Risk analysis and management of repetitive actions: a guide for applying the OCRA system (occupational repetitive actions)

444 Pages·2017·18.37 MB·English

by  Colombini

Risk Analysis
and Management of
Repetitive Actions
A Guide for Applying the OCRA System
(Occupational Repetitive Actions)
T H I R D E D I T I O N
Ergonomics Design and Management:
Theory and Applications
Series Editor
Waldemar Karwowski
Industrial Engineering and Management Systems
University of Central Florida (UCF) – Orlando, Florida
Published Titles
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Risk Analysis
and Management of
Repetitive Actions
A Guide for Applying the OCRA System
(Occupational Repetitive Actions)
T H I R D E D I T I O N
Daniela Colombini
Enrico Occhipinti
This book was previously published in Italian entitled, L’Analisi E La Gestione Del Rischio Nel Lavoro
Manuale Ripetitivo-Manuale Per I’uso del Sistema OCRA, published by FrancoAngeli s.r.l., Milano
Italy, 2014.
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Version Date: 20160805
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Dedication
It has always been my greatest wish to thank all those, like
me, who have dedicated and dedicate their life to safety and
prevention and to these artists of ergonomics I dedicate these
beautiful phrases of an artist par excellence, Van Gogh.
“The beginning is probably more difficult than any other
thing … be confident … and everything will go well.”
“There’s safety in the middle of the danger … what
would life be … without the courage to try?”
“Looking back … with a soft regret … I’ll think of what
I could have done … but … now I do what I can.”
“I do always what I am not able to … in order to learn how to do it.”
from Dani the Jefa

Contents
Preface..................................................................................................................xxiii
Author ....................................................................................................................xxv
Chapter 1 Introduction ..........................................................................................1
1.1 The Reference Framework ........................................................1
1.2 A Glance at the Regulations ......................................................2
1.2.1 European Directives .....................................................2
1.2.2 The Machinery Directive .............................................4
1.3 Approach to Risk Evaluation and Management ........................5
1.3.1 First Level .....................................................................7
1.3.2 Second Level ................................................................7
1.3.3 Third Level ...................................................................8
Chapter 2 Simplified Analysis of Workplace Organization: From a Macro-
to a Micro-Analysis of the Workplace and the Basis for Risk
Exposure Assessment among Workers (and Homogeneous
Worker Groups) ....................................................................................9
2.1 Introduction: Sectors and Classification of Work Activities .....9
2.2 How Products Are Made .........................................................11
2.3 How a Manufacturing Unit Is Structured: Definitions of
Machinery Types and Workstations ........................................11
2.4 How to Analyze a Department: Identification of
Production Areas, Machinery, Assembly Stations, and
Operator Allocation .................................................................12
2.5 Job Analysis: A Few Basic Definitions ...................................12
2.5.1 Repetitive Task: Definition .........................................15
2.5.2 Cycle: Definition .........................................................16
2.6 Job Analysis: Tasks Performed by Operators at One or

More Workstations ..................................................................16
2.7 Repetitive Task Analysis: Type and Content of the Work
Cycle Making Up the Task ......................................................17
2.8 Repetitive Task Analysis: Micro-Analysis of the
Structure of the Task within the Cycle ....................................21
Chapter 3 Initial Identification and Preliminary Assessment
(Pre-Mapping) of Potential Risks ......................................................23
3.1 ISO/TR 12295: Key Enters and Quick Assessment ................23
3.1.1 Key Enters ..................................................................23
3.1.2 The Quick Assessment ...............................................25
ix
x Contents
3.2 Pre-Mapping of Hazards, Dangers, and Discomfort ...............27
3.2.1 Foreword .....................................................................27
3.2.2 The Pre-Mapping Model ............................................28
3.2.3 First-Level Pre-Mapping (Key Enters) .......................28
3.2.3.1 Details Concerning the Place of
Employment ................................................28
3.2.3.2 Key Enters for Identifying Priorities
Related to the Risk of Biomechanical
Overload ......................................................30
3.2.3.3 Key Enters for Identifying Indoor
Lighting Problems ......................................33
3.2.3.4 Key Enters for Identifying Problems
Relating to Outdoor Work/UV
Radiation ...............................................33
3.2.3.5 Key Enters for Identifying Problems
Relating to Noise ........................................33
3.2.3.6 Key Enters for Identifying Problems
Relating to Micro-climate ..........................37
3.2.3.7 Key Enters for Identifying Problems
Relating to Tools/Equipment ......................37
3.2.3.8 Key Enters for Identifying Problems
Relating to Exposure to Vibrations .............37
3.2.3.9 Key Enters for Identifying Problems
Relating to the Use of Machinery or
Machine Parts .............................................37
3.2.3.10 Key Enters for Identifying Problems
Relating to Pollutants (Chemical Risk,
Biological Risk) and Other Specific
Risk Factors ................................................37
3.2.3.11 Key Enters for Identifying
Organizational Problems ............................37
3.2.3.12 Key Enters for Identifying Potential
Work-Related Stress Inducers ...................44
3.2.4 Second-Level Pre-Mapping (Quick Assessment) .......44
3.2.4.1 Quick Assessment of Repetitive Tasks .......46
3.2.4.2 Quick Assessment of Manual Load
Lifting .......................................................48
3.2.4.3 Quick Assessment of Manual Load-
Carrying Tasks ............................................52
3.2.4.4 Quick Assessment of Load Pushing
and/or Pulling .............................................55
3.2.4.5 Description and Initial Inspection of
Chemical Pollutants ....................................59
3.2.5 Summary Results of Pre-Mapping .............................59
3.2.6 Examples of Pre-Mapping Results .............................63