Ben Zavitz, CPEErgonomist207-442-2219Benjamin.zavitz@gdbiw.com

2013 Marine Chemist Association

Shipyard Ergonomics

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Agenda

Introduction to Ergonomics

Definition, Objectives, Risk Factors, Injuries

Human Performance View of Ergo

OSHA & Ergonomics

Shipyard Ergonomic Solutions

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What is Ergonomics?

Science of optimizing jobs, equipment, tools, and workplace to fit people based on human capabilities and limitations

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Injury Perspective

1. Reduce Risk of Injury • Employee Pain / Discomfort• Recordable / Lost Time Injuries• Workers Compensation $• Return To Work• OSHA Responsibilities

Objective of Ergonomics

Traditional View of ErgonomicsTraditional View of Ergonomics

Ergo

SafetyMedical

Workers Comp

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Human Performance Perspective

2. Maximize Human Performance & Efficiency

• Reducing Non-Value Added Motions

• Overburden of human systems

• Internal Productivity

• Same amount of work with less effort

• More work within confines of human biological & psychological systems

Objective of Ergonomics

Human Performance View of ErgonomicsHuman Performance View of Ergonomics

Ergo

QualityManagement

Engineering

& Design

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Internal Productivity Demo

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Overburden Example

75% employees injured

Job requires a repetitive grip force of 75lbs

Average max. female grip strength is 75lbs

Job demands require 100% effort and resulted in “overburden” of the person to the point of injury

75% employees injured

Job requires a repetitive grip force of 75lbs

Average max. female grip strength is 75lbs

Job demands require 100% effort and resulted in “overburden” of the person to the point of injury

Job was designed without human capabilities in mind

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What are MSDs (musculoskeletal disorders)? Overuse injuries (similar to athletics)

RRepetitiveepetitive S Straintrain I Injuriesnjuries (RSIs) (RSIs) CCumulative TTrauma DDisorders (CTDsCTDs)

Soft tissue injuries nerves, tendons, muscles, ligaments wrists, elbows, shoulder, back, neck, knees

Develop gradually over time symptoms last longer than few days

fatigue, pain, discomfort, inflammation, numbness when symptoms don’t go away = serious

lost work days, permanent disability or surgery

Report symptoms early, Identify Risks & Solve

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Ergonomic Risk Factors

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OSHA & Ergonomics

Does OSHA have a Federal Ergonomics Standard?

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1970: OSH Act signed

1978: OSHA 1st Ergo citation to Eastman Kodak ($4,320)

1979: OSHA hires Dr. Roger Stephens as its 1st Ergonomist

1983: OSHA offers 1st Ergo training course

1987: OSHA Office of Technical Support issues 1st Ergonomics Directive, CPL 2.78 (still in effect)

OSHA Ergonomics History

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1987 -1992: OSHA issues significant citations:

1987: International Beef ($2M)1988: John Morrell Meatpacking($4.3M)1988-1996: Pepperidge Farms ($1.4M)1992-2000: Beverly Nursing Homes 1989-1993: Chrysler, Ford, GM, Honda

1999: OSHA promulgates Ergo Standard

2001: Congress rescinds standard using the Congressional Review Act (for the first/only time)

OSHA returns to the General Duty Clause

2002 – Present: Industry Guidelines

OSHA Ergonomics History

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OSHA will place special emphasis on industries using the “General Duty Clause” (Section 5 (a)(1) of the OSHA Act) where ergonomic hazards exist and employers are not making good faith efforts to prevent injuries.

OSHA Enforcement Policy

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Section 5(a) (1) of the OSH Act:

Each Employer :

“shall furnish to each of his or her employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his or her employees.”

