INITIAL ERGONOMICS RISK

ASSESSMENT REPORT

Company Name:

……………………………………………………

……………………………………………………

……………………………………………………

……………………………………………………

Assessment date:

……………………………………………………

Assessor’s Name:

……………………………………………………

NRIC No:

……………………………………………………

Initial Ergonomics Risk Assessment Report

EXECUTIVE SUMMARY
Introduction Type of Assessment: Initial Ergonomics Risk Assessment
Assessment Date:
Assessor’s Name:
Objective(s) of
Assessment
Department and Department:
Task Task 1:
Task 2:
Task 3:
Methods 1. Self-Assessment Musculoskeletal Pain/Discomfort Survey Form
2. Musculoskeletal Assessment: Nordic Musculoskeletal
Questionnaires
3. Ergonomics Risk Factors Assessment: Initial Ergonomics Risk
Assessment Checklists
Results 1. Musculoskeletal Assessment
Task 1 Task 2 Task 3
Any Pain/ Discomfort Yes
(Yes/No)
Body Parts (if Yes) Neck,
Shoulder

2. Ergonomics Risk Factors Assessment

Task 1 Task 2 Task 3
(Y/N) (Y/N) (Y/N)
Awkward Posture Yes
Static and sustained work No
posture
Forceful exertion Yes
Repetition No
Vibration No
Lighting No
Temperature No
Ventilation No
Noise No
Recommendations Engineering Control
Administrative Control
Personal Protective Equipment

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 Table of Content

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1.0 INTRODUCTION

Initial ergonomics risk assessment had been conducted in production area at Minebea
Electronics Motors (M) Sdn Bhd during 26th June 2019 until 17th July 2019. The assessment
conducted was based on Guidelines on Ergonomics Risk Assessment at Workplaces
published by Department of Occupational Safety and Health (DOSH) in year 2017.

COMPANY BACKGROUND

COMPANY NAME
LOCATION/ADDRESS
ESTABLISHMENT

PRODUCTION AREA
PRODUCTION ITEM
PERSONNEL
ORGANIZATION
WORKING HOUR
PRODUCT
PRODUCTION
CAPACITY
etc

OBJECTIVES OF THE ASSESSMENT

The objectives of this assessment are as follow:

a) To identify most ergonomics risk factors that may cause harm to employees;
b) To determine the likelihood of harm arising from exposure to the ergonomics risk
factors;
c) To recommend appropriate control measures towards risk reduction.

SCOPE AND LIMITATION

a) The assessment were conducted at processes or tasks involved in the participating

departments only
b) The assessments were conducted only to the tasks which were observed during the
assessment period only
c) The assessments are also limited to the photographs and videos released by the
management of the company due to security and confidentiality reasons.

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2.0 DEPARTMENT AND TASK

DEPARTMENT/UNIT

DESCRIPTION OF TASK ASSESSED

General Location:
Information Working Hours:
Breaks:
No of Workers:
Other information (such as no of parts produces or frequency of
maintenance activities etc)
Description of Task/Activity:
Task/Activity
SOP or Flow of activity (Actual) – Description with photo for each
steps.

Ergonomics
related
concern

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3.0 METHOD

The ergonomics risk assessment was conducted based Guidelines on Ergonomics Risk
Assessment at Workplace 2017.

The methods used for the assessment includes interviews, body symptom survey
(Musculoskeletal Assessment), Ergonomics Risk Factors Assessment (Initial Ergonomics Risk
Assessment Checklist), observation, photo and video analysis.

To Initiate the Initial ERA, Self-Assessment Musculoskeletal Pain/Discomfort Survey forms were
distributed to all / 40 workers from production department . The results were analysed and
concluded it needs to proceed with Initial ERA due to the pain/discomfort complaints.

Initial Ergonomics Risk Assessment (Initial ERA) was conducted by conducting

musculoskeletal assessment using Nordic Musculoskeletal Questionnaires on 40 workers from
production department.

