Managing Workplace Ergonomics An Update on Current Practices

Transcription

1 Managing Workplace Ergonomics An Update on Current Practices Walt Rostykus, MSPH, CSP, CPE, CIH Vice President and Ergonomics Engineer

2 Objectives Share current approaches used by organizations to manage ergonomics. Provide a systematic approach to develop and sustain an effective ergonomics process. Share lessons from successful programs. Provide a view from outside the Telecommunications Industry.

3 Ergonomics the science of fitting workplace conditions and job demands to the capabilities of the working population. Ergonomics is an approach or solution to deal with a number of problems among them are work-related musculoskeletal disorders. NIOSH

4 Ergonomics the science of fitting workplace conditions and job demands to the capabilities of the working population. Ergonomics is an Making Workplace And Tools Fit The Capabilities of People approach or solution to deal with a number of problems among them are work-related musculoskeletal disorders. NIOSH

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6 Fitting Workplace to the Capabilities of People Before After

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9 Current Approaches in Managing Ergonomics Add Value to Several Aspects of Business Integrate with Other Initiatives and Processes Proactive Management of Risk Follow a Common Management System Track Progress Toward Measurable Improvement Goals Establish Expertise Within the Organization

10 What business problem are you trying to solve? Health & Safety Productivity Compliance

11 Work Related Musculoskeletal Disorder (WMSD) Cumulative Trauma Disorder Repetitive Motion Injury Repetitive Strain Injury Carpal Tunnel Syndrome Low Back Pain Tendonitis/Tenosynovitis

12 Risk Factors for WMSD + Mechanical Stress Temperature Vibration

13 WMSD Continuum

14 What business problem are you trying to solve? Health & Safety Productivity Compliance

15 Productivity Improvement Initiatives Six Sigma Lean Manufacturing Flow Engineering Total Quality Management Design for Assembly Constraint Management

16 Example Productivity Improvement Operators must bend to pallets Lifts eliminate bending Save 4.5 seconds per cycle

17 Example Productivity Improvement Seconds Pick part from pallet Place part in holder Cycle machine Retrieve part from machine Current Projected Projected Time Reduction for All Four Steps - 40%

18 Example Return On Investment 3 work cells affecting 27 operators $56,395 estimated investment Economic impact (conservative)» Payback = 3 months» 1 year ROI = 298%» 3 year FOI = 1,095%

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20 Ergonomics: An Improvement Tool Six Sigma -Improve Quality Lean -Increase Productivity Ergonomics Safety & Health -Prevent WMSD

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22 What business problem are you trying to solve? Health & Safety Productivity Compliance

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25 Management System Definition: A systematic approach to managing day to day operations which ensure business requirements and customer expectations are consistently met over time. Examples: ISO 14001, BSI OHSMS 18001, ANSI Z10, ILO OSH-2001, Six Sigma,

26 Elements of EHS Management Systems 1. Policy 5. Management Review 2. Planning 4. Checking and Corrective Action 3. Implementation and Operation

27 Elements of EHS Management Systems 1. Policy 5. Management Review ACT CHECK PLAN DO 2. Planning 4. Checking and Corrective Action 3. Implementation and Operation

28 Continuous Improvement Model

29 Ergonomics Process Model

30 Strategic Activities: Management Team Establish an infrastructure and management system that Sustains tactical activities and improvements

31 Strategic Elements

32 Status & Scope California RMI Standard. Country Standard. Company Ergonomics Standard. Company Health & Safety Management System. Lean Manufacturing Process. Unacceptable Level of Injuries Quality Issues Other? st Qtr 2nd Qtr 3rd Qtr 4th Qtr Back Injuries Cumulative Trauma Lacerations Slips/Falls Burns

33 Example of Long Term Goals By FY06 all identified ergonomic risk factors will be reduced to a low/no level. (Risk assessment score < 1). All new equipment, tools, and processes will pose a low/no level of ergonomic risk factors. By FY05 all job tasks cycle time will have < 10% non-value added motions. In 5 years, the WMSD incident rate will be reduced by 80%.

