Initial Ergonomic Risk

Assessment
By Mr ABDUL JALIL BIN ABDUL RAHMAN
18-19 June 2024

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1 Table of Content 2

2 Declaration 3

3 Workplace Information 4

4 Executive summary 5

5 Introduction 6

6 Description of work tasks and activities in work 7

units;
7 Objectives 8

8 Legal Requirement 8

9 Methodology 9

10 Risk evaluation and the score of initial ERA; 10

11 Recommendations 11

12 Hierarchy of Control and Significant Risk factor 12

13 Reference 13

14 Appendix: Checklist 14

APPENDIX 1: Self-Assessment Form

Appendix 2: Ergonomics Complain form

Appendix 3: Cornell Score

Appendix 4: Additional Information

Appendix 5: Ergonomic Risk Checklist (Illustration)

Appendix 6: Ergonomic Risk Checklist (Score)

Appendix 7: Trained Person Information

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Date : 25nd February 2023
Company/Factory:

Employee involved:
Name: XXXX

Ref: Initial Ergonomic Risk Assessment at Logistic Department in XXXX Sdn Bhd

This is to certify that initial ergonomic risk assessment for the above employee has been
conducted and explained to both, employee and employer / employer representative
(stakeholder) members.

Employer’s has acknowledge on the outcomes of the Initial Ergonomic Risk Assessment and will
take necessary action and all the recommendations recommended in this report

Employee has agrees to participate with the initial ergonomic risk assessment
and provided information requested and agrees for the outcomes of the
assessment to be discussed with the employer

Date of Assessment: 25th February 2023

Signature of Initial ERA Assessor: Report received by: (Employer/Employer

Rep)
Signature:
(Video presentation report)

Signature :
Name: Mr XXXX
Name :
Competency Number:
Designation : Manager
Date of receipt report: 7th April 2023
This is to certify that Signature of Employee:
 The statement in the self assessment
form and ergonomic and musculoskeletal
form are true. (Video presentation report)
 I give consent to the ergonomic assessor
for Initial Ergonomic Risk Assessment
(ERA) to assess and to communicate with
Date: 7th April 2023
the management regarding my work
capability after discussion with me
 The implication of the Initial Ergonomic
Risk Assessment results has been
explained to me by the Ergonomic
Assessor

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 2. Workplace information
XXXX Sdn Bhd is a manufacturing company that produces air conditioner the supplies the
demand in ASEAN country like Malaysia, Singapore, Thailand and Indonesia. The factory
started its operation since 2001 and has been in the air conditioning manufacturing for
the past 18 years.

The factory has a total of 450 employee including executives and administrative
department. XXXX also participate in local Systematic Occupational Health Enhancement
Level Program (SoHELP) organized by Department of Occupational Safety & Health
(DOSH).

All of XXXX employees are members of employee insurance scheme under Social
Security Organization (SOCSO). Located in the district of Seremban in Negeri Sembilan
State XXXX is set under the Sarawak State DOSH. XXXX has 5 main department
which is casting and molding, assembly, quality assurance, maintenance and logistic.

3. Executive Summary
The initiation of initial Ergonomic Risk Assessment was advised by the in-house
occupational health doctor after did a health surveillance on Mr XXXX
. Mr XXXX, a 35 years old employee have been working Summary Of Initial ERA Score
Result Need
in company XXXX factory for 2 years complaining of lower
Risk factors of Advanced
back, shoulder and arm pain. His works in Logistic Initial ERA?
department involve transferring of product 15 kg air- ERA
condition from one pallet to another. Awkward 7/13 Yes
Postures
Self assessment musculoskeletal pain Static and 0/3 No
and discomfort form together with ergonomic Sustained
musculoskeletal complaint form was filled by Mr Work
Mr XXXX. The Cornell charts was used as Posture
Forceful 1/3 Yes
guidance for ergonomic risk assessment. Walk
exertion
through survey and workplace assessment was
2/5 Yes
obtained after consent given. Video was recorded Repetition
to assess the motion, mobility and posture of Mr Vibration 0/4 No
XXXX while working. Environmental risk 0/1 No
Lighting
parameters report were obtained from the
employer. 0/1 No
Temperature

Parameters assessed based on Initial 0/1 No

Ventilation
ERA Guidelines 2017 checklist. Parameters
Noise 0/2 No
assessed are mainly on awkward postures, static

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and sustained work posture, forceful exertion,
repetition, vibration, and environmental
parameters including lighting temperature
ventilation noise.

