Guidelines

forRetail

Grocery

Stores

OSHA 3192-05N

2004

U.S. Department of Labor

Ergonomics

for thePreventionof

Musculoskeletal Disorders

www.osha.gov
Guidelines for Retail Grocery Stores 1

U.S. Department of Labor

Elaine L. Chao, Secretary

Occupational Safety and Health Administration

John L. Henshaw, Assistant Secretary

OSHA 3192-06N

2004

Guidelines for Retail Grocery Stores

Ergonomics for the Prevention

of Musculoskeletal Disorders U.S. Department of Labor
2 Guidelines for Retail Grocery Stores

Executive Summary 3

Introduction 5

A Process for Protecting Workers 7

Provide Management Support 7

Involve Employees 7

Identify Problems 7

Implement Solutions 8

Address Reports of Injuries 8

Figure 1. Checklist for Identifying Potential Ergonomics

Risk Factors by Workplace Activity 9

Figure 2. Checklist for Identifying Potential JobSpecific Ergonomics Concerns 10

Provide Training 11

Evaluate Progress 11

Implementing Solutions 12

Storewide Ergonomic Solutions 13

Front End (Checkout, Bagging and Carryout) 17

Stocking 19

Bakery 21

Meat and Deli 23

Produce 25

Additional Sources of Information 26

References 27

Contents
Guidelines for Retail Grocery Stores 3

OSHA’s Ergonomics for the Prevention of

Musculoskeletal Disorders: Guidelines for Retail

Grocery Stores provide practical recommendations to help grocery store employers and

employees reduce the number and severity of

injuries in their workplaces. Many of the workrelated injuries and illnesses experienced by

grocery store workers are musculoskeletal

disorders (MSDs), such as back injuries and

sprains or strains that may develop from various

factors, including lifting, repetitive motion

disorders such as carpal tunnel syndrome, or

injuries resulting from overexertion. MSDs

may also be caused partly or wholly by factors

outside of work.

More remains to be learned about the

relationship between workplace activities and

the development of MSDs. However, OSHA

believes that the experiences of many grocery

stores provide a basis for taking action to better

protect workers. As the understanding of these

injuries develops and information and technology improve, the recommendations made in this

document may be modified.

Grocery stores that have implemented injury

prevention efforts have said they have successfully reduced work-related injuries and workers’

compensation costs. Many times, these efforts

have reduced injuries and led to increased worker

efficiency and lowered operating costs. For

example, designing checkstands to reduce

ergonomic risk factors such as twisting or extended reaching can improve cashier effectiveness and productivity (1). The purpose of these

voluntary guidelines is to build on the progress

Executive Summary

that the grocery store industry has made in

addressing causes of work-related injuries and

illnesses.

These guidelines are intended only for retail

grocery stores and combined full-line supermarket and discount merchandisers including

warehouse retail establishments. The discussion

is intended primarily for grocery store managers

and store employees, but may also be useful for

corporate managers or corporate safety

professionals. OSHA did not develop these

guidelines to address warehouses, convenience

stores, or business operations that may be

located within grocery stores, such as banks,

post offices, or coffee shops. However, operations in retail or distribution that involve similar

tasks or operations as those addressed in these

guidelines may find the information useful.

The information in these guidelines provides

grocery stores with effective approaches, as well

as useful references to be used when determining

the need for ergonomic solutions. The recommendations and information presented here are

intended as a general guideline and flexible

framework to be adapted to the needs and

resources of each individual store. OSHA

recognizes that small employers, in particular,

may not have the need for as comprehensive a

program as would result from implementation of

every action and strategy described in these

guidelines. Additionally, OSHA realizes that

small grocery stores may need assistance to implement an appropriate ergonomics program.

That is why OSHA emphasizes the availability of

its free consultation service for smaller employers.
4 Guidelines for Retail Grocery Stores

The heart of these guidelines is the description

of various solutions that have been implemented

by grocery stores. OSHA recommends that

grocery stores consider these solutions in the

context of a systematic process that includes

the elements described in the pages that follow.

Such a process will make it more likely that the

solutions implemented in a particular workplace

are successful in reducing injuries and are cost

effective.

To develop these guidelines, OSHA reviewed

existing ergonomic practices and programs in

These guidelines are advisory in nature and informational in content. They are not a new standard or

regulation and do not create any new OSHA duties. Under the OSH Act, the extent of an employer’s

obligation to address ergonomic hazards is governed by the general duty clause. 29 U.S.C. 654(a)(1).

An employer’s failure to implement the guidelines is not a violation, or evidence of a violation of the

general duty clause. Furthermore, the fact that OSHA has developed this document is not evidence of

an employer’s obligations under the general duty clause; the fact that a measure is recommended in

this document but not adopted by an employer is not evidence of a violation of the general duty clause.

In addition, the recommendations contained herein were developed with the idea that they could be

adapted to the needs and resources of each individual place of employment. Thus, implementation of

the guidelines may differ from site to site depending on the circumstances at each particular site.

the grocery store industry and conducted site

visits to observe existing programs in action.

In addition, the Agency reviewed available

scientific information regarding work activities

that may benefit from ergonomic improvements

and specific solutions. OSHA also conducted

one-on-one and group meetings with major

stakeholder groups to gather the best available

information on typical workplace activities and

on practices, programs and processes that have

been used successfully in the grocery store

industry.
Guidelines for Retail Grocery Stores 5

Grocery stores provide a vital service to the

American public, and are a major source of

employment in the United States. In recent

years, the efforts of grocery store managers and

employees have resulted in fewer occupational

injuries and illnesses. Even with these efforts,

thousands of grocery store workers are still

injured on the job each year (2).

Many grocery stores have taken actions such

as those recommended in this document to help

reduce exposures to ergonomic risk factors in

their effort to reduce workplace injuries.

Some grocery store work can be physically

demanding. Many grocery store workers handle

thousands of items each day to stock shelves,

check groceries, decorate bakery items, and

prepare meat products. These tasks involve

several ergonomic risk factors. The most

important of these include force, repetition,

awkward posture, and static postures (4).

