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Ergonomics in Welding
An overview of WMSDs* hazardous exposures and solutions
*Work-related musculoskeletal disorders
What will You learn
• Identify WMSDs hazardous exposures in welding jobs
• Propose solutions for hazardous exposures
• Find further information about ergonomics in welding operations
Hazards
Welding operations are necessary in many industries such as construction, manufacturing, maintenance, etc.
Welding has several hazardous conditions for women and men in these jobs.
Hazards
Common hazards found in welding are: inhaling metals fumes,
eye exposure to welding arc light (UV, visible),
foreign objects in eyes,
burns,
noise,
cuts, bruises, etc.
WMSD Hazards
Welding also includes musculoskeletal disorders (WMSD) hazards such as:
awkward body postures,
lifting heavy equipment or materials,
static postures for prolonged periods,
awkward postures of the wrist, etc.
By Nature of Injury
Sprains account for more than 1/3 of the compensable claims among welders in the State of Washington.
Some of those could be caused by hazardous WMSD exposures.
WA State-funded compensable claims 1994-2004Welders, Cutters, Solderers
Hearing loss11%
I ll-Def Symptoms
9%
Neural5%
Other13%
Sprains32%
Contussion/Cut/
Scratches 16%
Fracture/Dislocation
14%
WA State-funded compensable claims 1994-2004Welders, Cutters, Solderers
Other15%
Ears11%
Back/ Neck/Shoulder
28%
Hand / Arm 26%
Foot/Leg
20%
By Body Part
The back, neck and shoulder together with the arm and hand regions make up more than one half of the injuries among welders in Washington State.
Preventive efforts should therefore focus on those body parts among welders at your workplace.
Welding is a strenuous occupation involving work in awkward postures and handling heavy equipment, usually with a high degree of sustained stress to arm and shoulders.
• Absences due to injury or illness and the transfer of welders to other tasks
• Overtime for replacement workers. Welders are skilled employees
• High employee turnover
• Increased training and supervisory time
• Reduced productivity and quality
Consequences of a poor working environment
• Rigorous manual precision requirements
– High degree of uniformity
• Awkward and static postures
– Difficult work position
• Heavy lifting, difficult material handling
– Heavy objects, heavy welding equipment
• Repetition
– High work intensity
OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT
WMDS hazards most common in welding
Duration (how long?)
Frequency (how often?)
Intensity (how hard?)
Hazard Elements
Working in front
Working at ground level
Working above the shoulders
Working at ground level, precision work
Working at ground level, confined space
Working above shoulders, confined space
‡From: Torner et al, 1991
Common postures adopted in welding
Torso twisting
Awkward postures in welding
Severe torso flexion
Kneeling, squatting
Bent wrists
Neck flexion/extension
Shoulder flexion/abduction (separation)
To simplify the welding performance for the welder and reduce the physical load during the work
•Automate physically demanding or repetitive jobs
•Expand the work content of welders (provide flexibility between jobs)
– Multi-skilled workers who are able to perform different tasks within a group)
The goal of a healthy work environment
• Often cost, ease of maintenance, space considerations drive the design process
• When hazards can’t be engineered out, using best practices is the alternative
• Examples of good design: providing opportunities for adjustments, providing different sizes, using good planning to eliminate unnecessary work
The Real World
Possible Ergonomic Improvements
Heavy Lifting
• Manipulators• Lighter welding
equipment, easier to handle
• Using lighter cables with low stiffness
• Use cable supporting devices(balancers)
• Utilize overhead hoists
• Utilize lifting and turning tables
Ergonomic improvements
Awkward Postures
• Position work between waist and shoulder, when possible
• Lifting tables• Motorized positioning
devices• Use welding guns with
swivels and designed for use in both hands
• Work stool
Ergonomic improvements
Team lifting helps reduce heavy, awkward lifting of equipment and materials.
AFTER
From: SIMA San Diego Ergonomics ProgramBEFORE
Ergonomic improvements
To reduce working with the back bent at ground level, any work table will help to adopt a safer posture
AFTER
From: Shipyard Ergonomics, 2003BEFORE
Ergonomic improvements
Pre-assembly and material handling equipment helps reduce unnecessary lifting or any other kind of manual material handling
Ergonomic improvements
This rotational clamp for pipe helps reduce awkward postures for the neck, shoulders and arms.
Ergonomic improvements
Tables for welding and transport reduce manual lifting, carrying of heavy materials.
The tables also have wheels.
Ergonomic improvements
Welding leads on pulleys help reduce heavy and awkward lifting, static postures for long periods.
Ergonomic improvements
Robotic automation, are also feasible solutions to highly repetitive motions with the arms and hands. May also reduce the exposure to fumes.
Not implementing some or all these ergonomics guidelines may result in the following…
Not implementing some or all these ergonomics guidelines may result in the following…
Possible Consequences
•Often occur when the physical demands of work cause wear and tear
•Involve soft tissues such as muscles, tendons, ligaments, joints, nerves, blood vessels
They are cumulative (occur over time and not a result of a single incident):
Work-related musculoskeletal disorders
Work-related musculoskeletal disorders
•Broken bones
•Cuts
•Slips
•Falls
•Trips
•Motor vehicle accidents
•Being struck by or caught with objects
They are not acute injuries such as:
• Back injuries• Shoulder pain/loss of range of motion• Tendinitis/Bursitis• Reduced muscle strength• Carpal tunnel syndrome• White finger• Knee joint diseases
• Back injuries• Shoulder pain/loss of range of motion• Tendinitis/Bursitis• Reduced muscle strength• Carpal tunnel syndrome• White finger• Knee joint diseases
Common disorders among welders
The Ergonomics Cycle
The ergonomics cycle provides with an organized way to start your ergonomics effort.
EmployeeInvolvement
Evaluateprogress
Management Support
ProblemIdentification
SolutionImplementation
Address Injuries
Training
SHARPSafety & Health Assessment &
Research for Prevention
Credits
The technical contents of this slideshow are based upon the presentation developed by Ninica Howard, MS, CPE, research ergonomist with the SHARP program at the Washington state Dept. of Labor and Industries.
More resources•Shipyard Ergonomics for purchase at Shipbuilders Council of America at www.Shipbuilders.org
•NIOSH’s Ergonomic Interventions in the Building, Repair, and Dismantling of Ships
•SHARP Program
•Easy Ergonomics. A practical approach for improving the workplace OR OSHA & CAL OSHA Services. www.cbs.state.or.us/osha/pdf/pubs/3347.pdf
•On WMSD hazardous exposures visit the WISHA webpage at:www.lni.wa.gov/Safety/Topics/Ergonomics
•Example Template of an accident prevention program :•www.lni.wa.gov/Safety/Basics/Programs/Accident
•Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas Bank
•You may also write us at:•[email protected]
Thank you