

Risk control measures

Alter the workplace

Place the box or carton on a stand to raise the working height to between mid-thigh and shoulder height and allow access to all sides of the box to reduce forward bending and reaching.

Place the box on a table to reduce forward bending and reaching. A tilted work surface or table can reduce excessive wrist bending.

Use mechanical aids

Use a raised fixed-height or height adjustable trolley. Consider using rollers on the trolley surface if the product is not on a pallet and needs to be moved again.

Figure 5 This fixed-height trolley keeps the load between mid-thigh and shoulder height and allows access to 3 sides of the load to reduce forward bending and reaching.

Use a turntable (figure 6) on a pallet lifter to bring items closer to the operator and reduce forward bending, reaching and exertion of force in an awkward posture.

Figure 6 A turntable on a pallet lifter enables this pallet of sacks to be lifted and turned. This improves posture and reduces forces.

Alter systems of work

Introduce appropriately designed job rotation in combination with other risk control measures to reduce exposure to hazardous repetitive wrist and forearm postures.

Repetitive lifting of bumps or biscuits from the floor or bale bag to a container or conveyor involves hazardous manual handling (figure 7). This is sometimes performed in the dye house or when loading wool for blending or scouring.

Risks

Sustained or repetitive

• bending the back forwards more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• lifting or lowering
• exerting force while in an awkward posture

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• applying sudden or unexpected forces
• exerting high force while in an awkward posture

Figure 7 Repetitive lifting of bumps from the floor in the dye house.

Risk control measures

Alter the workplace

Open the bale bag onto a table to reduce forward bending of the back to pick up bumps or biscuits.

Use mechanical aids

Put the bale bag inside a caged trolley with a spring loaded system to keep the load at a constant height.

Have bumps delivered in feed cylinders with spring-loaded bases (figure 8).

Figure 8 The bumps are now delivered in feed cylinders with spring loaded bases. This reduces forward bending of the back, lifting and the exertion of force in awkward postures.

Many workplaces hand stack boxes onto pallets on the floor (figure 9). Sometimes the boxes are large, heavy and awkward in size.

Risks

Sustained or repetitive

• bending the back forwards and twisting more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• lifting or lowering
• exerting force while in an awkward posture.

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• using a finger-grip or an open-handed grip to handle a heavy or large load
• two or more people need to be assigned to handle a heavy or bulky load
• stronger employees are assigned to do the task

Figure 9 Team handling of boxes

Risk control measures

Alter the workplace

Extend a conveyor (figure 10) or use an extension roller surface to reduce carrying loads over distances.

Figure 10 Conveyor reducing the need to carry loads.

Place the pallet on a stand to raise the working height to between mid-thigh and shoulder height and allow access to all sides of the pallet to reduce forward reaching and forward back bending.

Use mechanical aids

Use a rotating self-height adjusting palletiser (figure 11) to reduce the need to bend and reach forward to position boxes or sacks on the pallet.

Figure 11 A turntable on a pallet lifter enables this pallet of sacks to be lifted and turned. This improves postures and reduces forces.

Creel machines usually have several long rows, some of which can be above shoulder height (figure 12).

Risks

Repetitive or sustained

• backward bending of the back more than 5 degrees
• bending the head backwards more than 5 degrees
• working with one or both hands above shoulder height
• reaching forwards or sideways more than 30cm from the body
• gripping with the fingers pinched together or held wide apart
• exerting force while in an awkward posture

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• lifting, lowering or carrying heavy loads
• pushing or pulling objects that are hard to move or stop
• using a finger-grip or an open-handed grip to handle a heavy or large load
• exerting high force while in an awkward posture

Figure 12 Lifting bobbins above shoulder height to place onto creels.

Risk control measures

Alter the workplace

Reduce the height of the machine or creels so that the work doesn’t need to be performed above shoulder height (figure 13).

Figure 13 Lowering the height of the top row of the creel.

Figure 14 A purpose built scissor lift allows high placed objects to be more accessible.

Use mechanical aids

• use a height adjustable scissor lift to allow for easier access to objects (figure 14)
• design a single or multi bobbin lifter
• use fixed height platforms to allow better access to the creel

Figure 15 A height adjustable, moveable bobbin lifter.

