Design Error

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

2. The study of man's relationship with his workplace. Fitting the task to the man 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. What is Ergonomics?

3. Ergonomics Balance for Optimization Worker Capabilities Job Demands

4. Ergonomics CUMULATIVE TRAUMA DISORDERS (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.

5. Cumulative Trauma Disorders Your Job Trauma Your Body Healing Valve

6. Cumulative Trauma Disorders Your Job Trauma Your Body CTD Healing Valve

7. Production Quality Compliance Compensation Costs Ergonomics Win - Win Healthy Workforce Careers/Employment Safety Working Conditions

8. Ergonomics OSHAct 1970"General Duty Clause" DUTIES Section 5. (a) Each employer - (1) shall furnish to each of his 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 employees;

9. Ergonomics Voluntary Guidelines o OSHA Meatpacking Guidelines o General Industry Guidelines (dropped in lieu of standard) o Food Distribution Warehouses o ANSI HFS-100/1988; VDTs o ANSI Z-365; Control of CTDs

10. Ergonomics Nature of Injury Burns 3% Amputations 1% Contusions 9% Occ Illness 4% Dislocations 2% F.B. in Eye 3% CTDs 5% Fractures 9% Laceration/Puncture 11% Strains/Sprains 43% 1990 Ohio Injury/Illness Claims Information

11. Ergonomics Part of Body Arms 12% Hands 5% Trunk/Internal 11% Fingers 11% Back 20% Legs 13% Feet/Toes 5% Face/Neck 3% Mult/Major 13% Head 2% Other 15% Eyes 4% 1990 Ohio Injury/Illness Claims Information

12. Ergonomics CTD Recognition Rising In 1990, 59% of all Occupational Illness Claims are logged as CTDs One half of all CTD claims are logged as Carpal Tunnel Syndrome (CTS)

13. Ergonomics Ohio Back Injury Claims In 1990, $513 M was paid out by the BWC for back injuries alone

14. Ergonomics Average Total Claim Cost Direct Costs = Medical + Comp + Reserve Indirect costs are estimated anywhere from 4 up to 20 times direct costs 1980-1983 BWC data (Thousands)

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

16. Worksite AnalysisKey Elements I. Records Analysis

17. Worksite Analysis Records Analyses help identify & prioritize jobs to evaluate. Accident Production Personnel Employer/Employee Records Records Records Survey OSHA log 200 Seasonal Trends Turn-over Rate Symptoms survey Incidence Rate Quality Control Absenteeism Early reporting mechanism Prevalence Rate Model Changes Suggestion award program First-aid logs Bottlenecks Accident Invest. Workers’ Comp.

18. Worksite AnalysisKey Elements I. Records Analysis II. Risk Factor Recognition

19. OCCUPATIONAL RISK FACTORS Attributes of a job or task that we know increase the probability of developing a musculoskeletal cumulative trauma disorder (CTD) • FORCE (Internal & External) • POSTURE • REPETITION • INSUFFICIENT REST Worksite Analysis

20. OCCUPATIONAL RISK FACTORS Attributes of a job or task that we know increase the probability of developing a musculoskeletal cumulative trauma disorder (CTD) • FORCE (Internal & External) • POSTURE • REPETITION • INSUFFICIENT REST Worksite Analysis

21. Synovial Sheaths Extensor Tendons Carpal Ligament (Extensor Retinaculum)

23. TWO KINDS OF BACK INJURIES MUSCULAR SPINAL

24. Resting Dynamic Static blood flow supplied blood flow needed blood flow supplied blood flow needed blood flow needed blood flow supplied

25. Top View Vertebrae Side View

26. Micro-fractures in Vertebral Endplate Scar tissue from healing fractures hinders passage of nutrients to disc resulting in gradual weakening and de-generation.

27. Disc Degeneration

28. Ergonomics Hierarchy of Controls Engineering Controls FIRST CHOICE Workstation Design Tool Design Process Modification Mechanical Assist Administrative Controls Training Job Rotation Pacing Policy Job Enlargement Second Choice Personal Protective Equipment Gloves Wraps Shields Last & Least

29. BACKINJURIES

37. DECISION MAKING • LOW REPETITION ACTIVITIES • LOW FORCE APPLICATION • DELICATE FORCE APPLICATION • TAKING INSTRUCTION • HIGH REPETITION ACTIVITIES • HIGH FORCE APPLICATION • HAZARDOUS ENVIRONMENTS MAN VS. MACHINE

38. STATURE EYE 69.1” 68.6” 65.2” 65.1” N.A. E. A. L.A. 64.6” 64.4” 60.7” 60.9” N.A. E. A. L.A. SHOULDER 50th PERCENTILE MALE N.A. E. A. L.A. 56.7” 56.5” 52.8” 53.2” ELBOW N.A. E. A. L.A. 43.5” 43.3” 40.8” 40.9” HIP N.A. E. A. L.A. 36.0” 36.4” 32.7” 34.0” KNEE N.A. E. A. L.A. 21.67” 21.5” 19.3” 20.0” N.A.= NORTH AMERICA E.= EUROPE A.= ASIA L.A.= LATIN AMERICA

39. Horizontal Work Envelope E D B C A A-Normal reach radius B-Sitting/Standing distance C-Extended reach radius D-Beginning work distance E-Optimum work area Max = 15” Max = 9” Max = 22” Ideal = 4” 10” x 10”

40. SIT OR STAND? Type of Task Lifting more than 11lbs Work below elbow height (e.g. packaging or assembly) Extended horizontal reaching Light assembly with repetitive movements Fine manipulation and precision tasks visual inspection and monitoring Frequent moving around First Choice Standing Standing Standing Sitting Sitting Sitting Sit-Standing Second Choice Sit-Standing Sit-Standing Sit-Standing Sit-Standing Sit-Standing Sit-Standing Standing

44. Manual Tool Dimensions A > 4” B = (for power grips) 1.5” C = 3” to 3.5” (for precision operations) .45”