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Ben Zavitz, CPE Ergonomist
General Dynamics, Bath Iron Works 207-442-2219,
Ergonomics: Sprain & Strain Reduction
NSRP Risk Management Panel June 24, 2015 New Orleans, LA
Distribution Statement: Public – Approved for public release; distribution unlimited
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Agenda
Why Do We Care
Shipyard Ergonomics and Physically
Challenging Work
Ergonomics Review
10 Best Practices / Solutions
Bath Iron Works Program
Lessons Learned and Getting Started
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Why Do We Care About Ergo?
Ergo is about people
People are biggest source of quality,
productivity, cost and safety.
• Injury Rates = 30-50%
• Workers Comp Costs = 60-80%
• Productivity = 10-300%
• Human performance is shaped by the design
of workplace
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Source: 2014 Liberty Mutual Workplace Safety Index
Why Do We Care About Ergo?
= 35.6% and $21B
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Shipyard Ergonomics ….
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It’s Not Heavy…
….It Just Needs Handles
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What is Physically Challenging Work
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Definition - Physically Challenging
• Traditional definition
• “Heavy” or “Very Heavy” work classification
• New definition proposed at Applied Ergo Conference 2013
(2 part):
1. Ergo Risk factors @ upper end of human
capabilities
Force > 50%, Posture > 50%, High Vibration >5m/s2
2. Demanding Work Environment
Weather & Workplace
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Challenges with Physical Work
Most jobs are rated as high risk on risk
assessment tools (all red)
Most companies focus on injury data and
employee feedback
Difficult to make design changes due to the
nature of the product (i.e., ship)
High level of risk tolerance
Just because you can, does not mean you should
Demographics
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What is Ergonomics ……
…. All about people
Ergo = Work Nomics = Laws
Laws of Work related to people
When we violate principles of the
body we get:
• Poor performance
• Poor quality
• Increased fatigue
• Injuries
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Injury Perspective
1. Reduce Risk of Injury
• Employee Pain / Discomfort
• Recordable / Lost Time Injuries
• Workers Compensation $
• Return To Work
• OSHA Responsibilities
Objective of Ergonomics
Traditional View of Ergonomics
Ergo
Safety Medical
Workers
Comp
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Ergo –related Injuries
• Overuse injuries (similar to athletics)
• Nerves, tendons, muscles, ligaments, blood vessels
• Backs, Arms/Elbows, Knees, Shoulders, Hands/Wrist
• Develop gradually over time • Symptoms last longer than few days
• Can be serious if left untreated
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Common Signs (see) and Symptoms (tell)
• Muscle Fatigue = incapacity
• Discomfort = inconvenience
• Pain = unpleasant
experience
• Inflammation / Swelling
• Numbness / Tingling
• Decrease Range of Motion
• Loss of Function
• Chronic Injury Any symptom that gets
progressively worse over time
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How Do Injuries Occur
Injury occurs when the applied force (stress)
exceeds the tissue tolerance (i.e. strength and endurance)
of the body part.
Stress > Tolerance = Injury
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High Force
Acute Injury caused by single high force event
* Graph Credit Dr. Stu McGill, PhD, University of Waterloo, Canada
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Low Force, Repetitive & Constant
Repetitive
Grinding
Static Position
or Grip
* Graph Credit Dr. Stu McGill, PhD, University of Waterloo, Canada
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Human Performance Perspective
2. Maximize Human Performance & Efficiency
• Reducing Non-Value Added Motions
• Overburden of human systems
“Internal Productivity”
• Same amount of work with less effort
• More work within confines of human biological & psychological systems
Objective of Ergonomics
Human Performance View of Ergonomics
Ergo
Quality Management
Engineering
& Design
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5 Ergonomic Risk Factors
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Work Position Is Important
Work Position is one of the most important
factors in determining:
Strength
Endurance
Rate of Fatigue
Risk of Injury
When performing a task that involves a lift,
push, pull, or reach, ask yourself “Am I in the
Best Position”?
