Ergonomic Process Implementation: Ensuring Effective Ergonomic Interventions Lessons learned Hal W....

Ergonomic Process Implementation: EnsuringErgonomic Process Implementation: Ensuring Effective Ergonomic Interventions Effective Ergonomic Interventions

Lessons learnedLessons learned

Hal W. Hendrick, Ph.D., CPEHal W. Hendrick, Ph.D., CPE

Ergonomic Process Implementation: EnsuringErgonomic Process Implementation: Ensuring Effective Ergonomic Interventions Effective Ergonomic Interventions

Lessons learnedLessons learned

Hal W. Hendrick, Ph.D., CPEHal W. Hendrick, Ph.D., CPE

Good Ergonomics is Good EconomicsGood Ergonomics is Good EconomicsGood Ergonomics is Good EconomicsGood Ergonomics is Good Economics

Poor ErgonomicsPoor Ergonomics– Violates ergonomics technologyViolates ergonomics technology

and/orand/or

– Is Is notnot cost effective cost effective

Good ErgonomicsGood Ergonomics– Appropriately applies sound ergonomics technologyAppropriately applies sound ergonomics technology

andand

– Is cost effectiveIs cost effective

Poor ErgonomicsPoor Ergonomics– Violates ergonomics technologyViolates ergonomics technology

and/orand/or

– Is Is notnot cost effective cost effective

Good ErgonomicsGood Ergonomics– Appropriately applies sound ergonomics technologyAppropriately applies sound ergonomics technology

andand

– Is cost effectiveIs cost effective

ERGONOMICS Must Be COST EFFECTIVEERGONOMICS Must Be COST EFFECTIVE ERGONOMICS Must Be COST EFFECTIVEERGONOMICS Must Be COST EFFECTIVE

The language of business is The language of business is money!money!

Managers have to justify any Managers have to justify any expenditure in terms of the cost- benefit expenditure in terms of the cost- benefit ratio: How the project will affect the ratio: How the project will affect the bottom line.bottom line.

Must express ergonomic project Must express ergonomic project proposals in proposals in financial termsfinancial terms..

The language of business is The language of business is money!money!

Managers have to justify any Managers have to justify any expenditure in terms of the cost- benefit expenditure in terms of the cost- benefit ratio: How the project will affect the ratio: How the project will affect the bottom line.bottom line.

Must express ergonomic project Must express ergonomic project proposals in proposals in financial termsfinancial terms..

MeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of Ergonomic Interventions of Ergonomic InterventionsMeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of Ergonomic Interventions of Ergonomic Interventions

ExampleExample: : Tree Debrancher Leg ProtectorsTree Debrancher Leg Protectors

South African Forestry IndustrySouth African Forestry Industry

Redesigned UnitRedesigned Unit: Based on : Based on

anthropometric study; better anthropometric study; better

materials, better straps and materials, better straps and

fasteners. fasteners.

ExampleExample: : Tree Debrancher Leg ProtectorsTree Debrancher Leg Protectors

South African Forestry IndustrySouth African Forestry Industry

Redesigned UnitRedesigned Unit: Based on : Based on

anthropometric study; better anthropometric study; better

materials, better straps and materials, better straps and

fasteners. fasteners.

MeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of Ergonomic Interventions of Ergonomic InterventionsMeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of Ergonomic Interventions of Ergonomic Interventions

ExampleExample: : Tree Debrancher Leg Protectors Tree Debrancher Leg Protectors Ergonomically RedesignedErgonomically Redesigned

ResultsResults

BeforeBefore: 10 leg injuries per day among 300 workers : 10 leg injuries per day among 300 workers in a eucalyptus plantation; average of 5 lost in a eucalyptus plantation; average of 5 lost work days per injury!work days per injury!

AfterAfter: No leg injuries the next year; cost savings : No leg injuries the next year; cost savings of $250,000. Will save $4 million per year for of $250,000. Will save $4 million per year for entire South African Forestry industry.entire South African Forestry industry.

ExampleExample: : Tree Debrancher Leg Protectors Tree Debrancher Leg Protectors Ergonomically RedesignedErgonomically Redesigned

ResultsResults

BeforeBefore: 10 leg injuries per day among 300 workers : 10 leg injuries per day among 300 workers in a eucalyptus plantation; average of 5 lost in a eucalyptus plantation; average of 5 lost work days per injury!work days per injury!

AfterAfter: No leg injuries the next year; cost savings : No leg injuries the next year; cost savings of $250,000. Will save $4 million per year for of $250,000. Will save $4 million per year for entire South African Forestry industry.entire South African Forestry industry.

