Leveraging Ergonomics Teams in your VPP System Christy Lotz, CPE Senior Consultant / Ergonomics Engineer The 30-Inch View ®

Leveraging Ergonomics Teams in your VPP System

Christy Lotz, CPESenior Consultant / Ergonomics Engineer

The 30-Inch View ®

VPPPA Chapter VII Conference

© 2010 Humantech, Inc.

About Humantech



Goals of Presentation

• Key ingredients of a successful ergonomics team

• Core components of an effective ergonomics process

• Pitfalls to avoid when rolling out team-based program

• Roll of the team in recognizing, evaluating, and controlling exposure to ergonomic risks



Understanding the Ergonomics Maturity Curve




Incident investigation

Issue/complaint resolution

EHS



Issue/Complaint Resolution



Elbows Out

Shoulder too high

Issue/Complaint Resolution

Butts up






Lean/continuous improvement

Ergonomics risk management

EHS

Engineering



Risk Mapping



Ergonomics Risk Management



Ergonomics Risk Management



Change the Workplace – Simple Controls

Extension for line break valve

BEFORE AFTER






Lean/continuous improvement

Ergonomics risk management

Manufacturing design

Product design

EHS

Engineering

Designers



Design Standards and Guidelines



Take out a piece of paper……

• Draw a pig…..



Why Ergonomic Design Standards

• Variability in manufacturing process design results in…

• Missed opportunity to get it right the first time• Greater ergonomic risks• Productivity inefficiencies• Process stability issues• Quality concerns• Wasted effort later

• To help with your design standards…….



Handbook of Ergonomic Design Guidelines



Where Does Your Company Fall?



The Benchmarking Process

Purpose

• To better understand the current state and successful elements

of managing occupational ergonomics in today’s workplace.

Process• Identify participants (13, fortune 500 companies participated)• Provide preparation materials, address confidentiality, &

schedule meetings• Conduct interview (1½ to 2 hours)• Compile results and report



Results



Results: Key Elements for Success

• Strong Leadership & Culture (9):

• Common Approach & Tools (9)

• Focus on Reduction of Risk (6)• Common Metrics• Integrate with Other Initiatives• Common Plan for Improvement

• Defined Roles and Responsibilities (4)

• Involvement at All Levels of the Organization (5)• On-site Resources• Employee Awareness and Engagement• Engineering Ownership and Involvement

• Change the Workplace (2)

• Measure Improvement/Risk Reduction (3)

• Review/Audit the Process (2)

• Replicate Effective Solutions

• Provide Recognition



VPP Safety System

• Management Leadership & Employee Involvement

• Management Leadership• Visible Leadership

• Employee Involvement• Responsibility, Authority and

Accountability• Establish Standards • Resources• A Measurement System• Consequences• Application at All Levels

• Review of Program Operations• The Audit Trail• Root Cause Analysis• Impact of TQM Principles

• Safety & Health Training

• Worksite Analysis• Comprehensive Surveys• Change Analysis• Hazard Analysis• Safety & Health Inspections• Catching Hazards that Escape

Controls• Employee Reports of Hazards• Accident/Incident Investigations• Trend Analysis

• Hazard Prevention and Control

• Engineering Controls• Safe Work Practices• Administrative Controls• Personal Protective Equipment• Systems to Track Hazard Correction• Preventive Maintenance Systems• Emergency Preparedness• Medical Programs



Top 10 Common Elements of Top Performers

1. Develop Goals/Performance Metrics and Expectations

2. Management Support – Leadership and Culture

3. Process Lead/Support Infrastructure

4. Cross-functional Team

5. Common Approach and Tools

6. Training/Awareness

7. Budget/Resources

8. Employee Involvement

9. Communication

10.Sustainability/Integration



1. Develop Goals – Short- and Long-term

• Understand Current Ergonomic and EHS Policy

• Evaluate the current status of ergonomics in your shop/organization.

• Establish short- and long-term goals and a strategy to improve ergonomic conditions and performance.



1. Develop Goals – Short- and Long-term

• Lagging metrics

• Injury rates

• Workers compensation costs

• Activity metrics

• % of jobs assessed

• % of countermeasures implemented

• % of people trained

• Leading metrics

• % of jobs at low to moderate risk

• % of force exertions below threshold



2. Management Support

• Establish targets and metrics and tie it to performance appraisal system

• Define roles and responsibilities at all levels

• Align ergonomics and VPP with existing, non-safety initiatives (5S, 6σ, Lean etc.)

• Assign leadership and ensure accountability (ergonomics is not optional)

• Ensure support from all levels (VPs, Managers, Supervisors, Group Leads, Team Leads etc.)

