Using Human Factors to Stop       Hand Injuries    The “Birth” of KONG!          Mark Wiktorski      Director of Business ...
The Problem/Issue•  Getting started  o  Steering Committee met in July 2007 which consisted     of a collaborative, cross ...
The Problem/Issue•  Committee’s Analysis  o  Identified a consistent trend in     hand injuries       More specifically: ...
Costs of Workplace Injuries•  Direct Costs  o  Workers compensation costs/claim  o  Medical costs  o  Medical transportati...
Costs of Workplace Injuries                                        o  Attorney fees•  Indirect Costs                      ...
Costs of Workplace Injuries•  Each accident or injury is unique- impossible to estimate   an exact cost associated with ea...
The Solution•  There needed to be a two part solution  o  Part 1- change in “behavior”       Education       Training  o...
The Solution- Part 1•  The “behavioral” changes  o  Educating the workforce on hand safety with emphasis on     hand place...
The Solution- Part 2•  Personal Protection Equipment (PPE)  o  Approached ORR Safety Corporation to market,     inventory ...
The Solution- Part 2•  Developed specifications and requirements  o  Hi-Visibility  o  Cost effective  o  Breathable  o  W...
The Solution- Part 2•  Evaluate existing glove style features  o  Committee members were given (16) pairs of various     g...
The Solution- Part 2•  First Prototype  o    “Concept Glove” developed based on Steering       Committee’s input  o    ORR...
The Solution- Part 2•  First Prototype Results Review  o    January 24, 2008 Committee Meeting - results of field tests we...
The Solution- Part 2•  First Prototype Data  o  201 total testers surveyed  o  Date range of tests                        ...
The Solution- Part 2•  Field test recommendations  Steering	  Commi,ee	  Recommenda1ons	                        ORR	  and	...
Original
The Solution- Part 2•  Second Prototype Data  o  Targeted areas for improvement:         Grip                            ...
The Solution- Part 2•  Steering Committees Decision  o  (12) months of planning and development  o  (3) “prototype” gloves...
Lab Testing Results•  ORR hires University   of Wisconsin-   Milwaukee   Ergonomics   Department•  Performed (7) month   i...
Four versions currently being offered:
Performance (Participant #1)
Performance (Participant #2)
Where we are today?•  Glove Guideline for the Oil and Gas industry has been   developed and implemented•  Over 825,000 pai...
Did impact resistant gloves help?
The Job          300lbs.	  Skid	  Anchor	  
The Injury
The Glove!
Summary•  Keys to the success of this project   o  Collaboration          Cross functional groups- Operations and Safety ...
Questions?
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Kong Gloves - Safety@ProjectSalesCorp.com

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Kong Gloves is marketed in India by Project Sales Corp. www.facebook.com/KongGlove

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Kong Gloves - Safety@ProjectSalesCorp.com

