1. Ergonomics Program Development TM 655 Dr. Carter Kerk SDSMT Summer 2008

2. Ergonomics Program Guidelines (from OSHA Meatpacking Guidelines) Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

3. Top Management Commitment Visible & serious commitment Placing a priority on eliminating hazards Integrate S&H programs at the same level as production Assign responsibilities, authority, and resources

4. Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

5. Written Program Endorsed by top management Outlines goals and plans Estimated implementation dates Customized to each plant Available to all personnel Reviewed regularly

6. Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

7. Employee Involvement Suggestions & feedback encouraged Without fear of reprisal Prompt reporting of symptoms Prompt evaluation and possible treatment Membership on Ergo Team Ergo Team receives symptom reports & suggestions for evaluation

8. Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

9. Program Review & Evaluation Regular review (~ semi-annual) Analysis of trends in injury rates Employee surveys Before / After surveys of changes Records of job improvements New or revised goals

10. Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

11. Worksite Analysis Identification Evaluation Control

12. Worksite Analysis Analyze medical, safety, insurance records for evidence of CTDs Insure confidentiality of patient records Incident Rate Analysis Count incidences of properly diagnosed CTDs per 100 full-time employees per year

13. Incident Rate (# of new cases) (200,000 work hours) IR = _______________________________ # of hours worked 200,000 = (40 hrs/wk) (50 wk/yr) (100 workers) Evaluate trends by department, units, job titles, operations, work stations, etc.

14. Ergonomics Checklist Focused on physical / temporal risk factors Systematic Helps novices be “experts” ID higher and lower risk jobs Apply before & after changes Apply to planned and new workspaces

15. Body Part Discomfort Map

16. Employee Surveys & Interviews Interviews are usually superior, but more time consuming Get employees more involved Employees have a wealth of ideas

17. Worksite Analysis Checklist may suggest one or more advanced analyses: Biomechanical Psychophysical NIOSH Lifting Guide Physiological Postural Hand Tool Vibration

18. Worksite Analysis Performed by an ergonomist Ergonomics Team Ergonomist Occupational Health Nurse Design & Production Engineers Maintenance Employee representation Line Supervisor

19. Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

20. Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment

21. Engineering Controls Most desirable approach Redesign or Modify Workstation Tools Work Methods “Fit the worker”

22. Engineering Controls Establishing optimal work methods Adjustable workstations Tilt bins or containers Tool balancers Conveyors, Turntables Jigs, Fixtures Rounded or padded edges on worksurfaces Mechanical assist devices Selection of “ergonomic” tools

23. Work Surfaces Adjustability Ease of Adjustability Avoid sharp edges Consider sit/stand options

24. Placement & Storage of Materials Consider frequency and weight Store heaviest and most frequent at knuckle height, “Power Zone” Store medium items from knee to shoulder Store only light items below knee or above shoulder

25. Work Station Accessories Arm rests Wrist rests Foot rails and foot rests Document holders

29. Engineering Controls

31. Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment

32. Administrative Controls Secondary to Engineering Controls Insure proper methods are used Effective maintenance & housekeeping Proper use of tools & equipment Employee conditioning New employee conditioning

34. Administrative Controls Examples Limiting overtime on high risk jobs Ensuring “adequate” rest breaks Job rotation Job enlargement Training Teaming Reduce production rates Last resort

35. Microbreaks What is a microbreak? Take them frequently

36. Standing Fatigue Interventions Proper footwear Shoe inserts Anti-fatigue mats Footrails Promote good lower extremity circulation

37. Hazard Prevention & Control Engineering Controls Administrative Controls Personal Protective Equipment

38. After engineering & administrative controls are exhausted Gloves Finger cots Arm guards NOT PPE: Braces, splints, back belts

39. Wrist Splints

40. Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

41. Medical Management Involvement of “qualified” medical personnel Certified Occupational Physicians Certified Occupational Health Nurses Occupational/Physical Therapists Member of Ergonomics Team Active surveillance for symptoms Thorough diagnosis

42. Medical Management Conservative treatment Conservative return to work Systematic monitoring & follow-up Work hardening Consider light duty transition Recordkeeping Tracking trends Promote stretching & strengthening programs

44. Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

45. Keep employees informed of program Train: Production workers Engineers Maintenance & housekeeping personnel Supervisors & Managers Medical personnel

46. Training & Education Customized for each plant and its written program General & specific training levels Train on disorders & symptoms Risk Factor Awareness including Personal, psychosocial, non-occupational Engineering control strategies

47. Lifting Squat lift generally better than stoop bend with your knees, not your back keep the load close get a good hand hold move slowly, “no jerks allowed” know or test the load Avoid twists

48. More Lifting Tips Get help (from a person or an assist device) Eliminate lifts Reduce loads Store properly Get a strategic delivery Use proper technique on light loads

49. Ergonomics Program Guidelines Top Management Commitment Written Program Employee Involvement Program Review & Evaluation Worksite Analysis Hazard Prevention & Control Medical Management Training & Education

50. Barriers to Successful Ergonomics Programs Lack of funding Implementation delays Poor attendance by middle managers Viewing ergonomics as a productivity program Excessive dependence on consultants Failure to develop internal ergo expertise

51. A Bad Ergonomics Program?

52. Ingredients for Effective Ergo Programs Leadership commitment Clear purpose Worker / supervisor involvement Rigorous problem solving Active Ergo Team with expertise Ergo is a process, not a program Start small & expand - Kaizen

53. HW OEG (OSHA Ergonomics Guidelines) Read one of the available OSHA Ergonomics Guidelines and write a four page (double spaced) paper on how you would implement such a program from a manager’s standpoint. 50 points Due as soon as possible

54. HW OEG, Continued Guidelines Nursing Homes Poultry Processing Retail Grocery Shipyards Available from the course website and from www.osha.gov, Ergonomics, Guidelineswww.osha.gov

55. Assignment MacLeod, Chapters Five & Seven Gabriel, Chapter Four HW OEG CE 4 (Case Example 4) Exam II (covers material thru 6/3/08) Tuesday, June 10, 7 PM (90 Minutes) Closed Book Crib Sheet, 1-8.5”x11” paper, two-sided, hand- written original, hand in with exam