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Ergonomics Developing An Effective Process. Objectives. Understand the elements that can be used to develop an effective ergonomics process Discuss methods for getting commitment from people at all levels in the organization - PowerPoint PPT Presentation
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ErgonomicsDeveloping An Effective Process
Objectives
Understand the elements that can be used to develop an effective ergonomics process
Discuss methods for getting commitment from people at all levels in the organization
Outline strategies for developing an ergonomics team and written plan.
Increase awareness of key considerations and resources for all process elements.
Process versus Program
Process Natural Benefit driven Interdependent Dynamic Participatory On-going
Program Contrived Mandate driven Independent Static Controlled Implied ending
What characteristics help to make a process effective?
What characteristics help to make a process effective? Commitment Involvement Responsibility Communication Accountability Monitoring Integration On-going Improvement
Lets Play
Choose The Best Answer To The Following Questions
What Is Ergonomics ?
A) Selecting the right person for the job so injuries are less likely to occur.
B) Fitting jobs and job demands to the capabilities/limitations of the population.
C) A communist plot to make the American people weaker.
D) Using common sense to make jobs easier.
What Is Ergonomics ?
A) Selecting the right person for the job so injuries are less likely to occur.
B) Fitting jobs and job demands to the capabilities/limitations of the population.
C) A communist plot to make the American people weaker.
D) Using common sense to make jobs easier.
A Major Goal Of Ergonomics Is A) Reduce the frequency of injuries/illnesses
and costs associated. B) Design jobs so the average person can do
them safely and efficiently. C) Automate all jobs that require lifting and
repetitive motion. D) Confuse and frustrate people with
complicated formulas and charts.
A Major Goal Of Ergonomics Is A) Reduce the frequency of injuries/illnesses
and costs associated. B) Design jobs so the average person can do
them safely and efficiently. C) Automate all jobs that require lifting and
repetitive motion. D) Confuse and frustrate people with
complicated formulas and charts.
Potential benefits of an ergonomics process include: A) Improves employee safety and health,
productivity, and quality B) Fosters an environment of teamwork and
continuous improvement C) Makes employees think that
management cares about them D) All of the above
Potential benefits of an ergonomics process include: A) Improves employee safety and health,
productivity, and quality B) Fosters an environment of teamwork and
continuous improvement C) Makes employees think that
management cares about them D) All of the above
The principles of Ergonomics are derived from… A) The political agenda of bleeding heart
liberals B) Various sciences including
anthropometry and biomechanics C) Regulation-happy government agencies
that have nothing better to do D) All of the above
The principles of Ergonomics are derived from… A) The political agenda of bleeding heart
liberals B) Various sciences including
anthropometry and biomechanics C) Regulation-happy government agencies
that have nothing better to do D) All of the above
On Average, Back Injuries Account For Approximately
A) 10% of all lost-time injuries. B) 25% of all lost-time injuries. C) 50% of all lost-time injuries. D) 75% of the workers’ compensation cases
under investigation by the fraud department.
On Average, Back Injuries Account For Approximately A) 10% of all lost-time injuries. B) 25% of all lost-time injuries. C) 50% of all lost-time injuries. D) 75% of the workers’ compensation cases
under investigation by the fraud department.
