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Workplace ergonomics is getting a lot of attention nationwide in response to a sharp increase in incidents of repetitive strain injuries resulting in musculoskeletal disorders, such as carpal tunnel syndrome. Occupational diseases often mean repeated surgery, intractable pain, inability to work, time off for the affected employee, and, ultimately, higher costs for the employer. Factors including work surfaces at the wrong height, uncomfortable chairs, shelves and bins that are too high or out of reach, and awkward hand tools, all contribute to increased risk of musculoskeletal disorders injury and may offer a nega- tive impact on productivity. There is a wealth of options available to adjust the workspace to meet employees’ ergonomic needs and selecting the right ones can help employees reap significant bottom line rewards. Paying attention to ergonomics means removing barriers to work productivity. Comfortable employees stay at their desks or work stations longer, and complete more work in a given shift. Employers who pay attention to these four simple steps are well on their way to gaining these rewards. Ergonomics – designing the job to fit the worker Ergonomics is the science of designing a job to fit the worker, rather than physically forcing the worker’s body to fit the job. By adapting tasks, work stations, tools, and equipment to fit the worker, ergonomics seeks to reduce physical stress on a worker’s body and eliminate many potentially serious, disabling work-related muscu- loskeletal disorders (MSDs). If work tasks and equip- ment do not include ergonomic principles in their design, work- ers may have exposure to undue physical stress, strain, and overexertion, including vibra- tion, awkward postures, forceful exertions, repetitive motion, and heavy lifting. Step 1 – Review tasks for risk factors The first step to correcting problems is to understand the key workplace ergonomic risk fac- tors and review work tasks in your operation to see which ones apply. This can make a tremen- dous difference, since occupational safety profes- sionals estimate that reducing physical stresses could eliminate as much as half the serious Four Simple Ergonomic Steps to a More Productive Workplace Paying attention to ergonomics pays off By James Anderson Vertical Market Manager, Lista International Corp.

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Workplace ergonomics is getting a lot of

attention nationwide in response to a sharp

increase in incidents of repetitive strain injuries

resulting in musculoskeletal disorders, such as

carpal tunnel syndrome. Occupational diseases

often mean repeated surgery, intractable pain,

inability to work, time off for the affected

employee, and, ultimately, higher costs for the

employer.

Factors including work surfaces at the wrong

height, uncomfortable

chairs, shelves and bins that

are too high or out of reach,

and awkward hand tools, all

contribute to increased risk

of musculoskeletal disorders

injury and may offer a nega-

tive impact on productivity.

There is a wealth of

options available to adjust

the workspace to meet employees’ ergonomic

needs and selecting the right ones can help

employees reap significant bottom line rewards.

Paying attention to ergonomics means removing

barriers to work productivity. Comfortable

employees stay at their desks or work stations

longer, and complete more work in a given shift.

Employers who pay attention to these four simple

steps are well on their way to gaining these

rewards.

Ergonomics – designing the job tofit the worker

Ergonomics is the science of designing a job

to fit the worker, rather than physically forcing

the worker’s body to fit the job. By adapting

tasks, work stations, tools, and equipment to fit

the worker, ergonomics seeks to reduce physical

stress on a worker’s body and eliminate many

potentially serious, disabling work-related muscu-

loskeletal disorders (MSDs).

If work tasks and equip-

ment do not include ergonomic

principles in their design, work-

ers may have exposure to undue

physical stress, strain, and

overexertion, including vibra-

tion, awkward postures, forceful

exertions, repetitive motion,

and heavy lifting.

Step 1 – Review tasks for riskfactors

The first step to correcting problems is to

understand the key workplace ergonomic risk fac-

tors and review work tasks in your operation to

see which ones apply. This can make a tremen-

dous difference, since occupational safety profes-

sionals estimate that reducing physical stresses

could eliminate as much as half the serious

Four Simple Ergonomic Steps to a More Productive Workplace

Paying attention to ergonomics pays off

By James AndersonVertical Market Manager, Lista International Corp.

2

injuries that happen each year. Predicting what

might go wrong and modifying tools and the

work environment to make tasks safer for work-

ers is the first step to reducing problems. Table 1

(below) lists these key risk factors and notes the

injuries each may cause. Figure 1 (page 3) illus-

trates a few of these factors.

LISTA INTERNATIONAL CORP. FOUR ERGONOMIC STEPS TO A PRODUCTIVE WORKPLACE

Table 1 – MSD Risk Factors

Force Exerting excessive force can cause a variety ofinjuries.

Repetition Excessive repetition of movements can irritatetendons and increase pressure on nerves.

Awkward postures Positions that stretch physical limits can com-press nerves and irritate tendons.

Static postures Positions that a worker must hold for long peri-ods of time can restrict blood flow and damagemuscles.

Quick motions Increased speed or acceleration when bendingand twisting can increase the amount of forceexerted on the body.

