ERGONOMICS KEYS TO CONTROLS

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ERGONOMICSKEYS TO CONTROLS
Prepared Presented by Luann Romanelli, Account
Executive
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What will be covered.

• What is Ergonomics
• Ergonomic Statistics / Costs
• The benefits of an Ergonomic program
• Ergonomic related injuries
• Identifying Ergonomic Risk Factors
• Control Strategies to minimize risk
• What you can do to prevent injury

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What is Ergonomics?

• The science of fitting workplace conditions and
  job demands to the capabilities of employees. (
  U.S. Dept.of Health)
• Ergonomic principles are used to improve the
  fit between the worker and the workplace.
• A persons capabilities, physical attributes and
  work habits must be recognized to improve
  ergonomic factors in the workplace.

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Statistical Data

• DOL indicates 8 million workers report work
  related MSDs, resulting in 150 billion in lost
  production, turn over indirect costs
• In 2000 work related musculoskeletal disorders
  reached 375,000 cases.
• 1 out of every 3 spent on accident costs
  account for MSD cases
• On average MSD costs vary from a low as 100 to
  as high as 150K

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Accident Costs

• Direct Indirect Workers Compensation Costs have
  directly impacted organizations Bottom Line Cost
• Indirect Costs Usually 3 - 5 times more than
  the Direct Costs (NSC)

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Lost Time Data

• If employee is out of work for 6 months 50
  likely to return to work
• If employee is out of work 12 months 25 likely
  to return to work
• If employee is our 2 years 2 chance of return
  to work
• Costs Big

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Profit Margin

• Direct Incurred Cost 2,000
• Indirect Cost 8,000
• Total Cost 10,000
• Profit Margin _at_ 15 10,000 / .15
• 11,500
• Need 11,500 in sales to cover the 2,000

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Workers Compensation

• High WC loss ratio can result in unfavorable
  pricing
• MSD injuries have a direct impact on high loss
  ratios and high experience modifications
• Insurance carriers LC Consultants evaluate work
  place repetitive motion exposures to determine
  insurability
• LC Consultant will trend OSHA 300 Logs and WC
  loss runs for 3 5 years

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Insurance Loss Control Services

• Ergonomic Committees/Education
• Management / Supervisor Education
• Work Station Evaluations
• Effective Ergonomic Suggestions
• RM Loss Trending Target High Risk Tasks

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Ergonomic Analysis

• The analysis consisted of
• Evaluation of OSHA injury logs insurance loss
  runs
• Facility walkthrough
• Digital photographs / video
• Basic documentation / learn production
  requirements limitations
• Informal worker interviews

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Ergonomic Program Benefits

• Decreased injuries,illnesses, and workers
  compensation costs.
• Increased efficiency at work.
• Increased physical well being.
• Decreased absenteeism and turnover.
• Increase in employee morale.

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Common types of MSDs

• Tendonitis
• Carpal Tunnel Syndrome
• Tennis Elbow
• Neck and Back injuries
• Strains/Sprains
• Bursitis
• Thoracic Outlet Syndrome
• Trigger finger
• Low Back Disorder

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Ergonomic Related Injuries

• May be called
• CTDs (cumulative trauma disorders)
• RSIs (repetitive stress injuries)
• RMIs (repetitive motion injuries)
• Which are all considered
• MSDs (musculoskeletal disorders)
• MSDs can affect muscles, tendons, nerves, joints
  and spinal disks.

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Ergonomic Risk Factors

• Temperatures Extremes
• Contact Stress
• Vibration / Torque

• Repetition / Task Frequency
• Position / Posture (awkward static)
• Force

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Engineering Controls

• Human Factor design job to fit worker
• Environment temperature, lighting, vibration,
  noise, work pace
• Workstation bench, chair, floor, layout
• Tools type, use, ergo design handle,
  vibration/impact/torque controls, weight
• Process combine tasks, automation
• Materials

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Engineering Controls

• Combined job tasks or parts
• Use lift tables with different adjustability
• Design jigs / fixtures to reduce holding forces
• Eliminate screw clamps use air claims
• Use / enforce use of mechanical lifting aids
• Provide proper design tools

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Administrative Controls

• Job Rotation
• Implement Stretch Flex Programs
• Limit time perform high risk task
• Ergonomic Education
• Effective Rest Breaks
• PPE knee pads, vibration damping gloves, back
  belts, shoe inserts

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Personal Protection Equipment

• Back Belts / Supports pros / cons
• Joint Supports Wrist / Forearms Splints
• Vibration Damping Gloves
• Shoe Inserts, Anti Fatigue Mates
• Task Lighting

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Four Keys to Control

1. Keep the body in neutral
2. Minimize area of movement
3. Minimize force
4. Minimize repetition

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Keep the Body in Neutral

• Upper Extremities
• Adjust Workstation height
• Adjust Chair Height, Workstation Height
• Tilt the Work Piece or Work Table
• Bend the Tool Adjustable Tools
• Arms below Shoulders
• Elbows at Sides
• Low Back
• Lift, push at waist
• Torso near vertical
• Lift within arms length

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Minimize Area of Movement

• Upper Extremities
• Work in Frontal Range of Motion
• Dont reach behind body
• No over extending the arms / shoulders reaching
• Hands below shoulders
• Low Back
• Lift at waist height
• Acceptable lifting/lowering range shoulders to
  mid thigh
• Dont push/pull across the front of the body
• Avoid twisting at the waist
• Keep the object close

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3. Minimize Force

• Upper Extremities
• Pad blunt or sharp edges to minimize contact
  stress
• Use counter balances
• Hold work piece with a claim/fixture
• Fit tool handle to hand size
• Avoid pinch grips excess wrist flexing

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3. Minimize Force Cont . . .

• Lower Back
• Use built in handle grips
• Reduce lifting force
• No frequent lifting gt 30 lbs
• No occasional lifting gt 50 lbs
• -- Use anti fatigue mates
• -- Use carts, forklifts, cranes, hoists,
  conveyors

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4. Counteract the Effects of Repetition

• Upper Extremities Lower Back
• Frequent short rest breaks
• Perform task with either or both hands
• Job rotation
• Stretching, warm-up exercises before and during
  work shift

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Ergonomic Control Program

• Management
• Employee Involvement
• Written Program
• Regular Program Review

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Behavior Based Ergonomics

• Observing behavior, positive reinforcement
• Cultural change, occurs over time
• Its employee-owned
• Use to develop engineering controls

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Medical Management

• Establish a Pre and Post Injury Claims Management
  Program
• Identify an Occupational Provider to conduct post
  hire physicals and to treat on the job injuries
• Establish an effective Return to Work Program
• Ensure effective communication with the treating
  physician, employee and WC carrier.