Ergonomics: Problem Identification and Financial Support GE Aviation Services - Strother

1. Presented by members of the Strother VPP Ergonomics Team: Jason Hawpe, Mike Kendall, Eli Coury Ergonomics: Problem Identification and Financial SupportGE Aviation Services - Strother

2. Ergonomics: • What is Ergonomics? The study of the design and arrangement of equipment so that people will interact with the equipment in healthy, comfortable, and efficient manner.

3. Ergonomics: • How will it help? Decrease injury. Increase productivity. Reduce cost. Increase quality.

4. Ergonomics: Getting Started • Team Formation • 1. Identify Key People • Representatives from all areas/departments • No personal agenda’s • 2. Set Meeting Times, Agenda, and Location • 3. Schedule meetings to combine shifts • 4. Involvement ,Open door policy • 5. Hourly/Salary team effort

5. Ergonomics: Contractor Providing Training to GE Team Donald E. Day, M. S. Consultant in Ergonomics and Health Promotion 5840 S. Goldsmith Place Greenwood Village, CO 80111 (303)773-0261 FAX(303)773-0271 e-mail: ergoday@earthlink.net web site: www.ergonomicsprocess.com

6. GE Strother/Winfield Ergonomics VPP Team Members (alphabetically) Members Names in Red are Here! Danny Beard , Engine Mechanic Drew Beard , Process Engineer Eric Befort ,Maintenance Mechanic Scott Branine , Supervisor Flo Bruner , Engine Mechanic Mike Evinger , Engine Mechanic Felicia Hall , Engine Mechanic Jesse Hollingsworth , Supervisor Eli Courey, Engine Mechanic Mike Kendall , Engine Mechanic John Klick , Engine Mechanic Brad Ziegler , Engine Mechanic , Process Engineer Jason Hawpe , Environmental Health and Safety Specialist Louis Zink , Engine Mechanic Jamie Brazda, Process Engineer Jake Auguinaga, Maintenance William Pirlot, Engine Mechanic Kenny Burg, Machinist Kirk Lewis, Process Engineer Brett Brown Dave Coberley, Engine Mechanic Amber Quint, Process Engineer Danny Herman, Machinist Art Saavedra, Welder Bob Thomas, Process Engineer

7. Ergonomics: Finding Projects Ask Employees Housekeeping Audit, look for problems Productivity Quality Escapes Injury Data Near Misses Damaged equipment

8. Ergonomics: • Project Identification • 1. Collect Data • 2. Start a Prioritization list • 3. Follow-up

9. Ergonomics: Things to look for Reach Weights Work height Frequency Grips Travel distance Posture

10. Data Collection

11. Data Collection

12. Data Collection

13. Example of Niosh Lifting Equation

14. Example of Rodgers Muscle Fatigue Analysis

15. Example of Rodgers Muscle Fatigue Analysis

16. Example of Rodgers Muscle Fatigue Analysis

17. Ergonomics: 20/20 Rule activity

18. Priority List

19. Project Identification (cont.) • 4. Patience • Timing • Start with projects that require minimal effort with maximum results • Don’t Try to Boil the Ocean Ergonomics:

20. Education • How do you get funding? • Budget • Plan • ROI • Project Justification Ergonomics:

21. Continue Education • Most of our Ergonomics Team training stems from the Original training from outside contractor. Each year we compete as a company in the Ergo cup competition. The categories are: • Team-driven Improvements • EHS driven Improvements • Program Improvement • We leverage within GE at every opportunity. Ergonomics:

22. Continue Education • There is an APP available for Niosh lift equation (htLiftCalc). • Rodgers muscle fatigue downloadable • We attend VPP Conferences to share best practices with other companies. Ergonomics: http://www.theergonomicscenter.com/graphics/ErgoAnalysis%20Software/Rodgers%20Smart%20Form.xls

23. Continue Education • Training for Engineering and design personnel at a local level. • Training for Sourcing personnel at a local level. • Basic Ergonomics training to all employees on site annually. Ergonomics:

24. Ergonomics: Describe and calculate (where possible) the financial “payback” of the project. Use the following equation to calculate the simple ROI. + Injury PreventionSavings Annual Operational Savings Simple ROI = Cost of Solution • Injury Prevention Savings calculations should use the following cost per injury or illness value. This value includes both direct and indirect costs. The direct costs were determined using GE US WC data. The indirect costs were calculated using the OSHA recommended multiplier of 1.1. • GE Average Cost per Musculoskeletal Injury or Illness = $38,500 • The Cost of the Solution should include the cost of materials & equipment, as well as the costs related to the implementation of the solution.