CTD stands for:
A) Carpal Tunnel Disease B) Cumulative Trauma Disorder C) Completely and Totally Disabled D) Call The Doctor
CTD stands for:
A) Carpal Tunnel Disease B) Cumulative Trauma Disorder C) Completely and Totally Disabled D) Call The Doctor
On average, upper extremity CTDs account for: A) less than 10% of all lost-time injuries B) between 10% and 20% of all lost-time
injuries C) between 20% and 30% of all lost-time
injuries D) 75% of the workers’ compensation cases
under investigation by the fraud department
On average, upper extremity CTDs account for: A) less than 10% of all lost-time injuries B) between 10% and 20% of all lost-time
injuries C) between 20% and 30% of all lost-time
injuries D) 75% of the workers’ compensation cases
under investigation by the fraud department
Carpal Tunnel Syndrome is:
A) An irritation of one of the nerves that passes through the wrist
B) An injury to the tendons of the wrist C) A cumulative condition that develops
mainly in women who type a lot D) A “work-related injury” that just happened
to surface when video games and remote controls were invented
Carpal Tunnel Syndrome is:
A) An irritation of one of the nerves that passes through the wrist
B) An injury to the tendons of the wrist C) A cumulative condition that develops
mainly in women who type a lot D) A “work-related injury” that just happened
to surface when video games and remote controls were invented
The OSHA ergo standard would have made companies: A) Analyze and improve all jobs B) Analyze and improve jobs where MSDs
have occurred C) Waste a lot of money on expensive
consulting and training services D) Outsource jobs or move operations to
another country
The OSHA ergo standard would have made companies: A) Analyze and improve all jobs B) Analyze and improve jobs where MSDs
have occurred C) Waste a lot of money on expensive
consulting and training services D) Outsource jobs or move operations to
another country
The Three Major Occupational Risk Factors For CTDs Are:
A) Repetition, Force, and Posture B) Work ethic, Experience, and Attitude C) Gender, Age, and Medical History D) Labor Unions, Lawyers, and Poor
Labor/Management Relations
The Three Major Occupational Risk Factors For CTDs Are: A) Repetition, Force, and Posture B) Work ethic, Experience, and
Attitude C) Gender, Age, and Medical History D) Labor Unions, Lawyers, and Poor
Labor/Management Relations
Proactive Methods To Identify Risk For CTDs Include: A) Reviewing OSHA 200 logs, medical
records, and workers’ comp data. B) Calculating absentee/turnover rates. C) Observing employees, analyzing jobs,
and using symptoms surveys. D) Conducting pre-employment physicals,
drug screening, and background checks.
Proactive Methods To Assess Risk For CTDs Include A) Reviewing OSHA 200 logs, medical
records, and workers’ comp data. B) Calculating absentee/turnover rates. C) Observing employees, analyzing jobs,
and using symptoms surveys. D) Conducting pre-employment physicals,
drug screening, and background checks.
A good example of an ergonomic modification is: A) Hiring people who are young, strong, and
don’t complain B) Providing equipment that helps to reduce
the need for manual lifting C) Providing back support belts for jobs that
require lifting D) Removing twinkies and pork rinds from the
vending machines
A good example of an ergonomic modification is: A) Hiring people who are young, strong, and
don’t complain B) Providing equipment that helps to reduce
the need for manual lifting C) Providing back support belts for jobs that
require lifting D) Removing twinkies and pork rinds from the
vending machines
The Ohio Bureau of Workers’ Compensation is most like: A) An insurance company B) The Occupational Safety and Health
Administration (OSHA) C) Welfare D) All other government agencies that just
keep wasting my tax dollars
The Ohio Bureau of Workers’ Compensation is most like: A) An insurance company B) The Occupational Safety and Health
Administration (OSHA) C) Welfare D) All other government agencies that just
keep wasting my tax dollars
The best way to sell ergonomics to top management is by: A) Convincing them that government
regulations are inevitable B) Sending them information and hope that
they realize it is just the right thing to do C) Threatening them with unionization or
writing “protections” into the contract D) Providing cost/benefit studies that show
how it will improve the bottom line
The best way to sell ergonomics to top management is by: A) Convincing them that government
regulations are inevitable B) Sending them information and hope that
they realize it is just the right thing to do C) Threatening them with unionization or
writing “protections” into the contract D) Providing cost/benefit studies that show
how it will improve the bottom line
Ergonomics Process Flow Chart
Ergonomics Process Flow Chart Identifies the various steps and typical order
in which they should be developed Each box in the flow chart represents an
element that should be considered Depending on your organization, you may
not have to implement every step or address them in this exact order
How do you currently respond to potential ergonomic hazard? Ignore it and hope nothing happens Stop and offer assistance, and leave it at that Stop and ask the employee or supervisor more
about the job and the hazard Report the issue to the ergo/safety team or
coordinator and hope they take care of it Report the issue to the ergo/safety team or
coordinator and check for follow-through
Obtain Top Management and Union Commitment Top management and the union must
collectively agree to support and commit to the ergonomics process.
