Managing Workplace Ergonomics An Update on … Workplace Ergonomics An Update on Current Practices ... Station: Record: Elbow ... Posture Finger Press Ulnar Dev. Finger Press Ulnar

2004 International Telecommunications Safety Conference

© 2004 Humantech, Inc

Managing Workplace Ergonomics

An Update on Current Practices

Walt Rostykus, MSPH, CSP, CPE, CIH

Vice President and Ergonomics Engineer



Objectives

Share current approaches used by organizations to manage ergonomics.Provide a systematic approach to develop and sustain an effective ergonomics process.Share lessons from successful programs.Provide a view from outside the Telecommunications Industry.



Ergonomics

”the science of fitting workplace conditions and job demands to the capabilities of the working population. Ergonomics is an approach or solution to deal with a number of problems – among them are work-related musculoskeletal disorders.”

NIOSH



Ergonomics

”the science of fitting workplace conditions and job demands to the capabilities of the working population. Ergonomics is an approach or solution to deal with a number of problems – among them are work-related musculoskeletal disorders.”

NIOSH

MakingWorkplace And ToolsFit The Capabilities

of People





Fitting Workplace to the Capabilities of People

Before After







Current Approaches in Managing Ergonomics

Add Value to Several Aspects of BusinessIntegrate with Other Initiatives and ProcessesProactive Management of RiskFollow a Common Management SystemTrack Progress Toward Measurable Improvement GoalsEstablish Expertise Within the Organization



What business problem are you trying to solve?

Health & SafetyProductivityCompliance



• Cumulative Trauma Disorder

• Repetitive Motion Injury

• Repetitive Strain Injury

• Carpal Tunnel Syndrome

• Low Back Pain

• Tendonitis/Tenosynovitis

Work Related Musculoskeletal Disorder (WMSD)



Risk Factors for WMSD

Mechanical StressTemperatureVibration

+



WMSD Continuum







Productivity Improvement Initiatives

Six SigmaLean ManufacturingFlow EngineeringTotal Quality ManagementDesign for AssemblyConstraint Management



Example Productivity Improvement

Save 4.5 seconds per cycle

Lifts eliminate bendingOperators must bend to pallets



Example Productivity Improvement

2.81

4.72

0.7

4.77

3.6

5.6

1.1

0

2

4

6

8

10

12

14

16

18

Current Projected

Seco

nds

Pick part from palletPlace part in holderCycle machineRetrieve part from machine

Projected Time Reduction for All Four Steps - 40%



Example Return On Investment

• 3 work cells affecting 27 operators

• $56,395 estimated investment

• Economic impact (conservative)

» Payback = 3 months

» 1 year ROI = 298%

» 3 year FOI = 1,095%





Ergonomics: An Improvement Tool

Six Sigma-ImproveQuality

Lean-IncreaseProductivity

Safety & Health-Prevent WMSD

Ergonomics













Management System

Definition: A systematic approach to managing day to day operationswhich ensure business requirements and customer expectations are consistently met over time.

Examples:ISO 14001, BSI OHSMS 18001, ANSI Z10, ILO OSH-2001, Six Sigma,



5. ManagementReview 2. Planning

3. Implementationand Operation

1. Policy

4. Checking andCorrective Action

Elements of EHS Management Systems



5. ManagementReview 2. Planning

3. Implementationand Operation

1. Policy

4. Checking andCorrective Action

PLAN

DO

ACT

CHECK

Elements of EHS Management Systems



Continuous Improvement Model



Ergonomics Process Model



Strategic Activities: Management Team

Establish an

infrastructure and

management system that

Sustains tactical activities

and improvements



Strategic Elements



Status & Scope

California RMI Standard.Country Standard.Company Ergonomics Standard.Company Health & Safety Management System.Lean Manufacturing Process.Unacceptable Level of InjuriesQuality IssuesOther?