In the grocery store industry, the presence of

these risk factors increases the potential for

injuries and illnesses. In these guidelines, OSHA

uses the term musculoskeletal disorders (MSDs)

to refer to a variety of injuries and illnesses,

including:

■ Muscle strains and back injuries that occur

from repeated use or overexertion;

■ Tendinitis;

■ Carpal tunnel syndrome;

■ Rotator cuff injuries (a shoulder problem);

■ Epicondylitis (an elbow problem); and

■ Trigger finger that occurs from repeated use

of a single finger.

Just because an employee develops an MSD

does not mean it is work-related. As required by

OSHA’s recordkeeping rule (29 CFR 1904),

employers should consider an MSD to be workrelated if an event or exposure in the work

environment either caused or contributed to the

MSD, or significantly aggravated a pre-existing

MSD. For example, when an employee develops

carpal tunnel syndrome, the employer needs to

look at the hand and forearm activity required

Introduction

The Liberty Mutual Insurance Company’s Workplace

Safety Index shows the importance of ergonomic

issues.

The Index lists overexertion, bodily reaction, and

repetitive motion as three of the top ten causes of

workplace injury.

The three injury categories represented 43.8 percent

of the total costs of serious workplace injuries in

2001.

While the total number of serious workplace injuries

declined between 1998 and 2001, the cost grew 13.5

percent, or 4 percent after adjusting for inflation (3).

Putting merchandise in the front of a display case

improves the appearance of merchandise. However,

working in the back of a deep display case to face or

stock merchandise can be awkward and uncomfortable, especially when heavy items are involved.

One familiar solution to this problem is display cases

that are stocked from the back. The product, such as

cartons of milk, slides down an inclined shelf so that

it’s always in front of the customer. It’s also easier

for the employee stocking the shelf.

Recently a market extended this concept to frontloaded cases. The solution was a dummy back for

the case that was placed at the back of the shelf to

limit the reach. Now the merchandise is at the front

of the shelf, readily visible to the customer and

within easy reach for the worker.

At least one vendor has improved this concept by

providing cases with spring-loaded backs. When a

customer removes an item, the back pushes the

remaining items to the front, keeping them within

easy reach. The design makes it easier to stock cases

by eliminating the need to reach to the back of the

case. The stocker puts the first products in at the

front of the shelf, then pushes it back to make room

for more items (5).
6 Guidelines for Retail Grocery Stores

Packing produce and other products in ice keeps

them fresh and appealing. It also means handling

ice – shoveling it, lifting it and shoveling it again.

It’s heavy work and takes time.

Recently a market devised a method to reduce the

amount of time that it takes to put ice on products

and that also cut the amount of handling in half.

Originally an employee took a cart to the ice

machine, scooped up enough ice to fill a cart,

wheeled the cart to the display case, and finally

scooped the ice from the cart into the display case.

The new machine allows gravity flow of ice and has

space underneath for a cart containing four buckets.

The ice falls into the buckets and fills them,

eliminating half the shoveling. The buckets are

convenient to handle and can be picked up to pour

the ice into the display case, eliminating the rest of

the need to shovel. The net result – less strenuous

work, more time saved, and an attractive display (5).

for the job and the amount of time spent doing

the activity. If an employee develops carpal

tunnel syndrome, and his or her job requires

frequent hand activity, or forceful or sustained

awkward hand motions, then the problem may

be work-related. If the job requires very little

hand or arm activity then the disorder may not

be work-related.

Activities outside of the workplace that

involve physical demands may also cause or

contribute to MSDs. In addition, development

of MSDs may be related to genetic causes,

gender, age, and other factors. Finally, there is

evidence that reports of MSDs may be linked to

occupationally-related psychosocial factors

including job dissatisfaction, monotonous work

and limited job control (6). However, these

guidelines address only physical factors in the

workplace that are related to the development of

MSDs.

Grocery stores that have implemented injury

prevention efforts focusing on musculoskeletal

and ergonomic concerns have reported reduced

work-related injuries and associated workers’

compensation costs. Fewer injuries can also

improve morale, reduce employee turnover,

encourage employees to stay longer and discourage senior employees from retiring early.

Workplace changes based on ergonomic

principles may also lead to increased productivity by eliminating unneeded motions,

reducing fatigue and increasing worker efficiency. Healthier workers, better morale, and

higher productivity can also contribute to better

customer service.

These guidelines present recommendations for

changing equipment, workstation design, or

work methods with the goal of reducing workrelated MSDs. Many ergonomic changes result

in increased efficiency by reducing the time

needed to perform a task. Many grocery stores

that have already instituted programs have

reported reduced MSDs, reduced workers’

compensation costs, and improved efficiency.
Guidelines for Retail Grocery Stores 7

A Process for Protecting Workers

Many of the recommendations below are

practices taken from workplace ergonomics

and safety programs that grocery stores have

developed and that OSHA observed while

performing site visits at grocery stores. They

are intended to provide a flexible framework

that a grocery store manager can adapt to an

individual store. In many grocery stores,

ergonomics, other employee safety and health

efforts, workers’ compensation, and risk

management are integrated into a single program that is usually administered by the same

staff. OSHA recommends that employers

develop a process for systematically addressing

ergonomics issues in their facilities, and incorporate this process into an overall program to

recognize and prevent occupational safety and

health hazards.

Store and company management personnel

should consider the general steps discussed

below when establishing and implementing an

ergonomics program. It should be noted,

however, that each store will have different

needs and limitations that should be considered

when identifying and correcting workplace

problems. Different stores may implement

different types of programs and activities and

may assign different staff to accomplish the

goals of the ergonomics program.

Provide Management Support

Management support for reducing MSDs

and communicating support to employees is

very important. You have already demonstrated your interest in reducing MSDs by

reading these voluntary guidelines. Management support improves the grocery store’s

ability to maintain a sustained effort, allocate

needed resources, and follow up on program

implementation. OSHA recommends that

employers:

■ Develop clear goals,

■ Express the company’s commitment to

achieving them,

■ Assign responsibilities (training, job

analysis, etc.) to designated staff members

to achieve those goals,

■ Ensure that assigned responsibilities are

fulfilled, and

■ Provide appropriate resources.