25. Examples of Strother Projects • LPT Shaft Cleaner • Hydraulic Lifts • AGB Transport/Ass’y/Dss’y Fixture • CF34 OTL Retainer Removal Tool • Fixture Storage Rack GE Strother Ergonomics Projects:

26. CFM56 Low Pressure Turbine Shaft Cleaning Operation The TEAM Ergo Cup Project Leader: Eric Befort - Maintenance Ergo Cup Project Team Member #1: Steve Holtke - Maintenance Ergo Cup Project Team Member #2: Mike Kendall – Ergo Team Leader Ergo Cup Project Team Member #3: Brad Ziegler – Ergo Team Member Ergo Cup Project Team Member #4: Donnie Welch – Maintenance Supv. Ergo Cup Project Team Member #5: John Postelwait – EHS Specialist Ergo Cup Project Team Member #6: Nick Bowker – Component Repair Team Leader Ergo Cup Project Team Member #6: Bill Hartman – Component Repair Supv. Ergo Cup Project Team Member #7: Tina Lister – Chem Clean Mechanic

27. Background • The Problem • Coking, a build up of carbon deposits from overheated oil, becomes caked on the inside of Low Pressure Turbine Shafts in jet engines. This must be removed for the engine to perform effectively. • Because of the manual cleaning process, inconsistency in the quality of cleaning the shafts existed. The performance of this cleaning activity was often very labor intensive, with the operator forced to spend hours running the drill motor to get the shafts clean. • Often this work had to be repeated because the shafts were not cleaned sufficiently the first time. This caused severe stress to the person performing cleaning operation. Injury History (past two years) • Two reported first aid cases • One OSHA Recordable case

28. “Before” Situation: Tina, our model, is about 5’ 4”. Bottle brush mounted on air drill used to clean inside diameter of hollow Low Pressure Turbine Shaft. Bottle brush is almost six foot long, and very unwieldy. High torque from air motor caused injuries to employees.

29. Background: Injuries Injuries had been reported regarding the use of the old drill motor. One of the two reported within the past two years was severe enough to become a recordable injury. Analysis tools were then used to evaluate and understand the true scope of the problem……

30. Background • Defining the Problem Using the “STEPS” Process

31. Background • Defining the Problem Using the “STEPS” Process

32. Background • Defining the Problem Using the “STEPS” Process

33. Design Phase: Maintenance designed this machine in a matter of minutes on some scratch paper. Maintenance then fabricated this new machine in just a few days. It was installed and operational in less than a month. Original Concept Drawing

34. “After”: Simplicity Machine is capable of being run in either automatic or manual mode. Manual mode allows the brush to “dwell” in a heavy coking area inside the shaft if necessary. Using original part transfer cart, machine is loaded, start button is pushed and operator “Walks-Off” to do another task while part is being cleaned.

35. “As-Built” Solution: Finished Machine

36. Improvement: Return on Investment • The project cost less than $5k to implement. • Savings projected came to $97K over a one year period with one injury, less the cost of the machine. • $$$ ACCOUNTANTS TAKE NOTE: $$$ • This is a R.O.I of about three weeks. • IT HAS PAID FOR ITSELF 10 TIMES AS OF FW35!

