New figures from Health and Safety Executive show that a shocking 33.7 million working days were lost in the UK last year due to non-fatal injuries at work, with almost a fifth linked to poor manual material handling. I’m getting in touch as I’ve seen your previous coverage on materials handling and thought this might hold some interest?
Colin Barton, Director of Coldene Castors, is urging the sector to adopt “ergonomic excellence” to tackle rising musculoskeletal injuries, boost workforce resilience and reduce costly absences. He highlights the critical role of tailored training, smarter equipment design and proper reporting practices in preventing strain and fatigue on the job…
“The most recent data from the Health and Safety Executive (HSE) reports that 33.7 million working days were lost in the UK in 2023 due to non-fatal work injuries; a truly staggering figure. The same report showed that 32 per cent of work-related ill health and 17 per cent of non-fatal injuries are linked to poor manual handling practices.
“In the context of material handling – where workers frequently lift, lower, carry, push and pull heavy objects – the workplace environment has a very direct impact on employee health and productivity, and poorly designed systems can lead to significant issues with injury. As such, it’s critical to make sure these businesses are getting it right when it comes to protecting their staff – effective ergonomic design and comprehensive training are the answer to reducing these risks.
“Manual handling injuries can vary from mild strains that require minimal recovery time to severe conditions that may lead to long-term disability or chronic pain. Sprains and strains are among the most common injuries associated with manual handling, particularly affecting shoulders and lower backs, but the incidence of Musculoskeletal Disorders (MSDs) is also rising: HSE reported that in 2023/24, 543,000 UK workers suffered from MSDs, resulting in 7.8 million lost workdays for this issue alone.
“Workplace injuries naturally have a huge effect on the individual workers, but they also create a ripple effect throughout an organisation, leading to decreased productivity and morale at multiple levels if the conditions which led to the injury are left unchecked. Prolonged or frequent staff absences due to injury can erode workers’ confidence in their workplace and increase turnover rates, further straining resources.
“In material handling, these challenges are compounded further by factors such as repetitive motions, awkward postures and inadequate equipment. Workers often have to manoeuvre in tight spaces, deal with varying weights and perform tasks under time pressure, all of which can increase the risk of injury. Promoting proper ergonomic practices in material handling isn’t just a matter of compliance or ticking boxes; prioritising the health and well-being of workers is essential for these businesses to survive.
“Ergonomic principles focus on minimising physical strain by creating equipment and workspaces that support natural body movements, ultimately lowering injury likelihood, but many organisations make costly mistakes by ignoring this in their training approaches. One major error is relying on one-off training sessions about safe use of equipment without follow-ups, leading to a gradual decline in safe practices. Regular refresher courses should be integrated into the annual health and safety calendar to reinforce good habits.
“Another common issue is the use of generic training that fails to address the specific risks faced by different roles. Tailoring training to real-life tasks ensures relevance and engagement, enhancing its effectiveness. Many companies cling to outdated techniques that do not reflect current biomechanical knowledge, so regular updates to training materials, aligned with HSE guidelines, are pivotal to minimising injury risks. Neglecting to train supervisors also hinders progress; managers need to be well-equipped to recognise unsafe or sub-optimal practices and support their teams to address issues.
“I’ve witnessed firsthand how critical ergonomics is in the material handling sector. The science of ergonomics focuses on creating workspaces that enhance worker comfort and efficiency; within environments where heavy lifting and repetitive tasks are routine, the risks of injury are particularly high, so incorporating ergonomic principles into equipment design can significantly reduce these risks. We’re therefore advocating for a shift toward ergonomic excellence in industry standards to prioritise worker welfare. Workers must be protected against serious injury, but we want to see the same dedication to minimising the impact of ergonomic inefficiencies: letting minor injuries slip by can lead to ‘death by a thousand cuts’, adding up to a critical impact.
“It’s essential for stakeholders in the material handling industry to engage in ongoing dialogue about these issues. Progress is being made; for example, the UK Material Handling Association (UKMHA) this year launched a new incident-reporting portal aimed at enhancing the tracking of injuries, recognising the need for a collective effort to address safety concerns effectively.
“A recent white paper from the UKMHA also spotlighted the importance of near-miss and hazard reporting – critical to safety within the material handling industry, but often admin-heavy and inefficient – as a key area for improvement. We believe the same principle ought to apply to feedback from workers on ergonomics: they should be actively encouraged to report system flaws and suggest improvements which could reduce injuries.
“Those responsible for reviewing the challenges of the material handling industry should have the role of ergonomics at the forefront of their potential reforms. Such a commitment will enhance productivity through safeguarding the health of the workforce. In the meantime, we offer the following advice to frontline workers and decision-makers:
Practical Tips for Workers in Material Handling
1. Use Proper Lifting Techniques: Always bend at the knees, keep your back straight, and lift with your legs rather than your back. When handling materials, ensure that loads are close to your body to maintain balance and reduce strain.
2. Break Up Tasks: Avoid long periods of repetitive motion; instead, alternate between different types of tasks. For example, if you’re stacking boxes, take a break to perform a different task like operating a pallet jack, allowing your muscles to recover.
3. Utilise Equipment: Make full use of available ergonomic tools, such as pallet trucks, trolleys, or forklifts, to transport heavy items instead of lifting them manually. Ensure you’re trained on how to operate this equipment safely to maximise its benefits.
4. Take Regular Breaks: Schedule frequent short breaks to stretch and move around, particularly during tasks that require prolonged standing or lifting. Implement micro-breaks where you can perform simple stretches that target your back, shoulders, and legs.
Practical Tips for Management in Material Handling
1. Conduct Ergonomic Assessments: Regularly evaluate workspaces to identify potential ergonomic risks specific to material handling tasks. This includes assessing lifting techniques, workstation layout, and the equipment used for moving goods.
2. Provide Training: Offer training sessions on proper lifting techniques tailored to the specific materials being handled. Highlight the importance of ergonomics in the workplace, ensuring all workers understand how to use equipment safely and effectively.
3. Invest in Ergonomic Equipment: Equip workstations and material handling areas with ergonomic tools and machinery, such as adjustable lifting devices, anti-fatigue mats, and ergonomic castors. This investment can lead to long-term savings by reducing injury-related costs.
4. Encourage Open Communication: Create a culture where workers feel comfortable discussing ergonomic concerns and suggesting improvements. Regular feedback from frontline workers helps identify issues before they lead to injuries, fostering a proactive approach to safety.
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