Meaningful efforts by management also

improve employee participation, which is

another essential element for achieving

success.

Involve Employees

Employees are a vital source of information

about hazards in their workplace. Employees

help identify hazards and solve problems.

Their involvement can enhance job satisfaction, motivation, and acceptance of workplace changes. There are many different ways

employers can involve employees in their

ergonomics efforts, including the following:

■ Submit suggestions and concerns;

■ Identify and report tasks that are difficult to

perform;

■ Discuss work methods;

■ Provide input in the design of workstations,

equipment, procedures and training;

■ Help evaluate equipment;

■ Respond to surveys and questionnaires;

■ Report injuries as soon as they occur;

■ Participate fully in MSD case investigations;

and

■ Participate in task groups with responsibility for ergonomics.

Identify Problems

It is important to periodically review your

job site and the activities of employees to

identify possible ergonomic issues. This could

include a review of OSHA 300 and 301 injury

and illness information, workers’ compensation records and employee reports of problems.
8 Guidelines for Retail Grocery Stores

You can also identify ergonomic issues by

talking with employees and walking through

the grocery store to observe employees

performing their jobs. When reviewing the

various jobs in the grocery store, pay particular

attention to the risk factors listed below.

■ Force – the amount of physical effort

required to perform a task (such as heavy

lifting1

, pushing or pulling), handle merchandise, or maintain control of equipment

or tools;

■ Repetition – performing the same motion or

series of motions continually or frequently

for an extended period of time;

■ Awkward and static postures – assuming

positions that place stress on the body, such

as prolonged or repetitive reaching above

shoulder height, kneeling, squatting, leaning

over a counter, using a knife with wrists

bent, or twisting the torso while lifting (4);

and

■ Contact stress – pressing the body or part of

the body (such as the hand) against hard or

sharp edges, or using the hand as a hammer.

When there are several risk factors in a job,

there can be a greater risk of injury. However,

the presence of risk factors in a job does not

necessarily mean that employees will develop

an MSD. Whether certain work activities put

an employee at risk of injury depends on the

duration (how long), frequency (how often),

and magnitude (how intense) of the employee’s

exposure to the risk factors in the activity (6).

For example, performing cashier work for an

extended period of time without a break has

been associated with increased hand and wrist

problems (7) and could contribute to back and

lower limb problems (8).

The grocery store industry has developed a

number of protocols and checklists to assess

work activities. For example, Figures 1 and 2

contain checklists grocery stores may use to

help identify ergonomic concerns. The checklists include materials developed by the Food

Marketing Institute (4) as well as materials

developed by OSHA.

Implement Solutions

Examples of potential solutions for various

concerns are located in the Implementing

Solutions section of these guidelines.

 Address Reports of Injuries

The solutions recommended in these guidelines are intended to address factors that are

believed to be associated with MSDs in grocery

stores. They are not a guarantee against any

future injury occurring. Grocery stores rarely

have on-site medical staff to care for injured or

ill employees. Therefore, store managers or

other designated individuals should establish a

procedure for receiving reports of injuries and

responding to them appropriately. Early intervention is an effective method of handling

potential injuries. Employees should report

injuries early so that action can be taken to

address any potential job-related issues. Medical

treatment and possible work restrictions could

be necessary, but attention should be paid to

addressing root problems early to avoid more

costly actions if injuries are left unaddressed (9,

10, 11).

OSHA’s injury and illness recording and

reporting regulation (29 CFR 1904) requires

employers to keep records of work-related

injuries and illnesses. These reports can help

the retail grocery store identify problem areas

and evaluate ergonomic efforts. Federal and

state laws prohibit discriminating against

employees who report a work-related injury or

illness. 29 U.S.C. 660(c).

1

 There are varying opinions regarding the maximum amount of weight an employee should lift. OSHA does not

make a specific recommendation in these guidelines regarding this maximum amount but notes that employers

should take into account such considerations as the employees’ physical abilities and the number of times a lift

must occur. Industry groups such as the Grocery Manufactures of America and Food Marketing Institute

encourage the use of containers or packages weighing 40 pounds or less. Another industry group, The

International Mass Retail Association, suggests 50 pounds as a maximum weight for lifting.

(Continued on page 11)
Guidelines for Retail Grocery Stores 9

 Figure 1.

 Checklist for Identifying Potential Ergonomics Risk Factors by Workplace Activity

If the answer to any of the following questions is yes, the activity should be further reviewed.

Force in Lifting

■ Does the lift involve pinching to hold the

object?

■ Is heavy lifting done with one hand?

■ Are very heavy items lifted without the

assistance of a mechanical device?

■ Are heavy items lifted while bending over,

reaching above shoulder height, or

twisting?

■ Are most items lifted rather than slid over

the scanner?

Force in Pushing, Pulling, Carrying

■ Are dollies, pallet jacks, or other carts

difficult to get started?

■ Is there debris (e.g., broken pallets) or

uneven surfaces (e.g., cracks in the floor)

or dock plates that could catch the wheels

while pushing?

■ Is pulling rather than pushing routinely

used to move an object?

■ Are heavy objects carried manually for a

long distance?

Force to Use Tools

■ Do tools require the use of a pinch grip or

single finger to operate?

■ Are tools too large or too small for the

employee’s hands?

Repetitive Tasks

■ Are multiple scans needed?

■ Is a quick wrist motion used while

scanning?

■ Do repetitive motions last for several hours

without a break (e.g., slicing deli meats,

scanning groceries)?

■ Does the job require repeated finger force

(e.g., kneading bread, squeezing frosting,

using pricing gun)?

Awkward and Static Postures

■ Is the back bent or twisted while lifting or

holding heavy items?

■ Are objects lifted out of or put into cramped

spaces?

■ Do routine tasks involve leaning, bending

forward, kneeling or squatting?

■ Do routine tasks involve working with the

wrists in a bent or twisted position?

■ Are routine tasks done with the hands

below the waist or above the shoulders?

■ Are routine tasks done behind (e.g., pushing

items to bagging) or to the sides of the

body?

■ Does the job require standing for most of

the shift without anti-fatigue mats?

