ADVANCED ERGONOMICS

RISK ASSESSMENT REPORT

Company Name:

……………………………………………………

……………………………………………………

……………………………………………………

……………………………………………………

Assessment date:

……………………………………………………

Assessor’s Name:

……………………………………………………

NRIC No:

……………………………………………………

Initial Ergonomics Risk Assessment Report

 TABLE OF CONTENTS
1.0 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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2.0 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.

2.1 COMPANY BACKGROUND

COMPANY NAME
LOCATION/ADDRESS
ESTABLISHMENT

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

2.2 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.

2.3 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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3.0 METHOD

3.1 DESCRIPTION OF TASK ASSESSED

Department/Unit
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

3.1 METHODOLOGY AND DESCRIPTION OF TOOLS

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.

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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
(example only)

Initial Ergonomics
Risk Assessment
Checklist
Rapid Upper Limb
Assessment (RULA)
(example only)

Manual Handling
Assessment Chart
(MAC Tool)
(example only)

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FLOWCHART OF ASSESSMENT PROCESS

4.0 RESULTS

This section present the all results from the assessment process.

4.1 SELF-ASSESSMENT MUSCULOSK ELETAL 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.

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4.2 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.

BAR CHART or ANY TYPE OF ANALYSIS TOOLS OR FIGURES

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.

4.3 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:

Ergonomics Risk Factor: Awkward Postures

Ergonomics Risk Factors: Awkward Posture

Please tick (/) Remark / Picture
Max. Exposure
Body Part Physical Risk Factor
Duration Yes No

Work with hand above the

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

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 Please tick (/) Remark / Picture
Max. Exposure
Body Part Physical Risk Factor
Duration
Yes No

Work with head bent

More than 4 hours
downwards more than 45
per day
degrees
Head Work with head bent More than 2 hours
backwards per day
More than 2 hours
Work with head bent sideways
per day
Work with back bent forward
More than 2 hours
more than 30 degrees OR bent
per day
Back sideways
More than 2 hours
Work with body twisted
per day
Work with wrist flexion OR
More than 2 hours
extension OR radial deviation
per day
more than 15 degrees
Hand/ Work with arm abduction More than 4 hours
Elbow/ sideways per day
Wrist
Work with arm forward more
than 45 degrees OR arm More than 2 hours
backward more than 20 per day
degrees
More than 2 hours
Work in a squat position.
Leg/ total per day
Knees More than 2 hours
Work in a kneeling position
per day
Sub Total (Number of tick(s))
Ergonomics Risk Factors: Static and Sustained Work Posture
Please tick
Max. Exposure Remark / Picture
Body Part Physical Risk Factor (/)
Duration
Yes No

Work in a static
Trunk/ Head/ More than 1 minute
awkward position as in
Neck/ Arm/ Wrist continuously
Table 1

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

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 Please tick
Max. Exposure Remark / Picture
Body Part Physical Risk Factor (/)
Duration
Yes No
Work in static seated More than 30
position with minimal minutes
movement continuously
Sub Total (Number of tick(s))

Ergonomics Risk Factors: Repetitive Motion

Max. Exposure Please tick (/)
Body Part Physical Risk Factor Remark / Picture
Duration Yes No
Work involving repetitive
sequence of movement
more than twice per minute
More than 3 hours
Work involving intensive use on a “normal”
of the fingers, hands or wrist workday
or Work involving intensive
keying (Data Entry) OR
Neck,
shoulders, Work involving repetitive
More than 1 hour
elbows, shoulder/arm movement
continuously without
wrists, with some pauses OR
a break
hands, continuous shoulder/arm
knee movement
Work using the heel/base of
More than 2 hours
palm as a “hammer” more
per day
than once per minute
Work using the knee as a
More than 2 hours
“hammer” more than once
per day
per minute.
Sub Total (Number of tick(s))

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 Ergonomics Risk Factors: Forceful Exertion

Exceed limit? Remark / Picture

Activity (where applicable) Recommended weight
Yes No

Lifting and lowering only based on Table 3.3

based on Figure 3.1

Repetitive lifting and lowering
and Table 3.4

Twisted body posture while based on Figure 3.1

lifting and lowering and Table 3.5

based on Figure 3.1,

Repetitive lifting and lowering
Table 3.4 and Table
with twisted body posture
3.5