Ensuring Effective ErgonomicsEnsuring Effective ErgonomicsEnsuring Effective ErgonomicsEnsuring Effective Ergonomics

Ergonomics Training is an important Key to a Ergonomics Training is an important Key to a Successful programSuccessful program

Personal Example: Philippine Cottage Industry FactoryPersonal Example: Philippine Cottage Industry Factory

- I taught one-day ergonomics & safety seminar to the- I taught one-day ergonomics & safety seminar to themanager and two workers who spoke English. manager and two workers who spoke English.

- Then did a hazard analysis of the factory with them and - Then did a hazard analysis of the factory with them and made design improvements.made design improvements.

- - Manager then taught basic ergonomics safety to other Manager then taught basic ergonomics safety to other Philippine workers.Philippine workers.

Ergonomics Training is an important Key to a Ergonomics Training is an important Key to a Successful programSuccessful program

Personal Example: Philippine Cottage Industry FactoryPersonal Example: Philippine Cottage Industry Factory

- I taught one-day ergonomics & safety seminar to the- I taught one-day ergonomics & safety seminar to themanager and two workers who spoke English. manager and two workers who spoke English.

- Then did a hazard analysis of the factory with them and - Then did a hazard analysis of the factory with them and made design improvements.made design improvements.

- - Manager then taught basic ergonomics safety to other Manager then taught basic ergonomics safety to other Philippine workers.Philippine workers.

Ergonomics Training Ergonomics Training isis Important ImportantErgonomics Training Ergonomics Training isis Important Important

Personal ExamplePersonal Example: Ergonomics Training in a Philippine : Ergonomics Training in a Philippine Cottage Industry FactoryCottage Industry Factory

ResultsResults

- Minor injuries dropped from an average of one per - Minor injuries dropped from an average of one per week to one per month.week to one per month.

- Lost time injuries dropped from one every 2 months - Lost time injuries dropped from one every 2 months to none over the next year.to none over the next year.

- Ergonomics information used by manager to refine - Ergonomics information used by manager to refine design of our rattan furniture products.design of our rattan furniture products.

Personal ExamplePersonal Example: Ergonomics Training in a Philippine : Ergonomics Training in a Philippine Cottage Industry FactoryCottage Industry Factory

ResultsResults

- Minor injuries dropped from an average of one per - Minor injuries dropped from an average of one per week to one per month.week to one per month.

- Lost time injuries dropped from one every 2 months - Lost time injuries dropped from one every 2 months to none over the next year.to none over the next year.

- Ergonomics information used by manager to refine - Ergonomics information used by manager to refine design of our rattan furniture products.design of our rattan furniture products.


Lessons Learned from Actual CasesLessons Learned from Actual Cases

– Real management commitment essential:Real management commitment essential:

Deeds, not just words, required.Deeds, not just words, required.

Often reflected in commitment of resourcesOften reflected in commitment of resources

- Hiring professional ergonomics personnel- Hiring professional ergonomics personnel

- Providing ergonomics training to all employees - Providing ergonomics training to all employees

- Funding appropriate risk analyses- Funding appropriate risk analyses - Funding follow-up actions to correct deficiencies.- Funding follow-up actions to correct deficiencies.




Often reflected in commitment of resourcesOften reflected in commitment of resources

- Hiring professional ergonomics personnel- Hiring professional ergonomics personnel

- Providing ergonomics training to all employees - Providing ergonomics training to all employees

- Funding appropriate risk analyses- Funding appropriate risk analyses - Funding follow-up actions to correct deficiencies.- Funding follow-up actions to correct deficiencies.





Establishing rapport with key managers and raising Establishing rapport with key managers and raising their consciousness about full scope of their consciousness about full scope of ergonomics often essential to your long term ergonomics often essential to your long term success. This takes time and persistence - from my success. This takes time and persistence - from my experience, an average of about two years.experience, an average of about two years.




Establishing rapport with key managers and raising Establishing rapport with key managers and raising their consciousness about full scope of their consciousness about full scope of ergonomics often essential to your long term ergonomics often essential to your long term success. This takes time and persistence - from my success. This takes time and persistence - from my experience, an average of about two years.experience, an average of about two years.



Collaboration invariably works far better than Collaboration invariably works far better than confrontation.confrontation.

Respect the ownership of the design engineer for Respect the ownership of the design engineer for his/her work; be supportive of him/her and you will his/her work; be supportive of him/her and you will gain openness to, and acceptance of, your input.gain openness to, and acceptance of, your input.

