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OSHA Ergonomics Program. 2005 Ergonomics Conference & Expo Oconomowoc, WI October 19, 2005. Melvin Lischefski 920-734-4521. Objectives. Introduce partnerships as an alternative approach to ergonomics Documenting ergonomic interventions The business case for ergonomic improvements. - PowerPoint PPT Presentation


  • OSHA Ergonomics Program2005 Ergonomics Conference & ExpoOconomowoc, WIOctober 19, 2005Melvin Lischefski920-734-4521

  • ObjectivesIntroduce partnerships as an alternative approach to ergonomicsDocumenting ergonomic interventionsThe business case for ergonomic improvements

  • PartnershipsVoluntary activitiesOperated jointly and cooperatively by OSHA and its partnersStrength safety and health programsFind solutions to safety and health issues

  • OSHA Partnership Core ElementsID of PartnersPurpose/ScopeGoals/StrategiesPerformance MeasuresAnnual EvaluationsBenefits (Incentives)

    OSHA VerificationManagement and OperationER/EE Rights and ResponsibilitiesTerm of OSPSignatureWhat is missing from this list?

  • Partners

    Six Foundries in Northeast WisconsinOSHARegion V ErgonomistWisconsin Health Consultation ProgramLabor UnionsOSHA Health Response Team

  • Operation of the PartnershipEach stakeholderDesignates one rep to serve on FEP committeeHas written ergo programHas internal ergonomic committeeConducts training in the identification of MSDS stressors, signs and symptoms

  • Plant Visits by FEP CommitteeFEP Committee meets quarterly and conducts onsite ergo review at host plantProcesses are videotaped and digitally photographedAll have input on ergonomic solutionsWI Health Consultation participates in all onsite visitsOSHA office does not participate in inspections

  • Employee InvolvementUnion representatives given opportunity to participateErgo/Safety Committee member participates in onsite activitiesFEP interviews employees for recommendationsEmployees trained in procedures for recognizing and reporting MSDs

  • Management CommitmentFEP participants not exempt from programmed inspections.

    If FEP employer not acting in good faith, a verification inspection will be conducted.

  • FOUNDRY ERGO PARTNERSHIP (FEP)Goal #1: Analyze workstations and work processes for ergonomic hazards.MeasurementNumber of workstation analyzedNumber of risk factors/stressors identifiedNumber of stressors reduced or eliminatedReduction in frequency and severity of injuriesGoal #2: Document control measures including administrative controls and work practices.Measurementdevelop best practices handbook, video, and/or power point presentation illustrating possible solutions.

  • Our First ChallengeLack of uniformitySome more advanced than othersNo system in place to collect, report or analyze data

  • Ergonomic Assessment ToolWashington Ergonomic Assessment ToolsOpinion orientated assessment toolsone focusing on the back, a second focusing on hands and arms.Risk factors are assigned a value of 0 to 8 points by evaluator (ergo committee members, co-workers, operators, etc.).Points are totaledthe higher the score, the greater the stressors.

  • Back

  • Rating Factors - BackWeight - 50 is 8Position 8 when arms fully extended or above neck or below kneesFrequency degree refers to angle of back, 8 is more than 40 degrees, O if position can be changed often frequency 6 or more times per minute is an 8

  • Rating Factors - backTwist 6 if twist required, 8 if twist and bendGrasp good is 0, awkward is 8Footing 8 for unstable footingOpinion 0 is very easy, 2 is easy, 4 is moderate, 6 is hard, 8 is very hard

  • Hands And Arms

  • Hands And Arms RatingArm movement 8 for constant arm movement more than 30 times per minute (add 4 points for moderate force, 6 points for high force)Twist movement 8 for constant twisting more than 20 times per minute (also add points for force)Wrist movement 8 for more than 40 times per minute (also add points for force)

  • Hands And Arms RatingFinger movement 8 for more than 60 times per minute (add points for force)Head position 8 for heat bent backward or bent forward more than 30 degrees (0 if the head and neck position can be changed often)Back position 8 for more than 20 degrees forward (0 if position changed often)

  • Hands And Arms RatingElbow forward approach 8 as elbow is raised from neutral position to high front or backElbow from side 8 for more than 45 degreesForearm two charts, one for light and one for heavyWrist position 8 for wrist bent more than 30 percent of the time

  • Hands And Arms RatingForce/Grip 2 if object weighs more than 1 lb (add 2 points if you wear gloves)Pinch Grip 8 for an object weighing more than 1 lb (add 2 for gloves)Open Grip 8 for object weighing more than 1 lb (add 2 for gloves)

  • Hands And Arms RatingVibration 8 for constant or occasional severeEnvironment 8 for temperatures below 45 and above 95

