The ergonomic silver lining
Rather than feeling threatened by a storm of new OSHA proposals, companies should be looking at the advantages of good ergonomics.
By David Maloney -- Modern Materials Handling, 2/1/2000
Ron Rowe had never thought much about ergonomics until the day an OSHA inspector cited his mattress factory in Huntington, WV for the way dock workers manually lifted mattresses onto outbound trucks."The whole world is loading mattresses into trucks by hand," says Rowe, president of Imperial Bedding Company. "The first thing I did was get mad. Then we got training."
Although Rowe received his citation several years ago, his reaction is a common one among industry today, particularly in wake of recent new proposals by OSHA (Occupational Safety and Health Administration) that may force many employers to learn a fast lesson about ergonomics in the workplace.
While the process may be painful, it also may be good medicine for a company, as it has been for Rowe. He took a long look at his loading procedures, brought in experts to train staff, and automated the shipping area with a unique extending conveyor (Stewart Glapat Corp., www.adjustoveyor.com ).
"It's a hands-free deal," says Rowe, explaining that the adjustable conveyor even carries the next mattress to the top of the stack of products already in the truck. "It's a tremendous thing for us."
In many ways, Rowe looks back and realizes his company is better off now having survived the OSHA experience. For example, deluxe mattresses with double the weight of standard product have become more popular since Rowe received the citation. Mattresses that used to be 10 or 11 in. thick are now 20 in. If Imperial Bedding did not make the change when it did, Rowe would have lost good employees either to injury or fatigue from manually loading 200-lb. mattresses, especially considering Imperial ships 1,000 mattresses a day.
"The testimony of my workers was enough for me to justify the cost. It saved all that heavy lifting," says Rowe.
Ergonomics by the numbers
"The whole ergonomic issue seems to accelerate or subside based on OSHA regulations," says Tom Carbott of the Material Handling Industry of America.
Right now it is in full acceleration. OSHA will begin hearings on its latest proposals this month in Washington. No one knows what form they will take once turned into regulations, which OSHA says may be completed by year's end. Most analysts are betting though that the basic design, based on OSHA's mandate to protect all workers, will remain.
"Injuries all already costing American industry," says David Cochran, OSHA's special assistant for ergonomics. "We know if you change things, workers are healthier and able to do work better. It makes good business sense."
Such changes may be costly, however. OSHA estimates $4.2 billion dollars may be spent on upgrading facilities and workstations to curtail injuries. American business organizations think it will cost even more, pegging it as much as $18-26 billion. OSHA says the cost is worth it, as companies will save $9 billion on injuries.
While numbers may be debated, the fact that more regulations are coming is inevitable. Smart employers are searching for the silver lining.
The first obvious benefit of increased regulation will be reduced injury claims. OSHA is expecting 300,000 fewer musculoskeletal disorders (MSD) each year. These are injuries due mostly to repetitive motion. OSHA claims that MSDs account for 1/3 of lost workdays, or 650,000 days yearly nationwide. $15-20 billion are spent annually on claims, with indirect costs an estimated $60 billion each year.
"A lot of these injuries occur in materials handling," stresses Cochran. "Manufacturing and materials handling injuries together account for 60% of all injuries that result in lost work days, while they comprise only 28% of all workers."
Cochran adds that these workers are 3.85 times more likely to suffer injury.
Such injuries can add up to a lot of lost productivity, which can be an even more important factor to a company's bottom line.
"People have focused on occupational and health issues instead of productivity and product quality," says Steve Johnson, an industrial engineering professor at the University of Arkansas.
Johnson says that most ergonomic advancements have occurred because companies have been forced to make changes, rather than as the result of good business practices. Good ergo-nomics should result from continuous examination of employee work habits and elimination of those things likely to cause problems, such as extra movement, twisting, bending, repetitive motions and a combination of movements simultaneously. Any reduction in movement not only reduces potential injury, but makes work more efficient, thereby increasing productivity.
The tight labor market also makes employees more valuable than ever before. Replacing a trained employee due to injury is costly and can create downtime in operations that depend on skill and speed. The labor situation forces many companies to resort to overtime to complete work cycles, which can increase risk factors. A large number of injuries occur when employees are fatigued and not as alert as they should be.
Mechanization and automation of various handling tasks is another way companies can increase their productivity and lower their exposure to injury.
Lift tables, scissor lifts, turntables, load levelers, extendable conveyors, work positioners, manipulators, adjustable work stations, and cranes are just some of the equipment that help companies solve ergonomic problems while making operations more efficient. In most cases, the equipment will pay for itself.
"Very rarely does one piece of equipment solve the problem," notes Carbott. "It usually is a combination of things."
For a list of equipment and their functions, see the "click on" at the end of this article.
The OSHA proposal requires employers in manufacturing and materials handling to develop ergonomic plans. The plan, however, does not need to be implemented until the first injury in a particular job occurs. Employers are required to care for the injured worker and also adjust the jobs of all others that do the same or similar work to eliminate risk of further injury. No other jobs need be affected or altered unless the employer chooses or labor contracts demand it.
Eliminating risk is the obvious key to avoiding the first injury that triggers the requirements. Companies that design ergonomic programs before this occurs have a huge advantage in preventing injuries and the problems that come with them.
The proposals demand that employees be a part of the solution, as they are often the most knowledgeable about the things that cause them stress and fatigue.
Catherine Rae of Sandalwood Enterprises is a leading ergonomist who has designed much of the program at Ford Motor Co.
"I think a good ergonomics program is a necessary thing," she says. "I don't think people realize the costs they will incur if they don't have a program. It can be relatively easy and begins with identifying risks."
