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Ergonomic risk assessment
An ergonomic risk assessment for physical tasks in workplaces such as production and packing lines, warehouses, laboratories and commercial kitchens. Add each task as a space: what it involves, how many people do it, hours on the task and repeats per shift. Then work through an ergonomic checklist of risk factors: posture (overhead reach, bending, twisting), force and the heaviest item, repetition and duration, vibration, workstation layout and reach heights, tools and grips, and the environment. Record what the workers say and any aches or pain reported, rate each factor on your own low, medium or high scale, and add controls with a priority, owner and status. For a desk with a screen use the DSE assessment; for a full lifting assessment use the manual handling risk assessment.
For health and safety advisers, production and warehouse managers, team leaders and occupational health staff who need to look at a task people say is awkward or tiring, and agree what to change.
Notes for the UK (Management of Health and Safety at Work Regulations 1999, Manual Handling Operations Regulations 1992) and the US (OSH Act general duty clause). The factors and controls work anywhere.
- Each task as a space with hours, repeats per shift and photos, plus Walk Cam to film several cycles
- Posture, force, repetition, vibration, layout, tools and environment, each rated on your own scale
- Working height and highest, lowest and furthest reach, with measure from photo as an estimate
- What the workers say, and any aches or pain reported, by body area
- Controls from eliminate and redesign to aids, rotation and training, with priority, owner and status
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What is an ergonomic risk assessment?
An ergonomic assessment leads to change when it is based on watching the real task for several cycles and asking the people who do it. It records the awkward movement with a photo and a measured height, how often it repeats, and any aches reported, then agrees a fix to the task itself before falling back on rotation or training.
Last updated . Facts checked by the SiteSurvey team on 27 October 2026 against Management of Health and Safety at Work Regulations 1999, regulation 3, risk assessment, Manual Handling Operations Regulations 1992, regulation 4, duties of employers, HSE, Toolkit for assessing musculoskeletal disorders (MAC, V-MAC, ART, RAPP), Public Law 107-5 (2001), congressional disapproval of the Department of Labor ergonomics rule and 29 U.S.C. 654, duties of employers and employees (OSH Act section 5).
How to do an ergonomic risk assessment
Watch the task being done, talk to the people who do it, then rate and decide.
Pick the task
Add the task as a space and say what it involves, who does it, the hours on it and how often the main movement repeats.
Watch and film it
Watch several cycles. Take a wide photo of the workstation and one of the awkward part, or film it with Walk Cam.
Work through the factors
Tick what you saw for posture, force, environment and vibration, measure the reach heights, and rate each factor low, medium or high.
Ask the workers
Record what they say about the task and whether anyone has reported aches or pain, and where.
Agree controls
Start with removing or redesigning the task, then aids, rotation and training. Give each a priority, owner and due date, and set a review date.
What makes an ergonomic assessment lead to change
What the workers say about the task
Magazine loading, line 2. Operators say the magazine empties fast on the 12-pack so they top it up in a hurry; the shorter operators go on tiptoe to push the 9 kg bundle home at about 1.85 m. Two report shoulder or neck pain. They would like a side infeed at waist height.
Fictional example. Record the actual evidence and approved arrangements for your job.
A common recording mistake
Rating every factor from the office without seeing the task, or going straight to "training in lifting technique" when the problem is a loading point above head height.
What happens next
Give each control an owner and a date, put the quick fixes in first, tell the workers what will change, and reassess the task once the redesign is in.
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Every question in the ergonomic risk assessment template
An ergonomic risk assessment for physical tasks in warehouses, production and packing lines, labs and kitchens. Each task is a space: what it involves, workers, hours and repeats per shift, then posture (overhead reach, bending, twisting), force and the heaviest item, repetition and duration, vibration, workstation and reach heights (with measure from photo as an estimate), tools and grips, environment, what the workers say and any symptoms reported, a rating per factor on your own low, medium or high scale, and controls (eliminate, redesign, aids, rotation) with priority, owner and status. Notes for UK law and the US general duty clause. 4 sections and 79 questions. Follow-up questions and guidance appear only when an answer calls for them, so the person on site never sees the ones that do not apply.
