OSH2104 ERGONOMICS

ERGONOMICS RISK
ASSESSMENT

PREPARED BY:
Muhammad Asyraf Bin Rashidi
(DOSHM22040002)

LECTURER:
Ms. Fatehah Najwa Bt. Mohd Farith
 Subject: Ergonomics
Session: Apr-Aug 2023

TABLE OF CONTENT

1.0 INTRODUCTION..................................................................................................................... 3
1.1 Work Description................................................................................................................3
2.0 METHODOLOGY.................................................................................................................... 4
2.1 Permission and Consent....................................................................................................4
2.2 Interview............................................................................................................................ 4
2.3 Workstation and Activity Observation................................................................................ 5
2.4 Ergonomic Risk Assessment (ERA) Questionnaire...........................................................5
3.0 FINDINGS AND DISCUSSION............................................................................................... 6
3.1 Self Assessment Musculoskeletal Pain / Discomfort Survey.............................................6
3.2 Ergonomic Risk Factors: Awkward Posture.......................................................................7
3.3 Ergonomics Risk Factors: Forceful Exertion (Manual Handling)....................................... 8
3.4 Initial ERA........................................................................................................................ 11
4.0 RECOMMENDATION............................................................................................................12
4.1 Engineering Control......................................................................................................... 12
4.2 Administrative Controls....................................................................................................14
4.3 Personal Protective Equipment (PPE).............................................................................15
5.0 CONCLUSION.......................................................................................................................16
APPENDICES............................................................................................................................. 17
REFERENCES............................................................................................................................ 22

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1.0 INTRODUCTION

On 9th of July 2023, I have conducted Ergonomic Risk Assessment (ERA) at Bursa
Malaysia Berhad building located at Exchange Square, Bursa Malaysia Berhad,
30632-P, Bukit Kewangan, 50200 Kuala Lumpur, Wilayah Persekutuan Kuala Lumpur
(Refer Appendix 1.0). I had the permission of a company named Ilham Kasyaf Sdn.
Bhd, where they are doing mostly air conditioning service to buildings such as repairing,
installing, and maintenance and followed their workers to this work site for assessing
and observing their work routine to conduct my assessment before choosing on what
type of work activity to assess for my Initial ERA. There are five personnel tasked for
this working site consisting of four installers and one supervisor. There are multiple work
activities involved such as mounting indoor and outdoor air conditioning units, wiring,
and drilling holes for the mounting plate. The objective of this assessment is to identify
the effect of working activities towards an individual body parts and relate it to
ergonomics. This assessment has been conducted through observation, interview, and
analysis of the specific working activity. This report will further explain the findings that
have been found during this assessment.

1.1 Work Description

The type of working activities that have been selected was carrying an outdoor air
conditioning unit known as condenser coil (Refer Appendix 1.1) by using a ladder. This
activity has been performed on a daily basis depending on height of the bracket placed,
the amount of outdoor unit that needed to be installed, and depending on size and
weight of the unit. The duration of this work activity usually took two hours to complete
for one outdoor unit and 6-8 hours depending on the job and sites. For this activity, the
outdoor unit weight was 25.5kg per unit.

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Session: Apr-Aug 2023

2.0 METHODOLOGY

There are four methods that I have used in conducting this assessment. These methods
demanded focus and proper communication to gather data, information, understanding
of the task and relation to ergonomic risk factors, and to conclude the assessment.

2.1 Permission and Consent

To conduct the assessment, firstly, I contacted Kasyaf Ilham Sdn Bhd for their
permission and consent by handing out an official letter (Refer Appendix 2.0) prepared
by Ms. Fatehah Najwa. The permission also includes taking pictures of work activity,
observing the process, and interviewing the worker. As we reached an agreement, soon
I requested another permission from a worker named Syabri bin Alias for his consent to
interview and take pictures of him performing the work activity.

2.2 Interview

An interview session has been conducted with Mr. Syabri bin Alias, a 47-year old senior
and experienced worker who has worked for the company for nearly 15 years. His task
was installing the air conditioning outdoor unit by drilling holes in the wall for the
bracket, carrying and installing the outdoor unit on the bracket, and performing wiring
installation as well. With this session, I gather information about the routine, weight of
the outdoor unit which is 25.5kg per unit, the duration of the installation which is 2 hours
per unit, the preventive methods used by the company to avoid health risk, and many
more. By using Appendix 1 and Appendix 6 from Guidelines On Ergonomic Risk
Assessment At Workplace 2017 (Refer to Appendices) by DOSH, data has been
gathered to conclude the assessment.

