Ergonomic Risk Assessment

Inspection template for evaluating ergonomic risks using lifting, posture, and task factors, with scoring and intervention planning.

Inspection Scope and Job Information

• Job/task observed is clearly identified
  Record the job title, task name, department, and location being assessed.
• Primary task cycle and duration documented
  Capture the typical cycle time, shift duration, and frequency of the task.
• Recent complaints, discomfort reports, or injury trends reviewed
  Confirm whether employee reports, first aid logs, or injury trends were considered in the assessment.
• Task changes or new equipment since last assessment identified
  Note any process, staffing, layout, or equipment changes that may affect ergonomic exposure.

Lifting and Manual Handling

• Loads lifted are within acceptable weight limits for the task
  Assess whether the weight, frequency, and handling conditions create excessive strain for the worker population.
• Lift requires twisting, bending, or reaching outside neutral zone
  Identify whether the lift occurs below knee height, above shoulder height, or with trunk rotation.
• Two-person lift or mechanical aid used when needed
  Verify that carts, hoists, lift tables, or team lifts are used for awkward or heavy loads.
• Load is stable, easy to grasp, and does not require excessive grip force
  Check for slippery surfaces, poor handholds, sharp edges, or unstable contents that increase force demand.
• Lift frequency and recovery time are appropriate
  Assess whether repetitive lifting is balanced by adequate micro-breaks or task rotation.

Posture, Reach, and Workstation Setup

• Neutral wrist, shoulder, and neck posture maintained during task
  Observe whether the worker can keep joints in a neutral position without sustained deviation.
• Work surface height supports the task without excessive bending or reaching
  Verify that bench, table, or counter height is appropriate for the worker and task type.
• Frequently used items are within easy reach
  Confirm that tools, materials, and controls are placed within the primary reach zone to reduce shoulder extension and trunk flexion.
• Standing or seated posture is not held statically for prolonged periods
  Assess whether the task allows posture changes, sit-stand options, or movement breaks.
• Lighting and visibility support safe posture and task accuracy
  Check whether poor visibility is causing forward head posture, leaning, or awkward positioning.

Task Design, Repetition, and Force

• Task repetition rate is within acceptable limits
  Evaluate whether the same motions are repeated frequently enough to create cumulative strain.
• Forceful exertion is minimized
  Check for pushing, pulling, gripping, pinching, or tool use that requires excessive force.
• Task allows variation or rotation to reduce cumulative load
  Verify that workers have task variety, rotation, or recovery opportunities during the shift.
• Tools are ergonomically suitable for the task
  Assess handle size, trigger force, vibration, weight, and overall fit for the user and job.

Controls, Intervention Plan, and Follow-Up

• Existing controls are in place and effective
  Identify whether engineering controls, administrative controls, or PPE are reducing exposure as intended.
• Recommended ergonomic improvements documented
  List specific interventions such as redesign, lift assists, adjustable workstations, job rotation, or training.
• Responsible person and target completion date assigned
  Document ownership and due date for each corrective action or intervention.
• Follow-up review scheduled
  Confirm the date for reassessment after controls are implemented.