Figure 16 Fixed height, moveable platform.

Alter the systems of work

Introduce appropriately designed job rotation in combination with other risk control measures to reduce exposure to repetitive wrist and hand movements.

Many workplaces require machines to be loaded or unloaded. Frequently this involves bending to put on or take off bobbins, tubes, cones or other objects and awkward wrist or hand postures.

Risk

Repetitive or sustained

• bending the back forwards or sideways more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• gripping with the fingers pinched together or held wide apart
• exerting force while in an awkward posture

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• lifting, lowering or carrying heavy loads
• using a finger-grip or an open-handed grip to handle a heavy or large load
• exerting high force while in an awkward posture

Figure 17 Designs which place objects low down can increase the risk of MSDs to employees.

Risk control measures

Use mechanical aids

Increase the height of the machine or use individual pneumatic lifters to increase heights while loading or unloading.

Design a single or multi bobbin lifter.

Figure 18 A pneumatic system lifts the height when loading the creel.

Figure 19 A close-up view of the pneumatic system.

Figure 20 A mechanical lifter using an overhead gantry system.

Figure 21 An automated system to lift the bobbins out from under the machine.

Alter the systems of work

Introduce appropriately designed job rotation in combination with other risk controls to reduce exposure to repetitive wrist and hand movements.

Threading machines often requires sustained work above shoulder height.

Risks

Repetitive or sustained

• backward bending of the back by more than 5 degrees
• bending the head backwards by more than 5 degrees
• reaching forwards or sideways more than 30cm from the body
• working with one or both hands above shoulder height
• lifting or lowering
• exerting force while in an awkward posture

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

Figure 22 Above shoulder height threading involves awkward postures.

Risk control measures

Alter the workplace

Provide a work platform to raise the operator. This reduces work with hands above shoulder height and reduces sustained backward bending of the neck.

Figure 23 A raised work platform raises the operator and reduces the risk of MSDs to employees.

Provide mechanical aids

Provide an adjustable height platform to raise the operator. This reduces sustained backward bending of the neck and work with hands above shoulder height.

Provide a fixed height moveable platform with a braking system and a handle that incorporates a handrail to prevent falls.

Alter the systems of work

Introduce appropriately designed job rotation in combination with other risk control measures.

Lifting product on and off scales involves repetitive lifting and often involves unnecessary double handling.

Risks

Sustained or repetitive

• bending the back forwards and twisting more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• lifting or lowering
• gripping with the fingers held wide apart
• exerting force while in an awkward posture

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• lifting, lowering or carrying heavy loads
• stronger employees are assigned to do the task

Figure 24 Lifting product from the floor to the weighing scales involves unnecessary double handling.

Risk control measures

Alter the workplace

Ensure that scales are at the same height as the pick-up and delivery points. This may mean using self-height adjusting palletisers. This should enable employees to move product without forward bending of the back.

Use mechanical aids

Incorporate a trolley and scales to eliminate double handling the product on and off the scales.

Use a pallet-jack or hand pallet truck with built-in weighing scales.

Incorporate a conveyor with a built-in weigh station.

Figure 25 This large weigh station takes into account the weight of the trolley.

Figure 26 A conveyor with a built-in weigh station means the product doesn't have to be lifted on and off. Double handling is eliminated.

Rolls of fabric or carpet are often awkward shapes to handle in the workplace. Frequently, handling involves team lifting.

Risks

Sustained or repetitive

• bending the back forwards more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• lifting or lowering
• gripping with the fingers held wide apart
• exerting force while in an awkward posture

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• lifting, lowering or carrying heavy loads
• two or more people need to be assigned to handle a heavy or bulky load
• stronger employees are assigned to do the task
• exerting high force while in an awkward posture

Figure 27 Team lifting long rolls.

Risk control measures

Alter the workplace

Ensure that workstations are at a suitable height so that employees do not have to bend to reach rolls.

Use mechanical aids

Use roller conveyors to connect workstations and move rolls on boards. This will eliminate the need to lift rolls and enable employees to push/pull them easily between workstations.

