Ergonomics Program Development

TM 655Dr. Carter KerkSDSMTSummer 2008

Ergonomics Program Guidelines(from OSHA Meatpacking Guidelines)

Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Top Management Commitment

Visible & serious commitment Placing a priority on eliminating

hazards Integrate S&H programs at the

same level as production Assign responsibilities, authority,

and resources

Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Written Program Endorsed by top management Outlines goals and plans Estimated implementation dates Customized to each plant Available to all personnel Reviewed regularly

Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Employee Involvement Suggestions & feedback encouraged Without fear of reprisal Prompt reporting of symptoms Prompt evaluation and possible

treatment Membership on Ergo Team Ergo Team receives symptom

reports & suggestions for evaluation

Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Program Review & Evaluation Regular review (~ semi-annual) Analysis of trends in injury rates Employee surveys Before / After surveys of changes Records of job improvements New or revised goals

Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Worksite Analysis Identification Evaluation Control

Worksite Analysis Analyze medical, safety, insurance

records for evidence of CTDs Insure confidentiality of patient

records Incident Rate Analysis

Count incidences of properly diagnosed CTDs per 100 full-time employees per year

Incident Rate (# of new cases) (200,000 work hours)

IR = _______________________________

# of hours worked

200,000 = (40 hrs/wk) (50 wk/yr) (100 workers)

Evaluate trends by department, units, job titles, operations, work stations, etc.

Ergonomics Checklist Focused on physical / temporal risk

factors Systematic Helps novices be “experts” ID higher and lower risk jobs Apply before & after changes Apply to planned and new

workspaces

Body Part Discomfort Map

Employee Surveys & Interviews Interviews are usually superior, but

more time consuming Get employees more involved Employees have a wealth of ideas

Worksite Analysis Checklist may suggest one or more

advanced analyses: Biomechanical Psychophysical NIOSH Lifting Guide Physiological Postural Hand Tool Vibration

Worksite Analysis Performed by an ergonomist Ergonomics Team

Ergonomist Occupational Health Nurse Design & Production Engineers Maintenance Employee representation Line Supervisor

Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment

Engineering Controls Most desirable approach Redesign or Modify

Workstation Tools Work Methods

“Fit the worker”

Engineering Controls Establishing optimal work methods Adjustable workstations Tilt bins or containers Tool balancers Conveyors, Turntables Jigs, Fixtures Rounded or padded edges on worksurfaces Mechanical assist devices Selection of “ergonomic” tools

Work Surfaces Adjustability Ease of Adjustability Avoid sharp edges Consider sit/stand options

Placement & Storage of Materials

Consider frequency and weight Store heaviest and most frequent

at knuckle height, “Power Zone” Store medium items from knee to

shoulder Store only light items below knee

or above shoulder

Work Station Accessories Arm rests Wrist rests Foot rails and foot rests Document holders

Engineering Controls

Engineering Controls

Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment

Administrative Controls Secondary to Engineering Controls Insure proper methods are used Effective maintenance &

housekeeping Proper use of tools & equipment Employee conditioning New employee conditioning

Administrative Controls Examples Limiting overtime on high risk jobs Ensuring “adequate” rest breaks Job rotation Job enlargement Training Teaming Reduce production rates

Last resort

Microbreaks What is a microbreak? Take them frequently

Standing Fatigue Interventions Proper footwear Shoe inserts Anti-fatigue mats Footrails Promote good lower extremity

circulation

Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment

Personal Protective Equipment After engineering & administrative

controls are exhausted Gloves Finger cots Arm guards NOT PPE:

Braces, splints, back belts

Wrist Splints

Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Medical Management Involvement of “qualified” medical

personnel Certified Occupational Physicians Certified Occupational Health Nurses Occupational/Physical Therapists

Member of Ergonomics Team Active surveillance for symptoms Thorough diagnosis

Medical Management Conservative treatment Conservative return to work Systematic monitoring & follow-up Work hardening Consider light duty transition Recordkeeping Tracking trends Promote stretching & strengthening

programs

Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Training & Education Keep employees informed of

program Train:

Production workers Engineers Maintenance & housekeeping personnel Supervisors & Managers Medical personnel

Training & Education Customized for each plant and its

written program General & specific training levels Train on disorders & symptoms Risk Factor Awareness including

Personal, psychosocial, non-occupational

Engineering control strategies

Lifting Squat lift generally better than stoop bend with your knees, not your back keep the load close get a good hand hold move slowly, “no jerks allowed” know or test the load Avoid twists

More Lifting Tips Get help (from a person or an

assist device) Eliminate lifts Reduce loads Store properly Get a strategic delivery Use proper technique on light loads

Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

Barriers to Successful Ergonomics Programs

Lack of funding Implementation delays Poor attendance by middle managers Viewing ergonomics as a productivity

program Excessive dependence on consultants Failure to develop internal ergo

expertise

A Bad Ergonomics Program?

Ingredients for Effective Ergo Programs

Leadership commitment Clear purpose Worker / supervisor involvement Rigorous problem solving Active Ergo Team with expertise Ergo is a process, not a program Start small & expand - Kaizen

HW OEG (OSHA Ergonomics Guidelines) Read one of the available OSHA

Ergonomics Guidelines and write a four page (double spaced) paper on how you would implement such a program from a manager’s standpoint.

50 points Due as soon as possible

HW OEG, Continued Guidelines

Nursing Homes Poultry Processing Retail Grocery Shipyards

Available from the course website and from www.osha.gov, Ergonomics, Guidelines

Assignment MacLeod, Chapters Five & Seven Gabriel, Chapter Four HW OEG CE 4 (Case Example 4) Exam II (covers material thru 6/3/08)

Tuesday, June 10, 7 PM (90 Minutes) Closed Book Crib Sheet, 1-8.5”x11” paper, two-sided,

hand-written original, hand in with exam