25 Ways Ergonomics Can Save You Money

8/11/2019 25 Ways Ergonomics Can Save You Money

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jar of jam; once the jam starts to build up onthe lid, it requires more force and it takeslonger time. Likewise, a screw that is hard toturn takes longer to insert than one that moveseasily. Moreover, muscles under a heavy load

are harder to move with precision. Thusaccuracy of movement is reduced, which hasconsequences for both quality and efficiency.As with everything else in this list, the toolsof ergonomics can help to identify sources ofunnecessary exertion as well as ways toreduce the exertion.

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tive motions are a waste of time . . . literally.The more motions, the longer it takes toperform a task. A good ergonomics analysisseeks to identify the types of motions requiredfor different steps of the job. With suchfocus, it is possible to identify instanceswhere it is possible to improve the type ofmotion being used or reduce the number ofmotions, if not eliminate them entirely.Repetitive motions should be viewed both asa source of injuries and as a red flag forwasteful work.

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)3%/;3'9 Poor heights and reaches can affectproductivity in a couple of different ways. Ifyou cant reach an object at all, you may needto stop productive work and fetch a step stoolor take time to remove an obstruction. If theinappropriate height or the long reach causesyou to work in an awkward posture, you endup losing productivity for that reason.

L9 :;3)3 .' % B.)3/> G33, =%>.*53 %,B .+,'9 Almost any

new perspective on your workplace can helpyou identify ways to improve. But the toolsof ergonomics are especially useful becausethey focus on ways to eliminate problems like

fatigue, awkward working positions, andexcessive motions.

889EMNMMM &3%)' += @)+*)3''9 In a certain way,

ergonomics is nothing new. Humans havebeen doing ergonomics (that is, reducingthe physical demands of jobs) for a long time.We can say, tongue-in-cheek, that good ergo-nomic improvements include the stone ax, thewheel, and even sliced bread.

8!9DB3,>.=&.,* G%'>39 A good ergonomics task

analysis penetrates into operations step bystep, very similar to old-fashioned Time andMotion analysis. By evaluating items such asfatigue, motions, and exertion through a taskstep by step, it is possible to identify wastedactivities.

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Whenever humans are involved, using thetools of ergonomics may in fact be a prerequi-site for lean operations.

8E9D-@)+2.,* >;3 ;5-%,R'&'>3- .,>3)=%/39 The

term ergonomics was coined by aircraftdesigners for the British Royal Air Force inthe Second World War. Their goal was tocreate a cockpit that was more human com-patible, so that the pilots could physicallyreach all the knobs and switches as well asunderstand the increasingly complex array ofdials and indicators. Their objectives hadnothing to do with preventing back injuries or

Carpal Tunnel Syndrome. It was all aboutefficiency, using the special focus of studyingthe interface between humans and systems(or, to use the jargon of the time, man-machine systems).

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8"9(23)&+,3 A3,3=.>' =)+- ?,+G.,* >;3 S)5.+,

/+'>'9 Good ergonomics programs have cut

workers comp costs an average of 60% andup to 90% in some cases. You dont need toaccept high workers comp losses as a cost ofdoing business.

8K9Q)+>3/>.,* &+5) ;5-%, )3'+5)/3'9 The smaller

your organization, the greater risk you have ofdisruption due to the loss of a key person even if this loss is just a few days because ofback pain. Furthermore, you may not be ableto replace that person, even temporarily.

Even if a replacement is found, skill levelsmay not be the same or the learning curvemay be extended.

8L9D-@)+23B -+)%5),+23)9 Dissatisfaction caused by

fatigue, working in uncomfortable postures,and the pain and discomfort created by over-

exertion injuries may easily lead to increasedemployee turnover.

!89U3B5/3B %A'3,>33.'-9 A common reason why

workers are absent is that they are experienc-ing early stages of a musculoskeletal disorder.Work that hurts doesnt exactly encouragepeople to come ever day.

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G+)?=+)/39 Older employees have more

experience, tend to be more reliable, and arealready trained and educated. When ergo-nomic adaptations are made, older workerscan be as productive as younger workers, ifnot more so.

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Musculoskeletal Disorders (MSDs) are verycommon. You yourself may have experi-enced lower back pain from time to time or

have had a sore elbow or shoulder fromtendonitis. MSDs can be thought of as theeffects of everyday wear-and-tear.

Many MSDs are sports-related. We use theterm tennis elbow for swelling of the tendonsin the elbow from overuse. Almost everylong distance runner suffers from MSDs inthe legs: shin splints, sore knees and ankles,etc. One of the occupations with the highestrates of these types of injuries is professional

baseball.

These occurrences in sports help us under-stand the nature of the injuries. First of all,athletes tend to be in excellent condition, butstill have problems. So these disorders arenot simply caused by being out of shape.Additionally, athletes have no incentive tofake injuries to get out of work. So the under-lying problem is deeper than just malingering(although clearly some employees take advan-tage of the system).

Most of the time, these ailments healthemselves with a bit of rest. But sometimesthey can escalate into disabling injuries,especially when continually aggravated.

Although we may not be able to prevent allthe minor ailments that come with everydaylife, we can keep the little problems frombecoming big ones.

MSDs can be easily treated when identified intheir early stages. When recognized early,these disorders can be treated cheaply with

ibuprofen, ice packs, and rest. Moreover, thelikelihood of fully returning to normal isincreased. But if you wait too long, perma-nent damage may occur, which may thenrequire surgery, which is expensive andsometimes painful. Worse, the likelihood offull recovery is less.

MSDs typically account for about one-third ofworkplace reports of injury. But more impor-tantly, they often account for about 75% of

workers compensation costs.

The costs of various types of MSDs thatrequire surgery approximate the following: Wrist Disorder: $15,000 Shoulder Injury: $20,000 Back Injury: $40,000Although these figures are rough averages,they give an indication of how quickly costscan add up.

Good ergonomics can be effective in prevent-ing MSDs. Also, recognizing employees withproblems at early stages and providingconservative treatment is important.

The risk factors for MSDs are the same issuesthat can reduce productivity primarilyawkward postures, excessive force, excessivemotions, and static working positions.

Detailed guidance on workplace ergonomics is available from Dan MacLeod and Taylor & Francis:The Ergonomics Kit for General Industry, a manual on how to set up an ergonomics process, complete withforms and worksheets.The Rules of Work A Practical Engineering Guide, a down-to-earth text on principles, techniques, andquantitative methods of workplace ergonomics.

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25 Ways Ergonomics Can Save You Money