Once you make a recognized and respected Once you make a recognized and respected improvement to an engineer’s design (i.e., establish improvement to an engineer’s design (i.e., establish your credibility) you will have more work requests your credibility) you will have more work requests than you can handle.than you can handle.


Collaboration invariably works far better than Collaboration invariably works far better than confrontation.confrontation.

Respect the ownership of the design engineer for Respect the ownership of the design engineer for his/her work; be supportive of him/her and you will his/her work; be supportive of him/her and you will gain openness to, and acceptance of, your input.gain openness to, and acceptance of, your input.

Once you make a recognized and respected Once you make a recognized and respected improvement to an engineer’s design (i.e., establish improvement to an engineer’s design (i.e., establish your credibility) you will have more work requests your credibility) you will have more work requests than you can handle.than you can handle.



Ergonomists also can be System IntegratorsErgonomists also can be System Integrators

On System Development Projects, ergonomists On System Development Projects, ergonomists often know more about all of the various system often know more about all of the various system components than any other member of the components than any other member of the engineering design team. They thus can act as engineering design team. They thus can act as systems integratorssystems integrators and see possibilities that and see possibilities that others miss.others miss.


Lessons Learned from Actual CasesLessons Learned from Actual CasesErgonomists also can be System IntegratorsErgonomists also can be System Integrators

Personal ExamplePersonal Example: Addition of a medical air evacuation : Addition of a medical air evacuation configuration to the C141 Aircraft during its configuration to the C141 Aircraft during its development.development.

- I recognized that it could be added for very little I recognized that it could be added for very little additional expenditure. Change proposal to add it additional expenditure. Change proposal to add it was approved.was approved.

- This configuration saved many lives during the Viet This configuration saved many lives during the Viet Nam War.Nam War.


Lessons Lessons Learned from Actual CasesLearned from Actual Cases


Second ExampleSecond Example: A colleague working on : A colleague working on development of an Air Force bomber recognized development of an Air Force bomber recognized that the different hydraulic systems specified for that the different hydraulic systems specified for the aircraft used different hydraulic fluids that were the aircraft used different hydraulic fluids that were notnot compatible with one another! compatible with one another!

Had he not caught the error, the results could have Had he not caught the error, the results could have been both costly and disastrous.been both costly and disastrous.

Lessons Lessons Learned from Actual CasesLearned from Actual Cases


Second ExampleSecond Example: A colleague working on : A colleague working on development of an Air Force bomber recognized development of an Air Force bomber recognized that the different hydraulic systems specified for that the different hydraulic systems specified for the aircraft used different hydraulic fluids that were the aircraft used different hydraulic fluids that were notnot compatible with one another! compatible with one another!

Had he not caught the error, the results could have Had he not caught the error, the results could have been both costly and disastrous.been both costly and disastrous.


Lessons Learned from Actual Cases Lessons Learned from Actual Cases

–Participatory ergonomics is the proven way to Participatory ergonomics is the proven way to establish an ergonomics safety culture and establish an ergonomics safety culture and sustain improvements.sustain improvements.

Workers know problems with their jobs best.Workers know problems with their jobs best.

They know what ergonomic alternatives will be They know what ergonomic alternatives will be most satisfying and acceptable to them.most satisfying and acceptable to them.

Get employee “buy-in” to changes. Get employee “buy-in” to changes.


–Participatory ergonomics is the proven way to Participatory ergonomics is the proven way to establish an ergonomics safety culture and establish an ergonomics safety culture and sustain improvements.sustain improvements.

Workers know problems with their jobs best.Workers know problems with their jobs best.

They know what ergonomic alternatives will be They know what ergonomic alternatives will be most satisfying and acceptable to them.most satisfying and acceptable to them.

Get employee “buy-in” to changes. Get employee “buy-in” to changes.


Participatory ergonomics is the proven way to establish an Participatory ergonomics is the proven way to establish an ergonomics safety culture and sustain improvements.ergonomics safety culture and sustain improvements.

Example: Large Petroleum Distribution company. Example: Large Petroleum Distribution company.

Results*Results* Reductions AfterReductions After2 years2 years 9 Years 9 Years

Motor Vehicle AccidentsMotor Vehicle Accidents 51%51% 63%63%Industrial AccidentsIndustrial Accidents 54%54% 70%70%Lost WorkdaysLost Workdays 94%94% 97%97%

* Imada (2002)* Imada (2002)

Participatory ergonomics is the proven way to establish an Participatory ergonomics is the proven way to establish an ergonomics safety culture and sustain improvements.ergonomics safety culture and sustain improvements.

