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Ergonomics in Welding

Ergonomics in Welding. How to identify causes of sprains and strains in welding jobs Propose solutions for hazardous exposures Find further information about ergonomics in welding operations. What You Will Learn:.

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Ergonomics in Welding

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  1. Ergonomics in Welding

  2. How to identify causes of sprains and strains in welding jobs Propose solutions for hazardous exposures Find further information about ergonomics in welding operations What You Will Learn:

  3. If you have any of the following hazards in your workplace we recommend that you include them in your Accident Prevention Program (APP).

  4. Inhaling metal fumes Eye exposure to welding arc light Foreign objects in eyes Burns Noise Common hazards found in welding are:

  5. Welding also includes hazards that can cause sprains and strains such as: Awkward body postures Lifting heavy equipment or materials Static postures for prolonged periods Awkward postures of the wrist Sprains and Strains

  6. Washington State-funded compensable* claims 1994-2004Welders, Cutters, Solderers By Nature of Injury Sprains are about 1/3 of the compensable* claims among welders in the State of Washington. *Compensable claims are those the involve time loss or disability payments

  7. Washington State-funded compensable claims 1994-2004Welders, Cutters, Solderers By Body Part The back, neck and shoulder together with the arm and hand regions make up more than one half of the injuries among welders in Washington State. Preventive efforts at your workplace should therefore focus on those body parts among welders. Welding is a strenuous occupation involving work in awkward postures and handling heavy equipment, usually with a high degree of sustained stress to arm and shoulders.

  8. Absences due to injury or illness and the transfer of welders to other tasks Overtime for replacement workers; welders are skilled employees High employee turnover Increased training and supervisory time Reduced productivity and quality Consequences of a poor working environment

  9. Detailed hand precision requirements High degree of uniformity Awkward and static postures Difficult work position Heavy lifting, difficult material handling Heavy objects, heavy welding equipment Repetition High work intensity Common causes of sprains and strains in welding Often, more than one of these is present

  10. Duration (how long?) Hazard Elements Frequency (how often?) Intensity (how hard?)

  11. Common postures adopted in welding Working in front Working at ground level, precision work Working at ground level Working at ground level, confined space Working above shoulders, confined space Working above the shoulders

  12. Awkward postures in welding Severe torso flexion Torso twisting Kneeling, squatting Bent wrists Neck flexion/extension Shoulder flexion/abduction (separation)

  13. To simplify the welding tasks for the welder and reduce the physical load during the work Automate physically demanding or repetitive jobs Expand the work content of welders (provide flexibility between jobs) (Multi-skilled workers who are able to perform different tasks within a group) The goal of a healthy work environment

  14. Often cost, ease of maintenance, space considerations drive the design of the workplace When hazards can’t be designed out, using best practices is a good alternative Examples of good design: providing opportunities for work station adjustments, providing different types of tools, using good planning to eliminate unnecessary work The Real World

  15. Ergonomic Solutions for Welding

  16. Heavy Lifting Use: • Manipulators • Lighter weight welding equipment • Lighter weight cables with low stiffness • Cable supporting balancers • Overhead hoists • Lifting and turning tables

  17. Awkward Postures • Position work between waist and shoulder when possible • Provide lifting tables • Use motorized positioning devices • Use welding guns with swivels and designed for use in both hands • Try work stools

  18. Team Lifting BEFORE Team lifting helps reduce heavy, awkward lifting of equipment and materials. AFTER From: SIMA San Diego Ergonomics Program

  19. Tables BEFORE AFTER This picture shows the worker with considerable bending over at the waist Because the work is on a table, the worker doesn’t have to bend over as far From: Shipyard Ergonomics, 2003

  20. Pre-Assembly Pre-assembly and material handling equipment helps reduce unnecessary lifting or any other kind of manual material handling

  21. Ergonomic improvements This rotational clamp for pipe helps reduce awkward postures for the neck, shoulders and arms.

  22. Ergonomic improvements Use wheeled tables for welding work and to transport stock and jobs. This reduces lifting and carrying of heavy materials.

  23. Ergonomic improvements (continued) Welding leads on pulleys help reduce heavy and awkward lifting, and minimize static postures.

  24. Ergonomic improvements (continued.) Robotic automation is a feasible solution to reduce highly repetitive motions with the arms and hands. May also reduce the exposure to fumes.

  25. Not implementing some or all these ergonomics guidelines may result in the following… Possible Consequences

  26. Sprains and Strains They are cumulative (occur over time and not a result of a single incident): • Occur when the physical demands of work cause wear and tear on the body. • Involve soft tissues such as muscles, tendons, ligaments, joints, nerves, blood vessels.

  27. Back injuries Shoulder pain/loss of range of motion Tendinitis/Bursitis Reduced muscle strength Carpal tunnel syndrome White finger Knee joint diseases Common sprains and strains among welders

  28. The ergonomics cycle shows an organized way to start your ergonomics effort. The Ergonomics Cycle

  29. The technical contents of this slideshow are based upon the presentation developed by Ninica Howard, MS, CPE, research ergonomist with the SHARP program at the Washington state Dept. of Labor and Industries. Credits

  30. NIOSH’s Ergonomic Interventions in the Building, Repair, and Dismantling of Ships SHARP Program Easy Ergonomics: A practical approach for improving the workplace OR OSHA Learn more about preventing sprains and strains. Helpful tools for your Accident Prevention Program (APP) Ideas to reduce hazardous exposures can be found in the Ergonomics Ideas Bank You can also e-mail us at: Ergonomics@Lni.wa.gov More resources

  31. Help from L&I at no cost to you We offer free, confidential consultations to help you prevent sprains and strains in your workplace. To learn more: • Email us: Ergonomics@Lni.wa.gov • Call – (360) 902-5450 • Visit our website:http://www.lni.wa.gov/Safety/Consultation/

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