Shipyard Ergonomics
2013 Marine Chemist Association
Ben Zavitz, CPE
Ergonomist
207-442-2219
Benjamin.zavitz@gdbiw.com
Agenda

Introduction to Ergonomics

Definition, Objectives, Risk Factors, Injuries



Human Performance View of Ergo
OSHA & Ergonomics
Shipyard Ergonomic Solutions
2
What is Ergonomics?
Science of optimizing jobs, equipment, tools, and workplace to fit
people based on human capabilities and limitations
3
Objective of Ergonomics
Injury Perspective
1.
Reduce Risk of Injury
• Employee Pain / Discomfort
• Recordable / Lost Time Injuries
Workers
Comp
• Workers Compensation $
• Return To Work
• OSHA Responsibilities
Ergo
Medical
Safety
Traditional View of Ergonomics
4
Objective of Ergonomics
Human Performance Perspective
2.
Maximize Human Performance & Efficiency
•
Reducing Non-Value Added Motions
•
Overburden of human systems
•
Internal Productivity
Engineering
& Design
• Same amount of work with less effort
• More work within confines of
human biological &
psychological systems
Ergo
Management
Quality
Human Performance View of Ergonomics
5
Internal Productivity Demo
6
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
Job was designed without human capabilities in mind
7
What are MSDs (musculoskeletal disorders)?

Overuse injuries (similar to athletics)

Repetitive Strain Injuries (RSIs)
 Cumulative Trauma Disorders (CTDs)

Soft tissue injuries



nerves, tendons, muscles, ligaments
wrists, elbows, shoulder, back, neck, knees
Develop gradually over time

symptoms last longer than few days


when symptoms don’t go away = serious


fatigue, pain, discomfort, inflammation, numbness
lost work days, permanent disability or surgery
Report symptoms early, Identify Risks & Solve
8
Ergonomic Risk Factors
9
OSHA & Ergonomics
Does OSHA have a Federal
Ergonomics Standard?
10
OSHA Ergonomics History
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)
11
OSHA Ergonomics History
1987 -1992: OSHA issues significant citations:
1987:
1988:
1988-1996:
1992-2000:
1989-1993:
International Beef ($2M)
John Morrell Meatpacking($4.3M)
Pepperidge Farms ($1.4M)
Beverly Nursing Homes
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
12
OSHA Enforcement Policy
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.
13
OSHA General Duty Clause
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.”
14
Criteria for 5(a)(1) Violations
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.
15
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.
16
5(a)(1) Criteria: Causation
Causing or likely to cause serious physical harm?

Company injury records

No records

NIOSH Studies

National Academies Studies

Industry Studies
17
NIOSH Report (1997)
Risk factors are specific
to certain body parts
18
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
19
Panel Results
Conceptual Model
Risk Estimates
20
5(a)(1) Criteria: Feasible Abatement
Feasible means of abatement that will reduce or
eliminate exposures to employees
 Industry Studies and Guidelines (NIOSH, OSHA)
21
Ergo Guidelines Published by OSHA

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
22
OSHA Ergo Guidelines
Process for Protecting Workers
1.







Management Support
Involve Employees
Provide Training
Identify Problems
Implement Solutions
Address Reports of Injuries
Evaluate Ergonomic Efforts
Implementing Solutions
2.

Description, when to use, points to remember
23
Shipyard Solutions
1.
2.
3.
4.
5.
6.
Site-wide
Material/equip handling
Tools
Metal work
Shipside
PPE
BEFORE
AFTER
BEFORE
AFTER
24
OSHA Ergonomics Enforcement
Inspections in the last 10 years:

5,046 Ergonomic-related Inspections

23 Citations issued

850 Ergonomic Hazard Alert Letters issued
25
Where 5(a)(1) cannot be supported
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).
26
What is an EHAL?

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.
27
OSHA EHAL Follow-Up

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
28
Industry-Wide Alert Letters
Beverage Distribution Industry - Summer, 2011
29
Industry-Wide Alert Letters
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
30
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
31
So...
How do we keep OSHA out of our hair and have a proactive program ?
32
Ergonomic Data
33
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)
34
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”?
35
Work Position Visual
Back,
Neck,
Shoulders,
Elbows,
Knees
36
Test Your Knowledge
37
Test Your Knowledge
38
Raise-the-Work
39
Walk Behind Grinders
BEFORE
95% Risk Reduction
Eliminates Kneeling, Bending, Vibratory Tool
80% Improvement Productivity
AFTER
40
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
Unloaded
ISO Standard (8662)
Loaded
ISO Standard (5349)
41
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)
42
Measuring Acceleration
43
Exposure Time- Ready Reckoner
All values are
exposure points
Colors show
exposures
EAV & ELV
44
“Super Grinder”
Stone Grinder
65+% less vibration
2-3x removal rate
1/3 weight
45
Low Vibration Tools
Old Needle Gun
70-90% Less Vibration
Old - Die Grinders
75% less vibration
20% more removal
46
Long Reach Needlegun
75+% less vibration
Eliminates Kneeling
Weight holds it down
47
Mechanized Grinding
95% Risk Reduction
Eliminates force, rep. motion, vibration
2012 Ergo Cup Winner
50% Improvement Productivity
50% less consumables
48
Weld Shaver
95% Risk Reduction
Eliminates force, rep. motion,
vibration from hand grinding
40x faster
49
Blasting
Low Ergonomic Risk
90% Time Savings
50
Mag Base Drilling Tool
2013 Ergo
Cup People’s
Choice Award
for ROI
75% reduction in kneeling
100% reduction in hand drilling
80% Improvement Productivity
51
Tool Backpack
Shoulder straps reduce weight by 50%
Hip belt reduces weight by 25% more
Slimmer, does not catch
Fire Resistant
52
Paint Carrying Handle
53
Take Away

OSHA is primarily concerned with lagging
indicators (injury rates and employee feedback)

Best approach is to be proactive


Ergonomics is optimizing human performance
and can have a significant impact on Safety,
Quality, Cost, and Morale


Manage risk vs. consequences
Injuries are a by-product of poor job set-up/design
Ergo Cup Competition helps to engage
workforce
54
Questions
Ben Zavitz, CPE
Ergonomist
207-442-2219
Benjamin.zavitz@gdbiw.com
55