Use an overhead crane to eliminate lifting.

Figure 28 An overhead crane can eliminate manual lifting.

Install hydraulic lifting arms on machines to handle rolls.

Figure 29 Hydraulic lifting arms eliminate the need for manual lifting.

Figure 30 A probe lifter attachment on a forklift can eliminate manual lifting.

Use a tilting roll trolley or a long handle lever trolley which slides under a roll, to move rolls between workstations.

Use a forklift with a drum grabber appropriate for the load.

Use a probe lifter to move the roll supporting it through the core. This reduces the application of force in an awkward posture and enables the task to be performed by one employee.

Handling rolls of fabric or carpet involves high force, often with awkward postures.

Risks

High force

• lifting, lowering or carrying heavy loads
• two or more people need to be assigned to handle a heavy or large load
• stronger employees are assigned to do the task
• exerting high force while in an awkward posture

Figure 31 Team pushing large rolls of fabric.

Risk control measures

Install a roll barrier onto a pallet to allow the forklift to transport rolls on the pallet.

Figure 32 This pallet has been modified with a roll barrier to prevent contact with grease from the forklift mast. Previously rolls were handled manually to keep them clean.

Use mechanical aids

Use automated push off systems to move the rolls.

Figure 33 This automated push-off system eliminates hazardous manual handling.

• use an overhead crane to move rolls
• use a tilting roll trolley or a long handle lever trolley which slides under a roll, to move rolls between workstations
• use a forklift with drum grabber appropriate for the load
• use a probe lifter to move the roll supporting it through the core

Figure 34 Probe lifter attachment moving rolls. This reduces the application of force in an awkward posture and enables the task to be more safely performed by 1 employee.

Some storage racks require the operator to repeatedly obtain rolls of cloth from either floor level or above shoulder height.

Risks

Repetitive or sustained

• bending the back more than 20 degrees
• working with one or both hands above shoulder height
• reaching forward or sideways more than 30cm from the body
• exerting force while in an awkward posture

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• lifting, lowering or carrying heavy loads
• applying uneven, fast or jerky forces during lifting, carrying, pushing or pulling
• two or more people need to be assigned to handle a heavy or large load
• stronger employees are assigned to do the task
• exerting high force while in an awkward posture

Figure 35 Pulling rolls of cloth above shoulder height involves high force while in an awkward posture.

Risk control measures

• Reduce the forces required to store and retrieve the rolls by storing materials inside larger tubes.
• Store rolls in containers that can be moved from under racking and lifted with mechanical aids to an appropriate height for storing and retrieving.

Figure 36 By storing rolls inside larger tubes, the forces required to store and retrieve the rolls is reduced as they are not stored directly on top of each other.

Change the systems of work

Use a fixed height moveable platform with a braking system to allow better access to the rolls.

Figure 37 Fixed height moveable platform.

High level storage racks require the operator to climb or descend a ladder while holding onto a roll of cloth. This involves potential fall hazards and hazardous manual handling.

Risks

Repetitive or sustained

• bending the back more than 20 degrees
• reaching forward or sideways more than 30cm from the body
• exerting force while in an awkward posture
• working above shoulder height

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• lifting, lowering or carrying heavy loads
• applying uneven, fast or jerky forces during lifting, carrying, pushing or pulling
• two or more people need to be assigned to handle a heavy or bulky load
• stronger employees are assigned to do the task
• exerting high force while in an awkward posture

Figure 38 Employee standing on a ladder lifting at height is unsafe due to the risk of falling, as well as increasing the risk of MSDs.

Risk control measures

Use mechanical aids

• use a forklift to bring the stillage to ground level
• use an elevated work platform (figure 39) to take the person to the rolls of cloth
• use a height adjustable work platform with stillage area to take the person to the rolls of cloth

Figure 39 Elevated work platform enabling the employee to easily access objects. For long rolls of cloth, appropriate storage facilities on the elevating work platform are highly recommended.

Figure 40 Scissor lift being used for storing and retrieving rolls of cloth.

