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General Industry 2015 ergo


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This is a draft ergo ppt that I used in 2015. I want to redo it for 2016. I am trying to make one for construction focusing on solutions that work.

Published in: Government & Nonprofit

General Industry 2015 ergo

  1. 1. Ergonomics John Newquist Draft 12 18 2015
  2. 2. Dec 2015  I need to take the time to thank John for everything he has done for my family and myself.  He may not see it as helping my family but when you save my knees, tendons, muscles etc from the daily wear of cleaning homes for hours on end it gives them a mother and wife who can function better.  I've been in a home scrubbing for over 2 hours now and my forearm hasn't given in to the repetitive motion.  No pain in my hands, forearm, or elbow, and my knees are happy as well.  I am so super grateful for your knowledge and expertise in job safety.  My body will get a 2 day break and then back at it.  Thank you for everything!
  3. 3. January 2015 Bayer using sit stand desks
  4. 4. March 2015 Uplift desk with adjustable keyboard and monitor
  5. 5. Dec 2013
  6. 6. ASSE 2010 Work Comp from PA Insurance ~4000 companies studied 200 Companies had 210 single losses over $250,000 21% were same surface falls (ice, slipping) 17% were ergo from non routine lifting
  7. 7. Carpal Tunnel  500,000 surgeries a year (NYT)  $29,000 average cost including rehab  Loss of some wrist strength is a complication that affects 10% to a third of patients.
  8. 8. Ergonomics  Demands of the task match the functional capacity of the worker
  9. 9. Definitions  Work-related: – an event or exposure in the work environment that either caused or contributed to the resulting condition. – Produces characteristic symptoms or injury
  10. 10. Strategy for Success: Goals: o Decrease ergonomic hazards o Reduce injuries and illnesses o Ensure flexibility and encourage innovation o Help prevent MSDs
  11. 11. Work Risk Factors  Forceful exertions  Repetitive movements  Over shoulder work  Heavy lifting
  12. 12. Work Risk Factors
  13. 13. Effective Ergonomics Programs  Injury & illness record keeping  Medical management  Training  Job/Task hazard analysis  Ergonomic control selection and evaluation
  14. 14. Selecting the Employee  The abdominal muscles support the lower back.  People with weak abdominal muscles tend to suffer from back pain.
  15. 15. Strength Testing  An objective way to ensure that only people with sufficient strength to perform a job will indeed be assigned that job.  Not fool proof.  Define task.  $150 is typical
  16. 16. Injury and Illness Recordkeeping  Is it accurate?  Is it useful?  How is it used?  By department  By body part
  17. 17. Trend Example Using DART Rates  Warehouse operators  2000 = 17.6  2001 = 21.5  2002 = 35.1  2003 = 32.9  W.O. Upper Extremity Injuries  2000 = 4.7  2001 = 6.3  2002 = 7.0  2003 = 8.2
  18. 18. What is the Ergo Stressor Here? Driver facing forward for driving Driver is supposed to drive backwards
  19. 19. Trend Example Using DART Rate  Facility  2001 7.4  2002 38.8  2003 35.6  Warehouse Operator Injuries  2001 = 21.5  2002 = 38.6  2003 = 54.7
  20. 20. What is the Ergo Stressor Here?
  21. 21. Medical Management  Recognize symptoms  Early reporting system to report signs and systems of ergo injuries  Physician used that is familiar with your company’s jobs/tasks  Provide job accommodation
  22. 22. Medical Treatment  Doctors and other health care providers cannot always pinpoint the exact cause of a patients' back pain.  Employee capabilities – work/no work  Employee restrictions – weight to be lifted  Follow-up  Information to provider  Information to employee
  23. 23. Back Facts  People who cope best with back pain are those that stay active.  Aging of the back begins before 30 for most people.  Smokers are more likely to get back pain.  People with previous back pain are likely to get it again within a couple of years.  The longer you stay off work due to a back injury, the less likely you are to return to work.  Even if your aches and pains last for a long time, it doesn't mean you have a serious injury. Back pain settles eventually, but we can't predict exactly when.  Back pain usually subsides without any medical treatment in four to six weeks.  NIOSH could not establish that back belts work to eliminate ergonomic back injuries.
  24. 24. Education and Training  Who receives it?  How do they use it?  Are they expected to use it?
