Prevent material handling accidents: 5 key steps

worker in a warehouse

The movement, storage and handling of materials is a critical process for the success of most businesses. When material handling is not properly considered, it leads to an increased risk of injury and can result in operational disruptions that have extensive financial impact. From a safety standpoint, injuries related to material handling are the leading cause of worker injuries resulting in days away from work. Recent data from the Bureau of Labor Statistics (BLS) indicates an alarming total of 976,090 cases of musculoskeletal disorders in the private sector during the most recent reporting period, with 502,380 of these cases resulting in days off work1. Read on to discover how effective material handling practices can safeguard your team from injury and protect your business.

Types of material handling

Generally speaking, material handling refers to the movement, control, storage and protection of materials, products and goods. It involves tasks and processes related to transporting, positioning and managing materials, such as raw materials, components, finished products, or equipment, throughout the stages of production and distribution. Material handling can be broadly categorized into two types: manual and mechanical.

Manual material handling

This involves tasks like carrying, lifting, holding, and moving materials by hand. Workers often perform these tasks individually, and the risk of injury increases with the weight and size of the materials, body position, and frequency of the task.

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Mechanical material handling

This includes the use of fixed and mobile equipment such as sorters, stackers, robotics, lift trucks, conveyers and cranes for rapid, repetitive movement of materials. While these machines can increase efficiency, they also bring their own set of safety challenges.

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Understand the risks

Both manual and mechanical material handling tasks pose distinct risks to workers. Factors like overexertion, poor ergonomics, lack of proper training, heavy loads, speed of movement, awkwardly shaped materials, and environmental conditions (such as slippery floors or inadequate lighting) contribute to the risk of injuries.

Manual material handling often results in musculoskeletal disorders (MSDs) such as strains, sprains and repetitive motion injuries due to the physical exertion required. These are rarely fatal but can have long-term, life-changing impact. 

Mechanical material handling involves greater force and/or speed, which often results in risks such as workers being caught in or struck by equipment. These forces and the size of the loads handled increase the risk of severe or fatal injury results. The NSC reports that Injuries resulting from contact with objects and equipment is the third leading cause of work-related deaths.

It is important to understand these material-handling injury risks, identify them within the workplace, and provide solutions to reduce these risks to prevent employee injuries.

The National Safety Council notes that MSDs remain the most common workplace injury in the United States and that these injuries cost nearly $18 billion a year for U.S. businesses in the private sector.

Steps for preventing material handling accidents

The management of material handling risks requires taking a proactive approach. Whether manual or mechanical, here are 5 prevention strategies to enhance workplace safety during material handling tasks:

1. Assess the tasks

Enlist the support of workers, managers and other key stakeholders to carefully evaluate the jobs performed by both machines and employees. The team should identify potential injuries that can arise from equipment use and manual tasks. Consider that some mechanical handling tasks include manual handling elements (e.g., rigging a load for movement by a crane). Conducting a Job Hazard Analysis (PDF) is one way to complete an assessment and develop needed controls.

2. Address ergonomics

Ergonomic design plays a crucial role in preventing musculoskeletal injuries, which often lead to lost work time.2 Analyze past incidents to identify problem areas and use Nationwide’s Ergonomic Screening Tool (PDF) to help identify risk factors and control options.

When lifting of materials must be done, one way to help minimize risk is to apply the acronym “KIND”:

  • K: Keep it close - keep the load close to the body. The further away the load is from the spine, the greater the force on the back. As the elbows extend past your side, the force is quickly multiplied.
  • I: In strike zone - keep the load within the “strike zone”, i.e., above the knees and below the chest.
  • N: Nose and toes aligned - if they are pointing in the same direction, then you aren’t twisting at the trunk.
  • D: Don’t lean over or look down - bending at the waist and tilting the head forward put the back out of its natural alignment. When lifting, think elevator instead of crane.

Designing lifting tasks with KINDness in mind and teaching employees to lift KINDly will go a long way to preventing lifting-related musculoskeletal disorders.

warehouse worker

3. Use machines and technology to your advantage

For smaller, less strenuous tasks, manual handling is sufficient. However, for larger and more demanding tasks, consider the use of mechanical handling equipment. According to the National Institute for Occupational Safety and Health (NIOSH), the recommended maximum weight for manual lifting is 51 pounds; however, this is only under ideal conditions. It will decrease based on the characteristics of the object and the task. Technology such as vacuum lifts and lift tables can minimize this risk. As noted, larger mechanical handling equipment can allow for increased load sizes and speed, so control of the work area is critical, the equipment must be well-maintained, and operators should be properly trained.

4. Prevent injuries through design

When designing tasks, prioritize material handling considerations. Thoughtful task design can minimize manual lifting issues and control mechanical handling risks. Developing job tasks with material handling in mind from the outset is easier and more cost effective than having to retrofit the area for the job task. According to the NIOSH, one of the best ways to control the risk of occupational injuries, illnesses and fatalities is by using a “prevention through design” process.

5. Use Nationwide as part of a team approach

Employees, engineers, maintenance personnel, managers and production workers should be engaged in brainstorming sessions to generate ideas for task design and injury prevention. Those working in job tasks with material handling can be great resources for different solutions to minimize risks. Employers can also consult equipment vendors and ergonomics experts to evaluate problematic areas. Importantly, Nationwide has several resources that can help to enhance current safety measures for both manual material handling, mechanical material handling, and utilizing a team approach to support the evaluation and control of hazards.

Resources

[1] Bureau of Labor Statistics. (2023 Nov. 8). Employer-Reported Workplace Injuries and Illness, 2021-2022. U.S. Bureau of Labor Statistics. https://www.bls.gov/news.release/osh.nr0.htm
[2] Occupational Safety and Health Administration. (2022, January 15). Ergonomics. OSHA. https://www.osha.gov/ergonomics

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