02468

10121416

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

Back InjuriesCumulative TraumaLacerationsSlips/FallsBurns



“By FY06 all identified ergonomic risk factors will be reduced to a low/no level. (Risk assessment score < 1).”“All new equipment, tools, and processes will pose a low/no level of ergonomic risk factors.”“By FY05 all job tasks cycle time will have < 10% non-value added motions.”“In 5 years, the WMSD incident rate will be reduced by 80%.

Example of Long Term Goals



Scheduled Completion DateDescription of Activity

Name of

OwnerO N D J F M A M J J A S

Present policy & plan to site mgmt.

Bob X

Identify Mgmt. Sponsor. Bob XAdd Ergo. Measures to business metrics.

Sue X

Recruit support Bob X

Train subject matter experts

Bob X

Train for Design Bob X X

Train Managers Harry X X

Train Employees Harry X X

Conduct risk assessments

Bob

Implement changes Bob

Verify risk reduction. Bob

Communicate results Bob/Al X X X

Improvement Plan



Ergonomic Process Measures

Measure Type of Measure

Tracking Method

Frequency

% Of Workstations/Jobs at Low Risk (Score <1).

ProactiveResults

Assessment Results

Quarterly

ProactiveActivity

Improvement Plan

Quarterly

% Of Targeted Employees Completing Appropriate

Level(s) of Training.

ProactiveActivity

Training Records

Quarterly

Injury/Illness Rate for WMSD.

LaggingResults

OSHA Record-keeping

Quarterly

% Of Targeted Workstations/Jobs Assessed for Risk.



Strategic Elements



Support Infrastructure



Roles & ResponsibilitiesRole Responsibilities

Management Sponsor

Ergonomics Process ManagerSubject Matter Expert (Ergonomics Team)Engineers, Maintenance & FacilitiesPurchasing

Employees

Managers and Supervisors

Occupational Health / Medical

Sponsorship by top management.

Coordinate rollout and management of site program.

Assess ergonomic risks. Identify solutions. Monitor for changes in workplace.

Specify, install, and maintain equipment correctly. Implement solutions

Specify and purchase correct equipment.

Operate equipment correctly. Work safely.

Ensure proper equipment and solutions are implemented and work is done correctly.Treat injuries effectively.



Skills TrainingWhat Who Why

1

2

3

4

5

Ergonomics Program Management

•Ergonomics Process Manager

•Understand initiative.•Establish plans for site.•Identify site participants.

Ergonomic Risk Assessment and Solutions

Subject Matter Experts (Ergonomics Team)

•Conduct risk assessments.•Identify solutions.•Lead improvements.

Ergonomics for Engineers Engineers, Maintenance & Facilities

Apply design criteria in selection, design, and modification of equipment.

Ergonomics For Managers Managers •Understand initiative. •Influence improvements.•Reinforce work practices.

Ergonomics For Employees

All Employees •Understand and apply ergonomic principles.•Improve work practices.



Strategic Elements



Scheduled Completion DateDescription of Activity

Name of

OwnerO N D J F M A M J J A S

Present policy & plan to site mgmt.

Bob X

Identify Mgmt. Sponsor. Bob XAdd Ergo. Measures to business metrics.

Sue X

Recruit support Bob X

Train subject matter experts

Bob X

Train for Design Bob X X

Train Managers Harry X X

Train Employees Harry X X

Conduct risk assessments

Bob

Implement changes Bob

Verify risk reduction. Bob

Communicate results Bob/Al X X X

Tracking Improvement Plan



Measure Q1YTD

Q2YTD

Q3YTD

Q4YTD

Annual Target

% Of Workstations/Jobs at Low Risk (Risk<1).

23 48 79 100

% Of Targeted Workstations/Jobs Assessed for Risk.

15 34 66 100

% Of Targeted Employees Completing Appropriate Level(s) of Training.