Top management and union leadership should have joint meeting(s) to discuss the ergonomic process and its components.
What are the key selling points for the following groups? Owners/shareholders Top management Department managers Engineers Maintenance Supervisors Hourly employees
Group Activity
Scenario II
You are the Top Management at your company. Your Safety Director wants to initiate an ergonomics process.
What kind of information do you as Top Management need to know before you can make a decision?
Bill Gates
Resources and Support needed from Top Management
Executive Summary (app. A-1)
A tool that is used to inform and/or sell the ergonomics process.
Outlines the intent of the ergonomic process and identifies expected outcomes of implementing a process.
Appendix A-1
Tools to help show support and commitment to the Process Letter of commitment
(Appendix A-2) Memorandum of understanding
(Appendix B-1)
Appendix A-2, B-1
Top Management And Union Commitment If top management and/or the union
is not willing to commit to the ergonomics process we recommended that you POSTPONE your efforts until a firm commitment can be agreed upon by both parties.
Bottom Line
Top Management needs cost benefit information before they can support an Ergonomics Process.
Cost And Benefits Associated With An Ergonomics Process
Costs of Developing an Ergonomics Process
Process Costs– – – – – – – –
Project Costs – – – – – – – –
Costs of Developing an Ergonomics Process
Process Costs– Team Meetings– Team Training– Employee Training– Materials and Forms– Equipment for Analysis
and Documentation– Medical management
consultation
Project Costs – Analysis/Research – Engineering– Equipment Purchase– Installation– Maintenance– Training– Production disruption
Materials and Tools for Ergo Process Development
Materials and Tools for Ergo Process Development Camcorder Digital Camera Tape Measure Push/Pull Gage Job Assessment Forms Assessment software Design Guidelines Reference Materials
Bulletin Board Suggestion Forms Training Videos Handout Materials
What Are The Benefits Of An Ergonomics Process ?
Benefits Of An Ergonomics Process
CostsErgonomics
Process
BenefitsReduced TurnoverReduced Recruiting and Training CostsReduced AbsenteeismIncreased ProductivityReduced Re-Work & ScrapIncreased Wages/BenefitsReduced Injuries/Comp CostBetter Morale Team Work
The Cost Of Injuries
The direct cost of an injury includes the medical and indemnity costs
Indirect costs of injuries are usually 1 to 4 times as much as the direct costs
Iceberg AnalogyAccident Cost
•Medical Payments•Compensation
Supervisor time to investigate
Breaking in substitute
Poor efficiency due tobreak-up of crew
Damaged tools/equipment
Down-timeOverhead $ while work disrupted
Failure to meet deadline/fill orders
Loss of production
Loss of good will
Overtime to make up production
Hiring costs
Lost time by fellow workers
Direct Costs
Indirect or HiddenCosts
Indirect Cost Multiplier
If Direct Injury Cost is:$0 - $2,999
$3,000 - $4,999
$5,000 - $9,999
$10,000 or more
Multiply by… 4.5
1.6
1.2
1.1
Example of Total Injury Cost Calculation
Assume an injury has a direct cost of $9,000
Estimated indirect cost = Direct Cost x Multiplier $9,000 x 1.2
= $10,800
Direct Cost + Indirect Cost = Total Cost of Injury
$9,000 + $10,800 = $19,800
A Better Way to Express the Costs of Injuries
To calculate an incident’s impact on your profitability, you should use your profit margin to determine the amount of sales required to pay for the incident.
Determining Impact of Injuries On Profitability
1) Divide your total profits by total sales to get your profit margin.
Total profits = Profit MarginTotal Sales
2) Divide the total cost of an injury/illness by your profit margin to determine how much sales your company must generate to pay for injury/illness.
Total Cost of Injury/Illness = Sales required to pay for Profit Margin injury/illness
Impact On Profitability Example
The total profits for a company is $1,000,000 with the total sales volume being $25,000,000. The profit margin for the company is:
Total Profits = Profit Margin = $1,000,000 = .04Total Sales $25,000,000
Impact On ProfitabilityExample (Continued)
What sales amount is required to pay for one $3,000 dollar carpal tunnel syndrome?