Make it your own: every question is editable
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Details you only enter once
Add this form to a project in SiteSurvey and it fills in what the project already knows, so nobody on site retypes it and every form on the job uses the same names. Anything filled in can still be changed.
- Project: the project name
- Site address: the site address, from the space or the project
- Business or site: the project's customer
Workplace and assessment details
- ProjectShort answer
Filled in from the project in SiteSurvey.
Fills in from the project name - Site addressShort answerFills in from the site address, from the space or the project
- Business or siteShort answerFills in from the project's customer
- Location (GPS)Short answer
- Assessment date*Date
- Assessed by*Short answer
- Type of workplace*Choose one
- Production or packing line
- Warehouse or distribution
- Laboratory
- Commercial kitchen
- Workshop
- Healthcare
- Retail
- Other
- Department, line or areaShort answer
For example line 3 packing, goods in.
- CountryChoose one
Sets which short note you see. It does not change the questions.
- UK (Great Britain)
- US
- Other country
- Workers and supervisors consultedShort answer
- Why this assessmentChoose one
- New or changed task
- Planned review
- Worker reported pain or discomfort
- After an injury or ill health report
- New equipment or line speed
- Other
- CheckThis looks at physical tasks at work: posture, force, repetition, vibration, layout, tools and environment. For a desk with a screen use the DSE assessment; for a full lifting or carrying assessment use the manual handling assessment. It does not diagnose anyone. Refer anyone with symptoms to occupational health or their doctor.
- GuidanceUK. Employers must make a suitable and sufficient risk assessment (Management of Health and Safety at Work Regulations 1999, regulation 3). Manual handling that involves a risk of injury must be avoided so far as reasonably practicable, or assessed and the risk reduced to the lowest level reasonably practicable (Manual Handling Operations Regulations 1992, regulation 4). Display screen workstations must be analysed (DSE Regulations 1992, regulation 2), and work liable to expose people to risk from vibration needs its own assessment (Control of Vibration at Work Regulations 2005, regulation 5).Shown when “Country” is “UK (Great Britain)”
- GuidanceUS. The Department of Labor's 2000 ergonomics rule was disapproved by Congress in 2001 and has no force or effect (Public Law 107-5). The general duty clause still applies: each employer must provide employment and a place of employment free from recognized hazards that are causing or likely to cause death or serious physical harm (OSH Act section 5(a)(1)). OSHA lists risk factors such as heavy lifting, bending, reaching overhead, pushing and pulling heavy loads, awkward postures and repetitive work.Shown when “Country” is “US”
- GuidanceHSE tools. HSE publishes free tools for assessing musculoskeletal risks: the MAC for lifting, lowering, carrying and team handling, the ART for repetitive tasks involving the upper limbs, and RAPP for pushing and pulling. If you use one, record its result in the notes for that factor.Shown when “Country” is “UK (Great Britain)”
Tasks
- GuidanceAdd each task as a space. Watch it being done for several cycles, talk to the people doing it, photograph the awkward part, then rate each factor and record the controls.
- Tasks assessedRepeat for each task. Each one asks:
- Task*Short answer
For example loading the label reel, palletising cases at the end of line 2.
- Workstation or locationShort answer
- What the task involves*Notes
The steps, what is handled, and how it arrives and leaves.
- Workers who do this taskNumber
- Hours on this task per shiftNumber
- Times per hour the main movement is repeatedNumber
- Repeats per shiftWorked out by the formShown when “Times per hour the main movement is repeated” is answered and “Hours on this task per shift” is answered
- Photos of the taskPhotos
One wide photo of the workstation, then the awkward part of the task.
- Posture: what you sawTick all that apply
- Reaching above shoulder height
- Reaching forward or to the side at arm's length
- Bending forward or stooping
- Twisting the trunk
- Kneeling or squatting
- Neck bent or twisted
- Wrist bent while gripping
- Standing in one place for long periods
- None of these
- Posture rating*Choose one
Your own rating, not a standard score.
- Low
- Medium
- High
- Not applicable
- Force: what you sawTick all that apply
- Lifting or lowering
- Carrying
- Pushing or pulling
- Pinch grip
- Pressing with the hand or thumb
- Holding a tool or part up
- None of these
- Heaviest item handled (kg)Number
Weigh it or take it from the label. This form sets no weight limit.