30 51 89 100

Tracking Process Measures



Tracking Process



Strategic Elements





Tactical Activities:

Identify and improve workplace conditions that reduce exposure to ergonomic risk factors.

•Engineers•Ergonomics Team•Safety Staff•Managers & Employees



Tactical Elements



Identify & Prioritize Job/Tasks

02468

10121416

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

Back InjuriesCumulative TraumaLacerationsSlips/FallsBurns

Screening MethodsLoss History & Injury Trends

Observation

Employee Input







Scheduled Completion DateActivity Owner

O N D J F M A M J J A SLoaders: Assess risks Bob X

Loaders: Develop and test solutions

Bob X X

Loaders: Implement solutions

Bob X X X

Loaders: Reassess risk Bob X

Tac Welders: Assess risk Jay X

Tac Welders: Develop and test solutions

Jay X X

Tac Welders: Implement solutions

Jay X

Tac Welders: Reassess risk Jay X

Warehouse: Assess risk Jean X

Warehouse: Develop solutions

Jean X X

Warehouse: Implement solutions

Jean X

Warehouse: Reassess risk Jean X X

Action Plan: Assessments & Improvements



Analysis Tools

Lifting guidelines (DOE ErgoEASER)Hand Arm Vibration Standards (ANSI S3.34)NIOSH Lifting Equation,UAW-GM Risk Factor ChecklistsThreshold limit values for physical agents (ACGIH)Rapid Entire Body Assessment (REBA)Rapid Upper Limb Assessment (RULA).Baseline Risk Identification of Ergonomic Factors (BRIEFTM)



Example Risk AssessmentBRIEF Survey BASELINE RISK IDENTIFICATION OF ERGONOMIC FACTORS

Identification: Directions

Job Name: Bumper SubassemblyDept: Date: 02/24/00Zone: Analyst: HumantechStation: Record:

Elbow Shoulder Elbow Shoulder Neck Back Legs

Pinch Grip Radial Dev. Forearm � 45° Pinch Grip Radial Dev. Forearm � 45° � 20° � 20° SquatRotation Rotation

Posture Finger Press Ulnar Dev. Finger Press Ulnar Dev. Sideways Twisted Stand on 1 legFull Arm Full Arm

Flex � 45° Extension Behind Body Flex � 45° Extension Behind Body Backwards Sideways Kneel

Ext. � 45° Ext. � 45° Twisted

Force � 10 lb. � 10 lb. � 10 lb. � 10 lb. + Weight � 20 lb. Foot � 10 lb.

Duration � 10 secs � 10 secs � 10 secs � 10 secs � 30% of Day

Frequency � 2/min � 2/min � 2/min � 2/min � 2/min � 2/min � 2/min

Total 3 3 3 3 2 2 15 4 4 5 4 4 3 3 2

Check the type of stressorpresent and shade the areaof the body affected.

Vibration (V) Mechanical Stress (M) Low Temperature (L)

3 24 3

High Risk SummaryLeft Right

Hands/Wrist Hands/Wrist

Legs

Back

Elbow

ShoulderShoulder

Elbow

Neck

4 4

� 10 secs � 10 secs

� 30 postures/min.� 30 postures/min.

Physical Stressors Comment / Observations

LeftHand and Wrist Hand and Wrist

Right

Pinch grip � 2lb.

Power grip � 10 lb.

Pinch grip � 2lb.


• Mark all the appropriate Posture, Force, Duration and Frequency boxes.• Total the number of marked boxes.• For body areas with a score of 2 or more, mark the body area in the Risk Summary box.

Version 2.1



Example Risk AssessmentBRIEF Survey BASELINE RISK IDENTIFICATION OF ERGONOMIC FACTORS











Total 3 3 3 3 2 2 15 4 4 5 4 4 3 3 2



3 24 3



Legs

Back

Elbow

ShoulderShoulder

Elbow

Neck

4 4





Right

Pinch grip � 2lb.


Pinch grip � 2lb.



