Innovative Ergonomic Solutions in Manufacturing “Cost ... · PDF filein Manufacturing...

Innovative Ergonomic SolutionsInnovative Ergonomic Solutionsin Manufacturingin Manufacturing

““Cost effective ergonomic Cost effective ergonomic improvementsimprovements””

Bryan SnowBryan Snow316316--523523--00560056

Spirit AeroSystems, Inc.Spirit AeroSystems, Inc.

Cost effective improvements can produce Cost effective improvements can produce significant benefits. significant benefits. Ergonomic solutions produce: Ergonomic solutions produce:

Risk reductionRisk reductionInjury reductionInjury reductionIncreased productivityIncreased productivity

Innovative Ergonomic SolutionsInnovative Ergonomic Solutionsin Manufacturingin Manufacturing

Vacuum Lift Vacuum Lift SystemSystem

ProblemProblem::Mechanics were required to Mechanics were required to lift heavy assemblies (150+ lift heavy assemblies (150+ lbs.) during breakout.lbs.) during breakout.

SolutionSolution::Introduced a vacuum system Introduced a vacuum system that makes use of existing lift that makes use of existing lift system to eliminate the system to eliminate the manual lift.manual lift.

Benefit:Benefit:Reduce risk of injury and partReduce risk of injury and partdamage. Reduce number of damage. Reduce number of people required to remove people required to remove part. part.

Dust ExtractionDust Extraction

ProblemProblem::Mechanics manually lift Mechanics manually lift heavy core assembly to heavy core assembly to extract dust generated extract dust generated during milling process.during milling process.

SolutionSolution::Existing transportation dolly Existing transportation dolly modified to add forklift tubes modified to add forklift tubes that allows rotation of that allows rotation of assembly to extract dust.assembly to extract dust.

Benefit:Benefit:Reduced risk of injury. Reduced risk of injury. Reduced time spent Reduced time spent manually moving parts. manually moving parts.

Pneumatic End Pneumatic End EffectorEffector

ProblemProblem::Risk of back sprain / strain is Risk of back sprain / strain is high due to manual lifting of high due to manual lifting of 737 nacelle panels out of 737 nacelle panels out of BAJ to floor during breakout BAJ to floor during breakout processprocess

SolutionSolution::Provide a vacuum powered Provide a vacuum powered endend--effector with post effector with post -- jibjiband air hoist to move panels.and air hoist to move panels.

BenefitBenefit::Reduced risk of injury and Reduced risk of injury and potential damage to potential damage to assembly.assembly.

Reduce Awkward PostureReduce Awkward PostureProblem: Accessing part requires bending and stooping.

Solutions:Light weight height adjustable frame built that eliminates the necessity to lift part during sanding process.

Benefits:Part accessibility improved thereby reducing awkward posture.

Tool Weight ReductionTool Weight Reduction

Problem: Tool weight excessive. Handles on outside edge creating bending concern.

Solutions:Tool weight reduced including handles relocated to reduce reach and bending

Benefits:Weight reduced by 20-30 lbs. with cutouts.

Tool SuspensionTool Suspension

ProblemProblem::Manual lifting of tools during Manual lifting of tools during assembly process creates assembly process creates fatigue for mechanics.fatigue for mechanics.

SolutionSolution::Incorporated column and jib Incorporated column and jib to suspend tools using zeroto suspend tools using zero--gravity balancer.gravity balancer.

Benefit:Benefit:Tools become more Tools become more accessible and reduces accessible and reduces fatigue from manually lifting fatigue from manually lifting tools during assembly tools during assembly process. process.

Articulating ArmArticulating Arm

ProblemProblem::Repetitive process that Repetitive process that results from using awkward results from using awkward posture while drilling posture while drilling creates ergonomic risk.creates ergonomic risk.

SolutionSolution::Incorporate articulating arm Incorporate articulating arm that suspends vertical drill.that suspends vertical drill.

Benefit:Benefit:Eliminate using awkward Eliminate using awkward posture while drilling. posture while drilling. Improve productivity by Improve productivity by improving hole quality.improving hole quality.

