vivarium ergonomics - innovive disposable cages, ivc racks and … · 2016-11-08 · on-site at...

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Vivarium Ergonomics: A Third-Party Analysis Between Washable and Disposable Cage Processing PRESENTED BY: Jim Fallon President & COO, Innovive Inc

Innovive Webinar Series

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1INNOVIVE LEARNING WEBINAR SERIES © Innovive Inc 2013 | 866 43 CAGES

Vivarium Ergonomics:A Third-Party Analysis Between Washable and Disposable Cage Processing

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Jim Fallon President & COO, Innovive Inc

As President and COO of Innovive Inc, Jim Fallon has led the implementation of disposable caging at over 100 facilities worldwide since 2005, including several large new-construction projects. He has seen first hand the dos and don’ts associated with this technology and been closely tied to the many innovations, best practices and standards that have emerged over the past 7 years.

EMAIL: [email protected]



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Webinar Agenda

I.  Intro

II.  Humantech Study

I.  Overview

II.  Framework

III.  Methodology

III.  Traditional Washing vs. Disposable Caging

IV.   Advantages of Disposable Caging

V.   Conclusion



Working in an animal facility can involve strenuous activities that can lead to expensive occupational health issues.

There are many steps involved in processing caging at traditional animal facilities, but when you use Innovive’s system it is a lot different. Our customers consistently tell us their work loads have gotten easier after they adopt our system.

We always knew that some aspects of it were better, but what about the system in total? How do you quantify the end-to-end ergonomic comparison between washable and recyclable caging?

That is what this webinar will cover.

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Ergonomics Matter



Traditional Washing Facility Cage Changing Process

• Clean cages are delivered from the clean cage storage to the animal holding rooms.

• Cages are changed inside the animal holding rooms.

• The soiled cages are taken into the dirty cage wash, where they are disassembled, dumped and loaded into a tunnel washer or rack washer.

• The cages enter the clean side of the cage wash where they are filled with bedding, reassembled and put onto racks.

• The cages are loaded into the autoclave before returning to clean cage storage to repeat the process.

These procedures require a lot of lifting and repetitive activities for this method of cage processing.

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Traditional Washing Facility: Involves Heavy Lifting and Repetitive Tasks



Disposable Caging Facility Cage Changing Process

• Double-bagged and irradiated cages are received into clean cage storage.

• Cages are changed inside the animal holding rooms.

• The soiled cages are prepared for recycling and are removed directly from the facility.

All activities for both traditional and disposable cage processing are considered because the analysis will then cover a true end-to-end comparison of the two different types of caging systems.

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Disposable Caging Facility: Eliminates Cage Washing



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The Third-Party Analysis



To guarantee a completely impartial observation, a third-party ergonomics consultancy called Humantech was selected.

Humantech: Ergonomic Experts

• Over 30 years of experience

• Performed ergonomic analysis at multiple animal facilities over the years

• Experience conducting independent studies on which they stake their name and reputation

“We are experts in ergonomics—the art and science of reducing problems that might arise from the interaction between, people, equipment, and the environment.“ - Humantech

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Humantech: Ergonomic Experts

We are experts in ergonomics – the art and science of reducing problems that might arise from the interaction between, people, equipment, and the environment. ”

“

–



Humantech’s Analysis: Framework

• Humantech conducts on-site observations and interviews.

• The entire process to be studied is fully documented and then analyzed from beginning to end.

• Various measurements are taken.

• Multiple ergonomic activities are scored.

• Photos and videos are documented for later analysis.

• Workers at each stage are interviewed.

• Supervisors and managers are also interviewed.

• Once all the data is collected, a thorough quantitative analysis is performed on the overall processes.

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Humantech Analysis: Framework

OBSERVATION à

INTERVIEWS à •  Lab Managers

•  Vivarium Managers

•  Technicians

•  Workstation Dimensions

•  Video/Photos

•  Operator Comments

QUANTITATIVE ANALYSIS

Based on data collected, Humantech evaluated ergonomic risks using industry standard methodology

à



Humantech Methodology: Two Scoring Systems

• NIOSH - A methodology for calculating the burden of activities that involve lifting, lifting frequency, etc.

