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ISS - Reducing Musculoskeletal inuries


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ISS - Reducing Musculoskeletal inuries

  1. 1. International Safety Systems, Inc. USA, India, China, Mexico, Brazil Ganesh Desai Toral Mehta, CIH Toral.Mehta@issehs.comIndia Cell: +91-9327547481 Global Cell: 1-203-685-8808 1
  2. 2.  Greek words  “Ergo” – Work, “Nomos” – Laws “Laws of Work“ Fitting Environment-Job, Tasks, Equipment, Machinery, Workstation-to the working person Musculoskeletal disorder (MSD) refers to a group of injuries or health problems caused by overuse or misuse of muscles, tendons, ligaments, joints, nerves and blood vessels. If these disorders are work related they are also called as Work related Musculoskeletal Disorders (WMSDs). 2
  3. 3. Objectives MethodologyA. Identify the areas/ activities A. Walkthrough Survey with potential risk B. Interviews with line managersB. Assess risk on each body part and employeesC. Comparing current C. A WMSD symptom workstation design with questionnaire recommended standard D. Ergonomics assessment for 11D. Finding major contributing activities using industrial factors ergonomic evaluation tool.E. Recommendations E. Observations, digital imagesF. Training captured F. Measurements of workstations G. Recommendations 3
  4. 4. Risk for Each Body Part Overall Activity Upper Arms/ Risk for Back Neck Shoulder Legs Activity Body Wrist Powder charging High Medium Medium High Low Low High Mixer Cleaning High High High Low High Low High Laboratory Test Low Medium Low Low High Low Low Pallet Loading High Low High Low Medium Low High Labeling of High Medium Medium High High Medium High ContainersFilling of containers Low Low Medium Low Medium Medium MediumPrinting on cartons High Low Low Low Low Low HighStacking of Cartons High Low High High High Low High on palletLoading of Cartons High Low Medium High Medium Low High on Truck Computer Workstation High Medium Low Low High Medium Medium (Laptop/Desktop) 4
  5. 5. A. Work postures and movements,B. Repetitiveness and Pace of Work (Frequency),C. Forces applied and Forceful ExertionsD. Static Load (Standing)E. DurationF. Contact Stress on sharp edges, flooringG. Environment - Vibration and TemperatureH. Workstation LayoutI. Tool selectionJ. Individual Risk FactorsK. Recovery/Work Ratio 5
  6. 6. Risk Factors and Contributory Factors: RecommendationsA. Bending of back - while lifting bags from A. Provide a scissor lift to adjust the height pallet of the palletB. Twisting of torso (upper body) – during B. Keep the raw material bags close to the transfer of cartons on pallet silo charging pointC. Twisting of ShoulderD. Bending side ways C. Consider providing tight fitting gloveE. Poor grip – due to and loose fitting gloves instead of loose fitting glovesF. Frequency and load lifted (25 kg each D. Train employees on safe manual material handling practices  bag) A D E F 6
  7. 7. Risk Factors and Contributory Factors: RecommendationsA. Continuous bending of back – while A. Consider providing movable cleaning the mixers for 10 to 12 minutes retraceable water hose stand forB. Employee has to continuously hold the high pressure (100 bars) water lance with wrist bending towards his supply, thumb the wrist (ulnar deviation) B. Consider providing mobile andC. The jet pump water pressure set to 100 portable pressure wash system bar with ergonomically designed handle. A B C 7
  8. 8. Risk Factors and Contributory Factors: RecommendationA. Neck bent at > 200 (flexion) for about A. Consider replacing manual stirring 10 to 12 min activity with automatic or magneticB. Bending of wrist backward (extension) stirrer. at 11 to 200 for about 10 to 12 minC. Rotating of wrist for stirring continuously for 10 to 12 minD. Too small grip of the stirrerE. Contact stress on first finger while stirring A E B+C D 8
