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Applied Ergonomics Conference

© 2004 Humantech, Inc

Simple, Straightforward and SystematicErgonomic Risk Reduction

The Job Improvement Process

Josh Kerst, CPE, CIE

Vice President and Ergonomics Engineer



Objectives

Describe a simple process to evaluate work for human capabilities - Find It» Work strain avoidance - forces and postures that are

overly fatiguing» Higher fidelity job assessment tools as needed

Eliminate non-value added activities – Fix It» Worker compatible machines - simple, highly reliable,

and easily improved » Workstation geometry & proper equipment

Reduce risk to control loss – Check for Success» “Ultimate waste” of human capital.» Reduced hassle and safer work environment» Describe a web-based solution library



Business Reality 101

In today’s business climate initiatives must deliver measurable value in the short to medium term.

Its about job improvement not just analysis….



Ergonomic Process Structure

Identify and improve workplace conditions that reduce exposure to ergonomic risk factors.



Simplify the Process

PDCA becomes



Using the Right Tool for the Job The Tools



Launching Point

Use a simplified approach to launch or invigorate the process.Provide tools that are easy to understand and focus on improvement not analysisUse a multi-level team approachMake changes that are:» High Visibility» High Impact



Launching Point

Use a simplified approach to launch or invigorate the process.Provide tools that are easy to understand and focus on improvement not analysisUse a multi-level team approachMake changes that are:» High Visibility» High Impact

Occurs RAPIDLY

with a focus on

Improvement



Kaizen Event to RAPID Event

Adopted the method developed to foster continual improvement within Toyota Production System Designated using a define block of time Cross functional team that focuses on finding and fixing issues to:» Unlock talents & abilities of employees,» Make decisions at the lowest level, in quickest time by people

who know the best solution.Benefits:» Accelerate improvement» Improve productivity» Gain time, space and labor savings» Collapse lead time and gain management support» Reduce WIP and scrap» Labor relations improvement



What’s the Team’s Purpose

To make rapid, simple improvements to the ergonomic conditions of the workplace that improve the safety, productivity, and quality of life of our employees.

Launch an initiative to allow the ergonomic process to gain a visible foothold at this site.



Use current deployments

Silos of Knowledge Integrated Approach

LEAN

DMA

I

C

ERGO

LEAN ERGO

DMAIC



Get the Right SWAT Team

Represent skills, abilities, & organizations on participative team :» Operators/employees» Maintenance, Engineering, Facilities» Supervisors, Managers » Health & Safety» Lean Production Officer, Six Sigma Green/Black Belts

Commitment to time & contribution based on roles» Leaders» Team players» Social and personable» Practical» Enthusiastic» Like to work towards change» Dedicated to improvement

Empowered by management and accountable for results



Hit List



Find the Postures



Simple tool

Horizontal Distance

Elbows Out Butts Up



Perspective changing Hit List

Fix It• Comfort Zone

• Don’t Give Me Static

Find It• Horizontal Distance

• Wash Rag

• Contact



Find the POSTURE

WashragElbows OutShoulders too high/lowHungry HeadButts UpHorizontal DistanceSit vs. StandTwist and ShoutContactBad Vibes



Apply the Appropriate RULE

Keep it straightKeep elbows at sidesKeep it in the comfort zoneKeep it in sightKeep it above the kneesKeep it closeIs it right for the taskKeep it in line with the spineDon’t lean on the machineDon’t hold it



Document it to CHECK FOR SUCCESS

Completed ImprovementsWithin 30 daysWithin 60 daysWithin 90 days



Tools Used



DOCUMENT ITRAPID Form

Mulch Plug 110February 10, 2003

Line 110

DayGreeneville, TN

Bob, Mary, Cam

Job Job InformationInformation

Page 1 – Job Information Page




Using tool at improper heights

Inserting bolts into unit at high heights

N/A

Knees in contact with table edges

N/A

3

Root CauseRoot Cause

Total of YesTotal of Yes



FIND ITWash Rag



Keep it Straight FIX IT



FIND ITWash Rag




- Lower height of fixture to improve working heights

- Use in-line tool, rather than pistol grip tool

Operator Operator InterviewInterview

- Install platform for operators- Tilt part to improve part orientation

Improvement Improvement IdeasIdeas

- Lower height of fixture to improve working heights

- Use in-line tool, rather than pistol grip tool




-Investigate use of proper tools-Install operator platforms

- Hands/Wrists sore from using tool- Back from lifting parts- Feet/Legs tired from standing on concrete floor all day

- Anti-fatigue matting- Gloves for using tool- Store parts off the ground

-Lifting heavy parts-Using tool for long periods of time

Operator Operator InterviewInterview




Immediate and Immediate and LongLong--Term FixesTerm Fixes

- Install platform for operators- Provide an in-line tool- Install workstation padding

ElbowsOut

Washrag

Contact

!!!