It was noted in the final result or score of Initial ERA found that, a further
Advance ERA is required in 3 main risk factors. The risk factors required advance
assessments are 1) Awkward posture,
2) Forceful Exertion and 3) Repetition.

Few short term recommendations include frequent breaks, method of lifting, back
support and two men carrying. The long term plan recommended includes redesign work
unit, referring for medical treatment and adjustment to the pallet used. If the Pallet
use is adjusted, elimination of ergonomic risk in hierarchy control may be possible.
Other Hierarchy control includes engineering control by use of robotics,
administrative control by frequent break, job rotation and training.

4. Introduction
4.1 Definition of Ergonomics

Ergonomics (or human factors) is the scientific discipline concerned with the
understanding of interactions among humans and other elements of a system, and the
profession that applies theory, principles, data and methods to design in order to
optimize human well-being and overall system performance.

4.2 Ergonomic Risk Factor

An ergonomics risk factor is any attribute, characteristic or exposure that may cause or
contribute to a musculoskeletal injury; the mere presence of a risk factor may not in
itself result in injury. In general, two or more risk factors may be present at one time,
thereby increasing the risk of injury. The ergonomics risk factors are defined as
follow:-

4.2.1 Awkward Posture

Need to fill with info. & explanation

4.2.2 Forceful and Sustained Exertions

Need to fill with info. & explanation

4.2.3 Repetitive Motion

Need to fill with info. & explanation

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4.2.4 Static and Sustained Posture
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4.2.5 Vibration

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4.2.6 Environmental Risk Factors

Environmental risk factors refer to stressful factors in the environment that affect
human comfort, activity and health. This includes thermal environments, illumination,
noise, and extreme atmospheric pressure environments.
Need to elaborate on each environmental factor.
5. Description of work tasks and activities in work unit
Name Employee: XXXX
ID:
Age: 35 years old
Duration of
2 years
employment:
Department: Logistic
Total Workers
8
in
Work-unit:
Working Hours: 8:00am – 5:00pm
Schedule Break: 1) 10:00am-10:15am
2) 1:30pm-2:00pm
3) 4:00pm-4:15pm
Total Working
Hours (excluding 8 hours
break)
Work Task: Transferring final product from one pallet (factory design) to
another pallet (transport design) before transport for
distribution
Carrying weight
15.0 kg
capacity:

6.Objectives
The objectives of conducting ERA are to: -

a) Identify most ergonomics risk factors that may cause harm to employees;

b) Determine the likelihood of harm arising from exposure to the ergonomics risk factors;

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c) Recommend appropriate control measures towards risk reduction.

7.Legal Requirement

Occupational Safety and Health Act 1994 Section 15 (2) (b) “the making of
arrangements for ensuring, so far as is practicable, safety and absence of risks to
health in connection with the use or operation, handling, storage and transport of
plant and substances”

Factory and Machinery Act 1967 Sectioon 12. No person shall be employed to lift,
carry or move any load so heavy as to be likely to cause bodily injury to him.

8.Methodology
Initial Ergonomic Risk Assessment was requested by In-House Occupational Health
Doctor during health surveillance in the factory. The Occupational Health Doctor noted
employee frequently complains of low back pain and there was frequent absenteeism
due to similar complaint.

Cornell Musculoskeletal Questionnaire was used as guidance to the symptoms that the
employee presented with.

