Manual handling risks can occur in warehouses, care settings, kitchens, workshops and offices. A task does not need to involve an obviously heavy object to warrant attention.
WorkSafe identifies features such as force, repetitive movement, awkward posture, sustained vibration, handling people or animals, and unstable or difficult-to-hold loads. When considering risk, factors include posture, movement, force, frequency, duration and environmental conditions. Read the manual handling guide.
Observe the whole task
Watch where an item starts, how it moves and where it ends. Ask workers about the parts that become difficult during a busy period or near the end of a shift. Include cleaning, restocking and unusual tasks where relevant.
Consider this illustrative example: cartons arrive on a low pallet, are carried through a narrow route and are placed on a high shelf. Investigating only the lift would miss the route and the final reach. A useful assessment considers the complete activity.
Look for changes to the work
WorkSafe’s guidance recommends first trying to remove the action creating the injury risk. Other options include changes to layout, tools, work systems or mechanical aids. Explore manual handling controls.
In the carton example, the business could investigate changes to delivery arrangements, storage position or handling equipment. The appropriate solution depends on the load, space and work performed. Trial the proposed arrangement with affected workers and check that it does not create a new problem.
Use training to support suitable controls
Instructions about lifting should not become the business’s main response to an unsuitable task. WorkSafe specifically cautions that “how to lift” training does not reduce hazardous manual handling risk. Read WorkSafe’s explanation.
Workers still need appropriate information and instruction for the equipment and arrangements they use. The aim is to support a safer task design and reliable controls.
Check whether the change helps
After implementation, observe the task again. Ask whether equipment is available when needed, whether the revised layout works during peak activity and whether workers still encounter difficult parts of the task. Reported discomfort can prompt investigation and review; avoid treating it as a diagnosis.
In Averto, record the task, affected workers, existing controls and evidence. Assign actions for changes to the work and schedule a check of their effectiveness. Seek competent advice where the task is complex or the risks and suitable controls are unclear.
This article provides a starting point. People handling and other specialised activities may require additional task-specific expertise.