Version 2.1

Features:•Validity•Differentiation

•Inter Job Differentiation•Intra Job Differentiation

•Reliability•Reproducibility



Quantifiable Risk Assessment

LOW

Score = 1

Posture Only

MODERATE

Score = 2

Posture + 1

HIGH

Score = 3 or 4

Posture + Many









Quantifiable Risk Assessment: Problem Defined



What’s the Priority?



Summary Left Right Rank Job Name

Hand Elbow Shoulder Hand Elbow Shoulder Neck Back Legs Score Body # 1 Cover & Feeder Stitcher 7 5 7 7 5 7 5 7 7 7 6 2 Stobb Stacker 7 4 4 7 6 4 4 6 5 7 2 3 Take off Stitcher 5 4 4 5 4 4 4 7 1 7 1 4 Pop Up Stacker 6 4 4 6 4 4 4 6 4 6 3 5 Quality Inspection 6 4 1 6 4 1 0 3 0 6 2 6 Water Brush Lathe 4 4 4 4 4 4 4 6 0 6 1 7 Roll Tending 6 0 0 4 0 0 0 5 0 6 1 8 Water Brush Change Out 5 4 0 5 4 4 4 5 5 5 4 9 Feeder 1/4 folder 5 0 0 5 0 0 4 5 0 5 3

10 Take off Stitcher - Mail Sack 4 4 5 4 4 5 0 5 0 5 3 11 Plate Change Out 4 4 4 4 4 5 0 5 1 5 2 12 Forklift / Clamp Truck 4 0 0 4 0 0 5 5 0 5 2 13 Take off 1/4 folder 4 4 4 4 4 4 4 4 5 5 1 14 Feeder Special Pack 4 4 4 4 4 4 4 4 4 4 9 15 Take off Special Pack 4 4 4 4 4 4 4 4 0 4 8 16 Roller Cage 4 4 4 4 4 4 4 2 0 4 7 17 Stitcher Wire 0 4 4 4 4 4 0 0 0 4 5 18 Card Feeder 4 0 0 4 4 4 0 2 0 4 4 19 Blanket Wash 0 0 0 4 0 4 0 4 0 4 3 20 Log Stacker 1 1 4 1 1 0 0 1 1 4 1

Assessment Results: Prioritization



Tactical Elements



Evaluate Alternatives

Anthropometric Data

Design Criteria

Brainstorm Solutions

Checklist for Standing Workstation Guidelines

Job Name: Workstation Location

Analyst: Dept:

Date: Operator:

Work Surface Criteria Dimension Acceptable Action

A. Height Precision Work 40” - 50” Yes NoLight Work 35” - 45” Yes NoHeavier Work 29” - 39” Yes No

B. Work Surface Angle Adj. from -6˚ to 30˚ Yes No

(-) = away from operator

(+) = towards operator

C. Rounded Edges Yes No

D. Footrail Height 6” Yes No

E. Knee Clearance Min: 23” Yes No

F. Toe Clearance Min: 4” Yes No

Anti-Fatigue Matting Yes No

B

A

C

D F



1. Laser Cut Parts2. Stamp Parts3. Pallet Lifts4. Hinged Fixture5. Suspend Tool6. Anti-Fatigue Matting7. Swivel Hose Coupling8. Closer Workstation9. Automatic Cut10. Tool Holster11. Closer Pallets/Waste Bins12. Clamps for Fixture13. In-Line Drill

Brainstorm Solutions



1. Laser Cut Parts2. Stamp Parts3. Pallet Lifts4. Hinged Fixture5. Suspend Tool6. Anti-Fatigue Matting7. Swivel Hose Coupling8. Closer Workstation9. Automatic Cut10. Tool Holster11. Closer Pallets/Waste Bins12. Clamps for Fixture13. In-Line Drill

High cost

High impact

Low impact

3

122

1

4

10

Lowcost

59

6 11

713

Prioritize Solutions



Stackable platforms for shorter people

Implement Workplace Changes: Simple



Implement Workplace Changes: OTS*

Electric cart with rollers

Gravity feed rollers

Powered tools

* Off The Shelf



Implement Workplace Changes: Complex



Implement Job Design Controls

Administrative ControlsJob RotationWork PaceAlternative TasksRest Breaks

Work Practices



Awareness Training

What Who Why1

2

3

4

5

Ergonomics Program Management

•Ergonomics Process Manager

•Understand initiative.•Establish plans for site.•Identify site participants.