Ergonomic Risk Factor Assessment Checklist from the Ergonomic Risk Assessment
at Workplace Guidelines was used. The approach for the ergonomic risk factors was
assessed based on 6 key features:

1) Awkward Posture
2) Static And Sustained Work Posture
3) Forceful Exertion
4) Repetitive Motion
5) Vibration : Hands-Arm And Whole Body
6) Environmental Risk Factors
a. Lighting
b. Temperature
c. Ventilation
d. Noise

Video recording was obtained to assess the work posture of the employee while
carrying the task. Environmental assessment report was obtained from the employer to
assess the 4 environmental risk factors.

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Written consent from the affected employee was obtained and the employee agrees on
the discussion of the outcomes of the investigations to be discussed with employer. The
consent includes recording of videos of employee performing the task.

Result of the assessment was documented in the checklist (Appendix) and the Final
Results of Initial ERA (Table 3.15 of Ergonomic Risk Assessment Guidelines) was
also documented (Appendix)

9.Risk evaluation and the score of initial ERA

Table 3.15: Initial ERA Form

A B C D E F
Any Pain or Discomfort due
Need
Minimum Result to risk factors as found in
Total Advanced
Risk factors requirement of Musculoskeletal Assessment
Score ERA?
for advanced Initial (refer Part 3.1)
(Yes/No)
ERA ERA (Yes/No)

Awkward 7 YES
13 ≥6
Postures YES / NO
Static and 0 If YES, please tick (√) NO
Sustained Work 3 ≥1 which part of the body
Posture
Neck
Forceful 1 Shoulder  YES
1 1
exertion Upper back
Upper arm  YES
Repetition 5 ≥1
2 Lower back 
Forearm
0 NO
Vibration 4 ≥1 Wrist
Hand
0 Hip/buttocks NO
Lighting 1 1
Thigh
0 Knee NO
Temperature 1 1
Lower leg
Feet
0 NO
Ventilation 1 1

Noise 2 ≥1 0 NO

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10. Recommendations
10.1 Proceed with advance ERA for:-

1) Awkward posture using RULA (Rapid Upper Limb Assessment)

2) Forceful exertion using MAC (Manual Handling Assessment Chart)
3) Repetitive motion using ART (Assessment of Repetitive Task)

10.2 Short Term Plan:-

a) To allow workers to have frequent breaks.

b) Advice employee on the correct method of heavy weight carrying.

c) Using a forklift to unload and load the object.

d) Adjust working / carrying procedure: two man carrying one object, this may
substantially reduce the weight capacity

e) To provide cargo bay, which is similar in height to the lorry cargo height, so
that the employer with load cargo but on a straight floor.

10.3 Long Term Plan:-

1. Redesign the work unit: incorporate the use of robotics into the work unit
2. Referring for medical treatment for investigations and treatment to prevent
long term effect and further deteriorating condition and limiting activities
3. Use the same pallet for transport and storage, thus can reduce the need to
transfer from one pallet to another.

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11. Hierarchy of Control and Significant Risk

1) Elimination:.

Need to fill with info. & explanation

2) Engineering Control:.

Need to fill with info. & explanation

3) Administrative Control:

Need to fill with info. & explanation

4) Personal Protective Equipment:

Need to fill with info. & explanation

11. Reference

1. Guidelines on Ergonomic Risk Assessment at Workplace 1st Edition 2017

2. Occupational Safety and Health Act and Regulations 1994 (ed March 2017)
3. Factory and Machinery Act 1967

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PART 3: PROCESS FOR INITIAL ERA

The process for conducting initial ERA is as follows:

Musculoskeletal Assessment

This musculoskeletal assessment should be conducted for all types of risk factor in order to
identify and validate the affected body parts.

In addition, a trained person may investigate any other complaint from the employee
concerned. For the musculoskeletal assessment, the trained person may use any available
forms such as Nordic Musculoskeletal Questionnaire, Dutch Musculoskeletal Questionnaire,
Cornell Musculoskeletal Questionnaire, etc.

An example of musculoskeletal assessment forms (Cornell Musculoskeletal Questionnaire)

is as given in Appendix 3.