• BEST - Calculates Job Hazard Score (physical stressors and amount of time operators spend performing the job), based on the activities that are selected by the BRIEF (Baseline Risk Identification of Ergonomic Factors) system.

Humantech has used these scoring tools in their customer engagements for years, and has developed a reliable and repeatable way to rate job activities in a manner that can predict the likelihood of future occupational health liability.

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Humantech Methodology: Two Scoring Systems

BRIEF (Baseline Risk Identification of Ergonomic Factors) – initial screening tool to identify ergonomic acceptability of job tasks. Examines nine body parts for work-related musculoskeletal disorder risk factors.

BEST (BRIEF Exposure Scoring Technique) – calculates an overall

Job Hazard Score for an operation based on the individual BRIEF scores, physical stressors, and the amount of time operators spend performing the job.

NIOSH (National Institute for Occupational Safety and Health) – calculates lifting factor such as location of load, lifting frequency, hand-to-object coupling, and lift geometry.

1.

2.



Two Scoring Systems: Risk Scale

• NIOSH – The score is calculated by taking the weight divided by the recommended weight for the task. A score less than or equal to 1 is “low”, greater than or equal to 3 is “high”, and in between is “medium”.

• BEST – The score is calculated by taking the BRIEF scores, physical stressors, and the amount of time the operator spends doing the job. A score between 0-9 is “low”, between 30-49 is “high”, and in between is “medium”.

These scales are accepted as viable measurement tools, especially when deployed by a credible organization such as Humantech.

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Two Scoring Systems: Risk Scale

BEST

NIOSH 1.

2.

≤ 1 1.01 – 2.99 ≥ 3

HIGH MEDIUM LOW

0-9 10-29 30 - 49

HIGH MEDIUM LOW



Humantech Analysis: Location

• An actual disposable caging facility in excess of 10,000 cages.

• An actual traditional caging facility in excess of 10,000 cages.

The analysis was conducted entirely by Humantech staff, and they completed their report independently. There was no Innovive staff present during any part of the analysis, on-site experiences or data capturing.

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Humantech Analysis: Location

LOCATION: On-site at actual vivarium operations Disposable Cage Facility

in excess of 10,000 cages Traditional Washing Facility

in excess of 10,000 cages



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Traditional vs. Disposable



Disposable Caging Facility: Cage Processing Tasks

This slide details all of the individual tasks that is done in a disposable caging facility relative to animal husbandry and cage processing. Example tasks that were analyzed:

• Unboxing the cages

• Delivering cages into clean cage storage

• Moving stacks of cages under the hood

• Opening the stacks of cages

• The basic cage change procedure

• Restacking the dirty cages

• Bagging the dirty cages

• Preparing the dirty cages for recycling

• Transferring the cages out to waste disposal and recycling

You can start to get a sense for thoroughness of the analysis.

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Disposable Caging Facility: Cage Processing Tasks

•  Transport pallets of caging and bottles from loading dock

•  Stage materials outside of barrier

•  Unbox bag of cages •  Breakdown boxes

and transport to ship bay

•  Transport rack from clean side

•  Transport rack of cages to clean cage wash room

CAGE HANDLERS (clean) •  Remove water bottle from

dirty cage and place in recycle bin

•  Remove lid and place food tray in clean cage

•  Move mice into clean cage •  Top off food •  Lift food bag 20 times per

day (33 lbs) •  Place lid/cover on cage •  Place clean water bottle onto

lid •  Lift clean cage onto rack (200

times per day) •  Stack 28 soiled cages and

bag for transfer to dirty cage processing room

•  Transport rack of clean caging and bottles

•  Prepare change station (sanitize)

•  Lift bag/stack of clean cages from rack (21 lbs)

•  Remove stack from bags

•  Lift cage from rack and place in laminar flow hood

CARE TAKERS •  Fill pallet with dirty cages •  Transfer pallet to

shipping area (15 pallets every 3 weeks pushed 900 feet)

•  Crush dirty bottles and transport bag to shipping area for recycling (1 bag each day)

CAGE HANDLERS (dirty)