Pushing and Pulling based on Table 3.6

Handling in seated position based on Figure 3.2

Carrying factors based on Table 3.7

Sub-Total (Number of tick(s))

Ergonomics Risk Factors: Vibration

Max. Exposure Please tick (/) Remark /

Body parts Physical Risk Factor Picture
Duration Yes No
Hand-Arm Work using power tools (e.g. More than 80% in
battery powered/ electrical hour
(segmental pneumatic/ hydraulic) without
vibration) PPE
Work using power tools (ie: More than 60% in 8
battery powered/electrical hours shift work
pneumatic/hydraulic) with PPE
Whole body Work involving exposure to whole More than 60% in 8
body vibration hours shift work
Work involving exposure to whole More than 40% in 8
body vibration combined hours shift work
employee complaint of excessive
body shaking
Sub Total (Number of tick(s))

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 Ergonomics Risk Factors: Environmental Factors

Please tick (/) Remark / Picture

Physical Risk Factor
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))

SUMMARY RESULTS OF INITIAL ERA

Any pain or discomfort Need

Minimum Result of
Total due to risk factors as Advanced
Risk Factor Requirements for Initial
score found in MSD ERA
Advance ERA ERA
assessment (Yes/No)
Awkward posture 13 ≥6
Static and
sustained work 3 ≥1 If YES please tick
posture which part of body
Forceful exertion 1 1 Neck
Shoulder
Repetition 5 ≥1 Upper back
Vibration 4 ≥1 Lower back
Upper arm
Lighting 1 1 Elbow
Temperature 1 1 Lower Arm
Hand/Wrist
Ventilation 1 1 Thigh
Knee
Lower leg
Noise 2 ≥1 Ankle/ Foot

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4.4 ERGONOMICS RISK LEVEL ASSESSMENT

RESULTS OF ASSESSMENT BASED ON RESPECTIVE ASSESMENT TOOLS BEING APPLIED

5.O CONCLUSION AND RECOMMENDATION

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6.0 APPENDIX

CERTIFICATES OF ERGONOMICS TRAINED PERSON AND OTHER DOCUMENTS

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 ERGONOMICS RISK FACTORS: AWKWARD POSTURE
Please tick
Max. Exposure (/)
Body Part Physical Risk Factor Concern Remarks
Duration
Yes No
Work with hand above the Overall exposure
More than 2 hours
head OR the elbow above / time is less than
per day
the shoulder minimum
exposure time
More than 2 hours
Work with shoulder raised / required to be
per day
Shoulders considered as
Work repetitively by raising risks.
the hand above the head OR
More than 2 hours
the elbow above the / However,
per day
shoulder more than once per extreme posture
minute were observed
and expected to
Work with head bent
More than 2 hours expose to workers
downwards more than 45 /
per day to risk (tick in
degrees
concern column).
Head Work with head bent More than 2 hours
/
backwards per day Therefore, it is
recommended for
Work with head bent More than 2 hours
/ further
sideways per day
assessment for
Work with back bent forward advanced ERA
More than 2 hours
more than 30 degrees OR / /
per day
Back bent sideways
More than 2 hours
Work with body twisted / /
per day
Work with wrist flexion OR
More than 2 hours
extension OR radial deviation /
per day
more than 15 degrees

Hand/ Work with arm abduction More than 4 hours

/
Elbow/ sideways per day
Wrist Work with arm forward more
than 45 degrees OR arm More than 2 hours
/
backward more than 20 per day
degrees
More than 2 hours
Work in a squat position. /
total per day
Leg/
Knees More than 2 hours
Work in a kneeling position /
per day
Sub Total (Number of tick(s)) 0 13