34 Improvement Plan Description of Activity Present policy & plan to site mgmt. Name of Owner Bob Identify Mgmt. Sponsor. Bob X Add Ergo. Measures to business metrics. Sue Recruit support Bob X Train subject matter experts Bob Train for Design Bob X X Scheduled Completion Date O N D J F M A M J J A S X Train Managers Harry X X X Train Employees Harry X X X Conduct risk assessments Implement changes Verify risk reduction. Bob Bob Bob Communicate results Bob/Al X X X

35 Ergonomic Process Measures Measure Type of Measure Tracking Method Frequency % Of Workstations/Jobs at Low Risk (Score <1). Proactive Results Assessment Results Quarterly % Of Targeted Workstations/Jobs Assessed for Risk. Proactive Activity Improvement Plan Quarterly % Of Targeted Employees Completing Appropriate Level(s) of Training. Proactive Activity Training Records Quarterly Injury/Illness Rate for WMSD. Lagging Results OSHA Recordkeeping Quarterly

36 Strategic Elements

37 Support Infrastructure

38 Roles & Responsibilities Role Management Sponsor Ergonomics Process Manager Subject Matter Expert (Ergonomics Team) Engineers, Maintenance & Facilities Purchasing Employees Managers and Supervisors Occupational Health / Medical Responsibilities Sponsorship by top management. Coordinate rollout and management of site program. Assess ergonomic risks. Identify solutions. Monitor for changes in workplace. Specify, install, and maintain equipment correctly. Implement solutions Specify and purchase correct equipment. Operate equipment correctly. Work safely. Ensure proper equipment and solutions are implemented and work is done correctly. Treat injuries effectively.

39 Skills Training Ergonomics Program Management What Who Why Ergonomic Risk Assessment and Solutions Ergonomics for Engineers Ergonomics Process Manager Subject Matter Experts (Ergonomics Team) Engineers, Maintenance & Facilities Understand initiative. Establish plans for site. Identify site participants. Conduct risk assessments. Identify solutions. Lead improvements. Apply design criteria in selection, design, and modification of equipment. Ergonomics For Managers Managers Understand initiative. Influence improvements. Reinforce work practices. Ergonomics For Employees All Employees Understand and apply ergonomic principles. Improve work practices.

40 Strategic Elements

41 Tracking Improvement Plan Description of Activity Present policy & plan to site mgmt. Name of Owner Bob Identify Mgmt. Sponsor. Bob X Add Ergo. Measures to business metrics. Sue Recruit support Bob X Train subject matter experts Bob Train for Design Bob X X Scheduled Completion Date O N D J F M A M J J A S X Train Managers Harry X X X Train Employees Harry X X X Conduct risk assessments Implement changes Verify risk reduction. Bob Bob Bob Communicate results Bob/Al X X X

42 Tracking Process Measures Measure % Of Workstations/Jobs at Low Risk (Risk<1). Q1 YTD Q2 YTD Q3 YTD Q4 YTD Annual Target % Of Targeted Workstations/Jobs Assessed for Risk. % Of Targeted Employees Completing Appropriate Level(s) of Training

43 Tracking Process

44 Strategic Elements

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46 Tactical Activities: Identify and improve workplace conditions that reduce exposure to ergonomic risk factors. Engineers Ergonomics Team Safety Staff Managers & Employees

47 Tactical Elements

48 Identify & Prioritize Job/Tasks Screening Methods Loss History & Injury Trends Observation st Qtr 2nd Qtr 3rd Qtr 4th Qtr Back Injuries Cumulative Trauma Lacerations Slips/Falls Burns Employee Input