Compression or contact stress Grasping sharp edges like tool handles can concentrate force on small areas of the body,reduce blood flow and nerve transmission, anddamage tendons and tendon sheaths.

Recovery time Inadequate recovery time due to overtime, lackof breaks, and failure to vary tasks can leaveinsufficient time for tissue repair.

Vibration Excessive vibration from tools can decreaseblood flow, damage nerves, and contribute tomuscle fatigue. Whole body vibration can affectskeletal muscles and cause low-back pain.

Cold temperatures Working in cold temperatures can adverselyaffect a worker’s coordination and manual dex-terity and cause a worker to use more forcethan necessary to perform a task.

Source: Adapted from Ergonomics: The Study of Work, U.S. Department of Labor,Occupational Safety and Health Administration, OSHA 3125, 2000.

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LISTA INTERNATIONAL CORP. FOUR ERGONOMIC STEPS TO A PRODUCTIVE WORKPLACE

Figure 1 – Selected Risk Factors

Source: Elements of Ergonomics Programs, A Primer based on Workplace Evaluations ofMusculoskeletal Disorders

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Step 2 – Control risk factors withengineering and administrativecontrols, and personal equipment,where it is effective

Engineering controls, administrative controls,

and personal equipment are the three key ways

to control the risks identified earlier. Examine

each of these to see how each may be used to

control the risks identified in Step 1.

Engineering controls to improve ergonomic

risks may include changing the way parts and

materials are transported; changing the process to

reduce how workers are exposed to risk factors;

moving parts around to make it easier for work-

ers to reach them; or changing work station lay-

out, tool design, or access and assembly sequence.

Of equal impact are administrative controls,

adjusting work practices and policies to reduce

risk factors. Examples include rest breaks, job

rotation, or training to identify signs of ergo -

nomic stress.

Finally, personal equipment may be consid-

ered, including wrist supports, back belts, or

vibration attenuation gloves. However, it should

be noted that, although personal equipment may

reduce the duration, frequency, or intensity of

exposure to risk, their effectiveness in injury

reduction is considered inconclusive by National

Institute for Occupational Safety and Health

(NIOSH). Figure 2 is an illustration of the general

ways of reducing the risk factors identified in

Step 1.

LISTA INTERNATIONAL CORP. FOUR ERGONOMIC STEPS TO A PRODUCTIVE WORKPLACE

Figure 2 – Controlling Risk Factors

Source: Elements of Ergonomics Programs, A Primer based onWorkplace Evaluations of Musculoskeletal Disorders

5

Step 3 - Understand how to makethe work space work ergonomically

With any task, selecting the proper tool is

crucial. The key is to understand the work process

and employees’ safety needs involved. After iden-

tifying the likely risk factors in an operation,

develop a safer work environment by carefully

selecting the tools and work stations workers will

use. Start the process by asking these questions:

Does the work process involve handling•

heavy, bulky or awkward products?

Is there a high product mix, with many prod-•

uct changeovers per day?

Will work stations be integrated with mat -•

erial flow – with racks or conveyors, for

example?

Is there frequent job rotation, employees•

from different shifts or departments sharing

a work area?

Will employees work alone, back-to-back or •

in teams?

Does a work station need to include power•

tools, computer equipment, supplemental

lighting or storage space?

Issues frequently encountered include work

surfaces that are the wrong size or at the wrong

height; uncomfortable chairs; shelves and bins

that are too high or out of reach; and awkward

hand tools.

To counter these issues, it is important that

employees can rearrange work station elements

easily. Regardless of physical characteristics or the

tasks performed, employees should be able to

make adjustments to work surface height and

chair seat height, or change the elevation of work

shelves and work surfaces to increase worker

comfort and productivity.

LISTA INTERNATIONAL CORP. FOUR ERGONOMIC STEPS TO A PRODUCTIVE WORKPLACE

6

LISTA INTERNATIONAL CORP. FOUR ERGONOMIC STEPS TO A PRODUCTIVE WORKPLACE

Table 2 – Work Station Design Principles

Make the work station adjustable Large and small people should be able to fit comfortablyand reach materials easily.

Locate materials to reduce twisting Give enough space for whole body to turn.

Avoid static loads, fixed work postures

Avoid long periods of leaning, extending limbs, tiltinghead, and supporting body on one leg.

Set work surface according to typeof task

Above elbow height for fine visual work.Below elbow height for tasks needing downward force or heavy physical effort.

Provide adjustable chairs Include adjustments to seat height, back rest, lumbar support.Padding shouldn’t compress more than an inch.Chair must be stable (5-leg).

Allow workers to alternate betweenstanding and sitting

Floor mats for prolonged standing.

Support the limbs Provide elbow, wrist, arm, foot, back rests as needed.

Use gravity Consider ways to move materials using gravity rather thanlifting.