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 ERGONOMICS RISK FACTORS: STATIC AND SUSTAINED WORK POSTURE

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

Work in a static More than 1 /

Trunk/ Head/
awkward position as minute
Neck/ Arm/ Wrist
in Table 1 continuously

Work in a standing More than 2 /

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

Sub Total (Number of tick(s)) 0 3

ERGONOMICS RISK FACTORS: REPETITIVE MOTION

Max. Please
Body Part Physical Risk Factor Exposure tick (/) Concern Remarks
Duration Yes No
Work involving repetitive /
More than 3
sequence of movement more
hours on a
than twice per minute
“normal”
Work involving intensive use of workday /
the fingers, hands or wrist or
Work involving intensive keying OR
(Data Entry)
Neck, More than 1
/
shoulders 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)) 0 5

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 ERGONOMICS RISK FACTORS: FORCEFUL EXERTION (MANUAL HANDLING)

Female Male

Figure 3.A. Recommended Weight

Ergonomics Risk Factors: Forceful Exertion

(Manual handling – Lifting and/or lowering)

Exceed
Recommended Current limit?
Working height (where force is applied) weight weight
(male or female) handled Yes No

Between floor to mid-lower leg 10 50/2 = 25 /

Between mid-lower leg to knuckle /
Between knuckle height and elbow 15 50/2 =25 /
Between elbow and shoulder /
Above the shoulder /

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 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%

80%
More than 12 times per minute

Ergonomics Risk Factors: Forceful Exertion

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

If employee twists body from forward facing to the Weight* should be reduced
side by

45 degrees 10%

90 degrees 20%

Ergonomics Risk Factors: Forceful Exertion (Pushing and/or Pulling)

Recommended weight

Activity
Female
Male

Stopping or approximately 1000 kg load on approximately 750 kg load on

starting a load smooth level surface using well smooth level surface using well
maintained handling aid maintained handling aid

approximately 100 kg load on approximately 75 kg load on

Keeping the load uneven level surface using well
uneven level surface using well
in motion maintained handling aid
maintained handling aid

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 Ergonomics Risk Factors: Forceful Exertion
(Handling in Seated Position)

Female
Male

Box zone

Figure 3.B. Recommended Weight for Seated Position

Summary of Forceful Exertion (Manual Handling)

Exceed
Recommende limit?
Activity Concern Remarks
d weight
Yes No
Lifting and lowering only / Turning the wheel to
turn ON/OFF the
Repetitive lifting and penstock valve require
/
lowering high force. Hence,
Twisted body posture recommended for
advanced ERA
while lifting and /
lowering
Repetitive lifting and
lowering with twisted /
body posture
Pushing and Pulling /
Handling in seated
/
position
Carrying /
Sub Total (Number of tick(s)) 0 7

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 ERGONOMICS RISK FACTORS: VIBRATION

Please tick (/)

Max. Exposure
Body parts Physical Risk Factor
Duration Yes No

Hand-Arm Work using power tools (e.g. battery More than 80% in /
powered/ electrical pneumatic/ hour
(segmental hydraulic) without PPE
vibration)
Work using power tools (ie: battery More than 60% in /
powered/ electrical pneumatic/ 8 hours shift work
hydraulic) with PPE

Whole body Work involving exposure to whole body More than 60% in /
vibration 8 hours shift work

Work involving exposure to whole body More than 40% in /

vibration combined employee complaint 8 hours shift work
of excessive body shaking

Sub Total (Number of tick(s)) 0 4

ERGONOMICS RISK FACTORS: ENVIRONMENTAL FACTORS

Please tick
Physical Risk Factor (/)
Concern Remarks
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)) 0 5

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 INITIAL ERA FORM

A B C D E F

Minimum Any Pain or Discomfort

requirement Result due to risk factors as Need Advanced
Total
Risk factors for of Initial found in Musculoskeletal ERA?
Score
advanced ERA Assessment (Yes/No)
ERA (Yes/No)

Awkward If YES please tick which Yes

13 ≥6 0
Postures (Recommended)
part of body
Static and
Sustained Work 3 ≥1 0 Neck No
Posture
Shoulder X
Forceful exertion 1 1 1 Upper back Yes

Repetition 5 ≥1 0 Upper arm X No

Vibration 4 ≥1 0 Lower back X No

Elbow X
Lighting 1 1 0 No
Forearm
Temperature 1 1 0 No
Wrist X
Ventilation 1 1 0 Hip/Buttocks No
Thigh
Knee X
Noise 2 ≥1 0 No
Lower leg
Foot

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