Total Cost of an Injury/Illness = Sales to pay for an injury/illnessProfit Margin
$3,000 = $75,000 in sales required .04
U.S. General Accounting Office Study Results
Cost Reduction/ Case Studies Navistar - $1.4 Million (1993)
– Truck Assembly - 4,000 employees (Ohio) Reduced to $544,000 (1996)
SOCHS - $100,000 (1994)– Nursing Center - 780 employees (Maine)
Reduced to $70,000 (1996) Texas Instruments - $2.6 Million (1991)
– Defense/Electronics - 2,800 employees (Texas) Reduced to $244,000 (1996)
U.S. GAO Study Results
Cost Reduction/ Case Studies Continued... American Express Financial
Advisors - $484,000 (1992)– Financial planning/investment - 5,300 employees
(Minnesota) Reduced to $98,000 (1996)
AMP Inc. - $73,000 (1993)– Electronic Assembly - 300 employees (Pennsylvania)
Reduced to $28,000 (1996)
U.S. GAO Study Results
Benefits: Average $ per CTD Claim
0
5000
10000
15000
20000
25000
Before Ergo
After Ergo9123
1685
6601
2512
9518
486024693014
21946
5322
U.S. GAO Study Results
To Receive a Copy of the GAO Study:
Call US General Accounting Office or access their website
Report # GAO/HEHS-97-163phone (202) 512-6000www.gao.gov
U.S. GAO Study Results
Form Ergonomics Team
Team Structure
Steering/Advisory Group role (p. 9) In general, most teams are comprised of
6-10 members. Some teams have an “open seat” or sub-
teams.
Who Should Serve On The Ergonomics Team ?
Potential Ergonomic Team Members ( see page 11)
Facility or Operations Manager
Union Representative Supervisors Hourly Employees HR/Personnel Director
Engineers/Facilities Planning
Maintenance Personnel Plant Safety
Representative Health Care Provider Purchasing Personnel
How Do You Solicit Volunteers To Serve On The Ergonomics Team ?
OH PICK ME
PICK ME
Solicit Volunteers
Criteria for soliciting and choosing ergonomic team members should be created.– Desirable qualifications and characteristics
might include:
Ergonomics Team Members
Consider using an application form to solicit volunteers (sample form located in Appendix H-4).
Prospective Ergonomic team members must be solicited and asked to serve on the team on a voluntary basis, they should not be mandated to serve on such a team.
Appendix H-4
Round 2
A Management Responsibility In The Ergonomics Process Is: A) Deny all back injury and cumulative
trauma claims. B) Define responsibilities and hold people
accountable for ergonomics. C) Make people afraid to report symptoms. D) Eliminate all lifting and repetition from
jobs.
A Management Responsibility In The Ergonomics Process Is: A) Deny all back injury and cumulative
trauma claims. B) Define responsibilities and hold people
accountable for ergonomics. C) Make people afraid to report symptoms. D) Eliminate all lifting and repetition from
jobs.
One Supervisor Responsibility In The Ergonomics Process Is: A) Discipline people who don’t lift properly or use
good body mechanics. B) Encourage workers to promptly report aches and
pains and suggestions. C) Convince associates not to worry about things
like back pain and wrist pain because they usually just go away.
D) Avoid mentioning words like ergonomics and carpal tunnel syndrome.
One Supervisor Responsibility In The Ergonomics Process Is: A) Discipline people who don’t lift properly or use
good body mechanics. B) Encourage workers to promptly report aches and
pains and suggestions. C) Convince associates not to worry about things
like back pain and wrist pain because they usually just go away.
D) Avoid mentioning words like ergonomics and carpal tunnel syndrome.
One Employee Responsibility In The Ergonomics Process Is: A) Promptly report concerns and
suggestions to supervisors. B) Always use the squat lift technique. C) If your back starts to hurt, go to the store
and get a back support belt. D) Resist any changes to the way the job
has always been done.
One Employee Responsibility In The Ergonomics Process Is: A) Promptly report concerns and
suggestions to supervisors. B) Always use the squat lift technique. C) If your back starts to hurt, go to the store
and get a back support belt. D) Resist any changes to the way the job
has always been done.
