The MAC tool was developed to help the user identify high-risk workplace manual handling activities and can be used to assess the risks posed by lifting, carrying and team manual handling activities.

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It is designed to help you understand, interpret and categorise the level of risk of the various known risk factors associated with manual handling activities. It incorporates a numerical and a colour-coding score system to highlight high-risk manual handling tasks.

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Manual handling

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According to the Manual Handling Operations Regulations 1992 (MHOR), manual handling is defined as:

‘..any transporting or supporting of a load (including the lifting, putting down, pushing, pulling, carrying or moving thereof) by hand or bodily force’

The MHOR establish a clear hierarchy of measures for dealing with risks from manual handling:

• avoid hazardous manual handling operations so far as is reasonably practicable;
• assess any hazardous manual handling operations that cannot be avoided; and
• reduce the risk of injury so far as is reasonably practicable.

A detailed assessment of every manual handling operation could be a major undertaking and might involve wasted effort. Many handling operations, for example the occasional lifting of a small lightweight object, will involve negligible handling risk. To help identify situations where a more detailed risk assessment is necessary, HSE has developed filters to screen out straightforward cases (see Appendix of L23).

Using the MAC will help to identify high-risk manual handling activities within the workplace. However, the MAC is not appropriate for all manual handing operations, and may not comprise a full risk assessment. Therefore it is unlikely to be acceptable if relied upon alone. To be ‘suitable and sufficient’, a risk assessment will normally need to take account of additional information such as individual capabilities, and should conform to the requirements in the MHOR. People with knowledge and experience of the handling operations, industry specific guidance, and specialist advice may also be helpful. Remember to consult and involve employees and safety representatives.

Digital photo professional download. The V-MAC is a tool for assessing manual handling operations where load weights vary. It should be used in conjunction with the MAC tool.

The MAC tool was designed for assessing handling operations where the same weight is handled over the workday/shift. However, in practice, load weights are often variable (such as in order picking, parcel sorting, trailer loading/unloading, and parts delivery in manufacturing). The V-MAC was developed to help assess these kinds of jobs.

You may not need to use the V-MAC as it is more complex than is needed for assessing many manual handling operations. It is best suited for order picking and distribution systems which can automatically generate the data for importing into V-MAC.

You need to be aware that significant background knowledge is needed to use the V-MAC successfully. You can gain this from these support pages or through training.

There is more background information to the development of the tool in HSE Research Reports RR838 and RR1003.

HSE provides detailed guidance on the Manual Handling Operations Regulations 1992.

When can using the V-MAC help you?

When you are assessing jobs that involve regular manual handling operations and you find:

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• You can’t assess manual handling using the MAC alone, as the weights of the loads vary. The V-MAC is an alternative graph to be used alongside the MAC to give a more accurate indication of the level of risk for the load weight/frequency risk factor. Then use the MAC for the other risk factors and enter the data into the MAC score sheet.
• You can’t assess the job using the Assessment of Repetitive Tasks (ART) tool. The ART can help you assess repetitive tasks mostly involving the upper limbs.

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Before starting to use the V-MAC, find out more about its advantages and limitations and what you need to know to use it successfully.

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Detailed risk assessments

There is general advice from HSE on risk assessment related to musculoskeletal disorders (MSDs). Some manual handling operations need a detailed risk assessment that considers all the potential risk factors. The HSE guidance on the Manual Handling Operations Regulations 1992 will help you do this.

• Next page: Advantages and limitations of the V-MAC