rotacaster - manual materials handling: risk driven opportunities
DESCRIPTION
Slide deck for a presentation by Tim Strube at the Queensland Safety Show 20/06/2013. Review of risks and opportunities in the field of manual materials handling with a look of the current injury rate data, compounding facts including an increasingly ageing, unfit and obese workforce, and a lack of skill in areas of increasing materials handling. Solution: deliver for all stakeholders - the user, management and OHS. By improving the user experience - making it easier By improving productivity (management) - making it quicker By de-risking the task (OHS) - making it safe all key stakeholders have a vested interest in adopting the solution. Easier, quicker, safer works to deliver effective and implemented solutions.TRANSCRIPT
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MANUAL MATERIALS HANDLING: RISK DRIVEN OPPORTUNITIES
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THE STATS:
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75% OF WORKERS INVOLVED IN MANUAL MATERIALS HANDLING ARE INJURED
CANADIAN CENTRE FOR OCCUPATIONAL HEALTH AND SAFETY
h=p://www.ccohs.ca/oshanswers/ergonomics/mmh/hlth_haz.html
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MANUAL MATERIAL HANDLING CONTRIBUTES TO A LARGE PERCENTAGE
OF MUSCULOSKELETAL DISORDERS REPORTED ANNUALLY IN THE USA.
CalOSHA
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68% OF VICTORIA’S WORKERS’ COMP CLAIMS
ARE RELATED TO MANUAL MATERIALS HANDLING
www.worksafe.vic.gov.au
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VICTORIA’S AVERAGE WORKER’S COMPENSATIONS CLAIM IS $55,000.
www.worksafe.vic.gov.au
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WHEN AN EMPLOYEE REPORTS BACK PAIN, AN INVESTIGATION USUALLY
FOCUSES ON THE IMMEDIATE INCIDENT. HOWEVER, FATIGUED MUSCLES ARE MORE SUSCEPTIBLE TO INJURY.
Ohio Bureau of Workers’ Compensa[on
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IN SPITE OF CONSIDERABLE SAFETY PROGRESS, MANUAL MATERIALS
HANDLING PRESENTS RISKS THAT HAVE THE POTENTIAL TO IMPACT A WIDE
RANGE OF PEOPLE, POTENTIALLY FOR A LIFETIME.
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COMPOUNDING FACTS
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THE WORKFORCE IS AGEING.AROUND 13.5% ARE NOW AGED 65+
THAT WILL RISE TO ALMOST 23% BY 2050 MONASH UNIVERSITY’S VERONICA SHEEN
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AS WE AGE, ACTIVITY DECREASES.HUMAN RESOURCES & SKILLS DEVELOPMENT CANADA
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ONLY ABOUT 5 TO 7 PERCENT OF THE (U.S.) POPULATION ARE ACTUALLY
REGULARLY ACTIVE.BYU EXERCISE SCIENCE PROFESSOR LARRY TUCKER
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BUSINESS RISK OF OBESITYMAPLECROFT GLOBAL RISK ANALYTICS
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WHERE AND WHO?
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manufacturer
distribution retailconsumer
automated manual
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mechanical
skilled semileast skilled
automated manual
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THE FUTURE MANUAL MATERIALS HANDLING RISKS
WILL BE COMPOUNDED BY AN INCREASINGLY UNFIT, OBESE AND
AGEING POPULATION
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CHANGE IS DIFFICULT THESE RISKS ARE AN OPPORTUNITY
TO EFFECT NEEDED CHANGE.
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CASE STUDY
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A SIMPLE CHALLENGE:IMPROVE THE MOVEMENT OF PACKAGED AND CRATED MILK
FROM THE RECEIVING PALLET TO THE BACK OF THE SHELVES AND
OPTIMISE THE STACKING PROCESS
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THE STAKEHOLDERS:USER: MAKE IT EASIER
MANAGEMENT: MAKE IT QUICKEROHS: MAKE IT SAFER
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STEP 1: REINVENT THE HAND-‐TRUCK
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HAND-‐TRUCK VS ROTATRUCK
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Click here for video element hosted on youtube/rotacaster
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ROTATRUCKINNOVATION
HANDTRUCKTRADITION
Reduced effort • Improved Productivity •
Increased safety •
• Used to it• Cheaper hand-truck• Known risk
VS
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ROTATRUCKEASE BACK
HANDTRUCKPULL BACK
Easier pull-back effort and no need to stop at waypoints.
Need to park and pull back loads at waypoints increasing strain on musculoskeletal.
✔ ✘
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ROTATRUCKLOAD SUPPORT
HANDTRUCKSUPPORT LOAD
Reduced effort as the Rotatruck carries the load, not the operator.
Requires constant operator input to maintain load-balance, exerting strain and effort.
✔ ✘
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ROTATRUCKLEVER
HANDTRUCKLIFT
Lever rather than lift up curbs or over obstructions without reversing.
Operator exerts maximum effort to reverse and pull load up and over curb.
✔ ✘
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ROTATRUCKBALANCE
HANDTRUCKCARRY
Balance rather than carry the load over soft or uneven terrain.
Operator carries increased share of load to safely move across terrain.✔ ✘
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ROTATRUCKTHE SAVINGS
HANDTRUCKTHE COSTS
Heavy user: Couriers, warehouse personnel, food and beverage distribution...Productivity gain: 100+ hours/yrSavings: $2,500
✔ ✘
Moderate user: Large retailers, warehouse personnel, facilities services...Productivity gain: 50+ hours/yrSavings: $1,250Light user: Office, small retail, facilities services...Productivity gain: 25+ hours/yrSavings: $625
Costs per injury? The most common body part affected by MMH is the back, which often suffers strains, sprains, herniated discs, joint inflammation, and dislocation. The average cost of each low back injury is US$24,000, as reported by the National Council on Compensation Insurance. The direct costs can be many times that if the injury is severe or permanent
Loss of productivity? Losing a team member to injury, whether temporary or permanent, replacement labour and the loss of experience increase costs and reduce productivity in real terms.
Insurance rates? Are your insurance costs influenced by claims?
Regulatory risks?Are you taking all available steps to limit safety risk?
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INVENT A NEW LATCHING SYSTEM TO TRANSFER CRATES
EASILY, QUICKLY AND SAFELY
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Click here to video element hosted on youtube/rotacaster
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THE EVIDENCE
TRADITIONAL ROTATRUCK
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THE RESULT.WOOLWORTHS IS ROLLING OUT
THE PROGRAM ACROSS AUSTRALIA.ESTIMATED ROI -‐ 90 DAYS.
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IN CONCLUSIONBEING SAFE IS GOOD.
BEING SAFER AND MORE PRODUCTIVE IS GREAT.
BEING SAFER, PRODUCTIVE AND USER FRIENDLY
IS A WINNER, FOR EVERYONE.
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EASIER, QUICKER, SAFER.