Business case for ergonomics interventions
Source: Dr. Popov’s Projects
Practical Projects
Dr. Georgi Popov, QEP
Leigh Ann Blunt, Ed.D., ASP
John Zey, Ed.D., CIH
Anthony Hirner, CSP
Silicone Wire Problem Statement
• Silicone wire production involves variety of
hazardous chemicals, toxic materials, and
hazardous waste.
• Requires repetitive movements
• CTD’s, Lower back injuries, CTS
• HR reported difficulties hiring new employees
• High turnover rate
• High cost of training and re-training
Silicone wire
Wire Production Process and Materials
Step 1
• The first step is to
feed the raw
silicone into the
extruder. Talc
powder is applied
to the raw silicone
to improve the
process.
Step 2
• The next step is
to apply
fiberglass tread
on the basic
silicone wire.
Fiberglass tread
is applied
utilizing special
treading
machine.
Silicone wire extrusion process
Ovens
PIE
Steps 3 - 5
• Third step is to apply another
layer of silicone and heat it to
4800F in order to cure it.
• The same silicone extruder
like in step one is utilized.
• Fourth step is to apply
another layer of thicker
reinforcement layer of
fiberglass.
• The same fiberglasstreading machine is utilized
during this step.
• Fifth step is to apply final
layer of silicone and print ink.
Spark plug boots
• The final step is
to assemble the
ignition wire and
install spark plug
boots.
• The company
utilizes spark
plug boots made
of silicone.
Crimping silicone wires
• Manual Process
Next step
• Once the insulation is stripped, it will
expose the actual wire that conducts spark
to the spark plugs
Folding
• The workers are folding the wire over back
onto the insulated part of the plug wire
Crimping
• Employees put the end of the wire with
the terminal on it into crimping tool.
Fitting Spark Plug Boots
• Manual operation
• Apply milk like lubricant
• Test the wire
Project Cycle Efficiency Analysis
VAT - Work that customer would recognize as necessary
to create the product or the service they are about to
purchase.
TLT - How long the process takes from start to end.
FYI: Source: Wire Lean 2007 tab
Ergonomics
• Repetitive motion is
common for spark
plug boots
installation
operations.
• Unfortunately, the
nature of the work
requires a lot of
repetitive
movements. MSD’s
are common.
Countermeasures - Admin
• The administrative control option
• One possible option is to reassign the boots
installation workers from the morning shift 7AM –
11AM to the packaging department.
• The workers from the packaging department will
be cross-trained to install spark plug wire boots in
the afternoon.
• Cost - $ 1250 training
Semi-Automatic Crimping Machine
•
•
•
•
•
•
•
Initial investment – $17,500 per workstation
Engineering cost – $ 4700 per terminal
Utilities – $ 500 per year
Maintenance – $ 500 per year
Training – $ 2500 – 10 workers
Improved productivity
Employee morale
Full Automatic Terminal Crimping
Machine
•
•
•
•
•
•
•
Initial investment – $ 57,500 per workstation
Engineering cost – $ 5100 per terminal
Utilities – $ 500 per year
Maintenance – $ 650 per year
Training – $ 2700 – 10 workers
Improved productivity
Employee morale
Financial Analysis
FYI: Source: MS Excel Ergo Financial ROI
Financial Analysis
FYI: Source: MS Excel Ergo Financial: Financial tab
Financial Analysis
FYI: MS Excel Ergo Financial Compare proposals
Results
• The management selected Semi-Automatic
Crimping Machine (SACM) option
• 3 SACM Total $ 70,100
• Admin option was implemented for a short
time – insufficient results
• Reduced personnel from 90 to 47 (20%
reduction due to current economic
“difficulties”; 15% personnel reduction due to
improved productivity; 12% other).
• Production down only 11% from 2008
Project Cycle Efficiency Analysis –
Post Intervention
FYI: Source: Wire Lean PCM Lean tab
EHS INTERVENTION IS
NOT AN EXPENSE -IT IS AN INVESTMENT