Occupational Ergonomics: An Introductory Course

1. OCCUPATIONAL ERGONOMICS AN INTRODUCTORY COURSE WELCOME

2. COURSE OBJECTIVES • INTRODUCE ERGONOMICS AS A SAFETY SCIENCE & ESTABLISH ITS ROLE IN TODAY’S INDUSTRY. • INTRODUCE SOME BASIC SKILLS IN THE RECOGNITION & CONTROL OF OCCUPATIONAL ERGONOMIC HAZARDS. • PROVIDE BASIC RECOGNITION SKILLS FOR SUPERVISORS • DEFINE ERGONOMICS (DISPEL MYTHS).

3. COURSE OBJECTIVES (Continued) NOTE This Course Is Designed to Introduce Basic Skills in the Recognition of Ergonomic Stressors, It Will Not Make You an Expert. If You Feel That the Requirements of Your Job Are Above Your Level of Expertise the Services of a Professional Ergonomist or Medical Professional Should Be Sought.

4. BASIS FOR THIS COURSE • THOUSANDS OF WORKERS CAN BENEFIT FROM ERGONOMICS • DAILY EXPOSURE TO NUMEROUS ERGONOMIC STRESSORS • DAILY EXPOSURE TO NUMEROUS PHYSICAL HAZARDS • EFFICIENCY CAN BE GREATLY IMPROVED • OSHA SAFETY STANDARDS REQUIRE: • Establishment of a “safety” program • Training be conducted • Ergonomic stressors be assessed • Hazards and precautions be explained

5. 29 CODE OF FEDERAL REGULATIONS (PROPOSED REGULATION IN DEVELOPMENT) 29 CFR 1903.1, THE GENERAL DUTY CLAUSE ANSI HFS-100/1988, VIDEO DISPLAY TERMINALS ANSI Z-365; CONTROL OF CUMULATIVE TRAUMA DISORDERS MEATPACKING PLANT GUIDELINES (Previously) NIOSH LIFTING GUIDELINES (Beyond Scope) APPLICABLE REGULATIONS

6. GENERAL PROGRAM REQUIREMENTS ALL EMPLOYERS MUST: • REVIEW JOB SPECIFIC HAZARDS • INSTITUTE SAFE WORK PRACTICES • CONDUCT ERGONOMIC ASSESSMENTS • PROVIDE COMPLETE HAZARD INFORMATION • PROVIDE HEALTH SCREENING WHERE NEEDED • PROVIDE TRAINING TO ALL REQUIRED EMPLOYEES • INSTALL ENGINEERING CONTROLS WHERE POSSIBLE

7. TRAINING REQUIREMENTS • THE EMPLOYER MUST: • DETERMINE ERGONOMIC STRESSORS. • DISCUSS EMPLOYEE PROTECTIVE MEASURES. • REVIEW THE PROGRAM ON AN ANNUAL BASIS. • TRAIN ALL EMPLOYEES PRIOR TO JOB ASSIGNMENT. • DISCUSS PERIPHERALS SUCH AS LOCKOUT AND CONFINED • SPACES.

8. RETRAINING REQUIREMENTS • REQUIRED WHEN THERE IS A: • CLOSE-CALL EVENT • PROGRAM RELATED INJURY • CHANGE IN JOB ASSIGNMENT • NEW HAZARD OR EQUIPMENT • NEW HAZARD CONTROL METHODS • FAILURE IN THE SAFETY PROCEDURES • REASON TO DOUBT EMPLOYEE PROFICIENCY

9. The study of man’s relationship with his or her workplace. Fitting the task to the person rather than forcing him/her to adapt to the work environment. Designing the workplace to prevent occupational injury and illness. ERGONOMICS DEFINED VARIOUS AUTHORS DEFINE ERGONOMICS AS:

10. Discovering the capabilities and limitations of the human body. The art and science that addresses workers’ job performance and well-being in relation to their job tasks, tools, equipment and environment. The study of the relationship between people and machines or between employees and their environment. ERGONOMICS DEFINED (Continued) VARIOUS AUTHORS DEFINE ERGONOMICS AS:

11. The study of the interaction between the worker and the process at the workplace. ERGONOMICS DEFINED (Continued) VARIOUS AUTHORS DEFINE ERGONOMICS AS: WHAT OTHER DEFINITIONS HAVE YOU HEARD?