OSHA claims that companies who have such programs have reduced 70% of their injuries.
Ford established an ergonomics committee comprised of both management and line workers. An hourly employee is co-chair of the committee.
"The hourly workers are the first people I visit when I go into Ford," says Rae.
The input from the people who actually do the jobs is invaluable. The committee helps to design systems and workstations, and selects equipment that is ergonomically sound. They also look at tasks that have risk factors for injuries, such as lifting. Back injuries are the leading problem at Ford due to the heavy lifting involved in car production. Weights in excess of 60 lb are among those targeted for special attention.
Rae says that they are also concerned about lighter weights of 20-40 lb done on a repetitive basis, as this can be a leading cause of MSD. A basic formula she uses is to design a task to accommodate the capabilities of 75% of women. If they can do it without strain, then it is considered an acceptable risk for all workers.
Determining risk is not an exact science, however, and that is a problem for ergonomists. One person may be able to do a task repeatedly without any risk, whereas another can develop an MSD.
"We need to find a consistent way of determining risk," notes Rae, which is something not adequately addressed by the OSHA proposals.
Training is also an important element in avoiding injury, but is an area often neglected in industry.
"Many jobs are labeled unskilled," says Johnson. "That makes managers believe there is no need to train. Operators do not tend to gravitate towards doing things better on their own."
People usually do things the way they always have, which means that bad habits tend to stick around after years of practice. Often workers are trained by their fellow employees-"Spend some time with Sally and she will tell you what to do." This approach simply passes on the bad practices.
Companies instead should look to professional training that promotes proper lifting and good materials handling techniques. Once new equipment is installed, employees must be trained to use it. Johnson says that adjustable workstations, for example, are often overrated simply because operators fail to adjust them.
Other tips you can use
Much in ergonomics focuses on movement and interaction with equipment, but there is much more. Companies should also address environment issues, such as noise and lighting. Color coding of controls and switches, plus proper signage can also make a facility ergonomically-friendly.
Eliminate the use of numbers and letters in labeling that may be confused with one another, such as the number 0 with a capital letter "O", the letter "l" and the number 1, or the number 2 and the letter "Z."
Training should also extend to material handling designers who do not always design with ergonomics in mind.
Ergonomics committees should include maintenance managers and purchasing personnel, as they can have great influence on equipment selection.
Employers should additionally take a long look at the people who are hired to perform tasks that may have a higher risk of injury.
"The purpose of ergonomics is not to design the workstation to fit the person," Johnson says. "It should match the capabilities of the person with the requirements of the job."
Testing for risk can be tricky, especially with the types of movements that can cause MSD. Discrimination is also a concern if certain employees who deem themselves capable are not given a job. Johnson suggests discriminating on the values of the job and a person's physical ability to perform it, not on other factors that may be discriminatory, such as age or gender. The Americans with Disability Act can be helpful, as it provides guidelines that define jobs based on performance.
Johnson adds that while OSHA tends to regulate to the lowest common denominator, managers should design their tasks so that the maximum number of people can do the job while not hurting productivity. He defines it as "a maximum output of a person at a non-injury level."
"All people are not created identically," he says. "We must recognize the difference in people and capitalize on them. Our ability to handle the differences is the challenge."
Companies that take a serious approach to ergonomics and analyze their work environment for problems should not fear the OSHA proposals. Imperial bedding is one such company.
"I am one step ahead of them," says Rowe. "This system has made it possible."
Software to the rescue
The Material Handling Industry of America has produced a new software program that will aid companies in developing ergonomic programs. The Ergonomics Tool Box provides users with an overview of ergonomics and materials handling, a section on hazards featuring AVI video, descriptions and pictures of popular materials handling equipment, and a task analysis tool with several industry-accepted methods for measuring the risk factors in a particular job.
The program allows users to input job criteria and then receive materials handling parameters based on the job. These include the proper way of handling products, weight limits, what constitutes a safe load, the repetitive movements permissible before risking injury, and a recommendation on the types of materials handling equipment that is suited to a task.
The Ergonomics Tool Box can be ordered through the literature department at MHIA, 1-800-345-1815, www.mhia.org .
Highlights of the OSHA proposals
- Defines musculoskeletal disorders and the hazards related to them
- Manufacturing and materials handling companies must develop ergonomics plans
- Plans must be designed with employee participation
- Training must be conducted for employees in problem jobs
- An injury verified by a health professional triggers the plan into operation
- Injured employee is cared for and receives job protection
- Employee also receives full benefits and 100% pay for light duty or 90% pay for off duty
- Injury job and similar jobs must be adjusted in that workplace only.
> No other jobs affected
- Quick fixes to eliminate hazards are permitted under certain circumstances
- Programs must be evaluated and records maintained
The road to good ergonomics
- Keep lifting in the "Golden Zone"-waist to chest
- Move work as close as possible to workers
- Avoid repetitive movement, especially combinations of motions
- Vary employee posture and movements
- Adjust tables to proper work heights
- Use professionals to train employees on proper ergonomic techniques
- Catch problems when they are merely discomforts, before they become disorders
- Establish an ergonomics committee composed of management and line workers
- Ramp new employees into jobs slowly to allow their bodies to adjust to new tasks
- Install materials handling equipment to resolve ergonomic problems
- Place ergonomic requirements into equipment bid specifications
- Avoid overtime, which contributes to fatigue
- Consider environmental factors such as lighting, noise, and signage
- Screen applicants for at-risk jobs. Fit abilities to jobs
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