Ergonomics Risk Factors Assessment

The assessment depends on the types of ergonomics risk factors identified. The exposure
duration of each work posture may differ depending on the professional judgment of the
trained person. A summary or consolidated checklist of Initial ERA is as provided in
Appendix 6.

Awkward posture

The work posture of the employees should be observed using the checklist as given in
Table 3.1, and documented using audio visual and image capturing devices from various
perspectives such as from the front, back and sides.

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 Table 3.1: Checklist for Awkward Posture
Maximum Exposure Please
Physical Risk Duration tick (/)
Body Part Illustration
Factor (continuously or
cumulatively) Yes No

Working with hand More than 2 hours yes

above the head OR per day
the elbow above the
shoulder

Shoulders Working with More than 2 hours

shoulder raised per day

Work repetitively by More than 2 hours

raising the hand per day
above
the head OR the
elbow above the
shoulder more than
once per minute

Head Working with head More than 2 hours

bent downwards per day
more than 45
degrees

Working with head More than 2 hours

bent backwards per day

Working with head More than 2 hours

bent sideways per day

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 Maximum Exposure Please
Physical Risk Duration tick (/)
Body Part Illustration
Factor (continuously or
Yes No
cumulatively)
Back Working with back More than 2 hours
bent forward more per day
than 30 degrees OR
bent sideways

Working with body More than 2 hours

twisted per day

Hand/ Working with wrist More than 2 hours flexion

Elbow/ flexion OR extension per day
Wrist OR radial deviation
more than 15
degrees
Extension

deviation

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 Maximum Exposure Please
Physical Risk Duration tick (/)
Body Part Illustration
Factor (continuously or
Yes No
cumulatively)

More than 4 hours

Working with arm per day
abducted sideways

Working with arm More than 2 hours

extended forward per day
more than 45
degrees OR arm
extended backward
more than 20
degrees.

Leg/ Knees Work in a squat More than 2 hours

position. per day

Work in a kneeling More than 2 hours

position per day

Sub Total (Number of tick(s))

The maximum score for awkward posture is 13. YES score of 6 and above will initiate the
advanced ERA.

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Static and Sustained Work Posture

Static and sustained work posture should be assessed through interview and observation
of employee work activities to determine exposure duration for each body parts using the
checklist given in Table 3.2.

Table 3.2: Checklist for Static and Sustained Work Posture

Maximum Please tick

Physical Risk (/)
Body Part Exposure Illustration
Factor
Duration Yes No

Trunk/Head/ Work in a static Duration as

Neck/Arm/ awkward per table 3.1
Wrist position as in
Table 3.1

Leg/Knees Work in a More than 2

standing position hours
with minimal leg continuously
movement.

Work in seated More than 30

position with minutes
minimal continuously
movement.

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

The total score for static and sustained work posture is 3. YES score of 1 and above will
initiate an advanced assessment.

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Forceful Exertion

The assessment of forceful exertion should consider the weight of materials or force
relative to the types of activities or the manual handling task. The following information
should be gathered:

i) gender
ii) height of hand
iii) carrying distance
iv) lifting/lowering distance
v) frequency of forceful exertion
vi) obstruction along the pathway
vii) lighting, vibration
viii) physiological and psychological requirements

Lifting and lowering

For lifting and lowering operation, the recommended weight is shown in Figure 3.1. Use
Table 3.3 to assist the assessment.

Female Male

Figure 3.1: Recommended Weight

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Note: If the lifter’s hands enter more than one box during the operation, then the smallest
weight figure applies. An intermediate weight can be chosen if the hands are close to a
boundary between boxes.

Table 3.3: Recommended weight limit for forceful exertion

Recommended Current Exceed

Working Height limit?
weight limit weight
(where force is applied)
(male or female) handled Yes No

Between floor to mid-lower leg

Between mid-lower leg to knuckle 9kg 15kg

Between knuckle height and elbow 10kg 15kg

Between elbow and shoulder 8kg 15kg

Above the shoulder 4kg 15kg

Table 3.4: Recommended weight limit for lifting/lowering

with repetitive operation
If employee repeats operations Weight limit * should be reduced by

Once or twice per minutes 30%

Five to eight times per minute 50%

More than 12 times per minute 80%

* weight limit based on the Figure 3.1

Lifting and lowering with twisted body posture

If the manual handling task involve lifting and lowering with twisted body posture (if
applicable), reduce the recommended weight limit as shown in Table 3.5, with reference to
Figure 3.1.

