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Safety Policies & Programs


Material Handling

Policy Key Points

Purpose and Scope of this Policy

Poor lifting techniques, improper handling and storage of material, unorganized work areas, and not using proper personal protective equipment can all lead to injuries. By adhering to the material handling and back safety guidelines in this policy, we can eliminate most of the injuries associated with these unsafe acts.


Lifting Basics

    Lifting Limits
    • Single Person Limit is 40 lbs,
    • Two Person Limit is 60 lbs,
    • Larger items can be lifted by four people. Total weight should not exceed 100 lbs
    • Mechanical lifting equipment should be used for items that do not fall within Yaskawa's lifting guidelines.
      • Lifting equipment shall only be operated by individuals who are qualified to use the lifting equipment.
  • Monitor associate activities and behaviors to determine if associates should be removed from the worksite

All associates are responsible for:

  • Ensuring they are physically capable of performing their job function prior to performing any task,
  • Immediately reporting to their supervisor, another member of management, or Human Resources if they are taking over-the-counter or prescription drugs that may impair their ability to work safely.
    • NOTE: Associates must only report that they are taking a medicine that can affect their ability to safely perform the job. Associates should not report the specific medication that they are taking.

General Material Handling Requirements
  1. Associates are required to wear safety shoes while handling materials. (See PPE Policy for safety shoe requirements)
  2. There are many hazards associated with handling materials. Associates are required to adhere to the following methods of avoiding hazards when material handling:
    1. Perform a hazard assessment prior to performing any lift of materials.
    2. Keep work areas clean and organized. Untidy work areas and tool boxes are a major source of cuts and bruises - as people tend to reach in without looking.
    3. Be very cautions if you wear a ring while performing a lift. Rings, even a wedding band, can be dangerous as the ring can get caught on the object your lifting and pull away potentially causing severe damage to your finger.
    4. Watch out for sharp edges, burrs, and splinters.
    5. Take extra caution when handling objects that are hot, cold, greasy, or slippery.
    6. Never store tools so that the sharp edges are exposed. The next person to use the tool could be the person who suffers the injury. Always consider the next person.
    7. Be cautions of pinch points when you are lifting something.
    8. Do not lift something if you cannot see the top of it. There could be something on top of the object that could fall and strike you.
    9. Do not sweep up metal and wood scrapes with your hands. Use a broom or brush.

Safer Lifting Techniques

The object of safe lifting is to protect your back by letting your legs, not your back, do the work.

Standard Lift
  1. Straddle the load with both feet firmly on the floor.
  2. Squat down close to the load with your back straight, knees bent, and core (abdominal muscles) pulled in.
  3. Place your hands on diagonally opposite corners of the load so one hand pulls the load towards you and the other hand lifts.
  4. Grip the load firmly with both entire hands, not just the fingers.
    Do Not try to lift a load by "clamping it" with your hands. This puts excess pressure on your shoulders and arms.
  5. Lift the load keeping it close to your body. Keep your weight centered over your feet. Tuck your arms and elbows into your side and your chin into your neck.
  6. Stand up slowly, keeping your back straight and letting your legs do the lifting.
  7. Make sure you have a good grip and can see where you're going.
  8. Take small steps, keeping the load close to your body and no more than waist high.
  9. If you have to change direction while you're carrying a load, don't twist. Twisting is a major cause of back injuries. To change direction, move your feet.
  10. When you get to the landing zone, lower the load slowly, bending your knees so your legs do the work.

Refer to panel to see other lifting techniques.


Pulling parts from boxes and bins

If must reach into a bin to get something, it's going to become increasingly more difficult to lift properly the farther down into the bin you reach.

  1. Stand with your feet at shoulder distance apart and bend slightly at the knees.
  2. If you can squat, do so.
  3. Bend at the hip joint, not at the waist.
  4. Slide the load as close to your body as possible.
  5. Raise yourself using your leg and hip muscles as you lift and, if it's possible, rest your knees on the container side.
  6. It may be useful to cut down one side of the box so that proper lifting techniques may be used.

