Ergonomic Risk Assessment

Ergonomic risk assessment is a systematic process used to identify factors that may contribute to musculoskeletal injuries, excessive physical strain, and repetitive-task injuries.

It is particularly useful for workplaces involving manual handling, repetitive upper-limb movements, awkward postures, lifting, pushing, pulling, and prolonged physical tasks.

A practical ergonomic assessment can be organized into five key steps:

1. Describe the task → 2. Collect technical information → 3. Identify risk factors → 4. Implement improvements → 5. Review the results

Step 1: Describe the Task

Start by observing how the task is actually performed.

Speak with the workers involved and identify the main stages of the activity. Where appropriate and with consent, photographs or video recordings can help document important postures and movements.

For manual lifting tasks, consider:

• Load weight

• Frequency of lifting

• Lifting height

• Distance of the load from the body

• Bending or twisting

• Grip on the load

• Floor and environmental conditions

Goal: Understand what the worker actually does during the task.

Step 2: Collect Technical Information

Next, collect measurable information about the task and workplace.

This may include:

• Load weight

• Work surface height

• Lifting and reaching distances

• Storage height

• Frequency and duration of the task

• Observed working postures

Tools such as a measuring tape, weighing scale, photographs, and video recordings can provide useful information.

Accurate measurements help make the risk assessment more objective.

Step 3: Identify the Risk Factors

Use an appropriate ergonomic risk assessment tool to evaluate the information collected.

Depending on the task, tools such as:

• MAC Tool – Manual Handling Assessment Charts

• ART Tool – Assessment of Repetitive Tasks

• RAPP Tool – Risk Assessment of Pushing and Pulling

may be appropriate.

The assessment should document why a particular risk level has been assigned.

For example, a combination of heavy loads, frequent lifting, awkward posture, and excessive reaching may indicate a higher ergonomic risk.

Step 4: Implement Improvements

Once the risks are identified, practical controls should be introduced to eliminate or reduce them.

Possible improvements include:

Mechanical Assistance

Use hoists, trolleys, conveyors, lifting equipment, or other mechanical aids.

Workplace Reorganization

Reposition materials, tools, and equipment to reduce unnecessary reaching, bending, or twisting.

Safe Work Procedures

Develop clear procedures, method statements, or standard operating procedures for higher-risk tasks.

Worker Training

Train employees on the correct use of equipment and safe work practices.

The best solution is usually one that reduces the physical demand of the task rather than relying only on worker technique.

Step 5: Review the Improvements

An ergonomic assessment should not end after improvements are introduced.

Review the task to confirm that:

• Recommended controls have been implemented

• Workers are using them correctly

• The original risk factors have been reduced

• The new process is practical and effective

Where appropriate, the risk assessment tool can be used again to compare the new risk level with the original assessment.

Assess → Improve → Reassess

Common Ergonomic Risk Factors

During an assessment, pay particular attention to:

• Heavy or awkward loads

• Repetitive movements

• Bending and twisting

• Excessive reaching

• High or low working heights

• Poor grip

• Long carrying distances

• Forceful movements

• Prolonged static postures

• Poorly designed workstations

Identifying these factors early can help prevent work-related musculoskeletal problems.

Why Is Ergonomic Risk Assessment Important?

A structured assessment can help organizations:

• Identify workplace ergonomic hazards

• Reduce unnecessary physical strain

• Improve work processes

• Select appropriate control measures

• Reduce the likelihood of musculoskeletal injuries

• Improve workplace safety and efficiency

Conclusion

Ergonomic risk assessment is an ongoing process rather than a one-time activity.

By observing the task, collecting accurate information, identifying risks, implementing controls, and reviewing the results, workplaces can create safer and more efficient working conditions.

The key principle is simple:

Identify the risk → Control the risk → Review the result.