12. Improve quality. Improve absenteeism. Maintain a healthier work force. Reduce injury and illness rates. Acceptance of high-turnover jobs. Workers feel good about their work. Reduce workers’ compensation costs. Elevate OSHA compliance to a higher level of awareness. ERGONOMICS IS IMPORTANT ERGONOMICS PLAYS A ROLE IN APPROXIMATELY 50% OF ALL WORKPLACE INJURIES. ERGONOMICS WILL HELP:

13. ERGONOMICS IS IMPORTANT “It is estimated that in the United States, 97% of the money spent for medical care is directed toward treatment of an illness, injury or disability. Only 3% is spent on prevention.” Self-help Manual for your Back H. Duane Saunders, MSPT by Educational Opportunities

14. ERGONOMICS A MULTI-DISCIPLINARY APPROACH THINK ABOUT THE NUMBER OF WAYS ERGONOMICS IMPACTS OUR DAILY LIFE!

15. ERGONOMICS A MULTI-DISCIPLINARY APPROACH FOR EXAMPLE! THE SCIENCE OF ERGONOMICS IS CRITICALLY IMPORTANT IN THE CONTINUING DEVELOPMENT OF THE AUTOMOBILE!

16. Economics Sociology Physiology Psychology Biomechanics Physical Sciences Management Philosophies Engineering, Industrial Design Safety & Health, Human Factors Engineering ERGONOMICS A MULTI-DISCIPLINARY APPROACH THE FOLLOWING DISCIPLINES HAVE PLAYED A ROLE IN DEVELOPMENT OF THE AUTOMOBILE:

17. PERSONAL INTEREST DEDICATION MANAGEMENT COMMITMENT PROGRAM IMPLEMENTATION IMPLEMENTATION OF AN ERGONOMIC PROGRAM REQUIRES: NOTE: UNDERSTANDING AND SUPPORT FROM THE WORK FORCE IS ESSENTIAL, WITHOUT IT THE PROGRAM WILL FAIL!

18. WORK STATION DESIGN TOOL SELECTION AND DESIGN OFFICE SAFETY IMPROVEMENT VIDEO DISPLAY TERMINALS (VDT’S) SAFETY BACK INJURY REDUCTION AND PREVENTION MANUAL MATERIAL HANDLING IMPROVEMENT CUMULATIVE TRAUMA DISORDER (CTD) REDUCTION TYPICAL APPLICATIONS APPLICATIONS

19. RECOGNITION A determination of whether there are ergonomics related problems in the workplace. EVALUATION An identification of the nature and location of the problems. CONTROL The introduction of measures designed to eliminate or reduce the hazards. IMPLEMENTATION STRATEGY

20. TRAINING WORKSITE ANALYSIS MEDICAL MANAGEMENT ERGONOMICS WORKING GROUP HAZARD PREVENTION AND CONTROL KEY PROGRAM ELEMENTS

21. TRAINING JOB-SPECIFIC TRAINING TRAINING FOR ENGINEERS ANNUAL AWARENESS TRAINING TRAINING FOR: - Affected employees - Managers - Supervisors - Maintenance personnel KEY PROGRAM ELEMENTS(Continued)

22. WORKSITE ANALYSIS RECORDS REVIEW PERIODIC SURVEYS HAZARDS ANALYSIS SYSTEMATIC SITE ANALYSIS KEY PROGRAM ELEMENTS(Continued)

23. MEDICAL MANAGEMENT Follow-up Recordkeeping Symptom surveys Health surveillance Classify job demands Disability management Establish treatment protocols Periodic reviews with physicians Early symptoms reporting mechanism Health care providers must be part of the program KEY PROGRAM ELEMENTS(Continued)

24. ERGONOMICS WORKING GROUP WRITTEN PROGRAM EMPLOYEE INVOLVEMENT TOP MANAGEMENT COMMITMENT REGULAR PROGRAM ACTIVITY, REVIEW AND EVALUATION KEY PROGRAM ELEMENTS(Continued)

25. HAZARD PREVENTION AND CONTROL PPE REDUCTION ENGINEERING CONTROLS ADMINISTRATIVE CONTROLS OPTIMIZATION OF WORK PRACTICES KEY PROGRAM ELEMENTS(Continued)

26. CONSIDER THE FOLLOWING: THE SUPERVISOR’S ROLE • 1. DO (OR GET INVOLVED IN) THE ACCIDENT INVESTIGATION. • 2. IF YOU FEEL ERGONOMICS IS A FACTOR, OBTAIN • ASSISTANCE (IF NEEDED) FROM EXPERTS IN THE FIELD OF CONCERN. • 3. COMPLETE THE PAPERWORK (WORK ORDERS, POLICY • CHANGES, ETC.) TO MAKE CORRECTIVE ACTIONS. • 4. FOLLOW-UP ON THE ACTIONS YOU TOOK.

