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Successful Applications of Ergonomic Principles to Loss Prevention. Vern Anderson, Ph.D., Coordinator Retail Trades Occupational Health CDC/NIOSH Mike Leiner Manager Store Safety Target Corporation. Two Acknowledgments for Leadership in Safety. - PowerPoint PPT Presentation
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Vern Anderson, Ph.D., Coordinator Retail Trades
Occupational Health CDC/NIOSH
Mike Leiner
Manager Store SafetyTarget Corporation
Successful Applications of Ergonomic Principles to
Loss Prevention
Two Acknowledgments for Leadership in Safety
• 1. RILA recently signed a “Letter of Agreement” with the “Centers for Disease Control & Prevention” (CDC) and its Occupational Safety and Health Program CDC/NIOSH).
• 2. The Loss Prevention Foundation (LPF), known for its Certification and Training for Loss Prevention also signed a “Letter of Agreement” with (CDC/NIOSH).
• The purpose of both of these Letters of Agreement was to acknowledge the importance of workplace safety and to provide information on safety and health to their membership. In addition, the resources of CDC/NIOSH are committed to these same goals.
• Ergonomic is good business!
Take Away Message
• Correlates with business success• Adds value- provides competitive edge
– Quality, efficiency, profitability– Controls costs (direct and indirect)
It’s the right thing to do• Protection of our most valuable resource: employees!
But, we can do more to protect our employees/customers.
Purpose of our Presentations
.
We will show through examples how applying ergonomic principles can:
- improve productivity
- reduce loss of property
- reduce loss of work time
from preventable accidents
• What you may not know about ergonomics.• Why be concerned about MMH injuries? • Examples of Good Work Practices • Example of Ergonomic Solutions • Costs and Loss Prevention Goals• Matching Solutions to Problems
Presentation Outline
• Safety Activities: Phases (IAS)– Investigate –collect information – Analyze- assess and plan– Solve- develop solutions:
• Training: Takes time, re-training needed• Administrative: Management decisions• Engineering: i.e., Ergonomic solutions
Safety and Ergonomics
Ergonomic Solutions
???
.
Ergonomics is an engineering science to improve work efficiency
Ergonomics is about prevention through design.
What you may not know about ergonomics.
Ergonomics is about adapting work to fit your workforce: big or small*
Ergonomics is about how workers do their job and use tools (Logistics)
What you may not know about ergonomics
• Put aside the notion that workplace ergonomics is only about injuries
• Ergonomics makes good business sense:
• Healthy people work better
• Sick people perform poorly
Ergonomics : Some Facts
Why Address
Manual Material Handling?
Some Facts to Consider: (Retail/Wholesale)
• Affects 8-10% of workers yearly
• Accounts for 21-36% of workplace injuries
• Responsible for 33% -60% of workplace injuries costs
Because Lifting Injuries are important
They represent the biggest single contributor to worker injury in the United States
In short: Lifting Related Injuries
...and the application of good ergonomic design and good work practices can substantially reduce those incidences.
Problem: Stocking shelves or a gymnast
We can do better
Another Tough Lift: Unloading Boxes
We can do better
Problem: All to Common
We can do better
Training Administrative Ergonomics
What are our Solutions?
Manual Materials Handling JobsVarious Solutions:
Good Work Practices “Soft Ergonomics”
Engineering Changes “Hard Ergonomics”
Training and Administrative
Employees capabilities and Job DemandsGood Work Practices
Training and Administrative
Good Work Practice
Training and Administrative
Good Work Practices
Ergonomic Study Examples
More Ergonomic Study Example
Ergonomic Study ExampleHeight Adjusted Pallet Jack
Used a Height Adjustable Pallet Jack to elevate low boxes on pallet (bottom 1/3) to waist level when stocking on store floor, thereby reducing back bending & compressive forces on spine when cutting boxes open and lifting from pallets.
