Ben Zavitz, CPE Ergonomist 207-442-2219 Benjamin.zavitz@gdbiw

1. Shipyard Ergonomics 2013 Marine Chemist Association Ben Zavitz, CPE Ergonomist 207-442-2219 Benjamin.zavitz@gdbiw.com

2. Agenda • Introduction to Ergonomics • Definition, Objectives, Risk Factors, Injuries • Human Performance View of Ergo • OSHA & Ergonomics • Shipyard Ergonomic Solutions

3. What is Ergonomics? "Fitting" Work To People Science of optimizing jobs, equipment, tools, and workplace to fit people based on human capabilities and limitations

4. Injury Perspective Reduce Risk of Injury Employee Pain / Discomfort Recordable / Lost Time Injuries Workers Compensation $ Return To Work OSHA Responsibilities Objective of Ergonomics Workers Comp Ergo Medical Safety Traditional View of Ergonomics

5. Human Performance Perspective Maximize Human Performance & Efficiency Reducing Non-Value Added Motions Overburden of human systems Internal Productivity Same amount of work with less effort More work within confines of human biological & psychological systems Objective of Ergonomics Engineering & Design Ergo Quality Management Human Performance View of Ergonomics

6. Internal Productivity Demo

7. Overburden Example 75% employees injured Job requires a repetitive grip force of 75lbs Average max. female grip strength is 75lbs Job demands require 100% effort and resulted in “overburden” of the person to the point of injury Job was designed without human capabilities in mind

8. What are MSDs (musculoskeletal disorders)? Overuse injuries (similar to athletics) Repetitive Strain Injuries (RSIs) Cumulative Trauma Disorders (CTDs) Soft tissue injuries nerves, tendons, muscles, ligaments wrists, elbows, shoulder, back, neck, knees Develop gradually over time symptoms last longer than few days fatigue, pain, discomfort, inflammation, numbness when symptoms don’t go away = serious lost work days, permanent disability or surgery Report symptoms early, Identify Risks & Solve

9. Ergonomic Risk Factors

10. OSHA & Ergonomics Does OSHA have a Federal Ergonomics Standard?

11. OSHA Ergonomics History 1970: OSH Act signed 1978: OSHA 1st Ergo citation to Eastman Kodak ($4,320) 1979: OSHA hires Dr. Roger Stephens as its 1st Ergonomist 1983: OSHA offers 1st Ergo training course 1987: OSHA Office of Technical Support issues 1st Ergonomics Directive, CPL 2.78 (still in effect)

12. OSHA Ergonomics History • 1987 -1992: OSHA issues significant citations: • 1987: International Beef ($2M) • 1988: John Morrell Meatpacking($4.3M) • 1988-1996: Pepperidge Farms ($1.4M) • 1992-2000: Beverly Nursing Homes • 1989-1993: Chrysler, Ford, GM, Honda • 1999: OSHA promulgates Ergo Standard • 2001: Congress rescinds standard using the Congressional Review Act (for the first/only time) • OSHA returns to the General Duty Clause • 2002 – Present: Industry Guidelines

13. OSHA will place special emphasis on industries using the “General Duty Clause” (Section 5 (a)(1) of the OSHA Act) where ergonomic hazards exist and employers are not making good faith efforts to prevent injuries. OSHA Enforcement Policy

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

15. To support a General Duty Clause citation, OSHA must be able to prove a hazard is: Present Recognized by the employer or its industry Causing or likely to cause serious physical harm Feasible means of abatement that will reduce or eliminate exposures to employees. Criteria for 5(a)(1) Violations

16. 5(a)(1) Criteria: Evidence of Hazards Is an Ergo Hazard Present and Recognized? Injury Data OSHA 300 Logs Workers’ Compensation Claims Clinic visits First-aid records Medical records review Worker complaints/worker interviews References to trade publications, insurance reports, etc.

17. Causing or likely to cause serious physical harm? Company injury records No records NIOSH Studies National Academies Studies Industry Studies 5(a)(1) Criteria: Causation

18. NIOSH Report (1997) Risk factors are specific to certain body parts

19. National Academies (2001) Request from Congress to examine the causation, diagnosis, and prevention of musculoskeletal disorders Panel on MSDs and the Workplace was established by the National Research Council (NRC) and the Institute of Medicine (IOM) in Jan 1999 2 year study of workplace physical and psychosocial factors in the occurrence of MSDs of back and upper extremities and the effectiveness of various prevention strategies

20. Panel Results Risk Estimates Conceptual Model

21. Feasible means of abatement that will reduce or eliminate exposures to employees Industry Studies and Guidelines (NIOSH, OSHA) 5(a)(1) Criteria: Feasible Abatement

