ergonomics program development tm 655 dr. carter kerk sdsmt summer 2008
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Ergonomics Program Development
TM 655Dr. Carter KerkSDSMTSummer 2008
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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
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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
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Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education
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Written Program Endorsed by top management Outlines goals and plans Estimated implementation dates Customized to each plant Available to all personnel Reviewed regularly
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Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education
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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
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Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education
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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
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Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education
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Worksite Analysis Identification Evaluation Control
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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
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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.
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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
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Body Part Discomfort Map
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Employee Surveys & Interviews Interviews are usually superior, but
more time consuming Get employees more involved Employees have a wealth of ideas
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Worksite Analysis Checklist may suggest one or more
advanced analyses: Biomechanical Psychophysical NIOSH Lifting Guide Physiological Postural Hand Tool Vibration
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Worksite Analysis Performed by an ergonomist Ergonomics Team
Ergonomist Occupational Health Nurse Design & Production Engineers Maintenance Employee representation Line Supervisor
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Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education
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Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment
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Engineering Controls Most desirable approach Redesign or Modify
Workstation Tools Work Methods
“Fit the worker”
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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
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Work Surfaces Adjustability Ease of Adjustability Avoid sharp edges Consider sit/stand options
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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
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Work Station Accessories Arm rests Wrist rests Foot rails and foot rests Document holders
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Engineering Controls
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Engineering Controls
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Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment
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Administrative Controls Secondary to Engineering Controls Insure proper methods are used Effective maintenance &
housekeeping Proper use of tools & equipment Employee conditioning New employee conditioning
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Administrative Controls Examples Limiting overtime on high risk jobs Ensuring “adequate” rest breaks Job rotation Job enlargement Training Teaming Reduce production rates
Last resort
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Microbreaks What is a microbreak? Take them frequently
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Standing Fatigue Interventions Proper footwear Shoe inserts Anti-fatigue mats Footrails Promote good lower extremity
circulation
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Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment
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Personal Protective Equipment After engineering & administrative
controls are exhausted Gloves Finger cots Arm guards NOT PPE:
Braces, splints, back belts
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Wrist Splints
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Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education
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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
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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
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Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education
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Training & Education Keep employees informed of
program Train:
Production workers Engineers Maintenance & housekeeping personnel Supervisors & Managers Medical personnel
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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
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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
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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
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Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education
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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
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A Bad Ergonomics Program?
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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
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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
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HW OEG, Continued Guidelines
Nursing Homes Poultry Processing Retail Grocery Shipyards
Available from the course website and from www.osha.gov, Ergonomics, Guidelines
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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