Next, ergonomics risk factors assessment was conducted by using Initial Ergonomics Risk
Assessment Checklist (Appendix 6 from the Guidelines).

Finally, results were analyzed and recommendations for improvement were proposed.

The following are the description of the tools/methods applied in the assessment:

Tools/Methods Description
Self-Assessment
Musculoskeletal
Pain/Discomfort
Survey

Nordic
Musculoskeletal
Questionnaires

Initial Ergonomics
Risk Assessment
Checklist

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4.0 RESULTS

This section present the all results from the assessment process.

SELF-ASSESSMENT MUSCULOSKELETAL DISCOMFORT/PAIN SURVEY

To Initiate the Initial ERA, Self-Assessment Musculoskeletal Pain/Discomfort Survey forms were
distributed to all / 40 workers from production department . The workers filled-up the form
based on the experience on pain/discomfort when performing the task. The results were
analysed and concluded it needs to proceed with Initial ERA due to the pain/discomfort
complaints. Figure XXX shows the results of the complaints on pain/discomfort on body
parts using Self-Assessment Musculoskeletal Pain/Discomfort Survey forms.

MUSCULOSKELETAL ASSESSMENT – NORDIC MUSCULOSKELETAL QUESTIONNAIRES

Musculoskeletal Disorder (MSD) symptoms were investigated by using Nordic

Musculoskeletal Questionnaires. Total of 140 workers were interviewed. The results as shown
in Figure 3-6.

Figure 3 shows the overall results of percentage of complaints on pain/discomfort among

workers during the last 12 months. The highest complaints was low back with 46% of workers
followed by shoulders and knees with 36% each, neck 30% others. Table 3 shows complaint
of pain/discomfort within 12 months by department.

ERGONOMICS RISK FACTORS ASSESSMENT

The followings are results from ergonomics risk factors assessment using Initial Ergonomics
Risk Factors Checklist (Appendix 6 from the Guidelines).

The relevant ergonomics risk factors for this task are awkward postures, forceful exertion
and hand-arm vibration. For details ergonomics risk factors assessment, please refers to
Appendix 2.

The followings are the results of the relevant ergonomics risk factors for this task:

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 TABLE 3.1: ERGONOMICS RISK FACTORS: AWKWARD POSTURE

Please tick (/) Remarks or photos

Max. Exposure
Body Part Physical Risk Factor
Duration
Yes No

Working with hand above

More than 2
the head OR the elbow
hours per day
above the shoulder

More than 2
Working with shoulder raised
hours per day
Shoulders
Working repetitively by
raising the hand above the
More than 2
head OR the elbow above
hours per day
the shoulder more than
once per minute

Working with head bent

More than 2
downwards more than 45
hours per day
degrees

Head Working with head bent More than 2

backwards hours per day

Working with head bent More than 2

sideways hours per day

Working with back bent

More than 2
forward more than 30
hours per day
degrees OR bent sideways
Back
More than 2
Working with body twisted
hours per day

Working with wrist flexion OR

extension OR radial More than 2
deviation more than 15 hours per day
degrees
Hand/
Working with arm abduction More than 4
Elbow/
sideways hours per day
Wrist
Working with arm forward
more than 45 degrees OR More than 2
arm backward more than hours per day
20 degrees

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 Please tick (/) Remarks or photos
Max. Exposure
Body Part Physical Risk Factor
Duration
Yes No

More than 2
Work in a squat position. hours total per
Leg/ day
Knees
More than 2
Work in a kneeling position
hours per day

Sub Total (Number of tick(s))

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 TABLE 3.2: ERGONOMICS RISK FACTORS: STATIC AND SUSTAINED WORK POSTURE

Please tick (/) Remarks or photos

Body
Physical Risk Factor Max. Exposure Duration
Part
Yes No

Trunk/
Work in a static Duration as per Table
Head/
awkward position as in 3.1 (please refer
Neck/
Table 3.1 (awkward duration in awkward
Arm/
posture table) posture table)
Wrist

