1. Welcome to Basic Ergonomics

2. Objectives
Increase awareness of basic ergonomics concepts and principles
Identify occupational risk factors for strains, sprains, and cumulative trauma
Learn to use various tools for identifying ergonomic concerns and analyzing jobs
Understand basic control measures for improving ergonomic job design

3. Ergonomics - What is it?

4. Ergonomics - What is it?
Design Error
Most people look like this...

5. Ergonomics Design Error Most people look like this...
Some designers think that people look like this...

6. Definitions
Fitting the task to the person rather than forcing him/her to adapt to his working environment.
Designing the workplace to prevent occupational injury and illness.
Discovering the capabilities and limitations of the human body.

7. A Balance for Optimization
Working Definition
Job
Demands
Worker
Capabilities
A Balance for Optimization

8. Supporting Sciences ERGONOMICS Biomechanics Engineering Anthropometry
Physical
Sciences
Engineering
Psychology
ERGONOMICS
Anthropometry
Behavioral
Sciences
Biological
Sciences
Work
Physiology

9. Acute Vs. Cumulative Disorders
Result from a one time event
Cumulative:
Result from repeated wear and tear; however, a specific event may have been “the last straw” upon a previously weakened system and thus given the appearance that the problem is acute rather than chronic. {Stephen Konz. “Work Design; Industrial Ergonomics”, Third edition. 1990}

10. CTDs
Term assigned to identify a group of injuries that classically result from
long-term and repeated “wear and tear” on the musculoskeletal system.
CUMULATIVE indicates injuries that develop gradually over time, and result from many repeated stresses on a particular body part.
TRAUMA signifies bodily insult or injury from mechanical stresses.
DISORDERS describes the adverse health effects that arise from chronic exposure to repeated trauma.

11. CTD Trauma Bucket Balanced
Your Job
Trauma
Your Body
Healing Valve

12. CTD Trauma Bucket Unbalanced
Your Job
Trauma
Your Body
CTD
Healing Valve
CTD

13. Material Handling Operations

14. VDT / Computer Operators

15. Control / Display Design

16. Workplace / Workstation LayoutD E C B A

17. Assembly / Repetitive Hand Intensive Tasks

18. All Other Work/Play/Life

19. Why Ergonomics ?

20. Win/Win Higher Production Higher Quality Compliance
Lower Compensation Costs
Careers/Employment Longevity
Safe Working Conditions
Quality of life
Morale

21. Employee Benefits Quality of Life Fewer Aches, Pains, & Injuries
Career / Employment Protection & Longevity
Jobs More Intuitive
Less Fatigue

22. Production Benefits Less Fatigue Eliminates Unnecessary Handling
Reduces Bottlenecks
Increases Throughput
Optimization Cycle Time
Helps In Meeting Deadlines
Well Designed Jobs
Increase Profitability & Competitiveness

23. Quality Benefits Less Scrap & Re-Work Increased efficiency
Reduction of rushing and shortcuts
Less Fatigue
Improves Customer Satisfaction
Better accuracy

24. Compliance General Duty Clause Guidelines
NIOSH Elements of Ergonomics Process,1997
OSHA Meatpacking Guidelines, 1990
BSR/HFES-100/2002: VDT’s
Musculoskeletal Disorders (MSDs) and Workplace Factors – 1997
OSHA.GOV Ergonomics e-tools

25. Compliance
“General Duty Clause” OSHA Act 1970
Section 5.(a)
(1) Each Employer shall furnish to each of his employees employment and place of employment which is free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employee.

28. Workers’ Compensation / Loss Prevention
Prevent Injuries/Illnesses from Occurring in the first place
Reduction of the frequency of claims
Reduction of Worker’s Compensation Costs
Reduction absenteeism
Reduced turnover

29. Lost Time Injuries By Type of Cause
NSC Injury Facts 2004

30. U.S. Injury and Illness Trends
Numbers of injuries
Percentage of Recorded injuries that involve Backs
U.S. Bureau of Labor Statistics

31. U.S. Repeated Trauma Cases
U.S. Bureau of Labor Statistics

32. Claim Cost By POB
2001 and 2002 Costs
NSC Accident Facts 04

33. High-Risk Jobs CTD 2000-2001 Incident Rates
Meat packing
Motor vehicles & car bodies
Male trouser & slacks
Motorcycles, bicycles, & parts
Poultry processing
Engine electric equipment
Men’s footwear, except athletic
Motor vehicle parts
Silverware & plated ware
Ophthalmic goods
Household appliances, n.e.c.
812.0
726.9
224.8
123.8
374.0
258.2
256.7
221.1
144.3
132.5
170.8
711.0
691.9
448.4
389.0
320.2
312.6
250.5
218.9
214.6
205.4
201.1
2000
2001
Incidence rates = No. of illnesses per 10,000 workers
U.S. Bureau of Labor Statistics

41. CTD Costs
The average cost for Cumulative Trauma related Workers Compensation Claims filed in 2001 and 2002 equals $15,865
NSC Injury Facts 2004

42. Iceberg Analogy Accident Cost
Direct Costs
Medical Payments
Compensation
Breaking in substitute
Down-time
Efficiency due to break-up of crew
Overhead $ while work disrupted
Supervisor time to investigate
Indirect or Hidden
Costs
Loss of production
Overtime to make up production
Loss of good will
Damaged tools/equipment
Hiring costs
Failure to meet deadline/fill orders
Lost time by fellow workers

43. How much business does ABC Company need to generate
to recover this Loss?
What amount of business volume do you need to offset the costs of
the next accident in your organization?
C = Direct Injury Cost = $ 10,000
M = Profit Margin = 3 %
V = Business Volume required to break even from Injury (C)
= (C) / (M / 100) =
= ( 10,000) / (_3_ / 100) = $ 333,333.33
Or, including estimated indirect costs: 4X
total costs =$ 40,000
Business volume needed= $ 1,333,333