Ergonomics

John Newquist

Draft 12 18 2015

Dec 2015

I need to take the time to thank John for everything he has done for my family and myself.

He may not see it as helping my family but when you save my knees, tendons, muscles etc from the daily wear of cleaning homes for hours on end it gives them a mother and wife who can function better.

I've been in a home scrubbing for over 2 hours now and my forearm hasn't given in to the repetitive motion.

No pain in my hands, forearm, or elbow, and my knees are happy as well.

I am so super grateful for your knowledge and expertise in job safety.

My body will get a 2 day break and then back at it. Thank you for everything!

January 2015

Bayer using sit stand desks

March 2015

Uplift desk with adjustable keyboard and monitor

Dec 2013

ASSE 2010Work Comp from PA Insurance~4000 companies studied200 Companies had 210 single losses over $250,00021% were same surface falls (ice, slipping)17% were ergo from non routine lifting

Carpal Tunnel

500,000 surgeries a year (NYT)

$29,000 average cost including rehab

Loss of some wrist strength is a complication that affects 10% to a third of patients.

Ergonomics

Demands of the task match the functional capacity of the worker

Definitions

Work-related: – an event or exposure

in the work environment that either caused or contributed to the resulting condition.

– Produces characteristic symptoms or injury

Strategy for Success:

Goals: oDecrease ergonomic hazardsoReduce injuries and illnessesoEnsure flexibility and encourage innovationoHelp prevent MSDs

Work Risk Factors

Forceful exertionsRepetitive

movementsOver shoulder workHeavy lifting

Work Risk Factors

Effective Ergonomics Programs

Injury & illness record keeping

Medical management

TrainingJob/Task hazard

analysisErgonomic control

selection and evaluation

Selecting the Employee

The abdominal muscles support the lower back.

People with weak abdominal muscles tend to suffer from back pain.

Strength Testing

An objective way to ensure that only people with sufficient strength to perform a job will indeed be assigned that job.

Not fool proof.Define task.$150 is typical

Injury and Illness RecordkeepingIs it accurate?Is it useful?How is it used?

By departmentBy body part

Trend Example Using DART RatesWarehouse operators

2000 = 17.62001 = 21.52002 = 35.12003 = 32.9

W.O. Upper Extremity Injuries

2000 = 4.72001 = 6.32002 = 7.02003 = 8.2

What is the Ergo Stressor Here?

Driver facing forward for driving

Driver is supposed to drive backwards

Trend Example Using DART Rate

Facility

2001 7.42002 38.82003 35.6

Warehouse Operator Injuries

2001 = 21.52002 = 38.62003 = 54.7

What is the Ergo Stressor Here?

Medical Management

Recognize symptomsEarly reporting system

to report signs and systems of ergo injuries

Physician used that is familiar with your company’s jobs/tasks

Provide job accommodation

Medical Treatment Doctors and other health care

providers cannot always pinpoint the exact cause of a patients' back pain.

Employee capabilities – work/no work

Employee restrictions – weight to be lifted

Follow-up Information to provider Information to employee

Back Facts People who cope best with back pain are

those that stay active. Aging of the back begins before 30 for

most people. Smokers are more likely to get back pain. People with previous back pain are likely

to get it again within a couple of years. The longer you stay off work due to a

back injury, the less likely you are to return to work.

Even if your aches and pains last for a long time, it doesn't mean you have a serious injury. Back pain settles eventually, but we can't predict exactly when.

Back pain usually subsides without any medical treatment in four to six weeks.

NIOSH could not establish that back belts work to eliminate ergonomic back injuries.

Education and Training

Who receives it?How do they use it?Are they expected to use it?

Controls

EngineeringWork practiceAdministrativeAny combination of the above

40 boxes loaded per minute onto conveyor

AnalysisStep-by-Step Procedure

Observe the jobInterview the person performing the jobBreak the job into various actionsDescribe the actionsMeasure and quantify risk factorsIdentify conditions contributing to the risk factorsVerify the analysis of the job with the worker

Sample Analysis The following is an checklist to aid in an ergonomic hazard analysis of a specific job or workstation. It is

designed to used as a supplement to close visual observation or videotaping of the job/workstation.Person performing analysis: John Newquist Date: December 13, 2005Job location: WarehouseJob name: Warehouse Worker Job description: Load on/off conveyorNumber of employees on job: 12 Line speed: 15 (pieces/minute)Jobs rotated with: None Rotation schedule: None Break schedule: 2 15 minute breaks in the morning, 30 minute lunch

Workstation: ____ 1. Are there any sharp edges? No____ 2. What is the height of the work table? 30 inches from floor to conveyor.