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Push
Out
Lift
Up
Push
Down
Pull
Down Pull
In
What Position Is The Strongest
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100%
(whole Body)
80% 60% <50%
What Position Is The Strongest
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Learning to “SEE” (Shipyard Ergo Evaluation)
Avoid
Red
Back,
Neck,
Shoulders,
Elbows,
Knees
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1. Off The Floor
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1. Off The Floor
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2. Raise Employee
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2. Raise Employee
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Force
Bio-Mechanics (torque on joints)
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Position Affects Force Capability
Upper Body Weighs 50%
of Your Total Weight !
80% Less
Keep It Close
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3. Use a Wheel
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4. Lighten the Load
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4. Lighten the Load
Redistribute the Weight
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Equipment / Material Substitution
Aluminum Fittings - 67% Lighter
90lbs Vs. 30lbs = 5,000 lbs per ship
4. Lighten the Load
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5. Use Mechanical Assistance
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5. Use Mechanical Assistance
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Hand-Arm Vibration (HAV)
Vibration transmitted into hands/arms through the
palm/ fingers from pneumatic tools
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Why is HAV a Problem?
1. Muscle Fatigue 2. Cumulative Injury
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Measuring HAV
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Standards
EU Directive
ANSI
ACGIH
ISO
WISHA
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Ready Reckoner
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What Have We Learned?
HAV is Multifactorial and Complex
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6. Unloaded Vs. Loaded
Manufacturers /
Maintenance
Employee Exposure /
Health Risk
* Credit Chris Barbor, COHN-S, Bath Iron Works
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7. Speed
Match tool and consumable
7.57 m/s²
* Credit Chris Barbor, COHN-S, Bath Iron Works
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8. Maintenance
10-15% 200-300%
* Credit Chris Barbor, COHN-S, Bath Iron Works
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9. Design - Low Vibration Tool
65% less vibration
2x removal rate
1/3 of the weight
* Credit Chris Barbor, COHN-S, Bath Iron Works
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9. Design - Hands Away from HAV
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10. Design – Hands Free
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BIW Ergo Program
Ergo Culture, empowers management & employees
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Learning to “SEE” (Shipyard Ergo Evaluation)
Avoid
Red
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Engaging Employees to Solve Problems
1. Safety / Ergo Committees
2. PIIs
3. Ergo Cup Competition
Goal: Recognize and encourage the development of innovative ergonomic solutions by employees
Ergo Committee votes
Quarterly winners
Grand Champion
Attend Applied Ergo Conference
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Applied Ergo Conference
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2013 Excellence Award for “Cost Savings”
2012 Team-Driven Workplace Solution
Excellence Award, “Ergo Risk Reduction”
Ergo Cup Winners
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Share Successes with Others
• ErgoTalks and Newsletters
• Communication Meetings & Video
• Best Practices Solutions
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Impact of Program
50% Reduction
39% Reduction
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4 Lessons Learned
1. Awareness and Education
2. Involve Employees
3. Small Improvements • Can’t fix everything or eliminate all risk
4. Simple Solutions tend to work best • Introduce handles where there were none
• Use wheel instead of lifting & carrying
• Elevate the work area
• Provide padding to improve comfort
• Organize work / plan work
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• Ergo risk factors are
investments that take
time to complete
• High ergo risk factors (force, postures, vibration,
repetition) are high
capital investments
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Why is Ergonomics Important?
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First, Recognize the Risk
How Do You Start?
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https://www.osha.gov/dsg/guidance/shipyard-guidelines.html
OSHA Shipyard Guidelines
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Getting Started
• Define Current State / Scope
• Awareness & Education
• Build A Team
• Risk Evaluation
• Implement Solutions
• Document Success and Market
• Go to Next Area
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Questions
Ben Zavitz, CPE Ergonomist 207-442-2219
Ergonomics is optimizing human performance and has a
significant impact on Safety, Cost, Quality and Morale