Example: Large Petroleum Distribution company. Example: Large Petroleum Distribution company.

Results*Results* Reductions AfterReductions After2 years2 years 9 Years 9 Years

Motor Vehicle AccidentsMotor Vehicle Accidents 51%51% 63%63%Industrial AccidentsIndustrial Accidents 54%54% 70%70%Lost WorkdaysLost Workdays 94%94% 97%97%

* Imada (2002)* Imada (2002)

Participatory Ergonomics Participatory Ergonomics isis ImportantImportantParticipatory Ergonomics Participatory Ergonomics isis ImportantImportant

Example: Seven Companies Insured by Tokyo MarineExample: Seven Companies Insured by Tokyo Marine

One-day seminar on participatory ergonomics One-day seminar on participatory ergonomics methodology and materials given to cross-disciplinary methodology and materials given to cross-disciplinary ergonomics teams from 7 companies insured by ergonomics teams from 7 companies insured by Tokyo Marine; conducted by Bill Brough of Tokyo Marine; conducted by Bill Brough of Washington Ergonomics.Washington Ergonomics.

6 of the 7 teams used training and materials to 6 of the 7 teams used training and materials to implement a participatory ergonomics program in implement a participatory ergonomics program in their organizations.their organizations.

Example: Seven Companies Insured by Tokyo MarineExample: Seven Companies Insured by Tokyo Marine

One-day seminar on participatory ergonomics One-day seminar on participatory ergonomics methodology and materials given to cross-disciplinary methodology and materials given to cross-disciplinary ergonomics teams from 7 companies insured by ergonomics teams from 7 companies insured by Tokyo Marine; conducted by Bill Brough of Tokyo Marine; conducted by Bill Brough of Washington Ergonomics.Washington Ergonomics.

6 of the 7 teams used training and materials to 6 of the 7 teams used training and materials to implement a participatory ergonomics program in implement a participatory ergonomics program in their organizations.their organizations.

Participatory Ergonomics Participatory Ergonomics isis ImportantImportantParticipatory Ergonomics Participatory Ergonomics isis ImportantImportant

ExampleExample: Ergonomics Team Training: Ergonomics Team Training

ResultsResults for the 6 companies that used training for the 6 companies that used training

Strain injuries dropped from 131 in 6 months Strain injuries dropped from 131 in 6 months prior to implementation to 42 in six month period prior to implementation to 42 in six month period ending 18 months later for a net savings of ending 18 months later for a net savings of $1,348,748.$1,348,748.

For 7For 7thth company, injury rate actually company, injury rate actually increased!increased!

ExampleExample: Ergonomics Team Training: Ergonomics Team Training

ResultsResults for the 6 companies that used training for the 6 companies that used training

Strain injuries dropped from 131 in 6 months Strain injuries dropped from 131 in 6 months prior to implementation to 42 in six month period prior to implementation to 42 in six month period ending 18 months later for a net savings of ending 18 months later for a net savings of $1,348,748.$1,348,748.

For 7For 7thth company, injury rate actually company, injury rate actually increased!increased!

Ensuring Effective ErgonomicsEnsuring Effective Ergonomics Ensuring Effective ErgonomicsEnsuring Effective Ergonomics


True Ergonomics professionals and expertise required True Ergonomics professionals and expertise required for an effective program.for an effective program.

- - When not used, ergonomics safety programs usually When not used, ergonomics safety programs usually inadequate and excessive injuries often result.inadequate and excessive injuries often result.

-- Developing, implementing, and managing a Developing, implementing, and managing a professional ergonomics and safety program professional ergonomics and safety program requires professional knowledge and expertise.requires professional knowledge and expertise.


True Ergonomics professionals and expertise required True Ergonomics professionals and expertise required for an effective program.for an effective program.

- - When not used, ergonomics safety programs usually When not used, ergonomics safety programs usually inadequate and excessive injuries often result.inadequate and excessive injuries often result.

-- Developing, implementing, and managing a Developing, implementing, and managing a professional ergonomics and safety program professional ergonomics and safety program requires professional knowledge and expertise.requires professional knowledge and expertise.


Lessons Learned from Actual Cases Lessons Learned from Actual Cases True Ergonomics professionals and expertise True Ergonomics professionals and expertise

required.required.