Design for proper arm movements Arm movements should be continuous and curved.Movements should pivot around the elbow rather thanshoulder.Minimize movements or extensions more than 15 inches.

Consider computer monitors Should be adjustable to eye level.

Provide simple dials and displays Make sure they are easy to read, reach, and operate.

Consider environmental conditions Minimize excessive noise, heat, humidity, cold, poor lighting.

Source: Adapted from Elements of Ergonomics Programs, A Primer based on Workplace Evaluations ofMusculoskeletal Disorders. Adapted from checklists developed by Applied Ergonomics Technology.

Step 4 – Use work station designprinciples to improve ergonomics

Table 2 lists general work station design principles,

which include a range of considerations employers

should use when designing work stations.

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The most important principle to keep in mind

is that work is handled most efficiently when kept

within areas defined as “primary reach zones”.

These are the horizontal and vertical areas that

a worker can reach with minimal arm, head, or

trunk movement. Moving away from these pri-

mary zones requires more movement, and ulti-

mately more time. Ergonomic solutions help keep

most work tasks focused within these reach

zones. Figure 3 illustrates this concept – what it

shows is that work takes place within a 24 inch

radius; everything else should be considered

storage.

Figure 4 pictures workers within these hori-

zontal and vertical work zones.

To minimize stress and strain for seated

employees, the work station should be at the

proper height to support the particular task

being performed. Precision work usually requires

a higher work surface, while heavier work

demands a lower work surface. Generally speak-

ing, a 30.5 inch work surface height will accom-

modate 99.5 percent of all male and 99.9 percent

of all female workers.

But what if different shifts are using the same

bench and/or what if different tasks are being

performed on the same bench? If so, consider

an adjustable-height work station. With such a

bench, users can adjust the bench height with

the simple turn of a crank or with a motor drive,

and the work surface can move between approxi-

mately 27 and 38 inches. This would accommo-

date the height of the widest range of workers,

from about 5 feet to 6 feet 8 inches.

Other considerations include convenient

reach and accessibility to accessories, like hand

tools, small parts, nuts and bolts, a comfortable

and adjustable chair, foot rest, and proper light-

ing. A final consideration, and one that is becom-

ing more and more important, is the location of

computer monitors. It is important that they can

be adjustable up or down to be at the employee’s

eye level. With the rise of flat panel monitors,

employers are finding swing arms a useful tool

for properly positioning monitors to avoid strain.

The use of a negative-tilt keyboard tray is also

recommended for reducing wrist strain.

Case closed – ergonomic issuessolved

Nonin Medical Inc. of Plymouth, Minnesota

decided to pursue ergonomically preferable work

stations as part of its lean manufacturing imple-

mentation. The company, which specializes in

manufacturing precision devices that measure

physiological variables such as oxygen levels and

pulse rates, was seeking better access to tools and

parts, greater flexibility to adapt to ergonomic

challenges resulting from employees of different

sizes operating the same workbenches, as well as

improved lighting.

LISTA INTERNATIONAL CORP. FOUR ERGONOMIC STEPS TO A PRODUCTIVE WORKPLACE

Vertical Reach ZonesHorizontal Reach Zones

Figure 3 – Reach Zones

Figure 4 – Horizontal and Vertical Reach Zones

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The company eventually chose Lista’s Arlink®

8000 Modular Workstation System, which is

designed for extremely quick assembly and recon-

figuration. The work stations can be configured in

a variety of heights and lengths to suit unique

needs. The patented Definite Positioning System®

makes it extremely easy and fast to relocate and

adjust work surfaces, storage, shelving, lights,

power beams, and footrests, without requiring

any extra tools.

References

Ergonomics: The Study of Work, U.S. Department of Labor,

Occupational Safety and Health Administration, OSHA

3125, 2000 (Revised).

Elements of Ergonomics Programs, A Primer based on

Workplace Evaluations of Musculoskeletal Disorders, U.S.

Department of Health and Human Services, Public Health

Service, Centers for Disease Control and Prevention,

National Institute for Occupational Safety and Health,

1997.

Ergonomic Guidelines for Arranging a Computer

Workstation - 10 steps for users, Cornell University

Ergonomics Web, http://ergo.human.cornell.edu/

ergoguide.html, retrieved March 16, 2012.

Our workspace designs use ergonomic principles to mini-

mize injuries and maximize productivity, Lista International,

http://www.listaintl.com/general/ergonomics, retrieved

March 16, 2012

James Anderson is a Vertical Market Manager at Lista International Corp. He has decades of experience in the workbench field.

LISTA INTERNATIONAL CORP. FOUR ERGONOMIC STEPS TO A PRODUCTIVE WORKPLACE

For more information, contact:

Lista International Corporation

106 Lowland Street

Holliston, MA 01746-2094 USA

Phone: (800) 722-3020

Fax: (508) 626-0353

Internet: www.listaintl.com

E-mail: [email protected]

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