____ 3. Adjustability: None____ Can tools be moved around in the workplace? Not used____ Can the work surface height be adjusted vertically? No____ Can fixtures be tilted or rotated? No____ 4. What is the worker standing on? concrete floor____ 5. Is the floor or platform slippery? NoPostural____ 1. Can worker change postures (sit-to-stand or stand-to-sit)? No____ 2. What are the maximum reach distances in inches? Vertical = 30 to floor, Horizontal 33 inches across Miscellaneous____ 1. Are Packages or materials handled? Yes____ 2. What are they and what do they weigh? Name: Various Packages Weight up to 55 lbs.____ 3. What is the temperature of the work environment? 78F degrees (C./F.)____ 4. What personal protective equipment is used? None(e.g., gloves, hard hats, aprons)____ 5. Can the worker stop or control line speed? No____ 6. Are there opportunities for micro rest pauses? Yes If so, how many seconds? Up to 1-10 second between packages____ 7. Estimate exertion or effort required to do the job (1 to 5) 1=low, 5=high. This is a 4.

____ 8. How many total packages lifted in a day. 600 ____ 9. What is the total weight the employee moves in a day? Approximately 12,000 lbs.

Basic Screening ToolBody Part Associated With

MSD Incident

Risk Factors This Standard Covers Performing job or tasks that involve: Neck

ShoulderHand Wrist

ArmBack Trunk

HipLeg Knee

Ankle

Repetition

(1) Repeating the same motions every few seconds or repeating a cycle of motions involving the affected body part more than twice per minute for more than 2 consecutive hours in a workday.

 yes  yes Yes Yes

(2) Using an input device, such as a keyboard and/or mouse, in a steady manner for more than 4 hours total in a workday.  no No    

Force

(3) Lifting more than 75 pounds at any one time; more than 55 pounds more than 10 times per day; or more than 25 pounds below the knees, above the shoulders, or at arms’ length more than 25 times per day

 yes Yes Yes Yes

(4) Pushing/pulling with more than 20 pounds of initial force (e.g., equivalent to pushing a 65 pound box across a tile floor or pushing a shopping cart with five 40 pound bags of dog food ) for more than 2 hours total per day

 no No No No

(5) Pinching an unsupported object weighing 2 or more pounds per hand, or use of an equivalent pinching force (e.g., holding a small binder clip open) for more than 2 hours total per day;

   no    

(6) Gripping an unsupported object weighing 10 pounds or more per hand, or use of an equivalent gripping force (e.g., crushing the sides of an aluminum soda can with one hand), for more than 2 hours total per day.

  no     

Awkward Postures

7) Repeatedly raising or working with the hand(s) above the head or the elbow(s) above the shoulder(s) for more than 2 hours total per day  no No No  

(8) Kneeling or squatting for more than 2 hours total per day      no No

(9) Working with the back, neck or wrists bent or twisted for more than 2 hours total per day  yes Yes Yes  

Contact Stress

(10) Using the hand or knee as a hammer more than 10 times per hour for more than 2 hours total per day  no No No  

(11) Using vibrating tools or equipment that typically have high vibration levels (such as chainsaws, jack hammers, percussive tools, riveting or chipping hammers) for more than 30 minutes total per day

 no No No  

Vibration(12) Using tools or equipment that typically have moderate vibration levels (such as jig saws, grinders, or sanders) for more than 2 hours total per day.

 no no    

Before and After

Mechanical Lifts

Mechanical lifts raise the load to an easier lifting position.

Positioners

Here is a video. https://www.youtube.com/watch?v=Io9nAa-EzvcThey are at http://www.beacontechnology.com/lift-and-tilt-tables/Also many make similar.

Cost is about $3000

Lift Assisting Devices

Lift Assisting Devices

Palletizing

Pallet wrapping can be done by machines.

Double palletting can be used.

Hands, wrists, and forearms are straight, in-line and roughly parallel to the floor.

Head is generally in-line with the torso.

Shoulders are relaxed and upper arms hang normally at the side of the body.

Elbows stay in close to the body and are bent between 90 and 120 degrees.

Feet are fully supported by floor or footrest.

Back is fully supported with lumbar support when sitting vertical or leaning back.