OSHA General Duty Clause

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To support a General Duty Clause citation, OSHA must be able to prove a hazard is:

1. Present

2. Recognized by the employer or its industry

3. Causing or likely to cause serious physical harm

4. Feasible means of abatement that will reduce or eliminate exposures to employees.

Criteria for 5(a)(1) Violations

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5(a)(1) Criteria: Evidence of Hazards

Is an Ergo Hazard Present and Recognized?1. Injury Data

OSHA 300 Logs Workers’ Compensation Claims Clinic visits First-aid records Medical records review

2. Worker complaints/worker interviews

3. References to trade publications, insurance reports, etc.

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Causing or likely to cause serious physical harm? Company injury records

No records

NIOSH Studies

National Academies Studies

Industry Studies

5(a)(1) Criteria: Causation

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NIOSH Report (1997)

Risk factors are specific to certain body parts

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National Academies (2001) Request from Congress to examine the

causation, diagnosis, and prevention of musculoskeletal disorders

Panel on MSDs and the Workplace was established by the National Research Council (NRC) and the Institute of Medicine (IOM) in Jan 1999

2 year study of workplace physical and psychosocial factors in the occurrence of MSDs of back and upper extremities and the effectiveness of various prevention strategies

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Panel Results

Conceptual ModelConceptual Model Risk EstimatesRisk Estimates

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Feasible means of abatement that will reduce or eliminate exposures to employees

Industry Studies and Guidelines (NIOSH, OSHA)

5(a)(1) Criteria: Feasible Abatement

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Voluntary and flexible

Failure to implement is not a violation

Industry & Task Specific Guidelines Nursing Homes (March, 2003) Retail Grocery (May, 2003) Poultry Processing (September, 2004) Shipyards (March, 2008) Foundaries (2012)

Uses stakeholder info & best practices Public participation in guideline

development process

Ergo Guidelines Published by OSHA

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OSHA Ergo Guidelines

1. Process for Protecting Workers Management Support Involve Employees Provide Training Identify Problems Implement Solutions Address Reports of Injuries Evaluate Ergonomic Efforts

2. Implementing Solutions Description, when to use, points to remember

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Shipyard Solutions

1. Site-wide

2. Material/equip handling

3. Tools

4. Metal work

5. Shipside

6. PPE

BEFORE

BEFORE

AFTER

AFTER

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Inspections in the last 10 years:

5,046 Ergonomic-related Inspections

23 Citations issued

850 Ergonomic Hazard Alert Letters issued

OSHA Ergonomics Enforcement

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OSHA will:

Assess the extent of unaddressed ergo hazards

Identify existing efforts by employer in addressing ergo hazards and determine if need for further employer intervention.

If warranted, send employer an Ergonomics Hazard Alert Letter (EHAL).

Where 5(a)(1) cannot be supported

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Not a citation. The letter will:

Identify exposed employees, observed conditions that pose risk factors, incident and severity rates.

Provide examples of solutions that may reduce or eliminate risk factors, including suggestion of components of an effective ergonomics program.

List resources for assistance.

What is an EHAL?

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OSHA will review employer’s response If the employer does not respond, OSHA will

contact the employer within 1 year for follow-up OSHA will likely request:

Documentation of any control measures implemented, including those recommended in the initial EHAL

Copies of OSHA 300 Logs of Injuries and Illnesses Work hours of exposed employees for given years

OSHA may conduct an inspection if there is no response or the response is inadequate

OSHA EHAL Follow-Up

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Beverage Distribution Industry - Summer, 2011

Industry-Wide Alert Letters

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Beverage Distribution Letter sent to:

Alert employers of higher than usual rate of MSDs in the industry

Raise awareness to well-known, available technology to address hazards

Refer employers to existing NIOSH guidance

Encourage proactive efforts to address hazards

Industry-Wide Alert Letters

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EHAL Impacts

Not a citation … yet Lays the groundwork for a 5(a)(1) violation if

the employer does not address the issues Establishes a hazard Establishes it as recognized Establishes a link between the hazard and

serious physical injury Identifies feasible means of abatement

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So...

How do we keep OSHA out of our hair and have a proactive program ?How do we keep OSHA out of our hair and have a proactive program ?