Material Handling on Ramps and Sloped Surfaces

Wherever possible, a wheeled cart shall not be used on a sloped surface. When this is unavoidable, the following conditions must be met:

  • The slope shall not exceed 8.33%, or 1:12 maximum slope,
  • A cart that is designed for material handling, such as a Rubbermaid Utility Cart, shall be used,
  • If the cart is to be rolled outside of the facility, the cart shall have indoor/outdoor rated wheels,
  • The cart shall not be loaded with more than 50 lbs,
  • The cart shall have lips on each shelf to prevent items from sliding off,
  • The operator shall remain on the high side so if the operator loses control, they can let go and be free of the hazard, and
  • The operator shall ensure that no person is below the load and no hazardous conditions exist below the load that would cause a hazard if the operator loses control of the cart.

Utility Knife Safety

  • Proper Training: Only employees who have been trained in the safe use of utility knives are authorized to use them.
  • Approved Tools: Only company-approved utility knives with safety features, such as retractable blades or shielded blades, should be used.
  • Inspect Before Use: Always inspect the utility knife before each use. Check for dull, damaged, or rusty blades, and replace them as necessary.
  • Sharp Blade Use: Always use sharp blades. Dull blades require more force and increase the risk of slipping and injury.
  • Cut Away from the Body: Always cut away from your body and hands. Position the material being cut in a stable manner to avoid cutting toward your body.
  • Use Cutting Surface: Place the object you are cutting on a flat, stable surface. Avoid holding the object in your hand while cutting.
  • Do Not Force the Cut: Apply steady, even pressure while cutting. Forcing the blade can cause slips and lead to injuries.
  • Use Appropriate Cutting Tools: Use the correct tool for the job. For example, heavy-duty cutting jobs may require other tools.
  • Retract the Blade When Not in Use: Always retract the blade after each use to minimize the risk of accidental cuts.
  • Proper Blade Disposal: Dispose of used or broken blades in designated blade disposal containers. Do not throw blades directly into the trash.
Personal Protective Equipment (PPE)
  • Gloves: Employees are encouraged to wear cut-resistant gloves when using box cutters to reduce the risk of hand injuries.
  • Eye Protection: Wear safety glasses or goggles if there is a risk of flying debris while cutting.
Handling and Maintenance
  • Replace Blades Regularly: Change blades frequently to avoid using dull or damaged blades, which can increase the risk of injury.
  • Store Safely: Box cutters should be stored in a safe location when not in use, with the blade fully retracted.
  • Report Issues: Immediately report any malfunctioning or damaged box cutters to a supervisor, and do not use the tool until it is repaired or replaced.
Prohibited Practices
  • Do Not Use Box Cutters as Pry Tools: Never use a box cutter for purposes other than cutting. Do not use them to pry open objects or unscrew components.
  • No Horseplay: Do not engage in horseplay or improper handling of box cutters. Misuse of these tools can result in serious injury.
  • Do Not Hand Off an Open Box Cutter: Always retract the blade before passing a box cutter to another person.
Results of Breaches of Policy

Breaching this policy may result in an injury. Breaches of this policy may result in disciplinary action being initiated in accordance with Yaskawa America's discipline policy.


Training

All associates shall be provided with training related to this policy.

Revision History

Rev # Description Release Date Approved by
0 Conversion of old safety documents, rewrite, and issue electronic version 6/12/2016 Thurwanger
1 Added Utility Knife Safety 8/4/2019 Thurwanger
2 Added Material Handling on Ramps and Slopes 6/15/2025 Thurwanger

Program Review

Review Date Reviewed by Changes Required (Yes/No) Revision # if updated
2/15/2017 Thurwanger No
1/10/2018 Thurwanger No
1/17/2019 Thurwanger Yes 1
1/9/2020 Thurwanger No
1/19/2021 Thurwanger No
1/13/2022 Thurwanger No
1/26/2023 Thurwanger No
1/11/2024 Thurwanger No
1/16/2025 Thurwanger No

Policy Video

Proper Lifting Techniques