Table 3.5: Recommended weight limit for lifting/lowering

with twisted body posture

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

45 degrees 10%

90 degrees 20%
*weight limit based on the Figure 3.1
:

Table 3.7: Summary for carrying activity

Factor Condition Outcome

Floor Surface Dry and clean floor in good condition Acceptable

Dry floor but in poor condition, worn or uneven

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

Other No factors present Acceptable

environmental
factors One or more factor present (i.e. poor lighting condition, Conduct advanced
extreme temperature) ERA

Carry distance 2 m—10 m Acceptable

Conduct advanced
More than 10 m
ERA

Obstacles en No obstacles and carry route is flat Acceptable

route
Steep slope or up steps or through closed doors or trip hazards Conduct advanced
or using ladders ERA

Table 3.8: Summary table for a single manual handling activity (forceful exertion)

Recommended weight Exceed limit?

Activity (where applicable)
limit Yes No

based on Figure 3.1 and

Lifting and lowering only
Table 3.3

based on Figure 3.1 and

Repetitive lifting and lowering
Table 3.4

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 Recommended weight Exceed limit?
Activity (where applicable)
limit Yes No

Twisted body posture while lifting and lowering; or

based on Figure 3.1 and
Table 3.5

Repetitive lifting and lowering with twisted body posture; based on Figure 3.1,
or Table 3.4 and Table 3.5

Pushing and Pulling; or based on Table 3.6

Handling in seated position; or based on Figure 3.2

Carrying based on Table 3.7

Requires an advance assessment

Repetitive Motion

For analysis of repetitive motion, a trained person should use the checklist as shown in
Table 3.9.

Table 3.9: Checklist for Repetitive Motion

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

Neck, Work involving repetitive sequence

shoulders, of movement more than twice per
elbows, minute More than 3 hours on
wrists, a “normal” workday
Work involving intensive use of the
hands, knee
fingers, hands or wrist (excluding
OR
key-in) or work involving intensive
data entry (key-in)
More than 1 hour
Work involving repetitive continuously without
shoulder/arm movement with some a break
pauses OR continuous shoulder/arm
movement

Work using the heel/base of palm as More than 2 hours

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

a “hammer” more than once per

per day
minute

Work using the knee as a “hammer” More than 2 hours

more than once per minute. per day

Sub Total (Number of tick(s))

The total score for repetition is 5. YES score of 1 and above will initiate an advanced
assessment.

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Hands-Arm and Whole Body Vibration

For analysis of work involving hands-arm and/or whole body vibration, a trained person
should use the checklist as given in Table 3.10.

Table 3.10: Checklist for Vibration

Maximum Please
Body parts Physical Risk Factor Exposure tick (/)
Duration Yes No

Hand-Arm Work using power tools (ie: battery

More than 50
(segmental powered/electrical
minutes in an hour
vibration) pneumatic/hydraulic) without PPE*

Work using power tools (ie: battery More than 5 hours

powered/electrical in 8 hours shift
pneumatic/hydraulic) with PPE* work

Whole body More than 5 hours

Work involving exposure to whole body
vibration in 8 hours shift
vibration
work

Work involving exposure to whole body More than 3 hours

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

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

*PPE related with protection to vibration

The total score for vibration is 4. YES of score of 1 and above will initiate an advanced
assessment.

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Environmental Risk Factors

For analysis of environmental risk factors in the work area a trained person should
evaluate using methods such as:
a) interview
b) observation
c) measurement using equipment for a real time assessment.

The trained person should make a professional judgment based on methods above.

For advanced ERA of the work environment, a trained person should refer to applicable
Regulations, Industrial Code of Practice, Standard and Guidelines.