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51 Action Plan: Assessments & Improvements Activity Owne r Loaders: Assess risks Bob X Scheduled Completion Date O N D J F M A M J J A S Loaders: Develop and test solutions Bob X X Loaders: Implement solutions Bob X X X Loaders: Reassess risk Bob X Tac Welders: Assess risk Jay X Tac Welders: Develop and test solutions Tac Welders: Implement solutions Jay X X Jay Tac Welders: Reassess risk Jay X Warehouse: Assess risk Jean X Warehouse: Develop solutions Warehouse: Implement solutions X Jean X X Jean Warehouse: Reassess risk Jean X X X

52 Analysis Tools Lifting guidelines (DOE ErgoEASER) Hand Arm Vibration Standards (ANSI S3.34) NIOSH Lifting Equation, UAW-GM Risk Factor Checklists Threshold limit values for physical agents (ACGIH) Rapid Entire Body Assessment (REBA) Rapid Upper Limb Assessment (RULA). Baseline Risk Identification of Ergonomic Factors (BRIEF TM )

53 Example Risk Assessment BRIEF Survey BASELINE RISK IDENTIFICATION OF ERGONOMIC FACTORS Identification: Job Name: Bumper Subassembly Dept: Date: 02/24/00 Zone: Station: Analyst: Humantech Record: Directions Mark all the appropriate Posture, Force, Duration and Frequency boxes. Total the number of marked boxes. For body areas with a score of 2 or more, mark the body area in the Risk Summary box. High Risk Summary Left Right Hands/Wrist Hands/Wrist Elbow Elbow Shoulder Shoulder Neck Back Legs Hand and Wrist Left Right Elbow Shoulder Hand and Wrist Elbow Shoulder Neck Back Legs Pinch Grip Radial Dev. Forearm 45 Pinch Grip Radial Dev. Forearm Squat Rotation Rotation Posture Finger Press Ulnar Dev. Finger Press Ulnar Dev. Sideways Twisted Stand on 1 leg Full Arm Full Arm Flex 45 Extension Behind Body Flex 45 Extension Behind Body Backwards Sideways Kneel Ext. 45 Ext. 45 Twisted Pinch grip 2lb. Pinch grip 2lb. Force Power grip 10 lb. 10 lb. 10 lb. Power grip 10 lb. 10 lb. 10 lb. + Weight 20 lb. Foot 10 lb. Duration 10 secs 10 secs 10 secs 10 secs 10 secs 10 secs 30% of Day Frequency 30 postures/min. 2/min 2/min 30 postures/min. 2/min 2/min 2/min 2/min 2/min Total Physical Stressors Comment / Observations Check the type of stressor present and shade the area of the body affected. Vibration (V) Mechanical Stress (M) Low Temperature (L) Version 2.1

54 Example Risk Assessment BRIEF Survey BASELINE RISK IDENTIFICATION OF ERGONOMIC FACTORS Identification: Job Name: Bumper Subassembly Dept: Date: 02/24/00 Zone: Station: Hand and Wrist Analyst: Humantech Record: Directions Mark all the appropriate Posture, Force, Duration and Frequency boxes. Total the number of marked boxes. For body areas with a score of 2 or more, mark the body area in the Risk Summary box. Right Elbow Shoulder Hand and Wrist Elbow Shoulder Neck Back Legs Pinch Grip Radial Dev. Forearm 45 Pinch Grip Radial Dev. Forearm Squat Rotation Rotation Posture Finger Press Ulnar Dev. Finger Press Ulnar Dev. Sideways Twisted Stand on 1 leg Full Arm Full Arm Flex 45 Extension Behind Body Flex 45 Extension Behind Body Backwards Sideways Kneel Pinch grip 2lb. Left Ext. 45 Ext. 45 Twisted Pinch grip 2lb. High Risk Summary Left Right Hands/Wrist Hands/Wrist Force Power grip 10 lb. 10 lb. 10 lb. Power grip 10 lb. 10 lb. 10 lb. + Weight 20 lb. Foot 10 lb. Duration 10 secs 10 secs 10 secs 10 secs 10 secs 10 secs 30% of Day Frequency 30 postures/min. 2/min 2/min 30 postures/min. 2/min 2/min 2/min 2/min 2/min Total Physical Stressors Comment / Observations Elbow Shoulder Neck Back Legs Elbow Shoulder Features: Validity Differentiation Inter Job Differentiation Intra Job Differentiation Reliability Reproducibility Check the type of stressor present and shade the area of the body affected. Vibration (V) Mechanical Stress (M) Low Temperature (L) Version 2.1