Ways To Get All Employees Involved In An Ergonomics Process Are:
A) Tell a few employees and ask them to spread the word.
B) Use cash rewards and incentives. C) Through frequent communication and
involvement opportunities. D) Through coersion and intimidation.
Ways To Get All Employees Involved In An Ergonomics Process Are: A) Tell a few employees and ask them to
spread the word. B) Use cash rewards and incentives. C) Through frequent communication and
involvement opportunities. D) Through coersion and intimidation.
Decisions That An Ergonomics Team Should Make During Formation:
A) When, where, and how often the team will meet.
B) Who will be on the team and what are each person’s responsibilities.
C) How to communicate information throughout the organization.
D) All of the above
A) When, where, and how often the team will meet.
B) Who will be on the team and what are each person’s responsibilities.
C) How to communicate information throughout the organization.
D) All of the above
Decisions That An Ergonomics Team Should Make During Formation:
Important Criteria For Ergonomics Team Members To Possess Are:
A) Superior knowledge and technical skills
B) Avoids challenging company policies and established norms
C) Good communication skills and ability to work with others
D) Is the brother of the CEO
Important Criteria For Ergonomics Team Members To Possess Are:
A) Superior knowledge and technical skills B) Avoids challenging company policies or
established norms C) Good communication skills and ability
to work as a team player D) Is the brother of the CEO
Improvement Projects Should Be Prioritized Based On:
A) The number of people that will be affected by the change.
B) The frequency and cost of injuries in the operations.
C) The cost and ease of making the modifications.
D) Any of the above.
Improvement Projects Should Be Prioritized Based On: A) The number of people that will be
affected by the change. B) The frequency and cost of injuries in the
operations. C) The cost and ease of making the
modifications. D) Any of the above.
An Effective Ergonomics Process Is Characterized By: A) Posters and training classes that show
people how to use good posture and body mechanics.
B) Elimination of all manual work . C) Continuous improvements that make jobs
safer and more efficient. D) A system for rotating workers to various
jobs.
An Effective Ergonomics Process Is Characterized By: A) Posters and training classes that show
people how to use good posture and body mechanics.
B) Elimination of all manual work . C) Continuous improvements that make jobs
safer and more efficient. D) A system for rotating workers to various
jobs.
Ways To Keep All Employees Informed Of The Team Progress: A) Encouraging informal discussions
between employees and team members. B) Posting meeting minutes and project
logs on bulletin boards. C) Company newsletter D) All of the above
Ways To Keep All Employees Informed Of The Team Progress:
A) Encouraging informal discussions between employees and team members.
B) Posting meeting minutes and project logs on bulletin boards.
C) Company newsletter D) All of the above
Blueprint For Success (appendix D-1)
The Blueprint is a summary of steps that should be followed when writing an ergonomics plan
The examples are intended to provoke discussion and guide the team or organization through the process
The written plan should be a fluid document; meaning that as process improvements are developed, it should be updated
Appendix D
Steps 1 and 2 - Develop a Mission Statement and Goals Keep it brief Consider short term and
long term goals Be ambitious, but also
realistic Be specific Define activities, not
just outcomes Communicate it
Tools and Resources for Defining Mission and Goals Organizational values and mission OSHA ergonomics guidelines Ergonomic implications from compliance with other
regulatory agencies Statistics/Case studies/Success stories from others in
industry (competitors) Perception survey OCOSH Course - GEN 127 - Winning Management
Commitment
Steps 3 & 4 - Determine key members and responsibilities
Get management and labor representation
Specify roles and responsibilities
Define people who will serve as resources
Resources for Determining Roles and Responsibilities Job descriptions/day-to-day responsibilities Performance evaluation criteria related to
safety and ergonomics Team charter from other successful
committees or projects Formal education and Training records
Steps 5 & 6 - Define Operating Rules, Format & Logistics Establish regular time,
place, and format Determine how and
what types of info will be communicated
Determine where documentation will be kept
Tools and Resources for Developing Safety/Ergo Teams OCOSH courses
– GEN 370 - Developing Safety Involvement Teams– GEN 122 - Facilitating Safety Meetings
University outreach programs Companies specializing in organizational
development Facilitator training
Step 7 - Develop Training
Determine specific training needs
Consider in-depth training for team or coordinator
Provide overview of process for entire staff
Develop job-specific training for all
Resources for Ergonomics Training and Materials OCOSH Courses
– ERG 215 - Ergonomics for Office– ERG 218 - Ergonomics Applied– ERG 125 - Ergo and Safety for Healthcare
Corporate and other Internal Resources Colleges and Universities Safety and Ergonomics Web Sites Ergonomics Consulting Firms Product Vendors
Blueprint Group Activity
Blueprint Group Activity
You are an Ergonomics Team that will address the following steps from the Blueprint for Success to create your written program.– Steps 1 & 2– Steps 3,4,5, & 6– Step 7
Appendix D
Step 8 - Collect and Analyze Relevant Data Identify what is
relevant and available Determine where it is
and how to get it Avoid overanalyzing Look beyond the
strains and sprains
Collect & Analyze Trend/Historical Data
What kind of data do you have to help identify and analyze injury trends?