Examples of problemExamples of problem

–Warehouse type retail stores: Thousands of falling Warehouse type retail stores: Thousands of falling object injuries to customers each year.object injuries to customers each year.

– Railroads: A high incidence of back injuries.Railroads: A high incidence of back injuries.

Lessons Learned from Actual Cases Lessons Learned from Actual Cases True Ergonomics professionals and expertise True Ergonomics professionals and expertise

required.required.

Examples of problemExamples of problem

–Warehouse type retail stores: Thousands of falling Warehouse type retail stores: Thousands of falling object injuries to customers each year.object injuries to customers each year.

– Railroads: A high incidence of back injuries.Railroads: A high incidence of back injuries.


Lessons Learned from Actual Cases Lessons Learned from Actual Cases (continued)(continued)

Human-Centered Design of Products: Human-Centered Design of Products: The sure way to success!The sure way to success!

– Example: Fork lift truck redesignExample: Fork lift truck redesign


Human-Centered Design of Products: Human-Centered Design of Products: The sure way to success!The sure way to success!

– Example: Fork lift truck redesignExample: Fork lift truck redesign



Human-Centered Design of Products: The sure Human-Centered Design of Products: The sure way to success!way to success!

ExampleExample: Raymond Fork Lift Trucks: Raymond Fork Lift Trucks

– Raymond company market share had gone Raymond company market share had gone from 70% to 30% and was rapidly dropping.from 70% to 30% and was rapidly dropping.

– Alan Hedge and Cornell University Ergonomics Alan Hedge and Cornell University Ergonomics Lab and NY design firm, Pelican Design, jointly Lab and NY design firm, Pelican Design, jointly developed two new fork lifts for Raymond.developed two new fork lifts for Raymond.


Human-Centered Design of Products: The sure Human-Centered Design of Products: The sure way to success!way to success!

ExampleExample: Raymond Fork Lift Trucks: Raymond Fork Lift Trucks

– Raymond company market share had gone Raymond company market share had gone from 70% to 30% and was rapidly dropping.from 70% to 30% and was rapidly dropping.

– Alan Hedge and Cornell University Ergonomics Alan Hedge and Cornell University Ergonomics Lab and NY design firm, Pelican Design, jointly Lab and NY design firm, Pelican Design, jointly developed two new fork lifts for Raymond.developed two new fork lifts for Raymond.


Human-Centered Design of Products: The Human-Centered Design of Products: The sure way to success!sure way to success!

ExampleExample: Fork Lift Truck Redesign: Fork Lift Truck Redesign






- Used “inside-out” human-centered approach: Built Used “inside-out” human-centered approach: Built truck around operators needs.truck around operators needs.

- Goal: Maximize comfort, minimize Goal: Maximize comfort, minimize

accident risks, maximize productivity accident risks, maximize productivity

via shortened task cycle times.via shortened task cycle times.



- Used “inside-out” human-centered approach: Built Used “inside-out” human-centered approach: Built truck around operators needs.truck around operators needs.

- Goal: Maximize comfort, minimize Goal: Maximize comfort, minimize

accident risks, maximize productivity accident risks, maximize productivity

via shortened task cycle times.via shortened task cycle times.




ResultsResults

- Market Share greatly increased.Market Share greatly increased.

- Stock value went from $6 perStock value went from $6 per

share to $30 per share.share to $30 per share.



ResultsResults

- Market Share greatly increased.Market Share greatly increased.

- Stock value went from $6 perStock value went from $6 per

share to $30 per share.share to $30 per share.



Pick the “low hanging fruit” first to obtain quick Pick the “low hanging fruit” first to obtain quick results and gain credibility with management --results and gain credibility with management --then expandthen expand..

– Example: AT&T GlobalExample: AT&T Global


Pick the “low hanging fruit” first to obtain quick Pick the “low hanging fruit” first to obtain quick results and gain credibility with management --results and gain credibility with management --then expandthen expand..

– Example: AT&T GlobalExample: AT&T Global

Example: AT&T GlobalExample: AT&T GlobalExample: AT&T GlobalExample: AT&T Global

Round 1: ActionsRound 1: Actions– Extensive worksite analysis to identify Extensive worksite analysis to identify

ergonomics deficiencies.ergonomics deficiencies.

–Made numerous workstation Made numerous workstation improvementsimprovements

Round 1: ResultsRound 1: Results–Workers compensation dropped over 75%, Workers compensation dropped over 75%,

from $400,000 to $94,000.from $400,000 to $94,000.

