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What is your Ergo IQ?

An Ergonomic Risk Assessment Model


ASSE/AIHA Professional Development Conference April 19, 2013
Bruce K. Lyon, CSP, P.E., ARM, CHMM Director, Risk Control Hays Companies Dr. Georgi Popov, QEP. Associate Professor University of Central Missouri

Whats your Ergo IQ?


An Ergonomic Risk Assessments Model
Definitions Assessment Process Assessment Tools

Ergonomics
(work) + (natural laws)

The science of properly matching work demands and environment with human capabilities.

Human Factors
Human-machine Interface Cognitive + Physical Aspects Designing for the End-user

Musculoskeletal Disorders (MSD)


a.k.a. Cumulative Trauma Disorders (CTD)

Disorders of the soft tissues Chronic in nature Caused by certain risk factors

Costs of Ergonomic Risks


Productivity Quality Employee
Work-related Musculoskeletal Disorders (WMSD) $40,000 - average cost for back surgery $29,000 - average for carpal tunnel surgery $20 billion a year US DOL

Ergonomic Risk Assessment (ERA)


Purpose
Identify Problem Jobs Involve employees Quantify Risk Factors Establish Baseline and Benchmark Improvements Reduce Potential Disorders and Improve Work

Establishing an ERA Process


Scope/context

Establishing an ERA Process


Scope/context
Who What When How

Establishing an ERA Process


Scope/context Goals/Objectives

Establishing an ERA Process


Scope/context Goals/Objectives
Specific Measurable Actionable Realistic Time-oriented

Establishing an ERA Process


Scope/context Goals/Objectives Responsibilities

Establishing an ERA Process


Scope/context Goals/Objectives Responsibilities
Defined & Communicated Specific & Measurable Aimed at Achieving goals Accountability

Establishing an ERA Process


Scope/context Goals/Objectives Responsibilities
Defined & Communicated Specific & Measurable Aimed at Achieving goals Accountability Management Ergo Coordinator Ergo Committee Engineering, Maintenance Medical, Workers Comp Supervisors Operators

Establishing an ERA Process


Scope/context Goals/Objectives Responsibilities Training

Establishing an ERA Process


Topic
Managing the Process Part 1

Who
GMs, Plant Managers Coordinator Engineers Maintenance Tooling Operators Supervisors

Objectives
Understand process Responsibilities Goals Ergo design guidelines Assessment tools Software Understand process Responsibilities ID risk factors and controls

Delivery
Internal

Updates
Every 3 years

Ergo for Engineering Design Ergo Awareness

Internal or outside approved vendor Internal

Every 3 years

Every year

Ergo Committee

Ergo Committee

Assessment tools Problem solving

Internal

Every year

Example

Establishing an ERA Process


Scope/context Goals/Objectives Responsibilities Training Resources

Establishing an ERA Process


Scope/context Goals/Objectives Responsibilities Training Resources Process Steps

ANSI Z590.3
Design Concept Preliminary Design Detailed Design Build or Purchase Commission (Install and Debug) Production Maintenance
Decommission

PtD guidance for Life-cycle assessments


19

Ergonomic Risk Assessment Process


Establish
Analyze

Ergonomic Improvement Process

Ergonomic Risk Assessment: Where to Start?


Loss History
Incident Data OSHA logs Workers Compensation Information

Employees
Input & Feedback Surveys

Workplace Observations
Visual Cues Job Analysis/Risk Factors

Performing an Assessment

Set Goal

Select Tool

ID Team

Gather Data

Record Data

Analyze Data

Develop Findings

Set Goals for Assessment


Measure Relative Risk Measure Risk Factors Baseline & Benchmarking
Team Assessments Involve Employees Create Ownership

Provide Guidance

Prioritize and Rank Target Efforts

Ergonomic Risk Assessment Process


Establish
Analyze

Prioritize
Ergonomic Improvement Process

Prioritize
Numerical Scores and corresponding Risk Ratings (RPN)
Exposure base

Recordable Incidents and Reports of Discomfort


Hot Spots Potential problems

Ergonomic Risk Assessment Process


Establish
Analyze

Prioritize
Ergonomic Improvement Process

Implement

Implement
Identify Effective Controls
Ergo committee brainstorming Use Hierarchy of Controls
1. Engineering 2. Administrative 3. Work Practices

Select Effective Controls


Communicate with employees

Implement Controls

Ergonomic Risk Assessment Process


Establish
Analyze

Prioritize
Ergonomic Improvement Process

Implement

Follow-up

Follow-up
Verify Controls are Correctly Implemented Obtain employee feedback Formal Review after break-in period

Ergonomic Risk Assessment Process


Establish
Analyze

Prioritize
Ergonomic Improvement Process

Measure

Implement

Follow-up

Measure
Short Term and Long Term Metrics
Lagging Long Term Measures
ergo incidents rates & DART rates Employee complaints

Proactive Short Term Measures


# of Assessments performed RPN reductions Ergo training Ergo assessments of new operations/MOC

Ergonomic Risk Assessment Process


Establish
Analyze

Communicate
Ergonomic Improvement Process

Prioritize

Measure

Implement

Follow-up

Communicate
Communication at all levels Collect employee feedback on ergo conditions regularly

Selecting the Right Tool


Application
General Industry Manual Handling Repetitive Tasks Hand Work Office / VDTs

Body Segment
Upper Extremities Lower Extremities Trunk Whole Body

Assessment Tool

Application
General Industry Repetitive Tasks General Industry Repetitive Tasks General Industry Manual Handling Office Settings Hand work Office Settings Hand work General Industry Repetitive Tasks General Industry Manual Handling General Industry Manual Handling General Industry Repetitive Tasks General Industry Manual Handling

Type
Qualitative Qualitative Quantitative Quantitative Semi-quantitative Semi-quantitative Semi-quantitative Quantitative Semi-quantitative Quantitative

Body Segment
Whole Body Upper Extremities Trunk Upper Extremities Trunk Upper Extremities Upper Extremities Upper Extremities Trunk Trunk Trunk Whole Body Trunk Lower Extremities

WISHA Checklists ANSI Z365 Tool


MI Energy Expenditure Prediction (EEP)

Strain Index
Hand Activity TLV

RULA Snook Tables NIOSH Revised Lifting Eq. REBA MI 3D SSP Software

Qualitative Tools
Commonly used Good for screening jobs Manual or Excel based
OSHA Basic Screening Tool WISHA Checklists ACGIH TLV for Lifting ANSI Z365 Tool NIOSH Checklists and others

OSHA Basic Screening Tool

WISHA
Calculators
Lifting Operations Hand/Arm Vibration

ACGIH TLV for Lifting

Semi-Quantitative Tools
More focused Specific risk factors/body regions
RULA REBA Snook Tables ACGIH TLV for Hand Activity Utah Back Compression others

Quantitative Tools
Require training/knowledge In depth analysis
NIOSH Revised Lifting Equation MI 3D Static Strength Prediction Model Strain Index Dynamic Work Analysis Static Work Analysis others

NIOSH Revised Lifting Equation

Michigan 3D Static Strength Prediction Model

Ergo Hot Spots


Simple Color-coding System

Ergonomic Action Plans


Team Solutions Cost/Benefit & ROI Assignments and Responsibilities Track Performance / Risk Scores