  • MSD Cost Analysis1-1-99 thru 10-1-03

    Body PartNumberAvg. CostCost RangeBack128$2,285$81 - $48,851Arm/Wrist39$4,941$79 - $38,638Shoulder29$5,017$59 - $52,532

  • BEFOREProblem: Lifting castings (2-110 lbs) out of baskets back bent at or over 90 degrees

  • AFTERSolution: 10 lift and tilt units, three load levelers

  • COST: $2500 per lift and tilt. $1500 per load leveler.COST RECOVERY TIME: Six monthsBENEFITS: Greatly reduced bending, lifting & reaching. Reduced strain & fatigue and increased productivity.BEFOREAFTER

    PositionFrequencyTwistingGraspOpinionTotalShot BlastWeightDegFreqGripFootBefore6808842642After6608042430

  • BEFOREProblem use hand dollies to manually move product

  • AFTERSolution: Power dollies

  • BEFOREAFTERCOST: $4000COST RECOVERY TIME: 4-8 monthsBENEFITS: Reduction of back/shoulder injuries. Increased productivity


  • BEFOREProblem pushing pattern cart caddy

  • AFTERSolution use mule to move carts

  • BEFOREProblem sanding 500-1000 castings (2-10 lbs) with many hand movements

  • AFTERSolution robotic arm is used to grasp the casting

  • COST: $176,000COST RECOVERY TIME: 6-12 monthsBENEFITS: Eliminated strain from repetition and force, increased productivity and reduced manpowerBEFOREAFTER

    MovementPositionForce/GripVibrationEnvironmentOpinionTotalFinishing Dept.SandingArmTwistWristFingerHeadBackElbow(fwd)Elbow(side)ForearmWristBefore4462820064284454After000000000000000

  • BEFOREProblem manually scoop aluminum from furnace and pour into mold

  • AFTERSolution -internally fabricated lift arms to suspend ladles allowing pourers to merely direct movement of the arm

  • COST: $5000COST RECOVERY TIME: Three to six months.BENEFITS: Eliminated all shoulder and back injuries and burns. Reduced cycle times and fatigue which increased production.BEFOREAFTER

    Perm MoldPositionFrequencyTwistingGraspOpinionTotalHydraulic PourerWeightDegFreqGripFootBefore8840648846After020000226

  • BEFOREProblem two men needed to manually pour molds (40 lbs)

  • AFTERSolution automatic pouring machine

  • COST: $35,000COST RECOVERY TIME: Six monthsBENEFITS: Eliminated burns, shoulder and back injuries, and manpower. Increased production.BEFOREAFTER


  • BEFOREProblem 30 lb ingots were picked up and tossed into furnace

  • AFTERSolution purchase tower jet melt furnace, ingots are loaded into a cart and rolled into an automatic feed

  • BEFOREAFTER COST: $276,000COST RECOVERY TIME: 7-12 monthsBENEFITS: Reduced fatigue and strain of lifting and throwing ingots. Eliminated burns. Also reduced smelt loss and natural gas use while aluminum melted quicker.


  • BEFOREProblem manually pushed molds off a conveyor, broke molds up over grating, picked up casting by hand (molds - 200 to 600#, castings 30 to 150 #)

  • AFTERSolution molds automatically moved down the line, dumped into shaker and removed by hoist

  • BEFOREAFTERCOST: $30,000COST RECOVERY TIME: Six monthsBENEFITS: Eliminated all back/shoulder strains and burns. Reduced manpower and fatigue. Productivity increased and new business created.


  • BEFOREProblem two men lift molding jacket sleeve (75 #) off mold after it was poured

  • AFTERSolution one person uses a hydraulic lifting device

  • COST: $800COST RECOVERY TIME: Two weeksBENEFITS: Elimination of back and shoulder injuries, reduced manpower and increased productivity.BEFOREAFTER

    Big End/OsbornPositionFrequencyTwistingGraspOpinionTotalRemoving jacketWeightDegFreqGripFootBefore8882024638After020200026

  • BEFOREProblem Manually removing castings from shakeout and placing castings in a basket behind the worker

  • AFTERSolution robotic arm to grasp castings and put in basket

  • COST: $25,000COST RECOVERY TIME: 8-12 monthsBENEFITS: Eliminated strains from bending & lifting and burns, reduced silica exposureBEFOREAFTER


  • BEFOREProblem robotic arm did not eliminate all stressors

  • AFTERSolution automated shakeout

  • COST: $125,000COST RECOVERY TIME: 2 yearsBENEFITS: Eliminated strains. Eliminated employee exposure to silica. BEFOREAFTER


  • BEFOREProblem used hand clamp to


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