906030



ErgonomicsFind It Fix It



Find It Fix It

Problem» Working at fixed height work

table is difficult for different height operators

Solution» Attached hydraulic legs so units

goes up and down



What About Results?

Changes that improve the workplace

A record of improvements (Before/After Photos)

Plans for longer term improvements (30-60-90 days)

Presentation of our process, results and plans

to site management



Some Examples



Completed ImprovementsLong term engineering controls» Within 30 days» Within 60 days» Within 90 days

Assign responsibilityPresented to site management team

DOCUMENT ITCheck for Success



Event Results22 Manufacturing Locations

6-18 people teams (Avg. 8)4 - 5 day events14-30 operations evaluated13-50 immediate changes made ($0-600)22-59 additional changes planned in 30-90 days22 Ergonomics Teams establishedCreate a pull for more training more involvement



Project Elements: RAPID Team Event

Ergonomics Event “Scorecard”



Project Elements: RAPID Team Results



Results

Breakthrough improvements in:» Health & Safety measures» Productivity/work flow

Sustainable impact in the immediate to short termSustainable ergonomics teamScalable to other sites and business groups and “proof of concept”



Keys to success

Simplified ApproachTeam Approach (be selective)Skill Development (training)Develop infrastructure (process model)Demand and expect resultsHarness the enthusiasm

Simply put….

Can you create a workplace that allows your people to work better



When to Use / Limitations Hit List

When to Use the Simplest Methods

» When the level of necessary detail about the job is low and/or

» When off-the-shelf solutions or skilled in-house resources are readily available

Limitations of the Ergonomics Hit List

» Does not provide measurable (quantitative) risk exposure

» Typically a posture driven model



Using the Right Tool for the Job The Tools



" Increase the probability of a certain outcome

" Do not guarantee that a certain outcome will occur

" Assist in the job improvement process by identifying root causes

Risk Factors



Ergonomic Job Analysis

Observation Discomfort Survey Risk Factor Survey



Completing the Risk Factor SurveyStep 2

! !

S

!!!

!

!!

!

!!

!

!

Pin Press Orangeburg, SC 22A9-12-02 Assembly 1st A47 Hinges

3 3 2 2 2 2 2 3 1

!

! ! !!!

! !



Scoring the BRIEF Low, Medium, or High



When to Use / Limitations of the BRIEF

When to Use the BRIEF SurveyWhen a high level of detail is necessary and/orWhen readily available off-the-shelf solutions are not feasible

Limitations of the BRIEF SurveyDesigned to analyze a job with specific tasks that are repeated throughout a cycle



The BESTThe BRIEF Exposure Scoring Technique

BRIEF SurveyBody Area Scores

BRIEF PhysicalStressors Scores

BEST Job Risk Factor Score

Time Exposure Multiplier

BEST Job Hazard Score



The Completed BEST Completed BEST

33

0.8

26.4

2

31

Pin Press Orangeburg, SC 22A9-12-02 Assembly 1st A47 Hinges

3 3 32 22 2 2 1

5 5 53 33 3 3 1

2



From Simple to Detailed

Simplified ApproachAll some or none options for analysisWeb-based and passwordInstant infrastructure (process model)Share results



Priorities

Low10 20 30 40 50 60 70

Medium High Very High

The BRIEF Exposure Scoring Technique

Priority

Low Medium High Very High

0 - 9 10 - 29 30 - 49 50+



Web-based Job Improvement Tool



On-line Solution Database



Suite of Risk Assessment Tools



Built-in Improvement Process Mapping



Search and Reapply……

Human Performance Ergonomics™Improvement Accelerated

www.humantech.com

requestedfile (2)

Documents

simple process

continual improvement

productivity gain time

participative team

quickest time

ergonomic conditions

ergonomic risk factors

inclaunching pointuse