Round 1: ActionsRound 1: Actions– Extensive worksite analysis to identify Extensive worksite analysis to identify

ergonomics deficiencies.ergonomics deficiencies.

–Made numerous workstation Made numerous workstation improvementsimprovements

Round 1: ResultsRound 1: Results–Workers compensation dropped over 75%, Workers compensation dropped over 75%,

from $400,000 to $94,000.from $400,000 to $94,000.

Example: AT&T GlobalExample: AT&T GlobalExample: AT&T GlobalExample: AT&T Global

Round 2: ActionsRound 2: Actions–Moved from assembly line process to one Moved from assembly line process to one

where each worker built entire cabinet (i.e, a where each worker built entire cabinet (i.e, a macroergonomic change to the work system).macroergonomic change to the work system).

Round 2: ResultsRound 2: Results–Workers compensation dropped to $12,000.Workers compensation dropped to $12,000.

– Lost workdays from injury went from 298 to 0 Lost workdays from injury went from 298 to 0 two years later.two years later.

Round 2: ActionsRound 2: Actions–Moved from assembly line process to one Moved from assembly line process to one

where each worker built entire cabinet (i.e, a where each worker built entire cabinet (i.e, a macroergonomic change to the work system).macroergonomic change to the work system).

Round 2: ResultsRound 2: Results–Workers compensation dropped to $12,000.Workers compensation dropped to $12,000.

– Lost workdays from injury went from 298 to 0 Lost workdays from injury went from 298 to 0 two years later.two years later.



Improvements to reduce accidents, WMSD’s, Improvements to reduce accidents, WMSD’s, etc. usually also improve productivity – etc. usually also improve productivity – sometimes dramatically.sometimes dramatically.

– Example: Union Pacific Railroad Palestine, Example: Union Pacific Railroad Palestine, Texas car repair facility.Texas car repair facility.


Improvements to reduce accidents, WMSD’s, Improvements to reduce accidents, WMSD’s, etc. usually also improve productivity – etc. usually also improve productivity – sometimes dramatically.sometimes dramatically.

– Example: Union Pacific Railroad Palestine, Example: Union Pacific Railroad Palestine, Texas car repair facility.Texas car repair facility.

Example: UP Palestine Repair FacilityExample: UP Palestine Repair FacilityExample: UP Palestine Repair FacilityExample: UP Palestine Repair Facility

Had worst back injury rate in UP systemHad worst back injury rate in UP system Joint AAR – UP project to reduce back Joint AAR – UP project to reduce back

injuries.injuries.– Used U of Michigan 2D program to evaluate Used U of Michigan 2D program to evaluate

back compression at all jobs.back compression at all jobs.

–Made ergonomic changes to reduce excess Made ergonomic changes to reduce excess lifting and awkward postures.lifting and awkward postures.

– Example: Storage table for coupler knuckle Example: Storage table for coupler knuckle storagestorage

Had worst back injury rate in UP systemHad worst back injury rate in UP system Joint AAR – UP project to reduce back Joint AAR – UP project to reduce back

injuries.injuries.– Used U of Michigan 2D program to evaluate Used U of Michigan 2D program to evaluate

back compression at all jobs.back compression at all jobs.

–Made ergonomic changes to reduce excess Made ergonomic changes to reduce excess lifting and awkward postures.lifting and awkward postures.

– Example: Storage table for coupler knuckle Example: Storage table for coupler knuckle storagestorage

Example: UP Palestine Repair FacilityExample: UP Palestine Repair Facility

Coupler Knuckle Storage TableCoupler Knuckle Storage Table

Example: UP Palestine Repair FacilityExample: UP Palestine Repair Facility

Coupler Knuckle Storage TableCoupler Knuckle Storage Table

Example: UP Palestine Repair FacilityExample: UP Palestine Repair FacilityExample: UP Palestine Repair FacilityExample: UP Palestine Repair Facility

Results (3 years later)Results (3 years later)

– Injuries went from 33 to 12; back injuries from 13 Injuries went from 33 to 12; back injuries from 13 to 0; lost days from 579 to 0; restricted work days to 0; lost days from 579 to 0; restricted work days from 190 to 40; absenteeism from4% to 1%.from 190 to 40; absenteeism from4% to 1%.

ANDAND

–Cars repaired per year went from Cars repaired per year went from

1,564 to 2,900!1,564 to 2,900!

Results (3 years later)Results (3 years later)

– Injuries went from 33 to 12; back injuries from 13 Injuries went from 33 to 12; back injuries from 13 to 0; lost days from 579 to 0; restricted work days to 0; lost days from 579 to 0; restricted work days from 190 to 40; absenteeism from4% to 1%.from 190 to 40; absenteeism from4% to 1%.

