Industrial Ergonomics

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Industrial Ergonomics
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Implement Solutions
Weve identified the problems, now what?

• Engineering Controls
• Administrative Controls
• PPE

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Engineering Controls

• Preferred method of control
• Changes to equipment, tools, workstations,
  controls and work flow that eliminate or
  significantly reduce ergonomic risk factors

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Engineering Controls

• Redesign workstations
• Redesign tools
• Modify workstation lighting
• Vibration control
• Noise control
• Automation
• Mechanical lifting device
• Material flow

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Administrative controls

• Changes to task responsibilities that reduce
  ergonomic risk factors
• Changes implemented to reduce the duration,
  frequency and severity of exposure to ergonomic
  risk factors
• Does not eliminate risk, it reduces risk
  exposure

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Administrative Controls

• Employee rotation
• Job task enlargement
• Adjustment of work pace
• Redesign of work methods
• Alternative tasks
• Rest Breaks

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Work Practice Controls

• Changes to procedures or work methods, work
  techniques procedures
• Does not eliminate risk factors but may reduce
  some contributing factors
• Requires continuing and ongoing supervision

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Work Practice Controls

• Work techniques and procedures
• Conditioning periods
• Training
• Personal protective equipment

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Ergonomic Guidelines
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Ergonomic Voluntary Guidelines
Industry Effective Date Meatpacking
Plants 1993 Furniture Manufacturing
Industry 2002 Telecommunications
Industry 2004 Nursing Homes 2003 Retail
Grocery Stores 2004 Poultry Processing 2004
Shipyard Industry In Process
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Industry Risk for MSDs

• Nursing personal care facilities
• Home health services
• Hospitals
• Transportation and public utilities
• Construction
• Manufacturing
• Agriculture
• Finance, insurance, real estate

Source BLS, 2001
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Job Tasks More Likely To Result In MSDs

• Meat processing
• Manufacturing
• Checkout scanning at a supermarket
• Keypunching
• Sewing knitting
• Activities of Butchers
• Surface Grinding
• Painting
• Activities of Dentists
• Assembly line work

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Problems Solutions
The Ladder Dolly http//www.humantech.com
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Problems Solutions
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After
Before
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Drum Handler
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Standing Workstation Challenge - Before
Design Guidelines
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Standing Workstation Dimensions
Design Guidelines
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Standing Workstation Challenge - After
Design Guidelines
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Material Handling Challenge - Before
Design Guidelines
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Material Handling Dimensions
Design Guidelines
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Material Handling Challenge - After
Design Guidelines
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Horizontal Work Reach Challenge - Before
Design Guidelines
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Horizontal Work Reach Dimensions
Design Guidelines
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Horizontal Work Reach Challenge - After
Design Guidelines
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Sitting Strength Challenge - Before
Design Guidelines
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Sitting Strength
Design Guidelines
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Sitting Strength - After
Design Guidelines
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Tool Challenge - Before
Design Guidelines
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Tool Dimensions
Design Guidelines
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Tool Challenge - After
Design Guidelines
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Manual Material Handling (MMH)

• CASE STUDY

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TELL ME.

• WHAT WOULD YOU RECOMMEND??
• Find It Fix It

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FINAL THOUGHTS..Cost Justification
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Financial Benefits of HS Improvements
Cost Justification

• Ergonomics positive impact on health and safety
  and the related costs.
• Direct Costs
• Costs than can be tracked to a WMSD incident
• Direct medical costs
• Workers compensation payments
• Indirect Costs
• Costs that increase when WMSDs occur
• Time (nurses, supervisors) to manage and treat
  WMSDs
• Cost to recruit and train replacement workers
• Poor quality due to missing operator

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Financial Benefits of HS Improvements
Cost Justification

• Although the direct and indirect costs can be
  substantial, they do not fit well into typical
  cost justification.
• Why?
• Worker Comp savings is really cost Avoidance
• It is difficult to capture all of the dollars
  spent on an injury
• Justification often needs to show an immediate
  impact on the bottom line
• So
• We must consider another approach...

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Financial Benefits of Performance Improvements
Cost Justification

• Ergonomics positive impact on production
  performance and the related costs.
• Quality
• Delivery
• Productivity
• These improvements have proven to be the most
  straightforward means of cost justifying
  ergonomic improvements.
• These improvements are simple to predict and
  quantify through the
• Elimination of non-value-added tasks
• Reduction in motion waste

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Value-Added
Cost Justification

• Value-added is anything that changes the shape or
  character of the product so it is more valuable
  to the customer.
• Examples
• Joining parts A and B
• Cutting materials to size
• Sanding a part edge

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Non-Value-Added
Cost Justification

• Non-value-added does not change the size or
  character of the part or assembly and a customer
  is not willing to pay more for your product.
• Examples
• Conveying parts to an assembly line
• Carrying finished material to a pallet
• Rework

If it doesnt add value, its waste.
Henry Ford
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Using Value-Added Analysis
Cost Justification

• Five steps can be used to perform a value-added
  analysis.
• Steps
• List the main tasks completed in an operation.
• Divide the tasks into task elements.
• Determine if each task element is value-added or
  non-value-added.
• Identify those non-value-added tasks and task
  elements that also contribute to ergonomic risk
  exposure.
• Develop an improvement plan that focuses on the
  non-value-added task elements that contribute to
  ergonomic risk.

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Applying Value-Added Analysis - Example
Cost Justification
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Applying Value-Added Analysis - Example
Cost Justification

• Success
• Time Savings 3.2 seconds.
• Ergonomic risk is reduced in this operation.

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Questions??
Thanks Everyone!! Have a Safe Drive Home!