Ergonomics in Welding

An overview of WMSDs* hazardous exposures and solutions

*Work-related musculoskeletal disorders

What will You learn

• Identify WMSDs hazardous exposures in welding jobs

• Propose solutions for hazardous exposures

• Find further information about ergonomics in welding operations

Hazards

Welding operations are necessary in many industries such as construction, manufacturing, maintenance, etc.

Welding has several hazardous conditions for women and men in these jobs.

Hazards

Common hazards found in welding are: inhaling metals fumes,

eye exposure to welding arc light (UV, visible),

foreign objects in eyes,

burns,

noise,

cuts, bruises, etc.

WMSD Hazards

Welding also includes musculoskeletal disorders (WMSD) hazards such as:

awkward body postures,

lifting heavy equipment or materials,

static postures for prolonged periods,

awkward postures of the wrist, etc.

By Nature of Injury

Sprains account for more than 1/3 of the compensable claims among welders in the State of Washington.

Some of those could be caused by hazardous WMSD exposures.

WA State-funded compensable claims 1994-2004Welders, Cutters, Solderers

Hearing loss11%

I ll-Def Symptoms

9%

Neural5%

Other13%

Sprains32%

Contussion/Cut/

Scratches 16%

Fracture/Dislocation

14%

WA State-funded compensable claims 1994-2004Welders, Cutters, Solderers

Other15%

Ears11%

Back/ Neck/Shoulder

28%

Hand / Arm 26%

Foot/Leg

20%

By Body Part

The back, neck and shoulder together with the arm and hand regions make up more than one half of the injuries among welders in Washington State.

Preventive efforts should therefore focus on those body parts among welders at your workplace.

Welding is a strenuous occupation involving work in awkward postures and handling heavy equipment, usually with a high degree of sustained stress to arm and shoulders.

• Absences due to injury or illness and the transfer of welders to other tasks

• Overtime for replacement workers. Welders are skilled employees

• High employee turnover

• Increased training and supervisory time

• Reduced productivity and quality

Consequences of a poor working environment

• Rigorous manual precision requirements

– High degree of uniformity

• Awkward and static postures

– Difficult work position

• Heavy lifting, difficult material handling

– Heavy objects, heavy welding equipment

• Repetition

– High work intensity

OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT

WMDS hazards most common in welding

Duration (how long?)

Frequency (how often?)

Intensity (how hard?)

Hazard Elements

Working in front

Working at ground level

Working above the shoulders

Working at ground level, precision work

Working at ground level, confined space

Working above shoulders, confined space

‡From: Torner et al, 1991

Common postures adopted in welding

Torso twisting

Awkward postures in welding

Severe torso flexion

Kneeling, squatting

Bent wrists

Neck flexion/extension

Shoulder flexion/abduction (separation)

To simplify the welding performance for the welder and reduce the physical load during the work

•Automate physically demanding or repetitive jobs

•Expand the work content of welders (provide flexibility between jobs)

– Multi-skilled workers who are able to perform different tasks within a group)

The goal of a healthy work environment

• Often cost, ease of maintenance, space considerations drive the design process

• When hazards can’t be engineered out, using best practices is the alternative

• Examples of good design: providing opportunities for adjustments, providing different sizes, using good planning to eliminate unnecessary work

The Real World

Possible Ergonomic Improvements

Heavy Lifting

• Manipulators• Lighter welding

equipment, easier to handle

• Using lighter cables with low stiffness

• Use cable supporting devices(balancers)

• Utilize overhead hoists

• Utilize lifting and turning tables

Ergonomic improvements

Awkward Postures

• Position work between waist and shoulder, when possible

• Lifting tables• Motorized positioning

devices• Use welding guns with

swivels and designed for use in both hands

• Work stool

Ergonomic improvements

Team lifting helps reduce heavy, awkward lifting of equipment and materials.

AFTER

From: SIMA San Diego Ergonomics ProgramBEFORE

Ergonomic improvements

To reduce working with the back bent at ground level, any work table will help to adopt a safer posture

AFTER

From: Shipyard Ergonomics, 2003BEFORE

Ergonomic improvements

Pre-assembly and material handling equipment helps reduce unnecessary lifting or any other kind of manual material handling

Ergonomic improvements

This rotational clamp for pipe helps reduce awkward postures for the neck, shoulders and arms.

Ergonomic improvements

Tables for welding and transport reduce manual lifting, carrying of heavy materials.

The tables also have wheels.

Ergonomic improvements

Welding leads on pulleys help reduce heavy and awkward lifting, static postures for long periods.

Ergonomic improvements

Robotic automation, are also feasible solutions to highly repetitive motions with the arms and hands. May also reduce the exposure to fumes.

Not implementing some or all these ergonomics guidelines may result in the following…

Not implementing some or all these ergonomics guidelines may result in the following…

Possible Consequences

•Often occur when the physical demands of work cause wear and tear

•Involve soft tissues such as muscles, tendons, ligaments, joints, nerves, blood vessels

They are cumulative (occur over time and not a result of a single incident):

Work-related musculoskeletal disorders

Work-related musculoskeletal disorders

•Broken bones

•Cuts

•Slips

•Falls

•Trips

•Motor vehicle accidents

•Being struck by or caught with objects

They are not acute injuries such as:

• Back injuries• Shoulder pain/loss of range of motion• Tendinitis/Bursitis• Reduced muscle strength• Carpal tunnel syndrome• White finger• Knee joint diseases

• Back injuries• Shoulder pain/loss of range of motion• Tendinitis/Bursitis• Reduced muscle strength• Carpal tunnel syndrome• White finger• Knee joint diseases

Common disorders among welders

The Ergonomics Cycle

The ergonomics cycle provides with an organized way to start your ergonomics effort.

EmployeeInvolvement

Evaluateprogress

Management Support

ProblemIdentification

SolutionImplementation

Address Injuries

Training

SHARPSafety & Health Assessment &

Research for Prevention

Credits

The technical contents of this slideshow are based upon the presentation developed by Ninica Howard, MS, CPE, research ergonomist with the SHARP program at the Washington state Dept. of Labor and Industries.

More resources•Shipyard Ergonomics for purchase at Shipbuilders Council of America at www.Shipbuilders.org

•NIOSH’s Ergonomic Interventions in the Building, Repair, and Dismantling of Ships

•SHARP Program

•Easy Ergonomics. A practical approach for improving the workplace OR OSHA & CAL OSHA Services. www.cbs.state.or.us/osha/pdf/pubs/3347.pdf

•On WMSD hazardous exposures visit the WISHA webpage at:www.lni.wa.gov/Safety/Topics/Ergonomics

•Example Template of an accident prevention program :•www.lni.wa.gov/Safety/Basics/Programs/Accident

•Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas Bank

•You may also write us at:•ergonomics@LNI.WA.GOV

Thank you