27. HOW TO DETERMINE IF ERGONOMICS PLAYS A ROLE (ERGONOMIC HAZARD INDICATORS): 1. STRAINS AND SPRAINS OFTEN RESULT FROM WORK ACTIVITY THAT CAN BE ALLEVIATED THROUGH ERGONOMIC IMPROVEMENTS. 2. IF WORKERS COMPLAIN ABOUT PAIN OR FATIGUE IN SPECIFIC MUSCLE GROUPS OR BODY PARTS. 3. HIGH TURNOVER RATES OF EMPLOYEES IN CERTAIN JOBS IS AN INDICATOR THAT AN ERGONOMIC ASSESSMENT SHOULD BE CONDUCTED. THE SUPERVISOR’S ROLE (Continued)

28. WRITTEN PROGRAMS MUST BE: DEVELOPED IMPLEMENTED CONTROLLED PERIODICALLY REVIEWED WRITTEN PROGRAM WHEN THE FINAL RULE FOR ERGONOMICS IS INTRODUCED

29. HEALTH SURVEILLANCE INCLUDES: EMPLOYEE BASELINES - (physicals). EMPLOYEE NOTIFICATION. EMPLOYEE’S SHOULD BE NOTIFIED WHEN THEY ARE PLACED IN JOB DESCRIPTIONS WITH KNOWN STRESSORS. PERIODIC HEALTH SURVEILLANCE - MONITORING THE STATUS OF KNOWN PROBLEMS OR LOOKING FOR THE BEGINNING OF PROBLEMS ASSOCIATED WITH THE JOB. HEALTH SURVEILLANCE

30. Hold regular meetings Document meetings Committees encourage employee involvement Employee complaints, suggestions, or concerns can be brought to the attention of management. Feedback without fear of reprisal should be provided to all employees The committee should analyze statistical data concerning ergonomic stressors, and make recommendations for corrective action Follow-up is critical ERGONOMICS WORKING GROUP

31. Employee surveys. Review of results of facility evaluations. Analysis of trends in injury/illness rates. Up-to-date records of logs of job improvements tried or implemented. Before and after surveys/evaluations of job/worksite changes. PROGRAM REVIEW AND EVALUATION EVALUATION TECHNIQUES INCLUDE:

32. INDUSTRIAL HYGIENE AND ERGONOMIC CONTROLS • ENGINEERING CONTROLS FIRST CHOICE •  Work Station Design  Tool Selection and Design •  Process Modification  Mechanical Assist •  ADMINISTRATIVE CONTROLS SECOND CHOICE •  Training Programs  Job Rotation/Enlargement •  Pacing  Policy and Procedures •  PERSONNEL PROTECTIVE EQUIPMENT LAST CHOICE •  Gloves  Wraps •  Shields  Eye Protection •  Non-Slip Shoes  Aprons

33. OCCUPATIONAL RISK FACTORS: Occupational risk factors are defined as any attribute of a job or task that we know increases the probability of injury or illness. INDUSTRIAL HYGIENE AND ERGONOMIC CONTROLS • INAPPROPRIATE 1. Force - Including- Internal or External 2. Posture - Such as - Extreme Twisting or Bending 3. Repetition - Including- Muscle Group Overexertion 4. Insufficient Rest - Including- Muscle Group Overexertion

34. WORKSITE ANALYSIS IS DIVIDED INTO FOUR MAIN PARTS: WORKSITE ANALYSIS 1. Gathering information from available sources. 2. Conducting baseline screening surveys to determine which jobs need a closer analysis. 3. Performing ergonomic job hazard analyses of those work stations with identified risk factors. 4. After implementing control measures, conducting periodic surveys and follow-up to evaluate changes.

35. WORKSITE ANALYSIS Continued • TANGIBLE INDICATORS: • Accident Records • Production Records • Personnel Records • Employee Surveys

36. WORKSITE ANALYSIS Continued SYMPTOM SURVEY 1. NOTE AREAS OF PAIN OR DISCOMFORT! 2. WHAT DO YOU FEEL IS THE SOURCE? 3. WHAT ENVIRONMENTAL CHANGES WOULD HELP? 4. WHAT OTHER FEEDBACK CAN BE GATHERED? BACK FRONT

37. WORKSITE ANALYSIS Continued WHAT TANGIBLE INDICATORS WOULD BE MOST USEFUL TO YOU?

38. INCIDENCE RATES: incidence rates for upper extremity disorders and/or back injuries should be calculated by counting the incidences of CTDs and reporting the incidences per 100 full time workers per year per facility. (NUMBER OF NEW CASES (200,000 WORK HRS*) PER FACILITY NUMBER OF HOURS WORKED/FACILITY/YR INCIDENCE RATE INCIDENCE RATES * 200,000 = APPROXIMATE ANNUAL WORK HOURS FOR 100 WORKERS. * THE SAME METHOD SHOULD BE APPLIED TO DEPARTMENTS, PRODUCTION LINES, OR JOB TYPES WITHIN EACH FACILITY.

