For occupational safety and health staff and supervisors drafting a Level 3 SOP or work instruction for repetitive motions, manual handling, pushing and pulling, exertion and awkward postures. Adapt it to actual workstations, responsibilities and applicable law, and obtain approval through document control.
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Document control
Company and site, document number and revision, prepared/reviewed/approved by, effective date and revision summary.
Purpose and scope
Identify workloads that may contribute to musculoskeletal disorders, reduce exposure and verify controls. List covered departments, tasks and workstations and determine whether contractor work under organizational control is covered.
Responsibilities
OSH staff coordinate reporting, assessment, verification and recordkeeping. Supervisors arrange observation and interviews, assign corrective actions and communicate changes. Occupational health staff summarize symptom trends, arrange consultations and refer workers as appropriate. Workers report difficulties and participate in trials and follow-up.
Procedure
- Collect reports, observations, NMQ responses and health-service summaries. Prioritize recurring symptoms, exposure and the number of people affected.
- Observe regular work with workers. Record posture, force, frequency, duration, load and breaks.
- Screen with an ergonomics checklist. Consider KIM-LHC for lifting and carrying, KIM-PP for pushing and pulling, and KIM-MHO for manual handling operations. Use the official form, scoring instructions and applicability criteria for the selected version.
- Prioritize removing or reducing high-load tasks through handling aids, adjustable benches, fixtures or tools. Add rotation, breaks or training as needed. Assign owners and deadlines and arrange health consultation or work adjustments where needed.
- Reassess with the same method and ask workers for feedback. If risk remains high, assign follow-up controls and a review date. Review changes to equipment, methods, output or work schedules.
Completed workstation example
Fictional example: Workers assembling electronic parts report neck, shoulder and wrist discomfort. Low parts and distant bins lead to repeated reaching and wrist rotation. The supervisor and OSH staff trial an adjustable fixture, reposition bins and test easier-to-grip tools. After two weeks, compare reach distance, wrist posture and repetition, and document worker feedback and follow-up.
Records and references
Keep workstation lists, assessments, action plans and follow-up under document control for the applicable retention period. Restrict individual health information to authorized staff and share only the summaries needed for workplace improvements.