  25. 25. Controls Engineering Work practice Administrative Any combination of the above 40 boxes loaded per minute onto conveyor
  26. 26. Analysis Step-by-Step Procedure  Observe the job  Interview the person performing the job  Break the job into various actions  Describe the actions  Measure and quantify risk factors  Identify conditions contributing to the risk factors  Verify the analysis of the job with the worker
  27. 27. Sample Analysis  The following is an checklist to aid in an ergonomic hazard analysis of a specific job or workstation. It is designed to used as a supplement to close visual observation or videotaping of the job/workstation. Person performing analysis: John Newquist Date: December 13, 2005 Job location: Warehouse Job name: Warehouse Worker Job description: Load on/off conveyor Number of employees on job: 12 Line speed: 15 (pieces/minute) Jobs rotated with: None Rotation schedule: None Break schedule: 2 15 minute breaks in the morning, 30 minute lunch  Workstation: ____ 1. Are there any sharp edges? No ____ 2. What is the height of the work table? 30 inches from floor to conveyor.  ____ 3. Adjustability: None ____ Can tools be moved around in the workplace? Not used ____ Can the work surface height be adjusted vertically? No ____ Can fixtures be tilted or rotated? No ____ 4. What is the worker standing on? concrete floor ____ 5. Is the floor or platform slippery? No Postural ____ 1. Can worker change postures (sit-to-stand or stand-to-sit)? No ____ 2. What are the maximum reach distances in inches? Vertical = 30 to floor, Horizontal 33 inches across Miscellaneous ____ 1. Are Packages or materials handled? Yes ____ 2. What are they and what do they weigh? Name: Various Packages Weight up to 55 lbs. ____ 3. What is the temperature of the work environment? 78F degrees (C./F.) ____ 4. What personal protective equipment is used? None (e.g., gloves, hard hats, aprons) ____ 5. Can the worker stop or control line speed? No ____ 6. Are there opportunities for micro rest pauses? Yes If so, how many seconds? Up to 1-10 second between packages ____ 7. Estimate exertion or effort required to do the job (1 to 5) 1=low, 5=high. This is a 4.  ____ 8. How many total packages lifted in a day. 600  ____ 9. What is the total weight the employee moves in a day? Approximately 12,000 lbs.
  28. 28. Basic Screening Tool Body Part Associated With MSD Incident Risk Factors This Standard Covers Performing job or tasks that involve: Neck Shoulder Hand Wrist Arm Back Trunk Hip Leg Knee Ankle Repetition (1) Repeating the same motions every few seconds or repeating a cycle of motions involving the affected body part more than twice per minute for more than 2 consecutive hours in a workday. yes yes Yes Yes (2) Using an input device, such as a keyboard and/or mouse, in a steady manner for more than 4 hours total in a workday. no No Force (3) Lifting more than 75 pounds at any one time; more than 55 pounds more than 10 times per day; or more than 25 pounds below the knees, above the shoulders, or at arms’ length more than 25 times per day yes Yes Yes Yes (4) Pushing/pulling with more than 20 pounds of initial force (e.g., equivalent to pushing a 65 pound box across a tile floor or pushing a shopping cart with five 40 pound bags of dog food ) for more than 2 hours total per day no No No No (5) Pinching an unsupported object weighing 2 or more pounds per hand, or use of an equivalent pinching force (e.g., holding a small binder clip open) for more than 2 hours total per day; no (6) Gripping an unsupported object weighing 10 pounds or more per hand, or use of an equivalent gripping force (e.g., crushing the sides of an aluminum soda can with one hand), for more than 2 hours total per day. no Awkward Postures 7) Repeatedly raising or working with the hand(s) above the head or the elbow(s) above the shoulder(s) for more than 2 hours total per day no No No (8) Kneeling or squatting for more than 2 hours total per day no No (9) Working with the back, neck or wrists bent or twisted for more than 2 hours total per day yes Yes Yes Contact Stress (10) Using the hand or knee as a hammer more than 10 times per hour for more than 2 hours total per day no No No (11) Using vibrating tools or equipment that typically have high vibration levels (such as chainsaws, jack hammers, percussive tools, riveting or chipping hammers) for more than 30 minutes total per day no No No Vibration (12) Using tools or equipment that typically have moderate vibration levels (such as jig saws, grinders, or sanders) for more than 2 hours total per day. no no
  29. 29. Before and After
  30. 30. Mechanical Lifts Mechanical lifts raise the load to an easier lifting position.
  31. 31. Positioners Here is a video. They are at Also many make similar. Cost is about $3000
  32. 32. Lift Assisting Devices
  33. 33. Lift Assisting Devices
  34. 34. Palletizing Pallet wrapping can be done by machines. Double palletting can be used.
  35. 35. Hands, wrists, and forearms are straight, in-line and roughly parallel to the floor. Head is generally in-line with the torso. Shoulders are relaxed and upper arms hang normally at the side of the body. Elbows stay in close to the body and are bent between 90 and 120 degrees. Feet are fully supported by floor or footrest. Back is fully supported with lumbar support when sitting vertical or leaning back. Thighs and hips are supported by a well-padded seat and generally parallel to the floor. Knees are about the same height as the hips with the feet slightly forward.