Manually rolling and tipping 200 litre drums still occurs in some workplaces.

Risks

High force

• lifting, lowering or carrying heavy loads
• applying uneven, fast or jerky forces during lifting, carrying, pushing or pulling
• pushing or pulling objects that are hard to move or to stop
• using finger grip, pinch grip or open handed grip to handle a heavy or large load
• holding, supporting or restraining a heavy object
• exerting high force while in an awkward posture
• two or more people need to be assigned to handle a heavy or bulky load
• stronger employees are assigned to do the task

Figure 41 Handling 200 litre drums involves hazardous manual handling.

Risk controls

Obtain liquid supplies in bulk containers. Supply can be piped direct to the process or small quantities can be decanted as needed. This eliminates the handling of drums and reduces the force involved by handling the liquid in smaller containers.

Use mechanical aids

• provide drum handling equipment
• provide drum handling equipment to reduce the exertion of force in awkward back, wrist or hand postures when moving drums

Figure 42 Drum handling equipment to reduce the exertion of force.

Lifting and handling 20 litre or other large containers may involve high force risk factors.

Risks

High force

• lifting, lowering or carrying heavy loads
• applying uneven, fast or jerky forces during lifting, carrying, pushing or pulling
• using finger grip, pinch grip or open handed grip to handle a heavy or large load
• holding, supporting or restraining a heavy object
• exerting high force while in an awkward posture
• stronger employees are assigned to do the task
• lifting and pouring from heavy containers above shoulder height

Figure 43 Lifting and pouring from a 20 litre container above shoulder height.

Risk control measures

Container size

Reduce the size of containers to reduce the force required for lifting.

Figure 44 Smaller and lighter containers are easier and safer to lift.

Alter the workplace

Install an automated dispensing system throughout the plant.

Figure 45 Installed automated dispensing system eliminating the need to manually pour liquid.

Use mechanical aids

Place the container on a trolley that can be rolled into position or tilted to reduce bending and twisting and the application of high force in awkward postures.

Using a bale attachment for inverting 4 bales at a time has reduced risk associated with hazardous manual handling. Bale bags can fall from the forklift attachment and lifting and pulling is required to get the bale bag out.

Risks

High force

• applying uneven, fast or jerky forces during lifting, carrying, pushing or pulling
• applying sudden or unexpected forces
• exerting high force while in an awkward posture

Figure 46 Employee reaching in and retrieving dropped bale bags which can involve high force. Ensure that the conveyor is effectively isolated.

Risk control measures

Use a hook (figures 47 and 48) attached to the forklift bale handler so that the forklift can be used to remove the bale bags. Refer to the manufacturer for guidance if alterations to plant are to be made.

Figure 47 Correct hook and chain attachment in use. The forklift can retrieve bale bags, eliminating hazardous manual handling.

Figure 48 Close up of hook attachment.

Alter the systems of work

Ensure maintenance of the spikes on the inside of the forklift bale handler.

Information, instruction and training

Ensure all operators are trained in the set-up procedure to minimise the number of falling bale bags.

Handling full beams involves standing them on end and manually lifting them onto a standard pallet so they can be moved with a forklift or pallet jack.

Risks

High force

• lifting, lowering or carrying heavy loads
• pushing or pulling objects that are hard to move or stop
• using a finger-grip or an open-handed grip to handle a heavy or large load
• exerting high force while in an awkward posture
• stronger employees are assigned to do the task

Figure 49 Moving a heavy beam to place it on a pallet involves high force risk factors.

Risk control measures

Use mechanical aids

Use a sling on a powered floor crane to remove the full beam from the machine. This will eliminate the high force required and reduce the need for team handling.

Use a roll carrier on a forklift to eliminate the high force required to team lift beams.

Figure 50 The correct probe attachment on a forklift will eliminate the high force risk associated with handling heavy objects.

Use a 'cradle' pallet to transport the beams. This eliminates the need to turn the beams from horizontal to vertical orientation. It also enables the use of a sling and a crane or a forklift to lift and move the beams to the cradle pallet. The exertion of high force in awkward postures while lifting, turning, pushing and pulling the beams is eliminated.

