1. by Gary Jones Manager, EHS Affairs Graphic Arts Technical Foundation Printing Industries of America 412/741-6860garyjgatf@aol.com Developing the Printing Industry ’ s Ergonomics Guidelines by Danielle Waterfield Government Affairs Associate Specialty Graphic Imaging Association 703/359-1304 dwaterfield@sgia.org

2. Printing Industry Background Size and Scope Size and Scope –One of the Largest Manufacturing Industries –100,000 Establishments and 1.5 Million Employees –Over 80%of Printers Have Less Than 20 Employees Types of Printing Types of Printing –Divided By Process Lithography, Screen, Flexography, Gravure, Digital Lithography, Screen, Flexography, Gravure, Digital –Divided By Product Books, Magazines, Flyers, Textiles, Packaging, Wall Paper, Flooring, Electronics, Dashboards, etc. Books, Magazines, Flyers, Textiles, Packaging, Wall Paper, Flooring, Electronics, Dashboards, etc.

3. Printing Industry and Ergonomics Printing Industry’s Response Strongly Opposed OSHA’s Regulation Strongly Opposed OSHA’s Regulation –Not Opposed To Ergonomics Only the Regulation –One Size Fits All, Trigger, Risk Factors, Job Protection, Grandfathering and Costs Embraced OSHA’s Four Point Plan Embraced OSHA’s Four Point Plan –First Industry To Sign an Alliance: 1 st Alliance signed in June, 2002 –Re-signed Alliance In February 2004 –Agreed To Work With Each Other To Identify Solutions To Ergonomic Concerns In Printing

4. Printing Industry OSHA Ergo Alliance Implementation Fund Raising Campaign For Ergo Guides Fund Raising Campaign For Ergo Guides GATF Awarded OSHA Harwood Training Grant GATF Awarded OSHA Harwood Training Grant –Printing Specific Ergonomics Guidelines Assembled Ergo Guide Development Team Assembled Ergo Guide Development Team –Printing Industry Safety Professionals –Printing Industry Association Safety Professionals –Hired Professional Ergonomist Dr. Phyllis King – U of Wisconsin Dr. Phyllis King – U of Wisconsin

5. Printing Industry OSHA Ergo Alliance Implementation Compiled Guidelines Compiled Guidelines –Collected Information On Existing Printer Programs –Conducted Plant Visits –Evaluated Options –Produced Suggested Solutions Developed Support Material Developed Support Material –Video –Fact Sheets and Pocket Cards –Leaders Guide

6. Printing Ergonomics Guidelines Design Principles Helpful But Not Prescriptive Helpful But Not Prescriptive Provide Basic Ergo Information Provide Basic Ergo Information –Assessments and Solutions Provide Specific Solutions Provide Specific Solutions –Focus On Jobs With Highest Injury Rates –Present Info On Printing Process Category Identify Additional Resources Identify Additional Resources Provide Material Appropriate For Audience Provide Material Appropriate For Audience Incorporate Visual Images Incorporate Visual Images

7. Printing Ergonomics Train-the-Trainer Program Materials Leaders Guide Leaders Guide –Guide for Presenting Material Guide Book Guide Book –Reference Guide for EHS, HR, Supervisors Facility Checklists Facility Checklists –General Awareness and Task Specific Fact Sheets Fact Sheets –10-12 for Supervisors and Employees Pocket Cards Pocket Cards –10-12 for Supervisors and Employees Videotape and MS PowerPoints Videotape and MS PowerPoints –For Employee Training - 1 Hour

8. Printing Ergonomics Train-the-Trainer Program Leader’s Guide Learning Process Learning Process Learning Styles Learning Styles Teaching Methods Teaching Methods Planning For Training Planning For Training Ergonomics Program Overview and Materials Ergonomics Program Overview and Materials

9. Printing Ergonomics Train-the-Trainer Program Employer Guidebook Introduction Introduction –Ergonomic Issues & Benefits Program Approaches Program Approaches –Mgt & Employee Participation Worksite Evaluation Worksite Evaluation –Find, evaluate, and identify solutions Controlling Ergonomic Issues Controlling Ergonomic Issues –Office Ergonomics –Common Solutions

10. Printing Ergonomics Train-the-Trainer Program Pre-Press –Plate Making –Stencil and Screen Preparation –Material Handling –Cleaning screen mesh –Computerized data and design inputPress –Loading/unloading paper on presses –Handling screens –Roll tending on web pre-press –Distribution of ink through screens –Stacking materials –Unloading/bundling signatures on presses Guidebook Worksite Focus Areas

11. Printing Ergonomics Train-the-Trainer Program Post Press –Guillotine operation and blade handling –Stencil removal from screens –Jogging and fanning –Pocket feeding –Loading finished bundles/products into boxes Shipping –Bagging mail –Loading/unloading trucks –Palletizing/shrink wrapping/strapping

12. Printing Ergonomics Train-the-Trainer Program Employer Guidebook Toolbox –Glossary –Ergonomic Factor Checklists –Ergonomic Factsheets –Pocket Cards –References –Contacts and Hotlinks

13. Printing Ergonomics Train-the-Trainer Program Facility Checklists General Awareness General Awareness –Preliminary Evaluation Task Specific Task Specific –Office & Computer Workstations –General Shop Workstations –Material Handling –Hand Tool Analysis –Production Activities

14. Printing Ergonomics Train-the-Trainer Program Fact Sheets One-Two Pages Long One-Two Pages Long Describes Ergonomic Issues and Solutions For A Particular Job Describes Ergonomic Issues and Solutions For A Particular Job Contains Images Showing Issues and/or Solutions Contains Images Showing Issues and/or Solutions

15. Printing Ergonomics Train-the-Trainer Program Pocket Cards Designed For Pockets Designed For Pockets –Laminated Provides Short Statements On Correct and Incorrect Practices For A Specific Job Provides Short Statements On Correct and Incorrect Practices For A Specific Job –Wrong vs. Right Contains Images Showing Wrong and Right Contains Images Showing Wrong and Right

16. Printing Ergonomics Train-the-Trainer Program Training Instruction Sample MS PowerPoint Slides Adult Learning Adult Learning –For Training Trainers On Presenting Material Ergonomics Trainer Ergonomics Trainer –Detailed Ergo Info and Areas of Concern/Solutions Employee Training Employee Training –Includes Basic Ergo Info Areas of Concern/Solutions –What’s Wrong With This Picture

17. Printing Ergonomics Train-the-Trainer Program Video - Working Smarter, Not Harder Provides General Awareness On Ergonomics Provides General Awareness On Ergonomics –15 Minutes Long Presents Printing Perspective Presents Printing Perspective –Common Risk Factors or Stressors Includes Examples With Suggestions On How Employees Can Do Their Jobs Safer Includes Examples With Suggestions On How Employees Can Do Their Jobs Safer

18. Printing Ergonomics Train-the-Trainer Program Training CD ROM Containing: –Electronic Fact Sheets –Extra Checklists –Sample MS PowerPoint Presentations –Training Evaluation Form –Employee Sign-in Sheets

19. Printing Ergonomics Train-the-Trainer Program Next Steps Materials Ready For Distribution Materials Ready For Distribution –Available for members and non- members Conduct Training Conduct Training –Train-the-Trainer Training at GATF –Regional Train-the-Trainer By PIA Affiliates –Web conferences conducted by SGIA Evaluation Evaluation

20. Printing Industry and Ergonomics Questions?