Shown only when the answers above make it relevant - Force rating*Choose one
Your own rating, not a standard score.
- Low
- Medium
- High
- Not applicable
- Repetition and duration rating*Choose one
Your own rating, not a standard score.
- Low
- Medium
- High
- Not applicable
- Repetition and breaksNotes
For example same reach every cycle, no rotation, breaks at 10:00 and 12:30.
- Vibrating tools or equipment used?Yes or No
- Which, and for how long per shiftShort answerShown when “Vibrating tools or equipment used?” is Yes
- Vibration rating*Choose one
Your own rating, not a standard score.
- Low
- Medium
- High
- Not applicable
- Working height from the floor (m)Number
Where the hands work. Measure from photo gives an estimate; use a tape for anything you will act on.
- Highest reach from the floor (m)Number
- Lowest reach from the floor (m)Number
- Furthest forward reach (m)Number
- Heights of the people who do itShort answer
Optional. For example shortest about 1.55 m, tallest about 1.90 m.
- Workstation layout and heights rating*Choose one
Your own rating, not a standard score.
- Low
- Medium
- High
- Not applicable
- Tools and gripsNotes
Handles, triggers, gloves, sharpness, weight, how parts are held.
- Tools and grips rating*Choose one
Your own rating, not a standard score.
- Low
- Medium
- High
- Not applicable
- EnvironmentTick all that apply
- Cold
- Hot
- Poor lighting
- Slippery or uneven floor
- Cramped space
- Noise making it hard to talk
- Time pressure or line speed
- None of these
- Environment rating*Choose one
Your own rating, not a standard score.
- Low
- Medium
- High
- Not applicable
- What the workers say about the task*Notes
Ask the people who do it: what is awkward, what slows them, what they would change.
- Has anyone reported aches, pain or discomfort from this task?*Yes or No
- WhereTick all that apply
- Neck
- Shoulders
- Upper back
- Lower back
- Elbows
- Wrists or hands
- Knees
- Feet
Shown when “Has anyone reported aches, pain or discomfort from this task?” is Yes - How many peopleNumberShown when “Has anyone reported aches, pain or discomfort from this task?” is Yes
- Offered a referral to occupational health or advised to see their doctor?Yes or NoShown when “Has anyone reported aches, pain or discomfort from this task?” is Yes
- WarningDiscomfort reported by the people doing the task is a reason to act on this task now, whatever the ratings say.Shown when “Has anyone reported aches, pain or discomfort from this task?” is Yes
- Factors rated highWorked out by the form
- Factors rated mediumWorked out by the form
- Overall risk for this task (your own judgement)*Choose one
- Low
- Medium
- High
- Controls recommendedRepeat for each control. Each one asks:
- Type of control*Choose one
- Eliminate the task
- Redesign the task or workstation
- Mechanical aid or better tool
- Job rotation or breaks
- Training in technique
- Other
- What exactly*Notes
- Priority*Choose one
- High
- Medium
- Low
- Owner*Short answer
- Due byDate
- Status*Choose one
- Open
- In progress
- Done, checked
- t_ctrl_countWorked out by the form
- t_ctrl_openWorked out by the form
- CheckThis task is rated medium or high, or people report symptoms, but no control is recorded.Shown only when the answers above make it relevant
- Walk Cam: film the taskWalk Cam video with voice-to-text
Optional. Film a guided walk-round on the SiteSurvey app.