■ Do employees work with their arms or

hands in the same position for long periods

of time without changing positions or

resting?

Contact Stress

■ Are there sharp or hard edges with which

the worker may come into contact?

■ Do employees use their hands as a hammer

(e.g., closing containers)?

■ Does the end of the tool/utensil (knife)

handle press into the worker’s palm?
10 Guidelines for Retail Grocery Stores

 Figure 2.

 Checklist for Identifying Potential Job-Specific Ergonomics Concerns

If the answer to any of the following questions is no, the activity may be a potential source of

ergonomic concern, depending on the duration, frequency, and magnitude of the activity.

Cashiering

■ Are items within easy reach?

■ Are keyboard supports adjustable?

■ Can the cashier work with items at about

elbow height?

■ Can the display be read without twisting?

■ Are all edges smoothed or rounded so the

cashier does not come into contact with

sharp or hard edges?

■ Are objects easily scanned the first time?

■ Are objects scanned without twisting hand

motions?

■ Can cashiers scan heavy/bulky/awkward

items without lifting them?

■ Are the scale, conveyor, and horizontal

scanner plates all the same height?

■ Is the scanner plate clean and unscratched?

■ Does the cashier have an anti-fatigue mat

and/or footrest?

Bagging and Carry Out

■ Can the bagger adjust the height of the bag

stand?

■ Are all edges smoothed or rounded so the

bagger does not come into contact with

sharp or hard edges?

■ Do bags have handles?

■ Can the bagger put bags into cart without

leaning over the checkstand or twisting the

back?

Produce

■ Are knives kept sharp?

■ Are worktables, etc. positioned so that the

work can be performed at about elbow

height?

■ Are carts used to move heavy items?

Shelf Stocking & Stockrooms

■ Are step stools/ladders used to reach high

shelves?

■ Is stocking performed with minimal twisting

or bending?

■ Do totes and boxes have handles?

■ Are gloves used for handling cold items?

■ Are box cutter blades sharp?

■ Are carts used to move heavy items?

■ Are carts or pallet jacks used to keep lifts at

waist height?

■ Are lightweight pallets used?

■ Are box weights within the lifting ability of

employees?

Bakery

■ Are counter heights and widths appropriate

for employees?

■ Are carts used to move heavy items?

■ Are routine job tasks performed without

holding hands/wrists in a bent or twisted

position?

■ Is work being performed at about elbow

height?

Meat and Deli Related Tasks

■ Are knives kept sharp?

■ Are counter heights and widths appropriate

for employees?

■ Are scales, grinders, slicers, etc. positioned

so that the work can be performed at about

elbow height?

■ Are routine job tasks performed without

holding hands/wrists in a bent or twisted

position?

■ Are box weights within the lifting ability of

employees?

■ Are tool handles the right size (not too large

or too small) for the worker?
Guidelines for Retail Grocery Stores 11

Sometimes the muscle soreness employees

experience when starting or returning to a job

can be confused with symptoms of MSD

injuries. In most cases muscle soreness from

conditioning lasts only a few days. Temporary

muscle soreness occurs most often with new

employees or workers who are returning to a

job after several weeks away. When the

symptoms linger or gradually get worse, an

MSD may be developing.

Provide Training

Training is critical for employers and

employees to safely use the solutions identified

in these guidelines. Training should be

provided in a manner and language that all

employees can understand. There are many

ways employers can integrate ergonomics

training into regular workplace activities, such

as new employee orientation or at staff,

department, or shift meetings. There are also

many sources of training materials, including

OSHA, trade associations, and insurance

companies. OSHA recommends training for

grocery store employees that provides:

■ Knowledge of the work tasks that may lead

to pain or injury;

■ Understanding of the proper tools and work

practices for tasks that employees will be

performing;

■ The ability to recognize MSDs and their

early indications;

■ The advantages of addressing early

indications of MSDs before serious injury

has developed; and

■ Awareness of the grocery store’s procedures

for reporting work-related injuries and

illnesses as required by OSHA’s injury and

illness recording and reporting regulation

(29 CFR 1904).

OSHA also recommends that management

and supervisory staff who coordinate and

direct ergonomics efforts receive training to

give them the knowledge to effectively carry

out their responsibilities. These designated

staff members will benefit from information

and training that will allow them to:

■ Appropriately use checklists and other tools

to analyze tasks in the grocery store;

■ Address problems by selecting proper

equipment and work practices;

■ Identify the potential benefits of specific

workplace changes;

■ Help other workers implement solutions;

and

■ Assess the effectiveness of ergonomics

efforts.

Grocery store employees will also benefit

from refresher training to address new

developments in the workplace and to

reinforce knowledge acquired in the initial

training.

Evaluate Progress

OSHA recommends that grocery stores

evaluate the effectiveness of their ergonomic

efforts and follow-up on unresolved problems.

Evaluation and follow-up help sustain

continuous improvement in reducing injuries

and illnesses, track the effectiveness of specific

ergonomic solutions, identify new problems,

and show areas where further attention is

needed. Grocery managers can use the same

methods they use to identify ergonomic

concerns (such as OSHA 300 and 301 injury

and illness information, workers’ compensation records, employee interviews, and

observation of workplace conditions) to

evaluate progress (10, 11). Employers can

also keep a list of activities and improvements

to track what has been accomplished and

provide data on the effectiveness of the

initiatives.

How often an employer evaluates the program will vary by the size and complexity of the

facility. Management should revise the program

in response to identified deficiencies and communicate the results of the program evaluation

and any program revisions to employees.

(Continued from page 8)
12 Guidelines for Retail Grocery Stores

The section on ergonomic solutions for

grocery stores describes changes to equipment,

work practices, and procedures that can

address ergonomic risk factors, help control

costs, and reduce employee turnover. These

changes may also increase worker productivity

and efficiency because they eliminate

unnecessary movements and reduce heavy

manual work. OSHA recommends employers

use engineering and administrative techniques,

where feasible, as the preferred method of

dealing with ergonomic issues in retail grocery

stores. The first solutions described are those

that are applicable to all or most areas of the

grocery store. Then, solutions for specific

grocery store departments are presented,

including:

■ Front end (checkout, bagging and

carryout);

■ Stocking;

■ Bakery;

■ Meat and deli department; and

■ Produce department.