ANDAND

–Cars repaired per year went from Cars repaired per year went from

1,564 to 2,900!1,564 to 2,900!



Simple ergonomic solutions often yield Simple ergonomic solutions often yield dramatic results.dramatic results.

ExampleExample: Poultry deboning knife used in : Poultry deboning knife used in

poultry packaging plant.poultry packaging plant.



ExampleExample: Poultry deboning knife used in : Poultry deboning knife used in

poultry packaging plant.poultry packaging plant.



ExampleExample: Poultry deboning knife, poultry : Poultry deboning knife, poultry packaging plant.packaging plant.

- High incidence of carpal tunnelHigh incidence of carpal tunnel syndrome, tendonitis, andsyndrome, tendonitis, and tenosynovitistenosynovitis

- $100,000 workers compensation$100,000 workers compensation costs per year.costs per year.


ExampleExample: Poultry deboning knife, poultry : Poultry deboning knife, poultry packaging plant.packaging plant.

- High incidence of carpal tunnelHigh incidence of carpal tunnel syndrome, tendonitis, andsyndrome, tendonitis, and tenosynovitistenosynovitis

- $100,000 workers compensation$100,000 workers compensation costs per year.costs per year.



ExampleExample: Poultry deboning knife, poultry : Poultry deboning knife, poultry

packaging plant.packaging plant.

Solution: Introduced new, Solution: Introduced new,

pistol grip knife that was pistol grip knife that was

commercially available.commercially available.


ExampleExample: Poultry deboning knife, poultry : Poultry deboning knife, poultry

packaging plant.packaging plant.

Solution: Introduced new, Solution: Introduced new,

pistol grip knife that was pistol grip knife that was

commercially available.commercially available.


Simple ergonomic solutions often yield dramatic Simple ergonomic solutions often yield dramatic results.results.

ExampleExample: Poultry deboning knife: Poultry deboning knife

ResultsResults

- - Immediate relief and increased worker satisfaction. Immediate relief and increased worker satisfaction.

- Workers Compensation reduced by $100,000 per year.- Workers Compensation reduced by $100,000 per year.

- Line speeds increased by 2% to 6%.- Line speeds increased by 2% to 6%.

- Greater profits from more efficient deboning.- Greater profits from more efficient deboning.

Simple ergonomic solutions often yield dramatic Simple ergonomic solutions often yield dramatic results.results.

ExampleExample: Poultry deboning knife: Poultry deboning knife

ResultsResults

- - Immediate relief and increased worker satisfaction. Immediate relief and increased worker satisfaction.

- Workers Compensation reduced by $100,000 per year.- Workers Compensation reduced by $100,000 per year.

- Line speeds increased by 2% to 6%.- Line speeds increased by 2% to 6%.

- Greater profits from more efficient deboning.- Greater profits from more efficient deboning.

Insuring Effective ErgonomicsInsuring Effective Ergonomics Insuring Effective ErgonomicsInsuring Effective Ergonomics


OSHA Guidelines* Really Do WorkOSHA Guidelines* Really Do Work

Are based on extensive researchAre based on extensive research

When OSHA ergonomics program elements When OSHA ergonomics program elements notnot present, ergonomics & safety program invariably present, ergonomics & safety program invariably notnot adequate. adequate.

*See OSHA 3123 E*See OSHA 3123 Ergonomics Program Management rgonomics Program Management Guidelines for Meatpacking PlantsGuidelines for Meatpacking Plants


OSHA Guidelines* Really Do WorkOSHA Guidelines* Really Do Work

Are based on extensive researchAre based on extensive research

When OSHA ergonomics program elements When OSHA ergonomics program elements notnot present, ergonomics & safety program invariably present, ergonomics & safety program invariably notnot adequate. adequate.

*See OSHA 3123 E*See OSHA 3123 Ergonomics Program Management rgonomics Program Management Guidelines for Meatpacking PlantsGuidelines for Meatpacking Plants

Insuring Effective ErgonomicsInsuring Effective ErgonomicsInsuring Effective ErgonomicsInsuring Effective Ergonomics


Macroergonomic interventions can yield Macroergonomic interventions can yield dramatic improvements.dramatic improvements.

Accident ratesAccident rates Scrap ratesScrap rates Production quality and/or quantityProduction quality and/or quantity Job satisfaction and commitmentJob satisfaction and commitment


Macroergonomic interventions can yield Macroergonomic interventions can yield dramatic improvements.dramatic improvements.

