What is your Ergo IQ? An Ergonomic Risk Assessment Model

ASSE/AIHA Professional Development Conference

April 19, 2013

Bruce K. Lyon, CSP, P.E., ARM, CHMM Director, Risk Control

Hays Companies

Dr. Georgi Popov, QEP. Associate Professor

University of Central Missouri

What’s your Ergo IQ? An Ergonomic Risk Assessments Model

• Definitions

• Assessment Process

• Assessment Tools

Ergonomics (work) + (natural laws)

The science of properly matching work demands and environment with human capabilities.

Human Factors

Human-machine Interface

Cognitive + Physical Aspects

Designing for the End-user

Musculoskeletal Disorders (MSD) a.k.a. Cumulative Trauma Disorders (CTD)

• Disorders of the soft tissues

• Chronic in nature

• Caused by certain risk factors

Costs of Ergonomic Risks

Productivity

Quality

Employee

Work-related Musculoskeletal Disorders (WMSD)

$40,000 - average cost for back surgery

$29,000 - average for carpal tunnel surgery

$20 billion a year – US DOL

Ergonomic Risk Assessment (ERA)

Purpose Identify Problem Jobs

• Involve employees

Quantify Risk Factors

• Establish Baseline and Benchmark Improvements

Reduce Potential Disorders and Improve Work

Establishing an ERA Process

• Scope/context

Establishing an ERA Process

• Scope/context

– Who

– What

– When

– How

Establishing an ERA Process

• Scope/context

• Goals/Objectives

Establishing an ERA Process

• Scope/context

• Goals/Objectives

Specific

Measurable

Actionable

Realistic

Time-oriented

Establishing an ERA Process

• Scope/context

• Goals/Objectives

• Responsibilities

Establishing an ERA Process

• Scope/context

• Goals/Objectives

• Responsibilities

– Defined & Communicated

– Specific & Measurable

– Aimed at Achieving goals

– Accountability

Establishing an ERA Process

• Scope/context

• Goals/Objectives

• Responsibilities

– Defined & Communicated

– Specific & Measurable

– Aimed at Achieving goals

– Accountability

Management

Ergo Coordinator

Ergo Committee

Engineering, Maintenance

Medical, Worker’s Comp

Supervisors

Operators

Establishing an ERA Process

• Scope/context

• Goals/Objectives

• Responsibilities

• Training

Establishing an ERA Process Topic Who Objectives Delivery Updates

Managing the Process Part 1

GMs, Plant Managers Coordinator

• Understand process

• Responsibilities • Goals

Internal Every 3 years

Ergo for Engineering Design

Engineers Maintenance Tooling

• Ergo design guidelines

• Assessment tools • Software

Internal or outside approved vendor

Every 3 years

Ergo Awareness

Operators Supervisors

• Understand process

• Responsibilities • ID risk factors and

controls

Internal Every year

Ergo Committee

Ergo Committee

• Assessment tools • Problem solving

Internal Every year

Example

Establishing an ERA Process

• Scope/context

• Goals/Objectives

• Responsibilities

• Training

• Resources

Establishing an ERA Process

• Scope/context

• Goals/Objectives

• Responsibilities

• Training

• Resources

• Process Steps

19

Design Concept

Preliminary Design

Detailed Design

Build or Purchase

Commission (Install and Debug)

Production Maintenance

Decommission

ANSI Z590.3

PtD guidance for “Life-cycle” assessments

Ergonomic Risk Assessment Process

Establish

Analyze

Ergonomic Improvement

Process

Ergonomic Risk Assessment: Where to Start?