OSHA is not providing specific solutions

for every department of every grocery store,

but the general recommendations should be

useful. OSHA expects that a grocery store

may need to implement a variety of solutions

to address issues in different areas of the store.

However, OSHA does not expect all of the

solutions to be used in a single grocery store.

The solutions are not intended to be an

exhaustive list. Grocery store managers are

encouraged to develop innovative ergonomic

solutions that are appropriate to their

workplace. These are only examples of

ergonomic solutions which individual store

managers should consider as a starting point.

Managers are encouraged to look for other

innovative methods that will meet their store’s

needs.

Employers should pay particular attention

to ergonomic issues when redesigning existing

stores or designing new ones. At that time,

major changes are easier to implement and

ergonomic design elements can be incorporated at little or no additional cost (12).

Implementing Solutions

King Kullen Grocery Company reported that they

initiated a three-fold approach to effectively manage

checkout repetitive motion concerns. First, they

initiated training for cashiers, store managers and

management personnel. They focused training for

checkers on awareness of repetitive motion issues,

good work practices, and the value of early injury

reporting.

Second, King Kullen changed the design of their

checkout stations and scanners. The changes included

using a combined scanner and scale to reduce lifting

and twisting arm motions, and locating the scanner

directly in front of the cashier to reduce torso twisting.

Finally, King Kullen worked to return injured employees

to work as quickly as possible. Under their program,

a nurse contacts injured employees within 48 hours of

their injury and monitors their care until they return

to work.

 According to King Kullen, by putting these changes in

place, they reduced MSD incidents from 21 in 1992 to

5 in 1996 (13).
Guidelines for Retail Grocery Stores 13

This section describes storewide ergonomic

principles on safe work practices employees can

follow to reduce their risk of injury. Employers

should train employees to use these techniques

and design stores to make it easy to do so.

Power Grips

A power grip uses the muscles of the hand and

forearm effectively, and is less stressful than a

pinch grasp. Consequently, a one- or two-handed

power grip should be used whenever possible.

A power grip can be described as wrapping all

the fingers and the thumb around the object that

is being gripped. It is sometimes described as

making a fist around the object being gripped.

The power grip can be used for many items,

including bags, cans and small boxes.

Power Lifts

When the item to be grasped is too heavy or bulky to

lift with a one-hand power grip, use the two-hand

power grip.

Pinch Grasps

A pinch grasp should never be used when a power grip

can be used instead. However, a pinch grasp is

acceptable for small, light items (e.g., a pack of gum,

etc.).

1994

1993

1992

Loss Control Savings

4% 5% 6% 7% 8% 9% 10% 11%

S T O R E W I D E

E R G O N O M I C S O L U T I O N S
14 Guidelines for Retail Grocery Stores

STOREWIDE ERGONOMIC SOLUTIONS

Lifting Safety

Most grocery store jobs involve some lifting. It is important that employers provide employees with help to lift

heavy or bulky items. Whether a particular lift will require assistance depends on several factors, including the

weight and size of the object, how frequently the object is lifted, how close the object is to the ground, how

high it must be lifted, how far it must be carried and whether it has handles. Assistance can include a dolly or

cart, or help from a co-worker. Employees should be trained in the use of appropriate lifting techniques for

different sizes of objects as well as to when it is appropriate to seek assistance.

When holding, lifting or carrying items

● Before lifting boxes and cases, check the weight so you can prepare to lift properly.

● Turn the body as a unit to avoid twisting at the waist.

● Keep the item close to your body.

● Keep your back straight.

● Use your leg muscles to do the lifting.

● Lift smoothly without jerking.

● Get close to where you want to set the item down.
Guidelines for Retail Grocery Stores 15

The Basics of Neutral Working Postures

STOREWIDE ERGONOMIC SOLUTIONS

Recommended Working Postures

Recommended Working Postures describe body positions that are neutral and comfortable to use. Using

postures other than those recommended will generally waste energy and motion as well as potentially raise

the risk of injury. It’s also important to change position frequently and stretch between tasks. This improves

circulation and lessens fatigue.

Shoulders and Arms

● Keep the shoulders relaxed – not

“shrugged-up” or “slumped-down.”

● Keep your elbows close to your body.

● Keep work at about elbow height.

Back

● Stand straight – avoid situations

that require bending (forward or

backward), leaning to the side or

twisting.

● A sit/stand stool will allow for

changes in posture.

● For work performed while sitting,

a back rest will help maintain

proper posture.

Head and Neck

● Avoid situations that require twisting the neck

or bending it forward, backward or to the side.

Hands and Wrists

● Keep the hands straight

and in line with the

forearms – avoid twisting

hands.

● Avoid working with wrists

pressed against sharp or

hard edges.

Feet and Legs

● Placing a foot on a

footrest or other support

will promote comfort.

● Provide toe space to

allow workers to stand

closer to counters. This

can reduce reaching.

● Good quality anti-fatigue

mats reduce back and

leg fatigue.
16 Guidelines for Retail Grocery Stores

STOREWIDE ERGONOMIC SOLUTIONS

Best and Preferred Work Zones

Performing work within the best and preferred work zones shown below facilitates productivity and comfort.

Work is safest when lifting and reaching is performed in these zones. Working outside these work zones

results in non-neutral postures that may increase the risk of injury. It is particularly important to perform heavy

lifting tasks within the best work zone.

Best Work Zone

● As far forward as your wrist when you hold

your arm slightly bent.

● As wide as the shoulders.

● Upper level at about heart height.

● Lower level at about waist height.

Preferred Work Zone

● As far forward as your hand when you hold your

arm out straight.

● A foot on either side of the shoulders.

● Upper level at shoulder height.

● Lower level at tip of fingers with hands

held at the side.

Best

Work Zone

Preferred

Work Zone

Best

Work Zone

Preferred

Work Zone
Guidelines for Retail Grocery Stores 17

● Provide footrests for cashiers. Alternately resting

the feet helps to reduce fatigue.