  9. 9. Risk Factors and Contributory Factors: RecommendationA. Bending back (back flexion) instead of A. Simple Fix: Use automated hand bending knees while lifting pallet truck every time during loading ofB. Lifting of weight - 70 - 100 kilograms the pallet in the packing machine.C. Traveling 20 to 25 ft. distance while Ensure facility has dedicated hand lifting pallet trucks for pallet loading activity.D. Force on wrists and elbow while pushing pallet underneath packing machineE. Risk of physical injury A B D Pneumatic or Powered Pallet Truck 9
  10. 10. Risk Factors and Contributory Factors: RecommendationsA. Bending forward to pick up empty A. Consider re-designing the Filling and container and labeling Packing area withB. Bending side ways to reach containers 1) sufficient space for storage of packingC. Stretching of upper body and working material, filled containers above shoulder height 2) Sitting arrangements (Sit/Stand stools)D. Neck bent at > 200 (flexion) for 12 minE. Sitting in awkward posture without lumber 3) Labeling activities on a conveyor belt support and contact stress with sharp egdes followed by filling activitiesF. Extension of wrist (bending of wrist B. Consider providing label applicator backward) at > 200 – while applying label- with ergonomically designed handle more than 10 labels per min for the labeling activity.G. Bent legs in awkward posture D F EG 10
  11. 11. Risk Factors and Contributory Factors: Recommendations A. Erect a stand for storing of the lids atA. Reaching up above shoulder level for the waist height to avoid stretching of container lids hands or working above shoulderB. Static posture for longer duration height.C. Poor grip B. Consider providing ergonomically designed anti-fatigue mat for the activities involved long duration static posture A C B 11
  12. 12. Risk Factors and Contributory Factors: RecommendationsA. Continuous bending forward at hips A. Simple Fix: Designate a workstation or (back flexion) a table for this activity. Increase theB. Bends his head backwards (neck height of the working surface to extension) around 70 cm (around waist height) A B B. Impart training to employees on such simple fixes 12
  13. 13. Risk Factors and Contributory Factors: RecommendationsA. Bending of back A. Consider providing a sizzer lift toB. Twisting of torso adjust the height of the palletC. Lifting of weight – each carton  To avoid bending of back during contains 6 containers of paints arranging cartons on lower layer weighing 23.5 Kgs. of palletD. Twisting of shoulders B. Enforce job rotation between threeE. Repetition of awkward posture working positions of Packing line.F. Extended duration of awkward Ensure no more than 2 hours of posture manual material handling of finished goods by one employee in a shift. A BD C 13
  14. 14. Risk Factors and Contributory Factors: RecommendationsA. Lifting heavy load (weight 23.5 kg) A. Considering loading of finished goodsB. Bending back while passing the carton on pallet to avoid manual material to the other employee. handling.C. Twisting of torso (upper body). B. Train the employees on safe manualD. Twisting of Shoulder material handling practices such as - Bending of knees and not back, takingE. Lateral Flexion – Bending side ways of step instead of twisting the torso,F. Handling 20-30 cartons in one minute. going close to the load while handling of the load. C C. Conduct stretching exercise for back B D and shoulders during the break. A 14
  15. 15. Risk Factors and Contributory Factors: RecommendationsA. Arms not supported on the arm rest A. Consider rearranging managers’B. Wrists elevated at angle > 250 workstation with the followingC. Lower back not supported recommended specifications.D. Contact stress – wrist pressed over the B. Consider using external mouse with a edge of workstation table wrist supportE. Leg not support – lack of leg rest C. Adjustable Foot RestF. Micro breaks were not observed D. Consider providing foot rest and document holders for computer B D C A D E 15
  16. 16. Conducting ergonomics assessment is the most effective approach in;  Ensuring health and safety of the employees,  Reduce WMSDs,  Reduce liability and compensation cost,  Improve morale and employee relation,  Reduce absenteeism and  Increase productivity. 16
  17. 17. Thank you 17