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 Subject: Ergonomics
Session: Apr-Aug 2023

2.3 Workstation and Activity Observation

This method has been used to obtain data for conducting the Initial ERA and identifying
the risk factors in relation to the work activity performed by the worker with assessing
the following ergonomic risk factors such as awkward posture, forceful exertion, static
and sustained posture, vibration, environmental stress, repetitive motion, and contact
stress. The job task selected was carrying an outdoor unit weight 25.5kg by using a
ladder (Refer Appendices).

2.4 Ergonomic Risk Assessment (ERA) Questionnaire

This method has been done after the work activity where the worker was asked based
on the given form to determine the harm arising from his work activity through exposure
of ergonomic risk factors. From the data obtained from the questionnaire, I can
conclude whether if the risk factors from Initial Era results exceeded the minimum
requirement for advanced assessment, risk factors that caused any pain or discomfort
due to the risk factors found in Musculoskeletal Assessment (Refer Appendices), and
whether it needs advanced ERA.

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Session: Apr-Aug 2023

3.0 FINDINGS AND DISCUSSION

3.1 Self Assessment Musculoskeletal Pain / Discomfort Survey

For the Appendix 1 (Picture Below), based on the interview I have conducted, the
worker feeling the pain / discomfort on his neck, shoulder, upper back, right upper arm,
right elbow, right lower arm, right hand, lower back, left and right thighs, and both knees,
comes from work. He usually felt the pain / discomfort right after performing the work.

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3.2 Ergonomic Risk Factors: Awkward Posture

Awkward posture refers to positions of the body deviating significantly from the neutral
position while performing work activities. When you are in awkward posture, muscles
operate less efficiently and you expend more force to complete the task.

To perform installation of the outdoor unit, the worker has to carry load himself on his
shoulder (Refer Appendix 3.2) and go up with the ladder to put it in the bracket that
has been installed earlier. While carrying 25.5kg on his shoulder by climbing the ladder,
his body was in an awkward posture thus the worker felt the pain on a few body parts.

Based on Appendix 6: Initial Ergonomics Risk Assessment Checklist form (Picture

Below), the workers has ticked 6 boxes according to body parts affected which are:

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Session: Apr-Aug 2023

● Shoulders: Working with shoulders raised with maximum exposure duration of

more than 2 hours per day and working repetitively by raising with elbow above
the shoulder more than once per minute with maximum exposure duration of
more than 2 hours per day. (Refer Appendix 3.2)
● Head: Working with hand bent sideways (Refer Appendix 3.2) with maximum
exposure duration of more than 2 hours per day.
● Back: Working with body twisted (Refer Appendix 3.2) with maximum exposure
duration of more than 2 hours per day.
● Hand / Elbow / Wrist: Working with arm abduction sideways with maximum
exposure duration of more than 4 hours per day and working with arm extended
forward more than 45 degrees with maximum exposure duration of more than 2
hours per day. (Refer Appendix 3.2)

3.3 Ergonomics Risk Factors: Forceful Exertion (Manual Handling)

Forceful exertion describes the amount of effort exerted by muscles to complete a job or
task. Normally consisting of heavy lifting or lowering, pushing or pulling.

Based on Appendix 6: Initial Ergonomics Risk Assessment Checklist form (Picture

Below), the worker has to lift an outdoor unit weighted 25.5kg from the floor up to his
shoulder.

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Session: Apr-Aug 2023

Based on the figure 3.1 Recommended weight for lifting in manual handling, from
between floor to mid-lower leg where the force is applied is 10 kg for male. The worker's
current weight handled was 25.5kg which exceeded the recommended weight. For
above the shoulder recommended weight limit is 10 kg for male, but the current weight
handled was 25.5 kg which exceeded the recommended weight as well.

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Therefore, with repetitive operation of lifting, once or twice per minute, the current
weight handled should be reduced by 30% which equals 3 kg. Hence, the
recommended weight for repetitive operation in lifting should be 7 kg. (Refer picture
below)

For twisted body posture during lifting (Refer Appendices), based on the checklist in
Appendix 6, if the employee twists the body from forward facing to the side 45 degrees,
the weight should be reduced to 10%. Hence, the total needed to be reduced was 0.7
kg, which is 6.3 kg from the recommended weight.