● Provide adequate toe space (at least 4 inches) at

the bottom of the workstation. Toe space allows

cashiers to move closer to the checkstand,

decreasing reaching requirements.

● Use footrests and anti-fatigue mats in areas where

workers stand for prolonged periods. Standing on

anti-fatigue mats, as compared to bare floors,

provides a noticeable improvement in comfort.

● Place the conveyor belt electronic eye close to the

scanner, but allow sufficient area between the eye

and the scanner to orient items and to ensure the

belt does not push items into the scanning field.

● Perform work within the preferred work zone.

● Use a powered in-feed conveyor to help cashiers

bring the items to their best work zone, rather than

leaning and reaching to get items further up the

conveyor.

● Use a “sweeper” to move items on the conveyor

within the checker’s reach.

● Locate commonly used items such as the cash

drawer and printer within easy horizontal reach.

● Place in-feed and take-away conveyor belts as

close as possible to the cashier to minimize

reaching.

● Consider using checkstands designed with an

adjustable sit/stand or lumbar support against

which cashiers can lean.

● Remove, round-off, or pad sharp or hard edges

with which the cashier may come into contact.

F R O N T E N D

(C H E C K O U T, B A G G I N G A N D C A R R Y O U T)
18 Guidelines for Retail Grocery Stores

● Set scanners and conveyors at the same height so

that cashiers can slide items across rather than lift

them.

● Establish a regular maintenance schedule for

scanners; clean dirty plates and replace scratched

ones.

● Use combined scales/scanners.

● Provide an adjustable-height bag stand. In

bagging areas, the tops of plastic bags should be

just below conveyor height.

● To avoid extended reaches when loading bags into

carts, move carts closer to the employee.

● Use bags with handles. Handles make the bags

easier and less stressful to carry.

● Use carts to carry bags and groceries outside the

store.

● Consider using powered-tugs when retrieving carts

from the parking area. Powered tugs facilitate

moving more carts with more efficiency and less

effort.

● Consider using keyboards to enter the quantity of

identical products rather than scanning each

individual item.

● Use keyboard to enter code if item fails to scan

after second attempt.

● Place keyboards on supports that adjust in height,

horizontal distance and tilt to keep work within the

preferred work zone.

● Use front facing checkstands to reduce twisting

motions and extended reaches to the side.

● Adjust the checkstand height to match the cashier’s

waist height, or use a platform.

● Place cash register displays at or slightly below eye

level.

● Use scan cards or scan guns for large or bulky

items to eliminate the need to handle them.
Guidelines for Retail Grocery Stores 19

● Use a step stool to reach items on the top of

pallets or on high shelves.

● Use a kneeler or stool when working at low

shelves for long periods of time. This reduces

stress on the knees and legs when squatting and

kneeling.

● Rotate stocking tasks to avoid prolonged kneeling,

squatting, and overhead reaching.

● Use a cart to move items from the pallet to the

shelving or case where they are stocked.

● Keep cart wheels well maintained. Wheels that are

in poor repair can be difficult to push. Racks or

carts with bad wheels should be removed from

service until they can be repaired.

● Keep cases close to the body when lifting and

carrying in order to reduce stress to the back.

● Use thermal gloves when stocking frozen foods.

Cold temperatures can reduce circulation,

causing stress on the hands. If pricing, use a

glove with textured fingertips to wipe frost from

frozen foods.

● Use knee pads when stocking low shelves for long

periods of time. This reduces the stress on the

knees and legs when kneeling.

CHEESE

CHEESE

CHEESE

CHEESE

CHEESE

CHEESE

CHEESE

CHEESE

CHEESE

CHEESE

STOCKING
20 Guidelines for Retail Grocery Stores

● Arrange shelves so that heavy items and fastmoving items are stored within easy reach. This

reduces the stress on the body caused by bending

or reaching overhead.

● Use the correct safety cutter for the job. Be sure

to supply a left-handed cutter if the employee is

left-handed.

● Keep safety cutters sharp. Using dull tools

requires more force. Replace cutter blades often.

● Report improperly stacked pallets to the supplier

to reduce future problems.

● Ensure that the floor areas are level and free of

debris and spills. Report any floor problems that

need repair immediately.

● Use boxes or totes with hand holds, where suitable.

● Work with suppliers to get lower weight boxes to

reduce the weight manually lifted. Industry groups

such as the Grocery Manufacturers of America and

Food Marketing Institute encourage all companies

to use containers and packages that weigh 40

pounds or less (14).

● Use carts with larger wheels so they are easier to

push. Use carts with raised bottom shelves so

the employee can maintain more neutral body

position when lifting or placing cases.

● Ensure that there is adequate room around carts

and pallets for lifting tasks. Workers should be able

to walk around the pallet or cart, rather than

reaching or bending.

● Avoid congestion in grocery store aisles so

employees have adequate room to sort cases,

open cases, mark merchandise, and stock shelves.

● Equip stockrooms and central processing areas

with roller bed conveyors and turntables to reduce

lifting and carrying. Maintain turntables so they

move easily and with little force required by the

worker. Maintain rollers to reduce the pushing and

pulling forces needed to handle cases.

● If a turntable is not used, place a flat piece of

stainless steel over the end section of the roller

bed preferably with a non-stick coating to allow

cases to be turned easily. The metal surface should

allow the cases to be pushed onto the roller bed

easily.

● Use a powered hand jack or scissors-lift to raise

the pallet to waist height. This prevents picking up

cases with a bent back.

● Work with suppliers to obtain freight with pallet load

heights that are within the reach of workers.
Guidelines for Retail Grocery Stores 21

● Make sure that there is toe-clearance under

counters and other work surfaces.

● Put buckets of icing and batter on risers (e.g.,

small stands or empty buckets) to raise them to

the best work zone.

● Use smaller containers of flour, sugar,

salt and other supplies to reduce the weights

that must be handled.

● When lifting keep large bags and containers of

ingredients close to the body to reduce stress on

the back.

● Use carts or rolling stands to move heavy items

like tubs of dough or bags of flour.

● Keep wheels on bakery carts well maintained.

Wheels that are in poor repair can be difficult to

push and should be removed from service until

they can be repaired.