22. Voluntary and flexible Failure to implement is not a violation Industry & Task Specific Guidelines Nursing Homes (March, 2003) Retail Grocery (May, 2003) Poultry Processing (September, 2004) Shipyards (March, 2008) Foundaries (2012) Uses stakeholder info & best practices Public participation in guideline development process Ergo Guidelines Published by OSHA

23. OSHA Ergo Guidelines Process for Protecting Workers Management Support Involve Employees Provide Training Identify Problems Implement Solutions Address Reports of Injuries Evaluate Ergonomic Efforts Implementing Solutions Description, when to use, points to remember

24. Shipyard Solutions Site-wide Material/equip handling Tools Metal work Shipside PPE BEFORE AFTER BEFORE AFTER

25. Inspections in the last 10 years: 5,046 Ergonomic-related Inspections 23 Citations issued 850 Ergonomic Hazard Alert Letters issued OSHA Ergonomics Enforcement

26. OSHA will: Assess the extent of unaddressed ergo hazards Identify existing efforts by employer in addressing ergo hazards and determine if need for further employer intervention. If warranted, send employer an Ergonomics Hazard Alert Letter (EHAL). Where 5(a)(1) cannot be supported

27. Not a citation. The letter will: Identify exposed employees, observed conditions that pose risk factors, incident and severity rates. Provide examples of solutions that may reduce or eliminate risk factors, including suggestion of components of an effective ergonomics program. List resources for assistance. What is an EHAL?

28. OSHA will review employer’s response If the employer does not respond, OSHA will contact the employer within 1 year for follow-up OSHA will likely request: Documentation of any control measures implemented, including those recommended in the initial EHAL Copies of OSHA 300 Logs of Injuries and Illnesses Work hours of exposed employees for given years OSHA may conduct an inspection if there is no response or the response is inadequate OSHA EHAL Follow-Up

29. Beverage Distribution Industry - Summer, 2011 Industry-Wide Alert Letters

30. Beverage Distribution Letter sent to: Alert employers of higher than usual rate of MSDs in the industry Raise awareness to well-known, available technology to address hazards Refer employers to existing NIOSH guidance Encourage proactive efforts to address hazards Industry-Wide Alert Letters

31. EHAL Impacts Not a citation … yet Lays the groundwork for a 5(a)(1) violation if the employer does not address the issues Establishes a hazard Establishes it as recognized Establishes a link between the hazard and serious physical injury Identifies feasible means of abatement

32. So... How do we keep OSHA out of our hair and have a proactive program ?

33. Ergonomic Data

34. Ergonomic Data Sources Three types of data sources available: • Historical - Injury rates • Current - Employee surveys/questionnaires • Predictive - Identify risk factors and poor human performance • Checklists (audit form) • Guidelines (NIOSH Lifting Equation), • Computer Models (3D SSPP, HumanCAD) • Direct Measurement (Vibration, EMG)

35. Work Position Is Important Work position and is one of the most important factors in determining: • Strength • Endurance • Rate of Fatigue • Risk of Injury When performing a task that involve a lift, push, pull, or reach, ask yourself “Am I in the Best Position”?

36. Work Position Visual Back, Neck, Shoulders, Elbows, Knees

37. Test Your Knowledge

38. Test Your Knowledge

39. Raise-the-Work

40. Walk Behind Grinders BEFORE 95% Risk Reduction Eliminates Kneeling, Bending, Vibratory Tool 80% Improvement Productivity AFTER

41. Hand Arm Vibration Is there a US Standard? • Only for tool manufacturers • Professional guidelines (ISO, ANSI, ACGIH) • Unloaded value There a European Standard • For tool users • Loaded value Unloaded ISO Standard (8662) Loaded ISO Standard (5349)

42. Vibration Measurements • Acceleration measured in meters per second squared (m/sec²) • European Standard for Hand-Arm Vibration Exposure: • Daily Exposure Action Value:2.5 m/sec² (8hrs) • Daily Exposure Limit Value:5.0 m/sec² (8 hrs)

43. Measuring Acceleration

44. Exposure Time- Ready Reckoner All values are exposure points Colors show exposures EAV & ELV

45. “Super Grinder” Stone Grinder 65+% less vibration 2-3x removal rate 1/3 weight

46. Low Vibration Tools 70-90% Less Vibration Old Needle Gun Old - Die Grinders 75% less vibration 20% more removal

47. Long Reach Needlegun 75+% less vibration Eliminates Kneeling Weight holds it down

48. Mechanized Grinding 95% Risk Reduction Eliminates force, rep. motion, vibration 50% Improvement Productivity 50% less consumables 2012 Ergo Cup Winner

49. Weld Shaver 95% Risk Reduction Eliminates force, rep. motion, vibration from hand grinding 40x faster

50. Blasting Low Ergonomic Risk 90% Time Savings