BEFORE AFTER
Okay, so not everybody gets excited about ergonomics
Tested a spring-loaded customized self-leveling cart to reduce the bending and stooping required to load/unload flat-bed carts and the forces on the back /spine
Ergonomic Study ExampleSelf-Leveling Cart Deli/Bakery
Ergonomic Study Example: Results
BEFORE AFTER
• Strong positive usability feedback and highly recommended (2 associates)
• Back, Shoulder, & Knee discomfort ↓dropped ≥ 30% (2 associates)
• Productivity ↑increased 1.9% (delivery time) = 5.3 min. savings/day
Spring Self leveling cart : Deli/Bakery
Ergonomic Results Example: Deli Bakery
BEFORE AFTER
• Also Positive usability feedback and recommended (1 associate)
• Reported Low Back discomfort ↓ 29% (1 associate)
• Productivity ↑ 9.2% (transport time) = 6.2 min. savings/day (1 associate)
Tested Battery powered adjustable cart to reduce carrying & Lifting
Findings from Ergonomic Studies
• Adjustable carts allowed products to be placed at waist level– Reduced -bending down to floor level – More workers were able to do this job – Did not affect productivity
• Workers liked the cart– Reported less back fatigue – Easy to use - felt to be more productive– Liked cart maneuverability
• Sprains/strains–muscles, ligaments, tendons
• Chronic pain affecting joints
• Disc injuries of the back or neck
• Compression of peripheral nerves
• Soft tissues disorders bruises
• Compression of blood circulation
Injuries from Manual Lifting Tasks
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What you don’t want.
• Median number of lost work days – 5 days for all workers with any injury– 25 days for workers with MSDs
• Average cost per injury– $1,100 for all other cases– $10,800 for an MSD
• MSDs tend to have – Longer durations – Longer treatment time– Greater work disability
Musculoskeletal Disorders
30
Accident Costs
1% Profit
2% Profit
3% Profit
$ 1,000 $ 100,000 $ 50,000 $ 33,000
$ 5,000 500,000 250,000 167,000
$ 10,000 1,000,000 500,000 333,000
$ 25,000 2,500,000 1,250,000 833,000
$100,000 10,000,000 5,000,000 3,333,000
SALES TO COVER COSTS*
It is necessary to sell an additional $250,000 in products or services to pay the cost of $5,000 annual losses
*
$ 5,000 $250,000
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Elimination Prevention Control LOSS
TARGET:
Reduce Injury/illness frequency
Use Ergonomics to focus oncontrolling
what precedesthe loss
Loss Prevention is Goal #1
33
MedicalMgmt
ClaimsMgmt.
PolicyStructure/Funding
LOSS
TARGET:
Reduce Injury/illness
severity
Use Administrative resources for
controlling whatfollows the loss
Loss Reduction is Goal #2
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Elimination Prevention ControlMedicalMgmt
ClaimsMgmt.
PolicyStructure/Funding
LOSS
Reduce Injury/illness severity with
AdministrativeResources
Reduce Injury/illness
frequencyWith
Ergonomics
Effective Program: Goal Integration
35
Use ALL Your Metrics
Elimination Prevention Control MedicalClaimsMgmt. FundingLOSS
LOSS REDUCTION
Past Loss measures of INCIDENCE /
CAUSETCIR, DART
WC Case Rate MSD Case Rate
Past Loss measures of SEVERITY/ COST
• Experience Modification rating• # Days away from work• Cost per man-hour• % cost due to cases > $20K• Reporting Delay
Loss Prevention
A New Research Initiative
36
CDC Campaign to Assist Businesses Maintain A Healthy Workforce in the Retail/Wholesale Trades
Focus on Manual Materials Handling: “We can and need to do better!”
NIOSH/UC Sponsored Purpose:
Manual Materials Handling Workshop
“Matching Solutions to Problems”
October 11-12, 2011
Hyatt Regency, Cincinnati, Ohio
Participants:
Practitioners/researchers
Industry/safety/loss prevention representatives
Manufacturers/vendors of MMH equipment
Contact: Vern Putz Anderson, NIOSH
vep1@cdc.gov, 513-533-8319
Purpose: Develop engineering solutions for high risk
manual materials handling (MMH) jobs in Retail, Wholesale, and Warehousing (RWW) Industries
37
Questions??
Next up:
Mike Leiner
Manager Store Safety:
Target Corporation
Ergonomics Designing Jobs to Fit Your Workforce
Person’sCapacities The Task
Load
Effort
Energy
The task demands exceed the person’s (workforce) capacities
Risk of overexertion injuries Turnover
Ergonomics Designing Jobs to Fit Your Workforce
Fulcrum
Person’s
Capacity
Load
The Task
Loss productivity - workers not challengedBoredom Turnover
Ergonomics: Achieving Balance
Fulcrum
Optimal work conditions Optimal Productivity Low Risk
Effort
EnergyLoad
Person’s Capacity
The Task
Balancing Capacity with the Task
Employees capabilities and Job DemandsPeople and Work Tasks
Good Work Practices
Identifying Risk Factors
Achieving Balance
Good Work Practices
Good Work Practices
Introducing Equipment to Maintain Balance
Balancing Capacity with Productivity
Questions??
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