B5

● Position cake-decorating turntables so that

the cake is at about elbow height for a more

comfortable working position. Adjustable

height tables are one solution, but you can also

put a riser under the turntable, use turntables

with different heights, or put in platforms for

shorter people to stand on.

● Use small decorating bags whenever possible

to reduce the stress on the worker’s hands.

The larger the bag, the more force required to

squeeze it.

● Have an adequate number of mixing bowls

available to reduce the need to transfer icing or

batters that are mixed in the store to other

containers.

● Use footrests and anti-fatigue mats in areas

where workers stand for prolonged periods.

BAKERY

These recommendations are based on information from grocery stores. OSHA recognizes that other bakery operations may be different

and that other solutions may be more appropriate for those operations.
22 Guidelines for Retail Grocery Stores

B4

● Whenever possible, break up continuous activities

such as cake decorating and dough handling with

less strenuous tasks during the shift.

● Use a short-handled scoop to put icing into

decorating bags. Shorter handles reduce the stress

to the wrist.

● Use spatulas, spoons, and other utensils that fit the

worker’s hand (not too wide or too narrow) and are

not slippery.

● Work from the long side of baking pans to reduce

reaches when handling dough.

● Use ambidextrous scoops which allow workers to

use either hand to dispense dough or batter.

● Use powered mixers whenever possible to mix

coloring into icing or purchase colored icing. This

reduces the stress to workers’ hands and arms

from manually mixing colors into icing.

● Ensure that the icing is of correct consistency. Icing

that is too thick will be difficult to squeeze

through decorating bags. If icing is mixed in the

bakery, add liquid to the recipe or warm the icing to

obtain the correct consistency. If icing is purchased

in buckets, store the buckets at room temperature

or warm them before use – cold icing is thicker

and hard to squeeze through decorating bags.

● Consider using cake decorating methods that

require less use of manual frosting bags. Using an

air brush or mechanical dispurser whenever

possible can reduce the stress on workers’

hands.

● Whenever possible work from the long side of the

donut glazing area to reduce reaches and forces

on the back. Some glazing stations can be pulled

out so that workers can work from the side.

● Use a step stool to reach items on high shelves.

● Look for cases and counter designs that allow the

employee to hand customers their selections

without high or long reaches.
Guidelines for Retail Grocery Stores 23

● If overhead storage is necessary, use it for light items

such as foam trays.

● Use a step stool to reach items on high shelves.

● Position scales so that they can be used in the

best work zone. Scales that are too high or too

low for a worker can cause employees to work in

awkward positions. If possible, make the scale table

adjustable so that all workers can work in comfortable

postures. Also, position the scale near the lowest part

of the counter so that neither the worker nor the

customer has to reach over tall deli cases for meat

packages.

● Provide a small stool for employees to sit on when

catching and traying meat from the grinder. Squatting

and bending at the waist can lead to back and leg

discomfort, especially when grinding for long periods

of time.

● Grind meat into a small lug and move it to a comfortable work surface for traying. This prevents the

awkward back posture that results from catching and

traying the meat immediately as it leaves the grinder.

Many of these solutions may also be useful for ©

the seafood and cheese departments.

● Keep wheels on racks well maintained. Wheels

that are in poor repair can be difficult to push.

Racks with bad wheels should be removed

from service until they can be repaired.

● Keep all grinders, cutters and other equipment

sharp and in good repair. Dull or improperly

working equipment requires more force to

operate.

● Provide thermal gloves for use when handling

frozen items.

● Avoid continuous cutting or grinding. Whenever

possible, break up these tasks with other, less

strenuous tasks throughout the shift.

● Work with suppliers to get meat and other

supplies in lower weight boxes to reduce the

weight manually handled.

● Keep large boxes and heavy items close to the

body. This helps to reduce stress on the back.

● Use a food processor to prepare ingredients for

stuffing and other items.

● Arrange the wrapping station so that labels are

within easy reach and workers do not have to

twist or walk to get to them.

● Remove, round-off, or pad sharp or hard edges

with which the worker may come into contact.

● Mount controls of the roller bed close to the

wrap station so that workers can reach it easily.

If there are two wrap stations, there should be

two sets of controls so that neither worker must

pull or lug trays down the conveyor.

● Align the roller bed and the wrap station so that

employees can slide the trays rather than lift

them to the station.

D E L I

CHEES

MEA

M E A T & D E L I
24 Guidelines for Retail Grocery Stores

D E L I

CHEESE

MEAT

● Whenever possible, incorporate adjustable work surfaces

into the department. Examples include cutting tables,

scales and deli slicers.

● Look for cases and counters that allow workers to serve

customers without excessive reaches.

● Use anti-fatigue mats, footrests, and sit/stand stools

where workers are required to stand for long periods

of time.

● Look for grinders that do not force the worker to bend

over to catch meat or to reach too high to dump meat

into the grinder.

● When using tongs select tongs with long handles to

reach items in the front of the case.

● Whenever possible, work from the long side of trays to

reduce reaches and the resultant high stresses

on the back.

● Avoid working with the hands/wrists held in a bent or

twisted position.

● Keep knives sharp. Workers should be trained in the best

knife sharpening methods. Knife sharpening systems

should be used regularly, and steels and mousetrap

sharpeners should be used to keep knives sharp

throughout the shift.

● Try different knives to see if they are more comfortable to

use. Some designs work well for specific cutting, trimming,

or portioning tasks and should be considered “special

purpose” tools.
Guidelines for Retail Grocery Stores 25

● Position scales and wrap stations so that they

can be used in the best work zone. Scales

that are too high or too low for a worker can

cause employees to work in awkward positions.

If possible, make the scale and wrap station

tables adjustable so that all workers can work

in comfortable postures.

● Keep boxes, melons, bags of potatoes, or

other heavy items close to the body when

lifting and carrying. This helps to reduce

stress on the back.

● Keep heavy items, such as watermelons, in

shipping containers and use pallet jacks to

move them.

● Consider using refrigeration rather than ice to

cool produce in order to eliminate the need to

shovel ice.

● Place heavier or fast-moving items on shelves

that are in the best work zone.

● Use carts to move heavy items; position carts

alongside displays to minimize reaching and

carrying.

