Using ergonomics to prevent injuries

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Using ergonomics to prevent injuries
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Ergonomics
Job demands
Worker capabilities
A balance for optimization
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Ergonomics is a win-win
Higher production Higher quality Compliance Lower
compensation costs
Careers/employment longevity Safe working
conditions Quality of life Morale
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Acute vs. cumulative disorders

• Acute Results from a one-time event
• Cumulative Results from repeated wear and tear
  however, a specific event may have been the last
  straw upon a previously weakened system and thus
  given the appearance that the problem is acute
  ratherthan chronic. Stephen Konz Work
  Design Industrial Ergonomics, Third edition.
  1990

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CTD trauma bucket balanced
Your job
Trauma
Your body
Healing valve
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CTD trauma bucket unbalanced
Your job
Trauma
Your body
CTD
Healing valve
CTD
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Two kinds of back injuries
Spinal
Muscular
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Common upper-Extremity CTDs

• Tendonitis
• Tenosynovitis
• Trigger finger
• Epicondylitis
• Thoracic outlet syndrome
• Carpal tunnel syndrome

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Carpal tunnel syndrome
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Occupational risk factors

• Repetition
• Forceful exertion
• Direct mechanical pressure
• Static posture
• Inadequate recovery time
• Awkward posture
• Environmental stressors

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Non-occupational risk factors

• Rheumatoid arthritis
• Diabetes
• Acute trauma
• Bruises, burns, lacerations
• Wrist size
• Gender
• Pregnancy
• Weight
• Previous trauma or surgery

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Control strategies
Engineering controls
Workstation design Tool design Process
modification Mechanical assist Education
Administrative controls
Training Job rotation Pacing Policy Job
enlargement
Band-aid solutions?!?
Splints Braces
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10 ergonomic design tips

• Improve the layout of the work area to minimize
  moving materials.
• Use carts, hoists, conveyors, etc. when moving
  materials.
• Use fixtures to hold materials.
• Minimize the weight of tools (except striking
  tools).
• For grips on hand tools, provide proper
  thickness, length and shape for easy handling.

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10 ergonomic design tips

• Choose tools you can operate with minimal force.
• Adjust the working height at elbow height or
  slightly below it.
• Place frequently used materials, tools and
  controls within easy reach.
• Provide adjustable work surfaces for workers who
  alternate between small and large objects.
• Involve workers in the improved design of
  workstations.

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Case studies
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CTD incident and lost days rates in manufacturing
n 208, per 200,000 hours worked, incident 32,
lost days 52 improvements
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Employee turnover rate in manufacturing
N 65, per 200,000 hours worked, 68 reduction
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Conneaut Leather

• Finisher of leather for upholstery business
• Tasks include antiquing, sorting, inspecting and
  cutting.
• Risk factors
• Trunk bending
• Reaching
• Static postures

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Conneaut Leather
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Conneaut Leather

• Solution
• Three scissor lift tables
• One hide stacker
• Total cost 48,665. (BWC contributed 38,933.)

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Conneaut Leather
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Conneaut Leather results

• CTD risk factor scores, averaged over two tasks,
  decreased 59 following the intervention.
• CTD lost days, restricted days and employee
  turnover rates were at zero (per 200,000 hours
  worked) the year prior to the intervention and
  remained at zero for two years following.
• Productivity, reported by the company, was at 18
  hides processed per day. With the intervention in
  place, productivity increased to an average of 28
  hides per day, a 55 improvement.

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CTD incident and lost days rates in extended care
n 30, per 200,000 hours worked, incident 37,
lost days 39 improvements
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Employee turnover rate in extended care
N 69, per 200,000 hours worked, 16 reduction
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Situation manual patient (resident) handling
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Best practice patient lifting devices
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Best practice ceiling lifts
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CTD incident and lost days rates in construction
n 30, per 200,000 hours worked, incident 32,
lost days 82 improvements
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SafetyGRANT case study DeSalvo
ConstructionHubbard, Ohio
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Situation

• General commercial/light industry construction,
  including masonry
• Risk factors
• Repetitive motion (_at_300 bricks per day)
• Force (8 to 30 lbs. per brick)
• Awkward postures
• Nine CTDs reported in two years

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Situation
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Situation
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Intervention
The Beast scaffolding system http//www.n
onstopscaffolding.com/beast.html
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Intervention
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Results after 18 months

• The cost was 52,000.
• CTD incidence rate went from 36 per 200,000 hours
  worked to zero.
• Lost days rate went from 4,104 per 200,000 hours
  worked to zero.
• Productivity reportedly increased 10-15.
• Scaffold building / dismantling went from 40
  hours to eight hours per job.

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BWC ergonomics resources

• Ergonomics consultants
• Library
• Video library
• OCOSH courses

For more information, call 1-800-OHIOBWC, or
visit ohiobwc.com.