• Monitor progress



2. Management Support

MeasureQ1

YTDQ2

YTDQ3

YTDQ4

YTDAnnual Target

% Of Jobs at Low Risk 23 48 79 100

% Of Jobs Assessed 15 34 66 100

% Of Employees Completing Appropriate Level(s) of Training

30 51 89 100

• Track progress to goal and show evidence of moving forward




• Safety Manager• Engineering• Operations

The foundation for success



4. Cross Functional Team

Union Rep

HR




• Selecting Team Members

• Operators/hourly employees• Management• Line supervision• Health and Safety • Human Resources• Engineering• Maintenance• Union Stewards/Representatives




• Motivated - to make positive changes to the work environment

• Initiative – accomplishes tasks quickly

• Teamwork – collaborates and works well with others

• Communication – presents ideas and information clearly

• Familiarity – knowledgeable about site operations and organization

• Influence – able to obtain assistance to make changes to workplace

• Authority – has been provided authority to direct and make workplace changes

• Availability – is available to participate on the team

• Enthusiasm – approaches all work activities positively and with an open mind to change




• Identify and Prioritize Tasks

• Screening Methods

• Loss History & Injury Trends (OSHA 300 log)• Employee Input• Observation

0

2

4

6

8

10

12

14

16

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

Back Injuries

Cumulative Trauma

Lacerations

Slips/Falls

Burns




• How’s Your Process? How’s Your Health?

• Employee involvement and communication

• Employees performing self-audits







• Develop Design Standards/Guidelines

• When someone asks you “where should we place controls”? …..you have an answer



Fixed It5. Common Approach and Tools




• Make investment in training more than a small group of people in theprocess

Awareness Training

Skills Training



7. Budget/Resources

• Have to actually get fixes done some how

• A budget should be available whether built into department budget or through CI or Engineering

• It does not have to be costly to be effective



7. Budget/Resources

Raise pallets in solvent shed

BEFORE AFTER



7. Budget/Resources

28"



7. Budget/Resources

BEFORE AFTER

Fabricate a step to facilitate access to basket on lift

28"



7. Budget/Resources

When implementing solutions, don’t forget the hierarchy of controls:

• Eliminate the Hazard

• e.g. Ensure that the installation force is below the guideline value

• Engineering Controls

• e.g. Design in a lifting point and provide a lift assist device to move the part

• Administrative Controls

• e.g. Reduce exposure to a hazard through job rotation

• Work Practices

• e.g. Ergo or safety key points, posture training

• Personal Protective Equipment

• e.g. Provide padded gloves to reduce impact stress.



7. Budget/Resources

• Demonstrate ROI in different ways

Injury/Cost

Quality/Delivery

Productivity/ Value Added

RELIABILITY

VIS

IBIL

ITY

$1

$5



7. Budget/Resources – Health and Safety

$5 TO $50LEDGER COSTS

$1 TO $3MISCELLANEOUS

COSTS

$5 TO $50LEDGER COSTS

$1 TO $3MISCELLANEOUS

COSTS

$1$1$1$1Incident COST ICEBERG

BUILDING DAMAGE

• Tool and equipment damage

• Product and material damage

• Production delays and

interruptions

• Legal expenses

• Expenditure of emergency

supplies

• Interim equipment rentals

INVESTIGATION TIME

• Wages paid for time lost

• Cost of hiring and/or training

replacements

• Overtime

• Extra supervisory time

• Clerical time

• Loss of business and goodwill 2003 SALCON, Inc. All Rights Reserved

INJURY & ILLNESS COSTS

• Medical

• Compensation Costs (Insured Costs)



7. Budget/Resources - Quality

Specific measures that can be used to demonstrate how ergonomics affects quality include the following:

• Warranty claims• Defects per part (DPP)• Direct run (parts coming off line with no

repairs or rework)• Customer approval ratings (JD Power)• Operator feedback



7. Budget/Resources – Productivity

• Rear Spoiler Install

• Change torsion bars out, drill holes, install new spoiler and torsion bars at TLS

• Overall ergonomic risk exposure reduced by 65%

• $262,000 annual impact

• 2764% ROI (3 years)Page 4




"Being involved in improving the work environment is the biggest source of a better quality of life for workers."

- Toyota Production System (Monden, 1998)

Ask The OperatorExpert




BEFORE AFTER

Tacked two fixtures together and placed them on a gear to allow them to rotate





9. Communication

• Visualization of progress. Set up visual controls to show:

• Plan to actual

• Successes

• Challenges

• HSE Newsletter

• Video Bulletin Boards

• Site Safety Meetings

• Replication Collaboration Sites

• Communicate progress on fixes even if they are not being addressed



9. Communication

Operator Report

Supervisor

Maintenance Requisition

Complete Fix OR Incomplete Fix

Maintenance Close-out

Supervisor and Operator Review

Final Close-out

Supervisor should review and rewrite

requisition if problem is not solved

Supervisor should report back to operator when implementation

timeline



10. Sustainability

• ISO 14001,OHSAS 1800, ANSI Z10 Mgmt. Systems

• Create an audit process to identify strengths and develop plan to strengthen weak points of the process



Common Elements of Top Performers

1. Develop Goals/Performance Metrics and Expectations

2. Management Support – Leadership and Culture


4. Cross-functional Team



7. Budget/Resources


9. Communication

10.Sustainability/Integration

Christy Lotz

734.476.3696

[email protected]

The 30-Inch View ®



And the Winner is……………….

Documents

Leveraging Ergonomics Teams in your VPP System Christy Lotz, CPE Senior Consultant / Ergonomics Engineer The 30-Inch View ®