● Keep manual food processing equipment (knives,

slicers, etc.) sharp and in good repair. Equipment

that is dull or is not working properly may require

excess force to operate.

● Use a lightweight shorthandled plastic shovel for

ice. This tool is less stressful to the body than

heavy shovels. A small shovel allows the worker to

move more ice in less time than a hand scoop.

● Use a portable ice case to transfer ice from the

ice machine to the produce displays.

©

PRODUCE
26 Guidelines for Retail Grocery Stores

The following sources may be useful to those

seeking further information about ergonomics

and the prevention of work-related musculoskeletal disorders in grocery stores.

Working Smart in the Retail Environment

Ergonomics Guide, Food Marketing Institute,

(202) 452-8444. FMI offers (for a fee) several

different guidelines and videos, including this

document. This guide instructs cashiers and

front line managers how to enhance safety,

comfort and productivity. The guide also

includes a Working Smart Quick Reference,

which summarizes the general and specific

techniques employees should use and avoid.

(1996, 68 pages)

In Search of Better Checkstands, United Food

and Commercial Workers International Union.

This document provides detailed information

on checkstand design, particularly the advantages of grocery scanners that reduce the need

for cashiers to grip and lift grocery items

across the scanner.

Easy Ergonomics, A Practical Approach

for Improving the Workplace; California

Department of Industrial Relations. This

document is designed to provide general

ergonomics advice and is not industry specific.

The document provides a simple, hands-on

approach to ergonomics to help employers,

supervisors and workers as they work toward

improving ergonomic conditions in their

workplace. (1999, 90 pages)

Elements of Ergonomics Programs, U.S.

Department of Health and Human Services –

National Institute for Occupational Safety and

Health, (800) 356-4674. The basic elements

of a workplace program aimed at preventing

work-related musculoskeletal disorders are

described in this document. It includes a

“toolbox,” which is a collection of techniques,

methods, reference materials and sources for

other information that can help in program

development.

Ergonomics for Very Small Business—Retail/

Wholesale (Poster); California Department of

Industrial Relations. A poster with examples

of safe ergonomic work practices for the very

small retail and wholesale employer.

In addition, OSHA’s Training Institute in

Arlington Heights, Illinois, offers courses on

various safety and health topics, including

ergonomics. Courses are also offered through

Training Institute Education Centers located

throughout the country. For a schedule of

courses, contact the OSHA Training Institute,

2020 South Arlington Heights Road,

Arlington Heights, Illinois, 60005, (847)

297-4810, or visit OSHA’s training resources

webpage.

There are many states and territories that

operate their own occupational safety and

health programs under a plan approved by

OSHA. Information is available on OSHA’s

website on how to contact a state plan directly

for information about specific state grocery

store initiatives and compliance assistance, or

different state standards that may apply to

grocery stores.

A free consultation service is available to

provide occupational safety and health

assistance to businesses. OSHA Consultation

is funded primarily by federal OSHA but

delivered by the 50 state governments, the

District of Columbia, Guam, Puerto Rico, and

the Virgin Islands. The states offer the

expertise of highly qualified occupational

safety and health professionals to employers

who request help to establish and maintain a

safe and healthful workplace. Developed for

small and medium-sized employers in

hazardous industries or with hazardous

operations, the service is provided at no cost

to the employer and is confidential. Information on OSHA Consultation can be found

at www.osha.gov or by requesting the booklet

Consultation Services for the Employer

(OSHA 3047) from OSHA’s Publications

Office at (202) 693-1888.

Additional Sources of Information
Guidelines for Retail Grocery Stores 27

References

(1) Food Marketing Institute. 1992.

Ergonomic Improvement of Scanning

Checkstand Designs. Washington, D.C.

(2) Clarke, Cynthia M., “Workplace injuries

and illnesses in grocery stores,” Compensation

and Working Conditions, Bureau of Labor

Statistics, December 19, 2003.

(3) Fall 2003 Liberty Mutual Workplace Safety

Index: Identifies the direct costs and leading

causes of workplace injuries. Liberty Mutual

Insurance Company. September 2003.

(4) Food Marketing Institute. 1995. Working

Smart in the Retail Environment – Ergonomics

Guide. Washington, D.C.

(5) E-mail from Supervalu Supermarkets, Inc.

to OSHA. 2003.

(6) National Institute for Occupational Safety

and Health (NIOSH). 1997. Musculoskeletal

Disorders (MSDs) and Workplace Factors – A

Critical Review of Epidemiologic Evidence for

Work-Related Musculoskeletal Disorders of

the Neck, Upper Extremity and Low Back.

National Institute for Occupational Safety and

Health (NIOSH) Publication #97-141. (3-18).

(7) Kennedy, S. et al. 1992. “Prevalence of

muscle-tendon and nerve compression

disorders in the hand and wrist of a working

population of grocery cashiers using laser

scanners.” Occupational and Environmental

Disease Research Unit, University of British

Columbia. March 15.

(8) Ryan, G. Anthony, “The prevalence of

musculo-skeletal symptoms in supermarket

workers,” Ergonomics, 1989, Vol. 32, No. 4,

359-371.

(9) Cohen, A., C. Gjessing, L. Fine, B.

Bernard, and J. McGlothlin. Elements of

Ergonomics Programs. March 1997.

National Institute for Occupational Safety and

Health (NIOSH). Publication # 97-117.

(10) Menzel, N. 1994. Workers’ Comp

Management from A to Z. OEM Press.

Chapters 11, 12, 19.

(11) Magyar, S. Jr. 1999. “Medical claim

management.” Professional Safety. March.

(12) Hendrick, H. W. 2003, Determining the

cost-benefits of ergonomics projects and

factors that lead to their success, Applied

Ergonomics. 34, 419-427.

(13) Allen, E. 1998. “Keeping grocery

checkout lines moving.” Risk Management.

January.

(14) Grocery Manufacturers of America, Food

Marketing Institute, Food Distributors

International. Supply Chain Packaging –

Voluntary Shipping Container Guidelines for

the U.S. Grocery Industry. 1999.
28 Guidelines for Retail Grocery Stores