Sample Mfg Company Ergo Eval Summary


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Executive summary presentation of a multiple workstation ergonomic evaluations, providing both general and job - specific corrective actions.

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Sample Mfg Company Ergo Eval Summary

  1. 1. Workstation Ergonomic Evaluation Report Sample Manufacturing Company, Order Fulfillment & Packaging Facility June 2008 Allen Jingst, CIE
  2. 2. Introduction <ul><li>Evaluation of Packaging Task Ergonomic Risks at Sample Manufacturing Company. </li></ul><ul><li>Ten tasks / Seven employees evaluated. </li></ul><ul><li>At least 2 Evaluation methods for each task. </li></ul><ul><li>Results Presented: </li></ul><ul><ul><li>General Conclusions </li></ul></ul><ul><ul><li>General Recommended Corrective Actions </li></ul></ul><ul><ul><li>Individual Task Evaluations, with Conclusions and Recommended Corrective Actions </li></ul></ul>
  3. 3. Ergonomic Risk Factors <ul><li>Direct and Indirect Elements create Ergonomic Risk Factors: </li></ul><ul><li>Direct Factors act upon the Task & include: </li></ul><ul><ul><li>Repetitive task cycles / Duration of the task. </li></ul></ul><ul><ul><li>Joint and muscle fatigue / stress due to repeated movements, especially near the limits of the joint’s range of motion. </li></ul></ul><ul><ul><li>Object Weight or the force required to grasp and move the object. </li></ul></ul><ul><li>Indirect Factors influence the direct factors: </li></ul><ul><ul><li>Limited “down” time between task cycle repetitions. </li></ul></ul><ul><ul><li>Location of materials, tools, equipment, supplies in relation to the worker. </li></ul></ul><ul><ul><li>Cold temperatures of environment or objects handled. </li></ul></ul><ul><ul><li>Use of gloves that limit sensory feedback or fit poorly. </li></ul></ul><ul><ul><li>Objects with unbalanced weight distribution, poor handles, oversized. </li></ul></ul><ul><ul><li>Contact stress to body parts that can inhibit blood flow, neural transmission, muscle – tendon activity </li></ul></ul><ul><ul><li>Job stresses: machine paced work, multiple sensory input, high external incentive levels. </li></ul></ul><ul><ul><li>Vibration of the object, work environment, directed to the worker. </li></ul></ul>
  4. 4. Executive Summary <ul><li>General Conclusions </li></ul><ul><ul><li>Work Cycles. Foam Line = 0.94 cycles / minute; Bubble Wrap = 1.59 / min. Skin Pack – 1.79 / min. Hand Pack = 1.84 / min. Auto Bag = 2.98 / minute. </li></ul></ul><ul><ul><li>Individual Tasks were less than workshift duration, however, similarities and multiple tasks daily produce daily duration of > 8 hour workshifts. </li></ul></ul><ul><ul><li>Direct ergonomic risk factors and some indirect factors were evident in all tasks evaluated. </li></ul></ul><ul><ul><li>“ Working height of the hands” were found to be a key postural risk factor (well above bench level). </li></ul></ul><ul><ul><li>Tasks are often stationary or semi-stationary, creating low back fatigue, even with use of floor mats. </li></ul></ul>
  5. 5. General Corrective Actions <ul><li>Fit the “Working Hands Height” to the Individual. </li></ul><ul><ul><li>Provide height adjustability to the workstation. </li></ul></ul><ul><li>Improve Standing Posture Stress to the Lower Back. </li></ul><ul><ul><li>Provide a foot rest above the floor for alternate leg use. </li></ul></ul><ul><li>Create Horizontal Work Flow. </li></ul><ul><ul><li>Stack pallets at the input and output end of each workstation </li></ul></ul><ul><ul><li>Use an adjustable pallet lift. </li></ul></ul><ul><ul><li>Use a self-leveling pallet positioning device. </li></ul></ul><ul><li>Reduce Wrist / Hand Postural Stress. </li></ul><ul><ul><li>Tilt parts boxes and bins. </li></ul></ul><ul><ul><li>Reduce reach distance to repetitively handled objects </li></ul></ul><ul><ul><li>Modify the wrapping method when bubble-wrapping objects. </li></ul></ul><ul><ul><li>Two hands when handling objects that weigh more than 5 lbs. </li></ul></ul>
  6. 6. General Corrective Actions <ul><li>Construct Job Rotation Schedules with Work Cycle Frequency and Object Weight / Force Considerations </li></ul><ul><ul><li>Bubble Wrap jobs combine high repetitions with object weight </li></ul></ul><ul><ul><li>Foam Line with heaviest objects but lower task frequency. </li></ul></ul><ul><ul><li>Hand & Skin Pack combine high repetitions with postural stresses. </li></ul></ul><ul><ul><li>Auto Bag with highest repetition and postural stresses. </li></ul></ul><ul><li>Utilize “micro-breaks” and time between work cycles to Stretch repeatedly used body parts. </li></ul><ul><ul><li>Train employees in counter stretch movements of short duration during what is otherwise considered “down time”. </li></ul></ul>