Loss History Incident Data OSHA logs Worker’s Compensation Information

Employees Input & Feedback Surveys

Workplace Observations Visual Cues Job Analysis/Risk Factors

Performing an Assessment

Set Goal Select Tool

ID Team Gather

Data Record

Data Analyze

Data Develop Findings

• Relative Risk Measure

• Baseline & Benchmarking Measure

Risk Factors

• Team Assessments

• Create Ownership Involve

Employees

• Prioritize and Rank

• Target Efforts Provide

Guidance

Set Goals for Assessment

Ergonomic Risk Assessment Process

Establish

Analyze

Prioritize Ergonomic

Improvement Process

Prioritize

• Numerical Scores and corresponding Risk Ratings (RPN)

– Exposure base

• Recordable Incidents and Reports of Discomfort

– Hot Spots

– Potential problems

Ergonomic Risk Assessment Process

Establish

Analyze

Prioritize

Implement

Ergonomic Improvement

Process

Implement

• Identify Effective Controls

– Ergo committee brainstorming

– Use Hierarchy of Controls

1. Engineering

2. Administrative

3. Work Practices

• Select Effective Controls

– Communicate with employees

• Implement Controls

Ergonomic Risk Assessment Process

Establish

Analyze

Prioritize

Implement

Follow-up

Ergonomic Improvement

Process

Follow-up

• Verify Controls are Correctly Implemented

• Obtain employee feedback

• Formal Review after break-in period

Ergonomic Risk Assessment Process

Establish

Analyze

Prioritize

Implement

Follow-up

Measure

Ergonomic Improvement

Process

Measure

• Short Term and Long Term Metrics

– Lagging Long Term Measures

• ergo incidents rates & DART rates

• Employee complaints

– Proactive Short Term Measures

• # of Assessments performed

• RPN reductions

• Ergo training

• Ergo assessments of new operations/MOC

Ergonomic Risk Assessment Process

Establish

Analyze

Prioritize

Implement

Follow-up

Measure

Communicate Ergonomic

Improvement Process

Communicate

• Communication at all levels

• Collect employee feedback on ergo conditions regularly

Application

• General Industry

• Manual Handling

• Repetitive Tasks

• Hand Work

• Office / VDTs

Body Segment

• Upper Extremities

• Lower Extremities

• Trunk

• Whole Body

Selecting the Right Tool

Assessment Tool Application Type Body Segment

WISHA Checklists General Industry Repetitive Tasks

Qualitative •Whole Body

ANSI Z365 Tool General Industry Repetitive Tasks

Qualitative •Upper Extremities •Trunk

MI Energy Expenditure Prediction (EEP)

General Industry Manual Handling

Quantitative

•Upper Extremities •Trunk

Strain Index Office Settings Hand work

Quantitative •Upper Extremities

Hand Activity TLV Office Settings Hand work

Semi-quantitative •Upper Extremities

RULA General Industry Repetitive Tasks

Semi-quantitative •Upper Extremities •Trunk

Snook Tables General Industry Manual Handling

Semi-quantitative •Trunk

NIOSH Revised Lifting Eq. General Industry Manual Handling

Quantitative

•Trunk

REBA General Industry Repetitive Tasks

Semi-quantitative •Whole Body

MI 3D SSP Software General Industry Manual Handling

Quantitative •Trunk •Lower Extremities

Qualitative Tools

• Commonly used

• Good for screening jobs

• Manual or Excel based

– OSHA Basic Screening Tool

– WISHA Checklists

– ACGIH TLV for Lifting

– ANSI Z365 Tool

– NIOSH Checklists and others

OSHA Basic Screening Tool

WISHA

Calculators

• Lifting Operations

• Hand/Arm Vibration

ACGIH TLV for Lifting

Semi-Quantitative Tools

• More focused

• Specific risk factors/body regions

– RULA

– REBA

– Snook Tables

– ACGIH TLV for Hand Activity

– Utah Back Compression

– others

Quantitative Tools

• Require training/knowledge

• In depth analysis

– NIOSH Revised Lifting Equation

– MI 3D Static Strength Prediction Model

– Strain Index

– Dynamic Work Analysis

– Static Work Analysis

– others

NIOSH Revised Lifting Equation

Michigan 3D Static Strength Prediction Model

Ergo “Hot Spots” Simple Color-coding System

Ergonomic Action Plans

Team Solutions Cost/Benefit & ROI Assignments and Responsibilities Track Performance / Risk Scores