  36. 36. Prolonged static work causes: - reduction in blood flow - increased pressure on sensitive tissues surrounding the joints
  37. 37. Long periods of sitting or standing
  38. 38. Standing  If you stand hours a day, you might have too much pressure on certain areas of your feet.  Red wing has a scanner that measures this pressure.  Their $60 orthotics for the heel are amazing.
  39. 39. Chair should have arm rests
  40. 40. Preferred viewing distance is 20 to 40 inches The top of the monitor should be at or slightly below eye level. The center of the computer monitor should normally be located 15 to 20 degrees below horizontal eye level
  41. 41. Wrist Rests
  42. 42. Ergo Keyboards and Mouse
  43. 43. Display screen is too high
  44. 44. Equipment  Evaluate – Hold vendor open houses • Try out different equipment – CNAs test equipment • Provide feedback  Consider types of devices – Overhead – Floor based total lift – Lateral assist – Sit to stand – Slide sheet  Select for resident population • Facility constraints
  45. 45. PERM MOLD POURING PROBLEM: Workers manually maneuver the ladle to scoop aluminum from the furnace well and pour into a mold. SOLUTION: Hydraulic lift arms have been fabricated internally to suspend the ladles, allowing pourers to merely direct the movements of the arm. COST: $5000 BENEFITS: Eliminated all shoulder and back injuries and burns. Reduced cycle times and fatigue which increased production.
  46. 46. DISA POURER PROBLEM: On the majority of molds on the Hunter 30 x 32 automatic Molding Machine, it took two workers to pour the mold. (Ladle weight – 40 lbs. each with metal) SOLUTION: Automatic pouring machine eliminates both workers from hand-pouring. COST: $35,000 COST RECOVERY TIME: Six months BENEFITS: Eliminated burns, shoulder and back injuries, and manpower; also increased production.
  47. 47. GRINDER/CHIPPER DIE PRESS OPERATOR PROBLEM: Small pneumatic hand grinders were used to finish parts, exerting strain on the wrists and arms. SOLUTION: A trim die is now used to trim parts. COST: $40,000 COST RECOVERY TIME: Six to twelve months BENEFITS: Reduced cycle time, eliminated ergonomic stressors including vibration, poor posture, and force.
  48. 48. Results Foundry 2009 Percentage Difference b/t Baseline and 2009 Rates TCIR Ergo -24% DART Ergo -48%
  49. 49. OSHA Inspections  General Duty Clause citations  Ergonomic Hazard Alert Letters (EHAL)
  50. 50. General Duty Clause - Section 5(a)(1) 1. The employer failed to keep the work place free of a hazard to which employees of that employer were exposed; 2. The hazard was recognized; 3. The hazard was causing or was likely to cause death or serious physical harm; and 4. There was a feasible and useful method to correct the hazard.
  51. 51. General Duty Clause - Section 5(a)(1) The employer failed to keep the work place free of a hazard to which employees of that employer were exposed. What is the hazard here?
  52. 52. General Duty Clause - Section 5(a)(1) The hazard was recognized;
  53. 53. General Duty Clause - Section 5(a)(1) The hazard was causing or was likely to cause death or serious physical harm;
  54. 54. Backs Ages 30 and 50 Aging process Sedentary life styles with too little exercise “Exercise may be the most effective way to speed recovery from low back pain and help strengthen back and abdominal muscles”
  55. 55. Ergo Audit Element  A. Have you identified and listed three ergonomic hazards?  Machine, job task or Process ID:  Comments:  B. List ergonomic corrective actions within last 12 months  Machine or Process ID:  Date:  Comments:  C. If you have had claims with the root cause of ergonomics, were corrective measures taken?  Comments:  D. Annual documented training on ergonomics (back safety, preventing hand fatigue, material handling) for all employees based on claim history. Is an outline or explanation of training available?  Topic:  Date:  Comments:  E. Are there material handling procedures implemented with a maximum single-person lift capacity?  Where posted:
  56. 56. Insurance Trust Results  0.84 EMR  ~20% members had no work comp claims in 2012  42% loss ratio vs. Ind Avg 60%  ~50% of members had audit score of 90%
  57. 57. Stretching  Controversial  One Insurance company says it can reduce ankle, knee, back, and rotator cuff injuries.  Morning and after lunch stretches.  30 second holds.
  58. 58. Summary  Determine high-risk jobs  Conduct evaluations  Develop corrective actions  Set annual ergonomic goals  Update the medical and recordkeeping program  Document ergonomic efforts  Audit the ergonomics process  Review workers' compensation claims Employees should like working for your company!