Gatlin Tool Gatlin Tool SuspensionSuspension

ProblemProblem::Repetitive process of lifting Repetitive process of lifting tool for extended periods.tool for extended periods.

SolutionSolution::Suspend tool from mobile Suspend tool from mobile stand to eliminate physically stand to eliminate physically holding tool for extended holding tool for extended periods.periods.

Benefit:Benefit:More productive employee More productive employee as a result of reducing as a result of reducing fatigue.fatigue.

Reasonable Reasonable AccommodationAccommodation

ProblemProblem::Mechanic with prosthetic Mechanic with prosthetic arm unable to actuate arm unable to actuate trigger of drill motor. trigger of drill motor.

SolutionSolution::Added foot actuator to Added foot actuator to process that allows process that allows mechanic to activate tool mechanic to activate tool with foot.with foot.

Benefit: Benefit: Improved productivity as a Improved productivity as a result of improving process.result of improving process.

Tool AccessTool Access

ProblemProblem::Tool configuration required Tool configuration required mechanics to stand on a box mechanics to stand on a box to perform the assembly to perform the assembly process.process.

SolutionSolution::Modify tool to accommodate Modify tool to accommodate multiple positions and multiple positions and eliminate mechanics eliminate mechanics necessity to stand on box and necessity to stand on box and stepper.stepper.

BenefitBenefit::Increased productivityIncreased productivity

Tool and Airline Suspension Tool and Airline Suspension Problem: Tool and airline weight excessive. Airline created a tripping hazard.

Solutions:Install overhead rail sufficient to support both tools and airline.

Benefits:Eliminates the repetitive process of holding tools and airline tripping hazard.

Tool Suspension Tool Suspension Problem: Mechanic uses multiple tools. Weight excessive.

Solutions:Install overhead rail sufficient to support each tool.

Benefits:Eliminates the repetitive process of holding tools for extended periods.

Squeeze HandleSqueeze HandleProblemProblem::

Current squeeze trigger Current squeeze trigger configuration stressful to configuration stressful to activate. At times mechanic activate. At times mechanic is standing on stepper and is standing on stepper and working overhead.working overhead.

SolutionSolution::Incorporate handle that Incorporate handle that extends beyond end of extends beyond end of squeeze and replaces squeeze and replaces trigger style with a more user trigger style with a more user friendly button style built into friendly button style built into the handle.the handle.

Benefit:Benefit: Creates a safer work Creates a safer work environment.environment.

Reduce Fatigue from Kneeling

Problem:Kneeling discomfort fromworking in confine spaces.

Solution:Eliminate setting and kneeling discomfort with off-the-shelf stool.

Benefit:Better access to assemblyand reduce fatigue.

Padding Reduces FatiguePadding Reduces Fatigue

Problem:Inadequate padding for mechanics in restricted space.

Solution:Provide new pad toreduce contact stress.

Scissor Lift Door CartScissor Lift Door Cart

Problem: Employees suffered back & upper extremity discomfort from leaning over standard cart for extended periods.Solutions:Modify standard door cart by cutting off wheels and attaching to hydraulic scissor lift.Benefits:Reduce potential for injury as a result of deviated posture for extended periods. Improve morale.

Stringer SeatStringer SeatProblemProblem::

Compression to legs and Compression to legs and thighs to employees thighs to employees working inside the cargo working inside the cargo area.area.

SolutionSolution::Provide a seat that Provide a seat that mechanics can lean/sit mechanics can lean/sit on when working.on when working.

Benefit:Benefit:Eliminates trauma from Eliminates trauma from extended squatting.extended squatting.

Power Tools

Headlamp

Knee Pads

GlovesTools designed with ergonomics in mindand support multiple assembly processes.

90° Drill

Lighter WeightPistol Grip Drill

St. Louis Drill(powerfeed)

Lighter Weight Squeezes

Petzel Tika Headlamps90° Drill

Lighter WeightPistol Grip Drill

St. Louis Drill(powerfeed)

Lighter Weight Squeezes

Petzel Tika Headlamps

SUMMARYSUMMARY

Cross functional ergonomic improvements, supporting multiple organizations to accomplish:

• Risk reduction

• Increased productivity

• Injury reduction

•Improved morale

QuestionsQuestions