  7. 7. Individual Task Evaluations <ul><li>Skin Pack </li></ul><ul><ul><li>Ergo Rating: Moderate </li></ul></ul><ul><ul><li>Risk Factors: </li></ul></ul><ul><ul><ul><li>Task Cycle = 1.79 / min. </li></ul></ul></ul><ul><ul><ul><li>Raised shoulder / abducted elbow posture </li></ul></ul></ul><ul><ul><ul><li>Workbench too high </li></ul></ul></ul><ul><ul><ul><li>Gloves add grip force </li></ul></ul></ul><ul><ul><li>Corrective Actions: </li></ul></ul><ul><ul><ul><li>Lower workbench </li></ul></ul></ul><ul><ul><ul><li>Tilt worksurface </li></ul></ul></ul><ul><ul><ul><li>Reposition wrap material </li></ul></ul></ul><ul><ul><ul><li>Gloves with better “feel” </li></ul></ul></ul><ul><li>Hand Pack </li></ul><ul><ul><li>Ergo Rating: Moderate </li></ul></ul><ul><ul><li>Risk Factors: </li></ul></ul><ul><ul><ul><li>Task Cycle = 1.84 / min. </li></ul></ul></ul><ul><ul><ul><li>Wrist-hand posture when reaching for parts. </li></ul></ul></ul><ul><ul><ul><li>Hand height at carton </li></ul></ul></ul><ul><ul><ul><li>Repeated hand movements at each step. </li></ul></ul></ul><ul><ul><li>Corrective Actions: </li></ul></ul><ul><ul><ul><li>Tilt parts bins </li></ul></ul></ul><ul><ul><ul><li>Tilt/lower packing carton </li></ul></ul></ul><ul><ul><ul><li>Mechanical label dispenser </li></ul></ul></ul>
  8. 8. Individual Task Evaluations <ul><li>Bubble Wrap </li></ul><ul><ul><li>Ergo Rating: Moderate </li></ul></ul><ul><ul><li>Risk Factors: </li></ul></ul><ul><ul><ul><li>Task Cycle = 1.59 / min. </li></ul></ul></ul><ul><ul><ul><li>Lifting from pallet </li></ul></ul></ul><ul><ul><ul><li>“ Clothes-wringing” motion when wrapping. </li></ul></ul></ul><ul><ul><ul><li>Shoulder / elbow posture </li></ul></ul></ul><ul><ul><ul><li>Raised box flaps add reach </li></ul></ul></ul><ul><ul><li>Corrective Actions: </li></ul></ul><ul><ul><ul><li>Wrap station </li></ul></ul></ul><ul><ul><ul><li>Gloves with better “feel” </li></ul></ul></ul><ul><ul><ul><li>Raise both pallet loads </li></ul></ul></ul><ul><li>Automatic Bagger </li></ul><ul><ul><li>Ergo Rating: Moderate </li></ul></ul><ul><ul><li>Risk Factors: </li></ul></ul><ul><ul><ul><li>Task Cycle = 2.98 / min. </li></ul></ul></ul><ul><ul><ul><li>Neck flexion </li></ul></ul></ul><ul><ul><ul><li>Stationary posture </li></ul></ul></ul><ul><ul><ul><li>Bending to reach tote </li></ul></ul></ul><ul><ul><ul><li>Position of controls </li></ul></ul></ul><ul><ul><li>Corrective Actions: </li></ul></ul><ul><ul><ul><li>Raise bagging machine </li></ul></ul></ul><ul><ul><ul><li>Lower monitor & controls </li></ul></ul></ul><ul><ul><ul><li>Output tote conveyor </li></ul></ul></ul><ul><ul><ul><li>Foot rest / work platform </li></ul></ul></ul><ul><ul><ul><li>Stool and Film roll access device </li></ul></ul></ul>
  9. 9. Individual Task Evaluations <ul><li>Foam Line: Carton set-up </li></ul><ul><ul><li>Ergo Rating: Moderate - High </li></ul></ul><ul><ul><li>Risk Factors: </li></ul></ul><ul><ul><ul><li>Task Cycle = 0.94 / min. </li></ul></ul></ul><ul><ul><ul><li>Foam insertion into cartons has posture risk due to carton height </li></ul></ul></ul><ul><ul><ul><li>Use of tool adds risk factor </li></ul></ul></ul><ul><ul><li>Corrective Actions: </li></ul></ul><ul><ul><ul><li>Pistol grip tape dispenser </li></ul></ul></ul><ul><ul><ul><li>Proper hand height when loading carton </li></ul></ul></ul><ul><ul><ul><li>Label dispenser </li></ul></ul></ul><ul><li>Foam Line: Load cartons </li></ul><ul><ul><li>Ergo Rating: High </li></ul></ul><ul><ul><li>Risk Factors: </li></ul></ul><ul><ul><ul><li>Task Cycle = 0.94 / min. </li></ul></ul></ul><ul><ul><ul><li>Step 3 (of 4) is key risk </li></ul></ul></ul><ul><ul><ul><li>Significant manual material handling risk. </li></ul></ul></ul><ul><ul><ul><li>Use of tool add risk </li></ul></ul></ul><ul><ul><ul><li>Job pacing (cure time of foam inserts) </li></ul></ul></ul><ul><ul><li>Corrective Actions: </li></ul></ul><ul><ul><ul><li>Raise height of input pallet load </li></ul></ul></ul><ul><ul><ul><li>Eliminate carry distance </li></ul></ul></ul><ul><ul><ul><li>Utilize bend and conveyor system on line – sequential production </li></ul></ul></ul>