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3.4 Initial ERA

This form is based on every methodology such as interview, checklist form, and work
observation. Initial ERA (Refer Picture Below) can conclude that the risk factors that
need advanced ERA are awkward postures and forceful exertion. For awkward posture,
the minimum requirement for advanced assessment score is more or equal to 6 out of
13, and from the result the score is 6. Therefore, an awkward posture risk factor needs
advanced ERA. For forceful exertion, the minimum requirement for advanced
assessment score is 1 out of 1, and from the result the score is 1. Therefore, the risk
factor for forceful exertion needs advanced ERA. The result also concluded that the
worker felt pain or discomfort on his neck, shoulder, upper back, upper arm, lower back,
forearm, hand, thigh, and knee, due to the risk factors as found in Musculoskeletal
Assessment.

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4.0 RECOMMENDATION

Ergonomic risk assessment is essential in identifying and mitigating potential hazards in

the workplace to ensure the health and well-being of employees. Two critical risk factors
that require special attention are awkward posture and forceful exertion. These factors
often contribute to musculoskeletal disorders and can result in absenteeism, decreased
productivity, and increased workers' compensation claims. To address these issues
effectively, employers should implement the following recommendations;

4.1 Engineering Control

Identify opportunities to introduce engineering controls that can reduce the need for
forceful exertions or awkward postures. This might involve using assistive devices,
automation, or mechanization to handle heavy loads or repetitive tasks, reducing the
strain on employees' musculoskeletal systems.

Engineering controls for reducing awkward posture and forceful exertion while carrying
an AC outdoor unit and climbing up a ladder can significantly minimize the risk of
musculoskeletal injuries. Here are some recommendations:

● Ladder with Assisted Climbing Mechanism: Provide a ladder equipped with an

assisted climbing mechanism, such as a ladder hoist or an inclined lift system.
These devices can help lift and transport heavy loads, like the AC outdoor unit,
up the ladder without requiring excessive force from the worker. The worker can
guide the unit's movement rather than fully carrying its weight, reducing the risk
of forceful exertion. (Refer Appendix 4.1)
● Mechanical Lifting Aid: Implement a mechanical lifting aid specifically designed
for carrying heavy objects up the ladder. This could be in the form of a pulley
system, a winch, or a manual or electric hoist. Using such aids will alleviate the
need for the worker to use excessive force and awkward postures while
ascending the ladder with the AC unit. (Refer Appendix 4.2)

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● Ramp or Platform Access: Whenever possible, set up a ramp or platform access

near the installation site for the AC unit. This way, the worker can slide or roll the
unit onto the elevated location rather than carrying it manually. The ramp or
platform should be designed to minimize any incline or obstacle that might cause
strain during the movement. (Refer Appendix 4.3)
● Equipment with Handles or Grips: Ensure that the AC outdoor unit has
well-designed handles or grips that are ergonomically positioned. This will allow
the worker to maintain a more natural and comfortable grip while carrying the
unit, reducing awkward postures and the risk of strain.
● Team Lifting Procedures: When carrying the AC unit, encourage a team-lifting
approach that involves two or more workers. Team lifting can help distribute the
load more evenly and allow for better coordination, reducing the individual force
required and promoting better posture during the task.
● Elevated Work Platform: Consider using an elevated work platform or scaffold
near the installation site. This will allow the worker to place the AC unit at an
appropriate height, avoiding the need to lift it all the way to the final location while
on the ladder. (Refer Appendix 4.4)

By implementing these engineering controls, employers can significantly reduce the

physical demands of carrying AC outdoor units up ladders, minimizing the risk of injuries
related to awkward posture and forceful exertion. Creating a safer work environment will
lead to increased productivity, fewer workplace injuries, and improved overall job
satisfaction among workers.

