Luann RomanelliMACNY ERGO 2 1 06 v2

ERGONOMICSKEYS TO CONTROLS: 

ERGONOMICS KEYS TO CONTROLS Prepared & Presented by: Luann Romanelli, Account Executive

What will be covered.: 

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

What is Ergonomics?: 

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.

Statistical Data: 

Statistical Data DOL indicates 8 million workers report work related MSD’s, 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

Accident Costs: 

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)

Lost Time Data: 

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 $$$$$$$$$$

Profit Margin: 

Profit Margin Direct Incurred Cost $ 2,000 Indirect Cost $ 8,000 Total Cost $10,000 Profit Margin @ 15% = $10,000 / .15 = $11,500 Need $ 11,500 in sales to cover the $2,000

Workers’ Compensation : 

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

Insurance Loss Control Services: 

Insurance Loss Control Services Ergonomic Committees/Education Management / Supervisor Education Work Station Evaluations Effective Ergonomic Suggestions RM Loss Trending – Target High Risk Tasks

Ergonomic Analysis: 

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

Ergonomic Program Benefits: 

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.

Common types of MSD’s: 

Common types of MSD’s Tendonitis Carpal Tunnel Syndrome Tennis Elbow Neck and Back injuries Strains/Sprains Bursitis Thoracic Outlet Syndrome Trigger finger Low Back Disorder

Ergonomic Related Injuries : 

Ergonomic Related Injuries May be called: CTD’s (cumulative trauma disorders) RSI’s (repetitive stress injuries) RMI’s (repetitive motion injuries) Which are all considered: MSD’s (musculoskeletal disorders) MSD’s can affect muscles, tendons, nerves, joints and spinal disks.

Ergonomic Risk Factors: 

Ergonomic Risk Factors Repetition / Task Frequency Position / Posture (awkward & static) Force Temperatures Extremes Contact Stress Vibration / Torque

Engineering Controls: 

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

Engineering Controls: 

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

Administrative Controls: 

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

Personal Protection Equipment: 

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

Four Keys to Control: 

Four Keys to Control Keep the body in neutral Minimize area of movement Minimize force Minimize repetition

Keep the Body in Neutral: 

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

Minimize Area of Movement : 

Minimize Area of Movement Upper Extremities Work in Frontal “Range of Motion” Don’t 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 Don’t push/pull across the front of the body Avoid twisting at the waist Keep the object close

3. Minimize Force: 

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

3. Minimize Force Cont . . .: 

3. Minimize Force Cont . . . Lower Back Use built – in handle grips Reduce lifting force No frequent lifting > 30 lbs No occasional lifting > 50 lbs -- Use anti fatigue mates -- Use carts, forklifts, cranes, hoists, conveyors

4. Counteract the Effects of Repetition: 

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

Ergonomic Control Program: 

Ergonomic Control Program Management Employee Involvement Written Program Regular Program Review

Behavior – Based Ergonomics: 

Behavior – Based Ergonomics Observing behavior, positive reinforcement Cultural change, occurs over time Its employee-owned Use to develop engineering controls

Medical Management: 

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.