  1. 1. Using Human Factors to Stop Hand Injuries The “Birth” of KONG! Mark Wiktorski Director of Business Development ORR Safety Corporation
  2. 2. The Problem/Issue•  Getting started o  Steering Committee met in July 2007 which consisted of a collaborative, cross functional group of safety managers and operations managers from:
  3. 3. The Problem/Issue•  Committee’s Analysis o  Identified a consistent trend in hand injuries   More specifically: –  Hairline fractures –  Bruising blows (back of the hand and fingers) –  Pinched fingers o  Set target goal to develop solutions to reduce or eliminate these hand injuries
  4. 4. Costs of Workplace Injuries•  Direct Costs o  Workers compensation costs/claim o  Medical costs o  Medical transportation o  Rehabilitation costs o  Property damage o  Damage of equipment
  5. 5. Costs of Workplace Injuries o  Attorney fees•  Indirect Costs o  Litigation (an average of > $100,000 per claim) o  Lost/decreased productivity o  Damages to equipment, machinery, o  Time to go to medical materials and facility appointments o  Higher Worker’s Comp premiums o  Production down time o  Reputation loss o  Administrative costs o  Degraded client loyalty and support or o  Additional overtime pay required loss of contract o  Time to replacement hire o  Managerial costs due to the accident o  Interviewing and training new including inspections, investigations, employee meetings and administration o  Delays in shipments and filling o  Loss of employee time associated with orders assisting with the accident, administering o  Loss of products or services first aid, and witness interviews o  Unwarranted negative media o  Loss of employee morale attention o  Slowed work pace due to other o  Potential OSHA penalties employees fear of injury
  6. 6. Costs of Workplace Injuries•  Each accident or injury is unique- impossible to estimate an exact cost associated with each type of accident or injury•  Indirect costs are typically 5x the direct costs•  The cost of one typical injury is far more expensive than upgrading an existing safety program or the salary of a safety professional•  Costs are important, but are not the most important driver for implementing a safety initiative- worker safety and having someone return home to their loved ones is!
  7. 7. The Solution•  There needed to be a two part solution o  Part 1- change in “behavior”   Education   Training o  Part 2- Personal Protection Equipment (PPE) designed specifically to address the needs of the industry   One size fits all canvas black dot gloves- didn’t offer protection needed for injuries being recorded   People would not wear
  8. 8. The Solution- Part 1•  The “behavioral” changes o  Educating the workforce on hand safety with emphasis on hand placement o  Continue to use the JSA (Job Safety Analysis) process to manage risk o  Wellworks/Drilling focus groups created (contractor and operator steering committees) o  Pinch Point Hunt o  Showed workforce graphic images of types of injuries o  Behavior Observation
  9. 9. The Solution- Part 2•  Personal Protection Equipment (PPE) o  Approached ORR Safety Corporation to market, inventory and distribute gloves   Nations largest privately held distributor of industrial safety products (PPE, industrial hygiene and fire related products and services) based in Louisville, KY o  ORR Safety partnered with Ironclad Performance Wear   Designer and manufacturer of mechanics style gloves based in Los Angeles, CA
  10. 10. The Solution- Part 2•  Developed specifications and requirements o  Hi-Visibility o  Cost effective o  Breathable o  Washable o  Wet/dry Grip o  Snug/contoured fit o  Reinforced thumb crotch o  Rolled finger o  Range of sizes
  11. 11. The Solution- Part 2•  Evaluate existing glove style features o  Committee members were given (16) pairs of various glove designs by Ironclad o  These gloves were taken to Oil & Gas Industry safety meetings and input was solicited from a cross section field personnel, safety professionals and managers o  Key features were identified and discussed with Orr Safety and Ironclad R&D
  12. 12. The Solution- Part 2•  First Prototype o  “Concept Glove” developed based on Steering Committee’s input o  ORR and Ironclad collaborated to develop 1st Prototype of the “Concept Glove” o  (200) pairs of 1st Prototype manufactured o  Prototype was evenly distributed to the Committee members for field tests o  Gloves were field tested and evaluated in a number of different job types, functions and environments
  13. 13. The Solution- Part 2•  First Prototype Results Review o  January 24, 2008 Committee Meeting - results of field tests were reviewed and analyzed
  14. 14. The Solution- Part 2•  First Prototype Data o  201 total testers surveyed o  Date range of tests Rating: 1 – 5   November 7, 2007 to January 18, 2008 ( 1=Low, 5=Best)
  15. 15. The Solution- Part 2•  Field test recommendations Steering  Commi,ee  Recommenda1ons   ORR  and  Ironclad’s  Recommenda1ons  Improve  grip-­‐  slippery  when  comes  in   Replace  black  synthe4c  fabric  layered  palm    contact  with  oil   &  adhere  impregnated  PVC  dots  to  the  palm    Improve  durability-­‐  significant  wear  a=er   Extend  glove  life  span  under  extreme  a  few  days     condi4ons  to  exceed  14  days  Increase  back  of  hand  protec1on   Increased  the  impact  absorbing   Thermoplas4c  Rubber  on  the  back  of  the   hand  Eliminate  Velcro  strapped  wrist-­‐  poten4al   Redesign  of  the  Glove  Cuff-­‐  Replace  the  snag  hazard   Velcro  wrist  band  with  a  solid  2½  inch   Neoprene  Cuff  with  elas4c  expansion  band  
  16. 16. Original
  17. 17. The Solution- Part 2•  Second Prototype Data o  Targeted areas for improvement:   Grip Rating: 1 – 5   Durability ( 1=Low, 5=Best) o  Improved performance in (5) categories Grip Improvement Durability Improvement 16.7% 18.5%
  18. 18. The Solution- Part 2•  Steering Committees Decision o  (12) months of planning and development o  (3) “prototype” gloves were created o  Prototypes were tested for 80,000 hours without a single hand injury o  (2) separate field tests were conducted o  Final design received a 4.32 overall rating o  June 2008 – Steering Committee approves final glove design o  ORR started shipping KONG in October 2008
  19. 19. Lab Testing Results•  ORR hires University of Wisconsin- Milwaukee Ergonomics Department•  Performed (7) month independent study 4.25X   10.73x   5x   Improvement  
  20. 20. Four versions currently being offered:
  21. 21. Performance (Participant #1)
  22. 22. Performance (Participant #2)
  23. 23. Where we are today?•  Glove Guideline for the Oil and Gas industry has been developed and implemented•  Over 825,000 pairs of KONG gloves shipped•  Recognition: o  Selected for Offshore Leadership Award 2010 o  Occupational Health & Safety: 2010 New Product of the Year Award•  Gloves are currently being shipped all over the world•  Philosophy is quickly spreading to all other industries that experience the same type of injuries
  24. 24. Did impact resistant gloves help?
  25. 25. The Job 300lbs.  Skid  Anchor  
  26. 26. The Injury
  27. 27. The Glove!
  28. 28. Summary•  Keys to the success of this project o  Collaboration   Cross functional groups- Operations and Safety   Manufacturers and distributors of safety products   Applying input from users in the field…..listening   Group was open about challenges each company faced with regards to injuries   Sharing of safety data on hand injuries o  Two step process- “Behavioral” change in conjunction with a highly engineered glove o  Impact resistant gloves supported and implemented by major Oil and Gas companies
  29. 29. Questions?

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