55 Quantifiable Risk Assessment LOW Score = 1 MODERATE Score = 2 HIGH Score = 3 or 4 Posture Only Posture + 1 Posture + Many

56 Quantifiable Risk Assessment

57 Quantifiable Risk Assessment

58 Quantifiable Risk Assessment: Problem Defined

59 What s the Priority?

60 Assessment Results: Prioritization Summary Rank Job Name Left Right Hand Elbow Shoulder Hand Elbow Shoulder Neck Back Legs Score Body # 1 Cover & Feeder Stitcher Stobb Stacker Take off Stitcher Pop Up Stacker Quality Inspection Water Brush Lathe Roll Tending Water Brush Change Out Feeder 1/4 folder Take off Stitcher - Mail Sack Plate Change Out Forklift / Clamp Truck Take off 1/4 folder Feeder Special Pack Take off Special Pack Roller Cage Stitcher Wire Card Feeder Blanket Wash Log Stacker

61 Tactical Elements

62 Job Name: Analyst: Date: Workstation Location Dept: Operator: Work Surface Criteria Dimension Acceptable Action A. Height Precision Work Yes No Light Work Yes No Heavier Work Yes No B. Work Surface Angle Adj. from -6 to 30 Yes No (-) = away from operator (+) = towards operator C. Rounded Edges Yes No D. Footrail Height 6 Yes No E. Knee Clearance Min: 23 Yes No F. Toe Clearance Min: 4 Yes No Anti-Fatigue Matting Yes No A B D F C Evaluate Alternatives Anthropometric Data Design Criteria Checklist for Standing Workstation Guidelines Brainstorm Solutions

63 Brainstorm Solutions 1. Laser Cut Parts 2. Stamp Parts 3. Pallet Lifts 4. Hinged Fixture 5. Suspend Tool 6. Anti-Fatigue Matting 7. Swivel Hose Coupling 8. Closer Workstation 9. Automatic Cut 10. Tool Holster 11. Closer Pallets/Waste Bins 12. Clamps for Fixture 13. In-Line Drill

64 Prioritize Solutions 1. Laser Cut Parts High impact 2. Stamp Parts 3. Pallet Lifts 4. Hinged Fixture 5. Suspend Tool Anti-Fatigue Matting 7. Swivel Hose Coupling 8. Closer Workstation 9. Automatic Cut High cost Low cost 10. Tool Holster 11. Closer Pallets/Waste Bins 12. Clamps for Fixture 13. In-Line Drill 6 Low impact 11 10

65 Implement Workplace Changes: Simple Stackable platforms for shorter people

66 Implement Workplace Changes: OTS* Gravity feed rollers Electric cart with rollers Powered tools * Off The Shelf

67 Implement Workplace Changes: Complex

68 Implement Job Design Controls Administrative Controls Job Rotation Work Pace Alternative Tasks Rest Breaks Work Practices

69 Awareness Training Ergonomics Program Management What Who Why Ergonomic Risk Assessment and Solutions Ergonomics for Engineers Ergonomics Process Manager Ergonomics Team Engineers, Maintenance & Facilities Understand initiative. Establish plans for site. Identify site participants. Conduct risk assessments. Identify solutions. Lead improvements. Apply design criteria in selection, design, and modification of equipment. Ergonomics For Managers Managers Understand initiative. Influence improvements. Reinforce work practices. Ergonomics For Employees All Employees Understand and apply ergonomic principles. Improve work practices.