Accident ratesAccident rates Scrap ratesScrap rates Production quality and/or quantityProduction quality and/or quantity Job satisfaction and commitmentJob satisfaction and commitment

Macroergonomics InterventionsMacroergonomics InterventionsMacroergonomics InterventionsMacroergonomics Interventions

Designing a New University CollegeDesigning a New University College

Transfer of Program from USC to DUTransfer of Program from USC to DU

Provided unique opportunity to create new College.Provided unique opportunity to create new College.

Built around M.S. Systems Management program Built around M.S. Systems Management program taught at 30 study centers throughout the U.S. and taught at 30 study centers throughout the U.S. and in Europe.in Europe.


Transfer of Program from USC to DUTransfer of Program from USC to DU

Provided unique opportunity to create new College.Provided unique opportunity to create new College.

Built around M.S. Systems Management program Built around M.S. Systems Management program taught at 30 study centers throughout the U.S. and taught at 30 study centers throughout the U.S. and in Europe.in Europe.

Macroergonomic InterventionMacroergonomic InterventionMacroergonomic InterventionMacroergonomic Intervention


Macroergonomic AnalysisMacroergonomic Analysis

Conducted a systems analysis of structural and Conducted a systems analysis of structural and process requirements. process requirements.

Extensive staff and faculty participation.Extensive staff and faculty participation.

Also involved an IBM educational analysis group Also involved an IBM educational analysis group using “User Systems Analysis” methodology.using “User Systems Analysis” methodology.


Macroergonomic AnalysisMacroergonomic Analysis

Conducted a systems analysis of structural and Conducted a systems analysis of structural and process requirements. process requirements.

Extensive staff and faculty participation.Extensive staff and faculty participation.

Also involved an IBM educational analysis group Also involved an IBM educational analysis group using “User Systems Analysis” methodology.using “User Systems Analysis” methodology.



Developed Streamlined Work SystemDeveloped Streamlined Work System

As compared with previous USC work system, new As compared with previous USC work system, new system more congruent with the program’s system more congruent with the program’s sociotechnical system characteristics.sociotechnical system characteristics.

First determined tasks requiring people – then chose First determined tasks requiring people – then chose equipment and software (i.e., user-centered design).equipment and software (i.e., user-centered design).


Developed Streamlined Work SystemDeveloped Streamlined Work System

As compared with previous USC work system, new As compared with previous USC work system, new system more congruent with the program’s system more congruent with the program’s sociotechnical system characteristics.sociotechnical system characteristics.

First determined tasks requiring people – then chose First determined tasks requiring people – then chose equipment and software (i.e., user-centered design).equipment and software (i.e., user-centered design).



ResultsResults (as compared with old USC work system) (as compared with old USC work system)

27% savings in operating expenses27% savings in operating expenses 23% reduction in campus staffing requirements23% reduction in campus staffing requirements 20% reduction in study center administrative time20% reduction in study center administrative time 67% reduction in average processing time for student 67% reduction in average processing time for student

registrations, grades, etc. from off-campus registrations, grades, etc. from off-campus locations.locations.


ResultsResults (as compared with old USC work system) (as compared with old USC work system)

27% savings in operating expenses27% savings in operating expenses 23% reduction in campus staffing requirements23% reduction in campus staffing requirements 20% reduction in study center administrative time20% reduction in study center administrative time 67% reduction in average processing time for student 67% reduction in average processing time for student

registrations, grades, etc. from off-campus registrations, grades, etc. from off-campus locations.locations.

Ensuring Effective Ergonomic Ensuring Effective Ergonomic Interventions: Lessons LearnedInterventions: Lessons LearnedEnsuring Effective Ergonomic Ensuring Effective Ergonomic Interventions: Lessons LearnedInterventions: Lessons Learned

Conclusion Conclusion

Proper application of ergonomics provides Proper application of ergonomics provides real value in terms of safety, health, real value in terms of safety, health, comfort, and productivitycomfort, and productivity

andand

is highly cost effective.is highly cost effective.

WE must get the message to management!WE must get the message to management!

Conclusion Conclusion

Proper application of ergonomics provides Proper application of ergonomics provides real value in terms of safety, health, real value in terms of safety, health, comfort, and productivitycomfort, and productivity

andand

is highly cost effective.is highly cost effective.

WE must get the message to management!WE must get the message to management!

Date post:	15-Dec-2015
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