Experiment No.

:-3
Objective:-To study the general safety consideration in material handling –manual and
mechanical handling.

Theory-
Material handling safety should be a top priority for all employers and employees. According to
the bureau of labor statistics (BLS), there are more than 3 million nonfatal work related injuries
and illness reported each year. While the exact cause of such injuries and illness varies, many of
them are the result of poor material handling practices.

Material handling is the movement, protection, storage and controls of materials and product
throughout manufacturing, warehousing, distribution, consumption and disposal. As a process
material handling incorporates a wide range of manual semi-automated and automated
equipment and system that support logistic and make the supply chain work.

There are two different ways to handle material in the workplace: Manually, involve worker
physically lifting and manipulating the respective material themselves, and Mechanically, which
involve the use of special machines and lifting equipment to perform the task. Both methods
can be used effectively to move materials, but there are nuances between the two that should
not go unnoticed.

Importance of proper Material Handling

In addition to reducing the risk of injury and illness, proper material handling can also improve
productivity labels in the workplace. “The efficient handling and storing of material are vital to
industry. In addition to raw material, these operations provide a continuous flow of part and
assemblies through the workplace and ensure that materials are available when needed.
Unfortunately, the improper handling and storing of material of one result in costly injuries.”

Manual Material Handling

Manual material handling is the lifting, carrying, lowering, pushing, pulling gripping pinching,
holding or moving of materials, article or things by hand. Many employers assume manual
material handling is the best choice for their operation, simply because there’s little to no cost
associated with it. If a pile of heavy pallets or drums needs moving from point A to point B, the
employer may ask one or more workers to perform this task.
But you have to realize the manual material handling task such as this places workers at a
higher risk of injury. So while direct cost associated with it are lower, the employer may end up
paying more in the long run if a worker sustain an injury while lifting and moving the material.

One of the of the more frequent, higher risk outcomes of manual material handling is
Musculoskeletal Disorders.

Musculoskeletal Disorders means an injury or disorder of the muscles, tendons, ligaments

joints, nerves blood vessels or related soft tissue, including sprain, strain or inflammation that
may occur to a worker in a workplace and that is caused or aggravated by any of the following:

1- A repetitive motion
2- A forceful exertion
3- Vibration
4- Mechanical Compression
5- A sustained and awkward posture
6- A limitation on motion or action
7- Any other factor that creates risk of Musculoskeletal Disorders

Safety Measures of Manual Material Handling

1- Ensure that object is light enough to lift, is stable and unlikely to shift or move.
2- Heavy or awkward loads should be moved using a handling aid.
3- Make sure the route is clear of obstruction.
4- Make sure there is somewhere to put the load down whenever it is to be moved to.
5- Stand as close to the load as possible, and spread your feet to shoulder width.
6- Bend your knees and try and keep the back’s natural upright posture.
7- Grasp the load firmly as close to the body as you can.
8- Use the legs to lift the load in a smooth motion as this offers more leverage reducing the
strain on your back.
9- Carry the load close to the body with the elbows tucked into the body.
10- Avoid twisting the body as much as possible by turning your feet to position yourself
with the load.

Mechanical Material Handling

On the other side of the fence is mechanical material handling, which was mentioned earlier
involves the use of special lifting machines and equipment to lift, move and manipulate heavy
objects. Arguably, the greatest benefit to using mechanical operations for material handling
task is the fact that it reduces the risk of worker injury. By replacing the burden on a lifting
machine, such as a mobile roll lifter, there’s little to no risk of worker injury.

Worker must be aware of both manual handling safety concerns and safe equipment operating
techniques. Employee should avoid overloading equipment when moving material mechanically
by letting the weight, size and shape of the material being moved dictate the type of equipment
used. All material handling equipment has rated capacity that determine the maximum weight
the equipment can safely handle and the conditions under which it can handle that weight.

Employers must ensure that the equipment rated capacity is displayed on each piece of
equipment and is not exceeded for load testing. Although workers may be knowledgeable
about powered equipment, they should take precautions when stacking and storing material.

Safety measures of Mechanical Material Handling

1- Physical plant must be safe- clear, marked, unobstructed work area.
2- Workers must be trained, evaluated and licensed.
3- Training must be equipment-specific and site-specific.
4- Equipment must be safe to operate- daily inspection, removal from service when repairs
are needed.
5- Service areas, such as battery charging, charging stations, must be safe in design and
operation.

Result- Hence the study of general safety consideration in material handling –manual and
mechanical handling has been completed.