70 Tactical Elements

71 Re-Assess BRIEF Survey BASELINE RISK IDENTIFICATION OF ERGONOMIC FACTORS Identification: Job Name: Bumper Subassembly Dept: Date: 02/24/00 Zone: Station: Analyst: Humantech Record: Directions Mark all the appropriate Posture, Force, Duration and Frequency boxes. Total the number of marked boxes. For body areas with a score of 2 or more, mark the body area in the Risk Summary box. High Risk Summary Left Right Hands/Wrist Hands/Wrist Elbow Elbow Shoulder Shoulder Neck Back Legs Hand and Wrist Left Right Elbow Shoulder Hand and Wrist Elbow Shoulder Neck Back Legs Pinch Grip Radial Dev. Forearm 45 Pinch Grip Radial Dev. Forearm Squat Rotation Rotation Posture Finger Press Ulnar Dev. Finger Press Ulnar Dev. Sideways Twisted Stand on 1 leg Full Arm Full Arm Flex 45 Extension Behind Body Flex 45 Extension Behind Body Backwards Sideways Kneel Ext. 45 Ext. 45 Twisted Pinch grip 2lb. Pinch grip 2lb. Force Power grip 10 lb. 10 lb. 10 lb. Power grip 10 lb. 10 lb. 10 lb. + Weight 20 lb. Foot 10 lb. Duration 10 secs 10 secs 10 secs 10 secs 10 secs 10 secs 30% of Day Frequency 30 postures/min. 2/min 2/min 30 postures/min. 2/min 2/min 2/min 2/min 2/min Total Physical Stressors Comment / Observations Check the type of stressor present and shade the area of the body affected. Vibration (V) Mechanical Stress (M) Low Temperature (L) Version 2.1

72 Verify Improvement 3 Right Shoulder 2 Neck 3 Left Shoulder 1 Right Shoulder 1 Neck 1 Left Shoulder 3 Right Elbow 3 Left Elbow 1 Right Elbow 2 Left Elbow 4 Right Wrist 3 Left Wrist 1 Right Wrist 2 Left Wrist 2 Back 1 Legs 1 Back 1 Legs Before After

73 Track Measures and Plans Activity Owne r Loaders: Assess risks Bob X Loaders: Develop and test solutions Scheduled Completion Date O N D J F M A M J J A S Bob X X Done Done Loaders: Implement solutions Bob X X X Loaders: Reassess risk Bob X Tac Welders: Assess risk Jay X Tac Welders: Develop and test solutions Tac Welders: Implement solutions Tac Welders: Reassess risk Jay X X Jay Jay Warehouse: Assess risk Jean X X X In Process Done Done Done Done On Track Warehouse: Develop solutions Warehouse: Implement solutions Jean X X Jean Warehouse: Reassess risk Jean X X X

74 Tactical Elements

75 Redeploy Effective Improvements Fix Once, Repeat Many.

76 Ergonomics Process Model

77 Cookeville, TN

78 Textron 90% Reduction in WMSD Rate

79 Honeywell 37% Increase in Productivity

80 Lucent 44% Reduction in Product Build Time

81 Verizon 52% Reduction in Workers Compensation Costs

82 Return On Investment Annual Savings (1999 baseline) $3,000,000 $2,500,000 $2,000,000 Year 2 Year 3 $1.2M 3-year total cost $920k fees & expenses $280k accessories (estimated) $1,500,000 $1,000,000 $500,000 $- Year 1 10 centers 23 centers 30 centers $6.1M 3-year savings $4.7M workers comp $1.4M revenue (1 business, 2 years) 408% 3-Year ROI

83 Characteristics of Successful Programs Add Value Systematic Approach» Manage risks not consequences.» Established goal and plan.» Address both strategic and tactical elements.» Integrated into existing processes and operations.» Uses common language and approach. Sustainable» Measurable.» Visible» Continuous improvement» Kept in perspective.

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85 Questions/Discussion Walt Rostykus CSP, CIH, CPE