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 Welders, Cutters, Solderers

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 Program BEFORE

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, 2003 BEFORE

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… 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

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. Employee Involvement Problem Identification Solution Implementatio n Address Injuries Training Evaluate progress Management Support

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 Ergonomics for purchase at Shipbuilders Council of America at NIOSH’s Ergonomic Interventions in the Building, Repair, and Dismantling of ShipsNIOSH’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. ErgonomicsA practical approach for improving the workplacewww.cbs.state.or.us/osha/pdf/pubs/3347.pdf On WMSD hazardous exposures visit the WISHA webpage at: Example Template of an accident prevention program : Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas BankErgonomics Ideas Bank You may also write us at:

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