Introduction to Ergonomics on the Production Floor

Musculoskeletal injuries are one of the most common types of injuries in the workplace. The objective of an ergonomics program is to identify, evaluate, and fix the work areas, tools and job tasks that cause those injuries. Ideally ergonomics is a team-based approach that strives to better fit the tools, tasks and the workspace to the employee instead of forcing the employee to make-do with "standard" equipment and procedures (ie. not based on any ergonomic data).

As an example, how does a company identify the lifting requirements of an average employee for a specific job? Too often many companies base their reasoning off existing needs and equipment rather than the actual lifting ability of an average worker - and then wonder why workers are injured, or turnover is so high. An effective corporate ergonomics program can result in fewer injuries, better workplace flow, and higher production.

Liberty Mutual Insurance and NIOSH (National Institute of Occupational Safety and Health) researched lifting abilities (and other things like pushing and pulling abilities) of an extensive cross section of the population. This was originally done because Liberty Mutual was the insurer for UPS. (You can imagine why that information would be valuable as boxes get quite large, awkward, and heavy.) The results of those lifting studies have resulted in checklists, formulas, and tables to make it easier to determine what the recommended weights for lifting, etc for a given percentage (75%) of a workforce population. (See the first link.)

Work areas that need targeted for evaluation can be determined by several factors such as: areas of poor work-flow or frequent congestion; work areas with a history of musculoskeletal injuries (back strains, carpal tunnel, tendinitis, etc.); repetitive motion jobs; areas with a high turnover (employees tend to bid out of or leave areas that cause them pain, or is excessively physically demanding); etc.

Once you have determined which area to check first, you will need to pick one specific task to observe. Start by observing current work practices across all shifts. Employees do tasks a certain way for a reason. Older employees or those that have been at that task the longest will have found work-arounds to some problems that newer employees may not have. Filming these tasks can be helpful, but only if the employee doesn't fear he himself is being evaluated. Identify job tasks and procedures that can be improved upon (including housekeeping aspects and tools). Be sure to include the employee in determining problem areas or issues. You will find that most times minor changes such as table lifts to eliminate bending, ergonomically designed hand tools, layout changes to minimize twisting, adjusting sizes and weights of packages, etc. will make huge improvements to the area.

Management involvement in corporate ergonomics is a must. However employee engagement and empowerment is key. The employee is the one most susceptible to injury. They are the one responsible for accomplishing the task. Their opinions and ideas are critical to finding solutions. If you engage and empower the employee as part of the process, they will better understand what ergonomics achieves and will take ownership of their area including pointing out other areas that need improvement.

I am including some other links for you to check out. If you have other questions or want more specifics, please contact me. I'd be happy to help. If you'd like some of the formulas and tables for recommended maximum lifting weight, etc. just let me know.

Links
http://www.cdc.gov/niosh/docs/97-117/default.html
http://www.safetycenter.navy.mil
http://www.cdc.gov/niosh/topics/ergonomics
Washington State Department of Labor and Industries
Liberty Mutual
MSD Prevention Toolbox
Analysis Tools for Ergonomists