Traditional Washing Facility: Cage Processing Tasks

Example tasks that were analyzed:

• Moving clean cages into storage

• Moving clean cages into the animal holding rooms

• The entire cage changing process (*similar to disposable caging but the materials are typically heavier than disposable caging)

• Dumping the dirty cages

• Putting the cages on a motorized tunnel washer

• Loading wire racks of bottles onto carts

• Putting bedding into the clean cages

• Filling water bottles

• Getting the cages ready for the autoclave

The analysis therefore covers an end-to-end view of the labors required for preparing clean cages all the way through to getting the dirty cages either out of the facility in the case of disposable caging, or back into clean cage storage in the case of traditional caging.

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Traditional Washing Facility: Cage Processing Tasks

•  Transport dirty cages to staging area

•  Disassemble cage components

•  Dump food and bedding into bin (slam against garbage bin if stuck)

•  Flip cage and place w/ wire lid upside down into wash station (new process requires wire lids to be separated)

•  Remove stoppers from bottles •  Lift rack into washer (34 lbs) •  Flip rack to dump water and load

into washer •  Load wire lids onto rack •  Load rack into washer

CAGE HANDLERS (dirty)

CA

GE H

AN

DLER

S (clean)

•  Stack cages as they are coming out of washer

•  Fill cages with bedding •  Dump bedding into hopper

(25.5 lbs) •  Place wire lid onto cage •  Lift clean cages (6) onto

“unit” (total 24 lbs)

•  Fill water bottles while on rack

•  Place stoppers in bottle •  Lift rack onto “unit” (34 lbs) •  Cover “unit” and store for

caretaker plundering

•  Prepare laminar flow hood for cage change

•  Lift cage of bottles onto floor from “unit”

•  Lift stack of clean cages into hood

•  Lift dirty cage from rack to hood •  Remove lid and water bottle

from dirty cage •  Insert new water bottle into

clean cage •  Transfer food to clean cage •  Top off food •  Lift food bag 20 times per day

(33 lbs)

•  Transport “unit” of cages and bottles from cage wash area to animal care room

•  Reposition racks in room if necessary

•  Transfer mice to clean cage •  Insert wire lid and plastic

cover •  Stack dirty cage onto “unit” •  Lift clean cage back onto

shelf

CARE TAKERS



Summary: Ergonomic Risk Rating

The left column shows the scores for traditional caging and the right column shows the scores for disposable caging. The center column shows the categories of activities that were scored.

• The first NIOSH score compares the loading of clean caging into clean cage storage. The two systems scored fairly evenly.

• Traditional caging (moving cages from the clean side of the cage wash into clean cage storage) results: 0.79.

• Innovive system (receiving caging, removing from boxes, placing the double-bags on a conveyor to be misted into the facility) results: 0.66.

• The second NIOSH score compares water bottle processing. The Innovive system scored much better.

• Traditional caging have bottles that are significantly heavier in weight, in addition to using heavy wire baskets to support them. Results: 1.18.

• Innovive bottles are packaged in 12 packs and are lightweight by comparison. Results: 0.18.

• The first and second BEST scores analyzes the dirty side and and clean side cage wash. This is where the major differences between the systems are, as these activities were scored as

continued on next page

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Dirty side cage wash

Clean side cage wash

Animal holding room

BEST

Preparing cages for clean cage storage

Processing water bottles

Summary: Ergonomic Risk Rating

0.79

1.18

0.66

0.18

36

36

34

N/A

N/A

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NIOSH

HIGH LOW

Traditional Disposable Caging

Overall Humantech Risk Rate Score



high risk in the washable cage facility and do not exist in the Innovive facility.

• Traditional: 36 and 36 respectively.

• Innovive: N/A.

• The third BEST score compares the process for the animal cage changing process. The cage change process is essentially the same for both caging systems, but due to the lightweight nature of the disposable cage, there is a meaningful decrease in the ergonomic risk taken by a technician who works in a disposable caging facility when compared to a washable caging facility.

• Traditional: 34.

• Innovive: 22.

At the bottom of the slide you can see Humantech rates the disposable caging process, from an ergonomic standpoint, as “LOW” versus traditional as “HIGH”. Considering the analytical framework and quantitative methodologies applied here, this is a fairly powerful statement.