37. Component Repair Solvent Spray Booth Lift Mechanism The Team: Project Leader:Eric Befort – Maintenance Mechanic (Ergo Team Member) Project Team Member #1:John Postelwait – EHS Specialist (Ergo Team Member) Project Team Member #2:Shawn Czaplinski – Engine Mechanic Project Team Member #3:Mike Kendall – Engine Mechanic (Ergo Team Leader) Project Team Member #4:Tina Lister – Engine Mechanic Project Team Member #5:Kerry Hoskins – Engine Mechanic

38. “Before” Situation: • Solvent Spray Booth was previously installed as provided by the manufacturer at a fixed height of 33” from the floor to the working height of the booth tabletop. • The top of the cabinet was at a fixed height of 69”. • The mechanics load parts into the booth and degrease them with pressurized PD-680 type II solvent contained within an internal pump system in the machine.

39. Solution: 12” of height adjustment Simple, 2 button Controls “Bottom” Position of Booth “Top” Position of Booth

40. Solution: Video of Booth in Action Variance in Height of Affected Employees The guys in the pictures are 6’3” and 6’4”. The young lady is 5’4”.

41. Solution: Details Installed Hydraulic Lifts to physically raise/lower entire machine. This required that we also install flexible exhaust stack to allow movement of the booth, and also to install flexible conduit and air lines. Flexible Connections

42. Innovation • The team was faced with ways to make existing equipment ergonomically usable. • This ergonomic solution was successfully achieved with minimal modification to existing equipment/process. • This ergonomic improvement now provides employees a selection of different potential working heights using existing equipment . • The team has plans to leverage this technology to other process equipment in the shop. • Wet Blast Booths (4 each) • Solvent blast Booths (3 each) • Shot Peen Booths (2 each)

43. Business Impact ($26.7K) Potential Injury Prevention Savings = = 7 Weeks ROI Cost of Solution ($3.5K) Average Cost per Musculoskeletal Injury or Illness = $26,700 New equipment modifications to existing equipment makes this workstation more tolerable for all employees, providing a better work environment.

44. AGB Transport Container Project Leader: Clint Austin, Engine Mechanic Project Team Member #1: Eric Befort, Maintenance Project Team Member #2: Kevin Myers, Engine Mechanic Project Team Member #3: Danny Beard, Engine Mechanic Project Team Member #4: Mike Kendall, Engine Mechanic Project Team Member #5: Jeff Tipton, Maintenance Project Team Member #6: Karl Murphy, Engine Mechanic Project Team Member #7: Dale Luce, Engine Mechanic Work Leader

45. “Before” Situation: 1 The AGB weighs ~150 lbs. 2 Mechanics had to manually turn the AGB to allow tooling attachment & safe transport. 4 3

46. Risk Factor Evaluation Risk Factor Evaluation ranked as High “Before” Details • Engine mechanics designed this solution after suffering injuries. Their feedback drove this ergonomic project. • Summary of the injuries & illnesses: • Experienced multiple first aid injuries including pinched fingers and strained backs

47. “Before” Details Department of Health and Human Services Centers for Disease Control and Prevention National Institute for Occupational Safety and Health NIOSH Lifting Equation Recommended Ergonomic Intervention

48. New Cart Solution: • Solution Specifications: • Needed cart that was easy to load/unload and transport • Minimized the footprint of the storage • Able to load/unload using equipment already available to the engine mechanics, without manual lifting • Allow for safe transport between areas • Material Requirements:All materials were locally purchased. Manufactured in-house by our maintenance department from steel tubing, casters, etc.

49. 1st Prototype Difficult to load 2nd Prototype Still turning part. Not secured Judging Criteria #2:Study & Experimentation A hydraulic engine lift was already available. Four versions were built, with the fourth being our ultimate solution. The 2nd prototype was a modified plastic basket with casters and 3 sides removed to allow employees closer access to the part when lifting and turning. Originally, the 1st prototype was a long wooden box with pallet style feet. It could only be moved with forklifts.

50. 3rd Prototype Strap point in wrong position Judging Criteria #2:Study & Experimentation The third prototype looked much like the final product with casters, but was widened in the final version so it could accommodate gearboxes from multiple engine models. The final version also required the hold down strap location be modified, because the original location created a trip hazard and an “ankle-biter”. It is also equipped with a brake.