Work in a standing
More than 2 hours
position with minimal
continuously
leg movement
Leg/
Knees
Work in static seated
More than 30 minutes
position with minimal
continuously
movement

Sub Total (Number of tick(s))

ERGONOMICS RISK FACTORS: FORCEFUL EXERTION (MANUAL HANDLING)

Female Male

Figure 3.1. Recommended Weight

TABLE 3.3: ERGONOMICS RISK FACTORS: FORCEFUL EXERTION

(Manual handling – Lifting and/or lowering)

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 Recommended Current Exceed Remarks or
Working height (where force is limit?
weight weight photos
applied)
(male or female) handled Yes No
Between floor to mid-lower leg
Between mid-lower leg to knuckle
Between knuckle height and elbow
Between elbow and shoulder
Above the shoulder
TABLE 3.4: ERGONOMICS RISK FACTORS: FORCEFUL EXERTION
(Manual handling – Repetitive handling)

If employee repeats operations Weight* should be reduced by

Once or twice per minutes 30%
Five to eight times per minute 50%
More than 12 times per minute 80%

TABLE 3.5 ERGONOMICS RISK FACTORS: FORCEFUL EXERTION

(Manual handling – Lifting and lowering with twisted body posture)

If employee twists body from forward facing to Weight* should be

the side reduced by
45 degrees 10%
90 degrees 20%

TABLE 3.6 ERGONOMICS RISK FACTORS: FORCEFUL EXERTION (PUSHING AND/OR PULLING)

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 Recommended weight
Activity
Male Female

approximately 1000 kg load approximately 750 kg load (equivalent to

Stopping or (equivalent to 200N pushing or
starting a load pulling force) on smooth level
surface using well maintained
handling aid
approximately 100 kg load
(equivalent to 100N pushing or
Keeping the
pulling force) on uneven level
load in motion
surface using well maintained
handling aid
150N pushing or pulling force) on smooth
level surface using well maintained
handling aid
approximately 70 kg load (equivalent
to 70N pushing or pulling force) on
uneven level surface using well
maintained handling aid

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 ERGONOMICS RISK FACTORS: FORCEFUL EXERTION
(Handling in Seated Position)

Female Male

Box zone

Figure 3.2. Recommended Weight for Seated Position

TABLE 3.7 ERGONOMICS RISK FACTORS: FORCEFUL EXERTION

Summary of Carrying Activity
Factor Condition Outcome Remarks or photos
Floor Surface Dry and clean floor in good
Acceptable
condition

Dry floor but in poor condition,

worn or uneven
Conduct
Contaminated/wet or steep advanced ERA
sloping floor or unstable surface
or unsuitable footwear

Other No factors present Acceptable

environmental
One or more factors present (i.e.
factors Conduct
poor lighting condition and
advanced ERA
strong air movements)

2 m—10 m Acceptable

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 Factor Condition Outcome Remarks or photos
Carry Conduct
10 m or more
distance advanced ERA

Obstacles en No obstacles and carry route is

Acceptable
route flat

Steep slope or up steps or through

Conduct
closed doors or trip hazards or
advanced ERA
using ladders

TABLE 3.8: SUMMARY OF SINGLE MANUAL HANDLING ACTIVITY (FORCEFUL EXERTION)

Exceed limit? Remarks or photos

Activity Recommended weight
Yes No
Lifting and lowering; or Figure 3.1 & Table 3.3
Repetitive lifting and
Figure 3.1 & Table 3.4
lowering; or
Twisted body posture while
Figure 3.1 & Table 3.5
lifting and lowering; or

Repetitive lifting and lowering based on Figure 3.1,

with twisted body posture; or Table 3.4 and Table 3.5

Pushing and Pulling; or based on Table 3.6

Handling in seated position; based on Figure 3.2

or

Carrying based on Table 3.7

Other Forceful Activity

Sub Total (Number of tick(s))

