Welcome to Basic Ergonomics

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Welcome to Basic Ergonomics
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Objectives

• Increase awareness of basic ergonomics concepts
  and principles
• Identify occupational risk factors for strains,
  sprains, and cumulative trauma
• Learn to use various tools for identifying
  ergonomic concerns and analyzing jobs
• Understand basic control measures for improving
  ergonomic job design

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Ergonomics - What is it?
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Ergonomics - What is it?
Design Error
Most people look like this...
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Ergonomics
Design Error
Most people look like this...
Some designers think that people look like this...
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Definitions
Fitting the task to the person rather than
forcing him/her to adapt to his working
environment. Designing the workplace to prevent
occupational injury and illness. Discovering the
capabilities and limitations of the human body.
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Working Definition
Job Demands
Worker Capabilities
A Balance for Optimization
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Supporting Sciences
Biomechanics
Physical Sciences
Engineering Sciences
ERGONOMICS
Engineering Psychology
Anthropometry
Behavioral Sciences
Biological Sciences
Work Physiology
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Acute Vs. Cumulative Disorders

• Acute
• Result from a one time event
• Cumulative
• Result 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 rather
  than chronic. Stephen Konz. Work Design
  Industrial Ergonomics, Third edition. 1990

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CTDs
Term assigned to identify a group of injuries
that classically result from long-term and
repeated wear and tear on the musculoskeletal
system.

• CUMULATIVE indicates injuries that develop
  gradually over time, and result from many
  repeated stresses on a particular body part.
• TRAUMA signifies bodily insult or injury from
  mechanical stresses.
• DISORDERS describes the adverse health effects
  that arise from chronic exposure to repeated
  trauma.

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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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Material Handling Operations
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VDT / Computer Operators
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Control / Display Design
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Workplace / Workstation Layout
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Assembly / RepetitiveHand Intensive Tasks
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All Other Work/Play/Life
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Why Ergonomics?
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Win/Win
Higher Production Higher Quality Compliance Lower
Compensation Costs
Careers/Employment Longevity Safe Working
Conditions Quality of life Morale
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Employee Benefits

• Quality of Life
• Fewer Aches, Pains, Injuries
• Career / Employment Protection Longevity
• Jobs More Intuitive
• Less Fatigue

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Production Benefits

• Less Fatigue
• Eliminates Unnecessary Handling
• Reduces Bottlenecks
• Increases Throughput
• Optimization Cycle Time
• Helps In Meeting Deadlines
• Well Designed Jobs
• Increase Profitability Competitiveness

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Quality Benefits

• Less Scrap Re-Work
• Increased efficiency
• Reduction of rushing and shortcuts
• Less Fatigue
• Improves Customer Satisfaction
• Better accuracy

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Compliance

• General Duty Clause
• Guidelines
• NIOSH Elements of Ergonomics Process,1997
• OSHA Meatpacking Guidelines, 1990
• BSR/HFES-100/2002 VDTs
• Musculoskeletal Disorders (MSDs) and Workplace
  Factors 1997
• OSHA.GOV Ergonomics e-tools

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Compliance
General Duty Clause OSHA Act 1970 Section
5.(a) (1) Each Employer shall furnish to each of
his employees employment and place of employment
which is free from recognized hazards that are
causing or are likely to cause death or serious
physical harm to his employee.
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Workers Compensation / Loss Prevention

• Prevent Injuries/Illnesses from Occurring in the
  first place
• Reduction of the frequency of claims
• Reduction of Workers Compensation Costs
• Reduction absenteeism
• Reduced turnover

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Lost Time Injuries By Type of Cause
NSC Injury Facts 2004
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U.S. Injury and Illness Trends
Numbers of injuries
Percentage of Recorded injuries that involve Backs
U.S. Bureau of Labor Statistics
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U.S. Repeated Trauma Cases
U.S. Bureau of Labor Statistics
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Claim Cost By POB
NSC Accident Facts 04
2001 and 2002 Costs
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High-Risk Jobs CTD 2000-2001 Incident Rates
Incidence rates No. of illnesses per 10,000
workers
U.S. Bureau of Labor Statistics
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CTD Costs
The average cost for Cumulative Trauma related
Workers Compensation Claims filed in 2001 and
2002 equals 15,865
NSC Injury Facts 2004
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Iceberg AnalogyAccident Cost
Direct Costs

• Medical Payments
• Compensation

Breaking in substitute
Down-time
Efficiency due to break-up of crew
Overhead while work disrupted
Supervisor time to investigate
Loss of production
Indirect or Hidden Costs
Loss of good will
Overtime to make up production
Damaged tools/equipment
Hiring costs
Failure to meet deadline/fill orders
Lost time by fellow workers
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• How much business does ABC Company need to
  generate
• to recover this Loss?
• What amount of business volume do you need to
  offset the costs of
• the next accident in your organization?
• C Direct Injury Cost 10,000
• M Profit Margin 3
• V Business Volume required to break even from
  Injury (C)
• (C) / (M / 100)
• ( 10,000) / (_3_ / 100) 333,333.33
• Or, including estimated indirect costs 4X
• total costs 40,000
• Business volume needed 1,333,333

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