39. 2 X 200,000 100 X (50 X 40 hrs) IR = 400,000 200,000 IR = 2 CASES OF CARPAL TUNNEL PER 100 PERSON-YEARS OF EXPOSURE IR = INCIDENCE RATES(Continued)  SAMPLE INCIDENCE RATE CALCULATION: (NUMBER OF NEW CASES (200,000 WORK HRS*) PER FACILITY NUMBER OF HOURS WORKED/FACILITY/YR IF YOU EXPERIENCED 2 CARPAL TUNNEL CASES LAST YEAR, IN A POPULATION OF 100 EMPLOYEES. WHAT IS THE INCIDENCE RATE? * 200,000 = APPROXIMATE ANNUAL WORK HOURS FOR 100 WORKERS. * THE SAME METHOD SHOULD BE APPLIED TO DEPARTMENTS, PRODUCTION LINES, OR JOB TYPES WITHIN EACH FACILITY.

40. ANTHROPOMETRY DEFINED • ANTHROPOMETRY: • The technology of measuring and quantifying various human physical traits such as size, weight, proportion, mobility and strength.

41. ANTHROPOMETRY DEFINED • ENGINEERING • ANTHROPOMETRY: • The application of anthropometric data to equipment, workplace and job design to enhance the efficiency, safety and comfort of the operator.

42. MEN WOMEN Physical Dimension 5th 50th 95th 5th 50th 95th 1. Stature 64.0 62.5 73.0 59.3 63.4 67.3 2. Eye ht. 59.6 64.2 68.7 55.3 59.3 63.4 3. Hip ht. 33.1 36.2 39.4 29.1 31.9 42.7 4. Elbow ht. 39.6 42.9 46.5 36.6 39.6 42.7 ANTHROPOMETRIC DIMENSIONS Inches Abbreviated Table of Anthropometric Dimensions

43. ERGONOMIC RISK FACTORS • PERSONAL RISK FACTORS • 1. Age • 2. Gender • 3. Attitude • 4. Training • 5. Strength • 6. Work method • 7. Anthropometry

44. ERGONOMIC RISK FACTORS Continued • JOB RISK FACTORS • 1. Weight of load • 2. Location/size of load • 3. Frequency of the Task • 4. Duration and pace of cycle • 5. Stability of load • 6. Coupling of load • 7. Travel distances of worker • 8. Reach distances of worker • 9. Symmetry between worker and the object held

45. ERGONOMIC RISK FACTORS Continued JOB RISK FACTORS • 10. Static work posture • a) Standing • b) Sitting • 11. Work platforms or stairs • 12. Torso flexion (bending) • a) Mild (up to 45 degrees) • b) Severe (greater than 45 degrees) • 13. Work heights (too high or too low) • 14. Floor surfaces (wet, smooth, vibration)

46. ERGONOMIC RISK FACTORS Continued JOB RISK FACTORS • 15. Environment • a) Hot (sweat, reduced grip, fatigue) • b) Cold (gloves reduce grip by as much as 30%) • 16. Lighting • a) posture problems (because of inability to see) • 17. Noise/vibration • a) Frequency very important • b) Can amplify through the body

47. WHAT ARE THE PRIMARY RISK FACTORS ASSOCIATED WITH YOUR JOB? ERGONOMIC RISK FACTORS Continued

48. JOB AND TASK ANALYSIS UNIT LOADS: DEFINED AS: The unit to be moved or handled at any one time. THE CONTAINER, CARRIER, OR SUPPORT USED TO MOVE MATERIALS MUST BE INCLUDED AS PART OF THE UNIT LOAD.

49. JOB AND TASK ANALYSIS Continued FACTORS AFFECTING UNIT LOADS • THE MATERIAL TO BE UTILIZED • THE QUANTITY OF MATERIAL TO BE HANDLED • THE SUSCEPTIBILITY OF THE MATERIAL TO DAMAGE • THE NUMBER OF TIMES THE UNIT LOAD IS HANDLED • THE RECEIVING, STORING, SHIPPING, AND HANDLING METHODS • THE ENVIRONMENTAL CONDITIONS TO WHICH THE LOAD IS EXPOSED

50. JOB AND TASK ANALYSIS Continued DESIGNING THE UNIT LOAD • OPTIMIZE THE WEIGHT OF THE LOAD • REDUCE THE SIZE OF THE LOAD • INSURE STABILITY OF THE LOAD • OPTIMIZE LOAD COUPLING - HAND TO LOAD - FOOT TO FLOOR