Summary
- Tasks assessedWorked out by the form
- Tasks rated highWorked out by the form
- Tasks with symptoms reportedWorked out by the form
- Factors rated high (all tasks)Worked out by the form
- Controls not yet doneWorked out by the form
- Main findingsNotes
- How the findings were shared with the workersNotes
Actions, review and sign-off
- Controls not yet doneWorked out by the form
- ResultWorked out by the form
- Other actions (not already a task control)Repeat for each action. Each one asks:
- Action*Notes
- PriorityChoose one
- Now
- Within a week
- Within a month
- Next planned change
- Who will do it*Short answer
- Due byDate
- Status*Choose one
- Open
- In progress
- Done, checked
- Photo when donePhotosShown when “Status” is “Done, checked”
- Actions still openWorked out by the form
- Decision*Choose one
- Risk acceptable: no further action
- Controls agreed: actions listed
- Change the task now: stop or restrict it until fixed
- Review dateDate
- Summary for managementNotes
- Assessor nameShort answer
- Assessor signature*Signature
- Manager responsible nameShort answer
- Manager responsible signatureSignature
See it filled in
A completed ergonomic risk assessment report, made by SiteSurvey from a fictional site visit: every answer, the photos, the guidance that applied and the sign-off, ready to send as a PDF.
Ergonomic risk assessment FAQs
Is an ergonomic risk assessment a legal requirement in the UK?
The duties that cover it are in general regulations. Every employer must make a suitable and sufficient assessment of the risks to their employees (Management of Health and Safety at Work Regulations 1999, regulation 3). Manual handling that involves a risk of injury must be avoided so far as reasonably practicable, or assessed and the risk reduced to the lowest level reasonably practicable (Manual Handling Operations Regulations 1992, regulation 4).
Sources: Management of Health and Safety at Work Regulations 1999, regulation 3, risk assessment and Manual Handling Operations Regulations 1992, regulation 4, duties of employers.
Does OSHA have an ergonomics standard?
The Department of Labor published an ergonomics rule in 2000 (65 Fed. Reg. 68261), but Congress disapproved it by a joint resolution approved on 20 March 2001, so it has no force or effect (Public Law 107-5). Employers still have the general duty under section 5(a)(1) of the OSH Act to provide a workplace free from recognized hazards that are causing or are likely to cause death or serious physical harm. OSHA lists heavy lifting, bending, reaching overhead, pushing and pulling heavy loads, awkward postures and repetitive tasks as risk factors for musculoskeletal disorders.
Sources: Public Law 107-5 (2001), congressional disapproval of the Department of Labor ergonomics rule, 29 U.S.C. 654, duties of employers and employees (OSH Act section 5) and OSHA, Ergonomics (osha.gov blocks scripts; read in the Wayback Machine copy of 17 October 2026).
Can I use HSE's MAC or ART tool with this form?
Yes. HSE publishes free tools: the MAC for lifting, lowering, carrying and team handling, the ART for repetitive tasks involving the upper limbs, and RAPP for pushing and pulling. HSE says some tasks need more than one tool. This form does not reproduce their scoring; if you use one, record its result in the notes for that factor.
Sources: HSE, Toolkit for assessing musculoskeletal disorders (MAC, V-MAC, ART, RAPP) and HSE, Assessment of Repetitive Tasks (ART) tool.
How is each factor rated?
On your own low, medium or high scale, or not applicable. The ratings are your judgement, not a standard score, and the form counts how many factors you rated high or medium for each task. If anyone reports aches or pain from a task, the form flags it for action whatever the ratings say.
How accurate are heights measured from a photo?
Measure from photo gives an estimate, good enough to show a loading point is above head height. For anything you will build or change, such as a platform or a new infeed, measure with a tape and record that figure. The form sets no height, reach or weight limits of its own.
Is this the same as a DSE or manual handling assessment?
No. A DSE assessment is for a desk with a display screen, and a manual handling assessment goes into lifting and carrying in detail. This form covers the whole task on a line, in a warehouse, lab or kitchen, including posture, repetition, tools and environment. Where the task is mostly lifting, use the manual handling form as well.
Related
Related templates
Templates that go with the ergonomic risk assessment form
Manual handling assessment using task, individual, load and environment: can it be avoided, risk factors, handling aids, controls and actions.
A workstation assessment with equipment, posture and work-pattern checks, user concerns, assessor review, adjustments and follow-up evidence.
A warehouse walk-through covering aisles, storage, pedestrian routes, loading areas, handling, emergency access and corrective actions.
A job hazard analysis, also called a job safety analysis: each step of the job with its hazards and controls, PPE, permits, emergency plan, crew sign-on and review. Written for US work to OSHA guidance, with an Activity Hazard Analysis mode for USACE EM 385-1-1 contracts.
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