Where do you find the data?
Appendix E
Step 9 - Develop Guidelines for Prioritizing Jobs and Issues Define key factors Determine ranking or
weighting for factors Provide data collection
forms and methods Use quantitative and
qualitative data Provide for flexibility Build on successes
Tools for Outlining Prioritization Methods
Perception surveys Cost data Symptoms surveys Ergonomics assessment software
Step 10 - Develop Procedures for Ergonomic Job Analysis
Develop standard data collection forms
Determine appropriate assessment tools
Use quantitative and qualitative data
List of authorized/ recommended analysts
Resources for Ergonomic Hazard Assessment Tools
NIOSH lifting guide - www.htec.com or www.industrialhygiene.com/calc/lift.html
Snook Guidelines for Pushing or Pulling Force - www.htec.com
State of Washington Risk Factor Checklists - www.lni.wa.gov/wisha/
BWC Consultants - 1-800-OHIOBWC
Step 11 - Establish Process for Solution Development
Develop ad hoc project team structure
Specify roles and responsibilities
Identify resources for information, ideas, and products
Provide cost/benefit estimating tools
Tools and Resources to Assist with Solution Development Brainstorming Fishbone diagramming Success stories Outside consultants Vendors Industry/Trade groups EMPLOYEES!
Step 12 - Devise Procedures to Assist with Approval Process Develop template for
presenting proposal Provide suggested cost
justification method and benchmark
Offer pre-presentation review process
List decision makers
Tools and Resources for getting approval for projects In-house resources Success stories from others in industry Cost/Benefit formulas Compliance - Knowledge of other safety
and health issues and requirements Success stories from other projects Grants
Step 13 - Outline the Solution Implementation Process
Develop ad hoc project team structure
Specify required steps and responsibilities
Provide expected timeframes for steps
Develop sign-off sheets and routing
Outline means of communicating status
Tools and Resources to assist with Implementation Process Action plan templates Input from people involved in similar types
of projects Input from employees Communication
Step 14 - Develop Project Evaluation Techniques
Define measurables Specify timeframes for
follow-up Specify person(s)
responsible Provide templates for
documentation Develop procedure for
follow-up on issues
Tools and Resources for Project Documentation Comparison with Ergonomic guidelines Follow-up assessments Post-intervention surveys Bulletin boards Various electronic means Project documentation forms (appendix H)
Step 15 - Develop Protocols for Medical Management
Define symptoms and reporting process
Institute transitional work policies
Develop standard forms for all aspects
Develop roles and responsibilities
Communicate to all
Resources for Medical Management Assistance
Managed Care Organizations (MCOs)
Transitional Work Developers
Local Hospitals and Medical Centers
Industrial Rehab Centers
Appendix G
Step 16 - Outline Methods for Monitoring the Overall Process
Develop objective measures
Focus on activities and outcomes
Relate successes with organizational values and business pursuit
Implement continuous improvement
Tools for Monitoring the Ergonomics Process Use the Process Monitoring Checklist
in Appendix H-26, to assess your company's current ergonomics process.
Appendix H-26
Any Questions ?
Thank You