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 TABLE 3.9: ERGONOMICS RISK FACTORS: REPETITIVE MOTION

Please tick (/) Remarks or photos

Max. Exposure
Body Part Physical Risk Factor
Duration
Yes No

Work involving repetitive More than 3

sequence of movement more hours on a
than twice per minute “normal”
workday
Work involving intensive use of
the fingers, hands or wrist or work
involving intensive data entry OR
Neck, (key-in)
shoulders, More than 1
Work involving repetitive hour
elbows, shoulder/arm movement with continuously
wrists, some pauses OR continuous without a
hands, shoulder/arm movement break
knee
Work using the heel/base of
More than 2
palm as a “hammer” more than
hours per day
once per minute

Work using the knee as a

More than 2
“hammer” more than once per
hours per day
minute.

Sub Total (Number of tick(s))

TABLE 3.10: ERGONOMICS RISK FACTORS: VIBRATION

Please tick (/) Remarks

Max. Exposure
Body parts Physical Risk Factor or
Duration Yes No
photos
Hand-Arm Work using power tools (e.g. battery More than 50
powered/ electrical pneumatic/ minutes in an
(segmental hydraulic) without PPE hour
vibration)
Work using power tools (ie: battery More than 5
powered/ electrical pneumatic/ hours in 8 hours
hydraulic) with PPE shift work

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Whole body Work involving exposure to whole More than 5
body vibration hours in 8 hours
shift work
Work involving exposure to whole More than 3
body vibration combined employee hours in 8 hours
complaint of excessive body shaking shift work
Sub Total (Number of tick(s))

TABLE 3.11: ERGONOMICS RISK FACTORS: ENVIRONMENTAL FACTORS

Please tick (/)

Physical Risk Factor Remarks or photos
Yes No
Inadequate lighting

Extreme temperature (hot/cold)

Inadequate air ventilation or poor IAQ

Noise exposure above PEL

Exposed to annoying noise more than 8 hours

Sub Total (Number of tick(s))

Initial ERA Form

A B C D E F
Risk Factor Total Minimum Result of Initial Any pain or discomfort Need
score Requirements ERA due to risk factors as advanced
for Advance found in MSD ERA
ERA assessment (Yes/No)
Refer Part 3.1
(Yes/No)
Awkward 13 ≥6
posture
If YES please tick which
Static and 3 ≥1 part of body
sustained
work posture

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Forceful 1 1 Lifting/ Neck
Lowering
exertion Shoulder
Pushing/
Pulling Upper back
Handling Lower back
Load in
Seated Upper arm
Carrying Elbow
Other
Lower Arm
Repetition 5 ≥1
Hand/Wrist
Vibration 4 ≥1
Thigh
Lighting 1 1
Knee
Temperature 1 1 Lower leg
Ventilation 1 1 Ankle/Foot
Noise 2 ≥1

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5.0 CONCLUSION AND RECOMMENDATION

CONCLUSION

Risk Factors Task 1: Task 2: Task 3:

Need Advanced Need Advanced Need Advanced
ERA (Yes/No) ERA (Yes/No) ERA (Yes/No)
Awkward posture
Static and sustained
work posture
Forceful exertion
Repetition
Vibration
Lighting
Temperature
Ventilation
Noise

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RECOMMENDATION

Task Existing Risk Ergonomics Control Measure Projected Outcome

Factors (Expected To Eliminate or
Reduce (Risk Factors)
Loading/ Awkward Engineering Control:
Unloading Posture,
Boxes Forceful
Exertion,
Noise Administrative Control:

Personal Protective
Equipment:

Engineering Control:

Administrative Control:

Personal Protective
Equipment:

Engineering Control:

Administrative Control:

Personal Protective
Equipment:

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6.0 AP PENDIX

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