Ergonomic Risk Assessment and Solutions

Ergonomics Team •Conduct risk assessments.•Identify solutions.•Lead improvements.

Ergonomics for Engineers Engineers, Maintenance & Facilities

Apply design criteria in selection, design, and modification of equipment.

Ergonomics For Managers Managers •Understand initiative. •Influence improvements.•Reinforce work practices.

Ergonomics For Employees

All Employees •Understand and apply ergonomic principles.•Improve work practices.



Tactical Elements



Re-AssessBRIEF Survey BASELINE RISK IDENTIFICATION OF ERGONOMIC FACTORS











Total 3 3 3 3 2 2 15 4 4 5 4 4 3 3 2



3 24 3



Legs

Back

Elbow

ShoulderShoulder

Elbow

Neck

4 4





Right

Pinch grip � 2lb.


Pinch grip � 2lb.



Version 2.1



Verify Improvement

4

Left Shoulder

Right Wrist Left Wrist

Left Elbow

Right Shoulder

Right Elbow

2 Neck

Back2

3

3

3

33

Legs1

1

Left Shoulder

Right Wrist Left Wrist

Left Elbow

Right Shoulder

Right Elbow

1 Neck

Back1

1

2

2

11

Legs1

Before After



Scheduled Completion DateActivity Owner

O N D J F M A M J J A SLoaders: Assess risks Bob XLoaders: Develop and test solutions

Bob X X

Loaders: Implement solutions

Bob X X X

Loaders: Reassess risk Bob X

Tac Welders: Assess risk Jay X

Tac Welders: Develop and test solutions

Jay X X

Tac Welders: Implement solutions

Jay X

Tac Welders: Reassess risk

Jay X

Warehouse: Assess risk Jean X

Warehouse: Develop solutions

Jean X X

Warehouse: Implement solutions

Jean X

Warehouse: Reassess risk Jean X X

Done

Done

Done

In Process

Done

DoneDoneOn Track

Track Measures and Plans



Tactical Elements



Fix Once, Repeat Many.

Redeploy Effective Improvements



Ergonomics Process Model



Cookeville, TN



Textron 90% Reduction in WMSD Rate



Honeywell 37% Increase in Productivity



Lucent 44% Reduction in Product Build Time



Verizon 52% Reduction in Workers’ Compensation Costs



$1.2M 3-year total cost$920k fees & expenses$280k accessories (estimated)

$6.1M 3-year savings$4.7M workers’ comp$1.4M revenue (1 business, 2 years)

408% 3-Year ROI

$-

$500,000

$1,000,000

$1,500,000

$2,000,000

$2,500,000

$3,000,000

10 centers 23 centers 30 centers

Year 1

Year 2

Year 3Annual Savings (1999 baseline)

Return On Investment



Characteristics of Successful Programs

Add ValueSystematic Approach» Manage risks not consequences.» Established goal and plan.» Address both strategic and tactical elements.» Integrated into existing processes and operations.» Uses common language and approach.

Sustainable» Measurable.» Visible » Continuous improvement» Kept in perspective.





Questions/Discussion

www.humantech.com

Walt Rostykus CSP, CIH, [email protected]

Documents

Managing Workplace Ergonomics An Update on … Workplace Ergonomics An Update on Current Practices ... Station: Record: Elbow ... Posture Finger Press Ulnar Dev. Finger Press Ulnar