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Ergonomic Benefits of Disposable Caging



Eliminates High-Risk Tasks of Cage Washing

• Cage washing and processing is the most physically demanding and risky role in a traditional facility.

• Many more forces are associated with the moving, loading and unloading of carts all day long in the cage wash.

• These activities can be eliminated through the use of disposable caging.

• Eliminating cage dumping can also reduce allergen exposure.

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Eliminates High-Risk Tasks of Cage Washing

Disposable caging eliminates repetitive awkward postures and high forces associated with cage washing.



Eliminates Cage Bedding Activities

• Disposable caging arrives pre-bedded, irradiated and ready to go.

• Disposable pre-bedded cages can be placed onto carts, and wheeled into clean cage storage and animal holding rooms.

• Avoids any major lifting activities.

• Does not require cage handlers to lift heavy bags of bedding on a daily basis.

• Innovive irradiates and double-bags all pre-bedded cages which is a biosecurity benefit.

By allowing Innovive to take over the entire bedding and sterilization process, you eliminate a significant portion of traditional cage and bedding handling.

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Eliminates Cage Bedding Activities

Disposable caging does not require cage handlers to add bedding. Arrives pre-bedded with corn cob or ALPHA-Dri®.



Reduces Weight When Handling Water Bottles

• Both Innovive disposable cages and traditional cages are compatible with pouch or bag sys-tems and autowatering facilities.

• Traditional bottles are heavier than Innovive bottles and are typically in large wire baskets for processing, which adds additional weight.

• Innovive bottles are packaged in 12 packs and 6 packs. They are super light weight, as well as easy to stack onto carts.

The left image on the slide depicts Innovive’s packaged water bottles stacked neatly on shelving units. These can be transferred 12 at a time onto a cart that would go into animal holding rooms, as depicted in the image on the right. This results in very low impact for managing the entire watering process in animal facilities.

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Reduces Weight When Handling Water Bottles

Weight from lifting water bottles is reduced by 83% from a 34 lb. rack at a traditional facility to a 6 lb. pack of 12 Aquavive® bottles.



Reduces Risks Associated with Cage Changing

• The lightweight design of disposable changing can vastly reduce of ergonomic risk for animal technicians.

• An animal technician changing 200 cages per day will lift 2,080 lbs. compared to 800 lbs. using lightweight disposable caging.

We have always made this point to customers, and we consistently hear positive feedback from technicians when they start using our system. This information is now supported by Humantech’s data.

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Reduces Risks Associated With Cage Changing

An animal technician changing 200 cages per day will lift 2,080 lbs. compared to 800 lbs. using lightweight disposable caging.



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Always Improving



At Innovive we’re always looking for ways to improve ourselves as well. After doing this analysis, Humantech advised us we needed to make a change on how we package our products.

Our products are double bagged before they are irradiated so that customers have the option to peel off one layer of bagging inside clean cage storage and peel off the second layer when they are inside the animal rooms. The layered bagging system provides flexibility and control to better match a facility’s barrier requirements.

Originally, two stacks of single-bagged cage bags were sealed in one larger bag, as depicted on the left side of the image of the slide. Therefore cage handlers were lifting a 42 lb. bag with two stacks of caging in it. Humantech advised us that we should double-bag the stacks individually, which results in cage handlers only lifting 21 lbs. at a time instead. This has become our current standard, so we learned something from this analysis as well.

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Package Redesign Implemented by Innovive

42 lbs. 21 lbs.

STACK OF 25 CAGES à Transitioned from single outer bag to two stacks of double-bagged cages

21 lbs.

Lighter stacks reduce impact to handlers.



Ergonomics are an important and often overlooked consideration when building an animal facil-ity. The reality is that facilities will reduce their occupational health costs, work-related injuries, absenteeism and overtime costs when they adopt our caging system, which are huge benefits to any program.

Thank you for interest in our webinar. We hope this has been useful information for you.

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Ergonomics Matter



vivarium ergonomics - innovive disposable cages, ivc racks and … · 2016-11-08 · on-site at...

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