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Ergonomic Data

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Ergonomic Data Sources

Three types of data sources available:

1. Historical - Injury rates

2. Current - Employee surveys/questionnaires

3. Predictive - Identify risk factors and poor human performance

Checklists (audit form)

Guidelines (NIOSH Lifting Equation),

Computer Models (3D SSPP, HumanCAD)

Direct Measurement (Vibration, EMG)

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Work Position Is Important

Work position and is one of the most important factors in determining:

Strength

Endurance

Rate of Fatigue

Risk of Injury

When performing a task that involve a lift, push, pull, or reach, ask yourself “Am I in the Best Position”?

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Work Position Visual

Back, Neck, Shoulders, Elbows, Knees

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Test Your Knowledge

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Test Your Knowledge

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Raise-the-Work

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Walk Behind Grinders

95% Risk ReductionEliminates Kneeling, Bending, Vibratory Tool

80% Improvement Productivity

95% Risk ReductionEliminates Kneeling, Bending, Vibratory Tool

80% Improvement Productivity

AFTERAFTER

BEFOREBEFORE

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Hand Arm Vibration

Is there a US Standard?• Only for tool manufacturers

• Professional guidelines (ISO, ANSI, ACGIH)

• Unloaded value

There a European Standard• For tool users• Loaded value

UnloadedISO Standard (8662)

LoadedISO Standard (5349)

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Vibration Measurements

Acceleration measured in meters per second squared (m/sec²)

European Standard for Hand-Arm Vibration Exposure:

Daily Exposure Action Value: 2.5 m/sec² (8hrs)

Daily Exposure Limit Value: 5.0 m/sec² (8 hrs)

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Measuring Acceleration

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Exposure Time- Ready Reckoner

All values areexposure pointsColors showexposuresEAV & ELV

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“Super Grinder”

65+% less vibration

2-3x removal rate

1/3 weight

65+% less vibration

2-3x removal rate

1/3 weight

Stone Grinder

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Old Needle Gun 70-90% Less Vibration

Low Vibration Tools

Old - Die Grinders

75% less vibration

20% more removal

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Long Reach Needlegun

75+% less vibration

Eliminates Kneeling

Weight holds it down

75+% less vibration

Eliminates Kneeling

Weight holds it down

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Mechanized Grinding

95% Risk Reduction Eliminates force, rep. motion, vibration

50% Improvement Productivity50% less consumables

95% Risk Reduction Eliminates force, rep. motion, vibration

50% Improvement Productivity50% less consumables2012 Ergo Cup Winner

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Weld Shaver

95% Risk ReductionEliminates force, rep. motion, vibration from hand grinding

40x faster

95% Risk ReductionEliminates force, rep. motion, vibration from hand grinding

40x faster

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Process Changes

Empire blast units Prep T-bars

Harding Plant – Due next week operational by July 10th

Panel Line – Due by July, operational by July 31st

Monitoring the No Paint Mark-up process to prevent paint removal

Continuing to move jobs to earlier stages of construction False Deck Mods; Electronic spaces

RCS Inspections

Trial Card reviews

Customer Walk-through Missing pieces, items built wrong, changes, shock hits

Low Ergonomic Risk

90% Time Savings

Blasting

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Mag Base Drilling Tool

75% reduction in kneeling100% reduction in hand drilling80% Improvement Productivity

75% reduction in kneeling100% reduction in hand drilling80% Improvement Productivity

2013 Ergo Cup People’s Choice Award

for ROI

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Tool Backpack

Shoulder straps reduce weight by 50% Hip belt reduces weight by 25% moreSlimmer, does not catchFire Resistant

Shoulder straps reduce weight by 50% Hip belt reduces weight by 25% moreSlimmer, does not catchFire Resistant

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Paint Carrying Handle

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Take Away

OSHA is primarily concerned with lagging indicators (injury rates and employee feedback)

Best approach is to be proactive

Manage risk vs. consequences

Ergonomics is optimizing human performance and can have a significant impact on Safety, Quality, Cost, and Morale

Injuries are a by-product of poor job set-up/design

Ergo Cup Competition helps to engage workforce

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Questions

Ben Zavitz, CPEErgonomist

207-442-2219Benjamin.zavitz@gdbiw.com