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Session: Apr-Aug 2023

4.2 Administrative Controls

Administrative controls complement engineering controls by focusing on the

organization's policies, procedures, and work practices to reduce the risk of awkward
posture and forceful exertion when carrying AC outdoor units and climbing ladders.
Here are some administrative control recommendations:

● Job Rotation and Task Planning: Implement job rotation to vary workers' tasks,
including those involving carrying AC units and climbing ladders. Rotating tasks
can help prevent overexertion and muscle fatigue associated with repetitive
actions, allowing employees to recover between physically demanding activities.
● Work Breaks and Rest Periods: Encourage regular work breaks and rest periods,
especially during physically demanding tasks. Providing scheduled breaks allows
employees to recover and reduce the risk of overexertion and awkward postures
caused by fatigue.
● Pre-Task Planning and Risk Assessment: Before starting any job involving lifting
AC units and climbing ladders, conduct a pre-task planning session with workers.
Identify potential hazards and discuss strategies to minimize awkward postures
and forceful exertions. Encourage workers to voice any concerns and
suggestions for improving safety during the task.
● Workload Management: Ensure that workers are not overloaded with tasks
requiring heavy lifting and ladder climbing. Adjust work schedules and staffing
levels to ensure sufficient manpower for physically demanding jobs, preventing
workers from rushing or using improper techniques due to time pressure.
● Training and Education: Provide comprehensive training on safe lifting
techniques, ladder safety, and ergonomic principles. Train workers to recognize
the signs of overexertion and discomfort, and emphasize the importance of
reporting any musculoskeletal issues promptly.

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4.3 Personal Protective Equipment (PPE)

Personal Protective Equipment (PPE) controls play a crucial role in safeguarding

workers from potential hazards associated with carrying AC outdoor units and climbing
ladders. While PPE should be considered the last line of defense after engineering and
administrative controls, it still plays a vital role in protecting workers. Here are some
PPE control recommendations:

● Safety Gloves: Provide workers with appropriate safety gloves designed to

enhance grip and reduce the risk of strain and discomfort during the handling of
AC units. Look for gloves with a good grip on the surface to prevent slippage and
make lifting tasks more manageable. (Refer Appendix 4.5)
● Back Support Belts: Consider offering back support belts for workers who are
required to carry heavy AC units. These belts can help stabilize the lower back
and promote proper lifting techniques, reducing the risk of musculoskeletal
injuries. (Refer Appendix 4.6)
● Personal Fall Protection: For work at elevated heights, such as climbing ladders,
personal fall protection equipment like harnesses and lanyards should be
provided and properly used to prevent falls. (Refer Appendix 4.7)

It's essential to train workers on how to use and maintain their PPE correctly.
Additionally, regularly inspect and replace PPE when necessary to ensure it remains
effective in protecting workers.

Remember, while PPE is essential, it should be combined with other control measures
(engineering and administrative) to provide a comprehensive approach to workplace
safety. By implementing PPE controls along with other safety measures, organizations
can significantly reduce the risk of injuries and promote a safer work environment.

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5.0 CONCLUSION

In conclusion, the ergonomics risk assessment for Mr. Syabri bin Alias and his task of
carrying a 25.5 kg AC outdoor unit highlights the critical importance of ensuring the
safety and well-being of workers engaged in this physically demanding task. The
assessment has identified potential hazards such as awkward posture and forceful
exertion, which can lead to musculoskeletal disorders and work-related injuries.

It is advised to take a variety of measures in order to successfully address these

threats. Engineering controls, such as the use of mechanical lifting aids and ergonomic
tools, can greatly lessen the physical stress that is placed on workers while they are
lifting and transporting objects. In order to provide a healthier work environment,
administrative measures like job rotation and careful task planning can assist prevent
overexertion and muscular fatigue.

Additionally, personal protective equipment (PPE) should be considered as a

supplementary measure to further safeguard workers. Properly fitting gloves, back
support belts, and slip-resistant footwear can contribute to reducing the likelihood of
injuries and discomfort during the task.

Furthermore, training and education play a vital role in equipping workers with the
knowledge of safe lifting techniques and proper body mechanics. By empowering
employees to recognize and address ergonomic risks, organizations can foster a culture
of safety and injury prevention.

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APPENDICES

Appendix 1.0

Appendix 1.1

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Appendix 2.0

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Appendix 3.0

Appendix 3.1

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Appendix 4.1 Appendix 4.2

Appendix 4.3 Appendix 4.4

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Appendix 4.5 Appendix 4.7

Appendix 4.7

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REFERENCES

● Ergonomics | Environmental, Health and Safety Services | Virginia Tech. (n.d.).

https://ehss.vt.edu/programs/ERG_express.php

● Chowdhury, S. S., Boricha, J., & Yardi, S. (2012). Identification of awkward

postures that cause discomfort to Liquid Petroleum Gas workers in Mumbai,

India. Indian Journal of Occupational and Environmental Medicine, 16(1), 3.

https://doi.org/10.4103/0019-5278.99679

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