Figure 51 Stackable pallets designed to handle beams.

High force or sustained forces can be required to move trolleys, especially if regular maintenance of wheels, castors and bearings is not undertaken. Poor handle orientation and design can contribute to hazardous manual handling and can increase the risk of MSDs to employees.

Risks

Repetitive or sustained

• bending the back forwards or sideways more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• twisting and turning actions with the hands or arms
• excessive bending of the wrist
• exerting force with one hand or one side of the body
• exerting force while in an awkward posture

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• applying uneven, fast or jerky forces during pushing or pulling
• pushing or pulling objects that are hard to move or to stop
• using a finger-grip or an open-handed grip to handle a heavy or large load
• exerting high force while in an awkward posture

Figure 52 Employee pushing a trolley

Risk control measures

Use suitable trolleys

Ensure trolleys are designed with suitable handle design and position, including height, width, diameter and configuration to allow for a more neutral wrist and forearm posture and to reduce awkward back postures. Vertical handles can cater for employees of different height.

Figure 53 Trolley with suitable handle design fits a wider range of users.

Ensure trolleys have suitable wheels for the terrain and that they are regularly cleaned and maintained. Large wheels or castors with low-friction bearings are used to reduce force. The configuration of the wheels and the placement of fixed versus swivel wheels on the trolley can also help to reduce force.

Ensure trolleys are equipped with suitable hand brakes where ramps are used.

Alter the workplace environment

Ensure floor surfaces are even and free of obstacles to reduce the incidence of uneven, fast or jerky forces during pushing and pulling.

High forces are required when trolleys are fully loaded. The further the trolley needs to be moved, the longer the high forces are sustained.

Risks

High force

• applying uneven, fast or jerky forces during pushing or pulling
• pushing or pulling objects that are hard to move or to stop
• using a finger-grip or an open-handed grip to handle a heavy or large load
• holding, supporting or restraining a heavy object
• exerting high force while in an awkward posture
• stronger employees are assigned to do the task

Figure 54 The use of high force to push a loaded trolley can be hazardous.

Risk control measures

Use mechanical aids

Use a tug (figure 55) to mechanically power the attached trolley.

Figure 55 The use of a tug eliminates or reduces the high force to move product.

Use a forklift or powered pallet truck to move the load (figure 56).

Figure 56 Some loads can only be moved by forklifts.

Control the weight that is loaded on to trolleys. Where possible, use trolleys (or alter existing ones) that cannot readily be overloaded.

Inspection tasks involve long periods of time looking down at fabric and sometimes involve throwing pieces of material onto a table.

Risks

Repetitive or sustained

• bending the back forwards or sideways more than 20 degrees
• bending the neck forwards more than 20 degrees
• reaching forwards or sideways more than 30cm from the body
• working with one or both hands above shoulder height

Long duration

Long duration is defined as work that is undertaken:

• more than 2 hours over a whole shift, or
• continually for more than 30 minutes at a time

High force

• applying fast or jerky forces during lifting
• throwing or catching

Figure 57 Sustained forward bending and reaching is hazardous manual handling.

Risk control measures

Alter the workplace

Provide options for sitting or standing or adjustable sit/ stand seating to reduce forward reaching and forward bending of the neck and back. Anti-fatigue matting or foot rests for prolonged standing work can improve working postures.

Figure 58 An angled work surface reduces forward bending of the back and neck.

Figure 59 A seat provides options for both sitting and standing.

Provide mechanical aids

Provide an adjustable angle table like a drafting board, to support items being inspected to reduce bending of the back and neck and reduce work at or above shoulder height. Providing a clamp so that the item remains stable when the table is tilted will also reduce the need for throwing the item on the table and the application of fast or jerky forces.

Alter the workplace environment

Provide an alternative lighting colour or lamp design to highlight faults in the thread or material and to reduce glare from the light source, or investigate whether lighting from underneath would make fault detection easier. This will assist in reducing sustained forward neck bending.

Alter systems of work

Introduce job rotation in combination with other risk controls to provide postural variety and reduce exposure to sustained awkward postures, especially forward bending of the neck and back