Thighs and hips are supported by a well-padded seat and generally parallel to the floor.

Knees are about the same height as the hips with the feet slightly forward.

Prolonged static work

causes:- reduction in blood flow - increased pressure on sensitive tissues surrounding the joints

Long periods of sitting or standing

Standing

If you stand hours a day, you might have too much pressure on certain areas of your feet.

Red wing has a scanner that measures this pressure.

Their $60 orthotics for the heel are amazing.

Chair should have arm rests

Preferred viewing distance is20 to 40 inches

The top of the monitor should be at or slightly below eye level. The center of the computer monitor should normally be located 15 to 20 degrees below horizontal eye level

Wrist Rests

Ergo Keyboards and Mouse

Display screen is too high

Equipment

Evaluate– Hold vendor open houses

• Try out different equipment– CNAs test equipment

• Provide feedbackConsider types of devices

– Overhead– Floor based total lift– Lateral assist– Sit to stand– Slide sheet

Select for resident population• Facility constraints

PERM MOLD POURING

PROBLEM: Workers manually maneuver the ladle to scoop aluminum from the furnace well and pour into a mold.SOLUTION: Hydraulic lift arms have been fabricated internally to suspend the ladles, allowing pourers to merely direct the movements of the arm. COST: $5000BENEFITS: Eliminated all shoulder and back injuries and burns. Reduced cycle times and fatigue which increased production.

DISA POURER

PROBLEM: On the majority of molds on the Hunter 30 x 32 automatic Molding Machine, it took two workers to pour the mold. (Ladle weight – 40 lbs. each with metal)SOLUTION: Automatic pouring machine eliminates both workers from hand-pouring.COST: $35,000COST RECOVERY TIME: Six monthsBENEFITS: Eliminated burns, shoulder and back injuries, and manpower; also increased production.

GRINDER/CHIPPER DIE PRESS OPERATOR

PROBLEM: Small pneumatic hand grinders were used to finish parts, exerting strain on the wrists and arms.SOLUTION: A trim die is now used to trim parts.COST: $40,000COST RECOVERY TIME: Six to twelve monthsBENEFITS: Reduced cycle time, eliminated ergonomic stressors including vibration, poor posture, and force.

Results Foundry 2009

Percentage Difference b/t Baseline and 2009 Rates

TCIR Ergo -24% DART Ergo -48%

OSHA Inspections General Duty

Clause citationsErgonomic

Hazard Alert Letters (EHAL)

General Duty Clause - Section 5(a)(1)1. The employer failed to keep the work place free

of a hazard to which employees of that employer were exposed;

2. The hazard was recognized;3. The hazard was causing or was likely to cause

death or serious physical harm; and4. There was a feasible and useful method to

correct the hazard.

General Duty Clause - Section 5(a)(1)

The employer failed to keep the work place free of a hazard to which employees of that employer were exposed.

What is the hazard here?

General Duty Clause - Section 5(a)(1)

The hazard was recognized;

General Duty Clause - Section 5(a)(1)

The hazard was causing or was likely to cause death or serious physical harm;

Backs

Ages 30 and 50Aging processSedentary life

styles with too little exercise “Exercise may be the most

effective way to speed recovery from low back pain and help strengthen back and abdominal muscles”

Ergo Audit Element A. Have you identified

and listed three ergonomic hazards?

Machine, job task or Process ID:

Comments: B. List ergonomic

corrective actions within last 12 months

Machine or Process ID: Date: Comments: C. If you have had

claims with the root cause of ergonomics, were corrective measures taken?

Comments:

D. Annual documented training on ergonomics (back safety, preventing hand fatigue, material handling) for all employees based on claim history. Is an outline or explanation of training available?

Topic: Date: Comments: E. Are there material handling

procedures implemented with a maximum single-person lift capacity?

Where posted:

Insurance Trust Results

0.84 EMR~20% members had

no work comp claims in 2012

42% loss ratio vs. Ind Avg 60%

~50% of members had audit score of 90%

Stretching

ControversialOne Insurance

company says it can reduce ankle, knee, back, and rotator cuff injuries.

Morning and after lunch stretches.

30 second holds.

Summary

Determine high-risk jobs Conduct evaluations Develop corrective actions Set annual ergonomic goals Update the medical and

recordkeeping program Document ergonomic efforts Audit the ergonomics

process Review workers'

compensation claims

Employees should like working for your company!