Lighting
Lighting intensity should consider the following:
a) Type of activity, including general work and precise work, industrial or office;
b) Type of lighting – natural and/or artificial.

It is recommended to use real time measurement using a lux meter. However, if the
equipment is not available, based on his observation or feedback from employee, a trained
person should decide the adequacy of the lighting and record the findings in Table 3.11.

Table 3.11: Checklist for Lighting

Please tick (/)
Physical Risk Factor
Yes No

Inadequate lighting

Any evidence of inadequate lighting in the workplace (YES, score = 1), requires an
advanced assessment (refer to Table 4.1).

Extreme temperature
In assessing extreme temperature, a trained person should consider hot or cold condition.

For heat stress, trained person should refer to DOSH Guidelines on Heat Stress
Management at Workplace, 2016. It is recommended to use a heat stress meter to assess
the temperature.

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However, if measurement tool is not available, based on his observation or feedback from
employee, a trained person should decide whether an employee is exposed to the extreme
temperature and record the findings in Table 3.12. Factors to consider include:
increase/decrease of sweat rate, hyper/hypoventilation, and increase/decrease of heart
rate.

Table 3.12: Checklist for Extreme Temperature

Please tick (/)
Physical Risk Factor
Yes No

Extreme temperature (hot/cold)

Any evidence of extreme temperature for the workplace (Yes, score = 1) requires
advanced assessment (refer to Table 4.1).

Ventilation
For assessment of adequate ventilation, refer to the previous record on ventilation
assessment of the workplace if available.

It is recommended that a trained person use an appropriate equipment to assess the

ventilation. However, if the equipment is not available, based on his observation or
feedback from employee, a trained person should decide the adequacy of air ventilation
and record the findings in Table 3.13. Factors to consider include: symptoms related to
respiratory, odor, irritation of nose, throat or eyes.

Table 3.13: Checklist for Air Ventilation

Please tick (/)
Physical Risk Factor
Yes No

Inadequate air ventilation

Any evidence of inadequacy of air ventilation in the workplace (YES, score = 1) requires
advanced assessment (refer to Table 4.1).

Noise
For assessment of noise at the workplace refer to previous record on noise monitoring that
is conducted based on the legal requirements under Factory and Machinery (Noise
Exposure) Regulations 1989.

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It is recommended that a trained person use a sound level meter to assess the noise level.
However, if the equipment is not available, based on his observation or feedback from
employee, a trained person should decide whether an employee expose to excessive noise
and record the findings in Table 3.14. Factors to consider include: difficulty in holding
conversation and temporary ear ringing.

Table 3.14: Checklist for Noise

Please tick
Physical Risk Factor
Yes No

Noise exposure above PEL

(based on previous reports or measurement)

Exposed to annoying or excessive noise during

working hours

The total score for noise is 2. YES score of 1 and above will initiate an advanced
assessment (refer to Table 4.1)

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Result of Initial ERA

Initial ERA should be scored based on each factor observed and analyzed. Each YES tick
gets a score of 1. The assessment score outcome is summarized in Table 3.15.

Table 3.15: Initial ERA Form

A B C D E F

Any Pain or
Discomfort due to
Minimum Result Need
risk factors as found
Total requirement of Advanced
Risk factors in Musculoskeletal
Score for advanced Initial ERA?
Assessment
ERA ERA (Yes/No)
(refer Part 3.1)
(Yes/No)

Awkward
13 ≥6
Postures YES / NO

Static and
If YES, please tick (√)
Sustained 3 ≥1
which part of the body
Work Posture
Neck
Forceful
1 1 Shoulder
exertion
Upper back
Repetition 5 ≥1 Upper arm
Lower back
0 Forearm No
Vibration 4 ≥1
Wrist
Hand
0 No
Lighting 1 1 Hip/buttocks
Thigh
0 Knee No
Temperature 1 1
Lower leg
Feet
0 No
Ventilation 1 1

Noise 2 ≥1 0 No

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