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What is your Ergo IQ? An Ergonomic Risk Assessment Model
ASSE/AIHA Professional Development Conference
April 19, 2013
Bruce K. Lyon, CSP, P.E., ARM, CHMM Director, Risk Control
Hays Companies
Dr. Georgi Popov, QEP. Associate Professor
University of Central Missouri
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What’s your Ergo IQ? An Ergonomic Risk Assessments Model
• Definitions
• Assessment Process
• Assessment Tools
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Ergonomics (work) + (natural laws)
The science of properly matching work demands and environment with human capabilities.
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Human Factors
Human-machine Interface
Cognitive + Physical Aspects
Designing for the End-user
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Musculoskeletal Disorders (MSD) a.k.a. Cumulative Trauma Disorders (CTD)
• Disorders of the soft tissues
• Chronic in nature
• Caused by certain risk factors
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Costs of Ergonomic Risks
Productivity
Quality
Employee
Work-related Musculoskeletal Disorders (WMSD)
$40,000 - average cost for back surgery
$29,000 - average for carpal tunnel surgery
$20 billion a year – US DOL
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Ergonomic Risk Assessment (ERA)
Purpose Identify Problem Jobs
• Involve employees
Quantify Risk Factors
• Establish Baseline and Benchmark Improvements
Reduce Potential Disorders and Improve Work
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Establishing an ERA Process
• Scope/context
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Establishing an ERA Process
• Scope/context
– Who
– What
– When
– How
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Establishing an ERA Process
• Scope/context
• Goals/Objectives
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Establishing an ERA Process
• Scope/context
• Goals/Objectives
Specific
Measurable
Actionable
Realistic
Time-oriented
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Establishing an ERA Process
• Scope/context
• Goals/Objectives
• Responsibilities
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Establishing an ERA Process
• Scope/context
• Goals/Objectives
• Responsibilities
– Defined & Communicated
– Specific & Measurable
– Aimed at Achieving goals
– Accountability
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Establishing an ERA Process
• Scope/context
• Goals/Objectives
• Responsibilities
– Defined & Communicated
– Specific & Measurable
– Aimed at Achieving goals
– Accountability
Management
Ergo Coordinator
Ergo Committee
Engineering, Maintenance
Medical, Worker’s Comp
Supervisors
Operators
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Establishing an ERA Process
• Scope/context
• Goals/Objectives
• Responsibilities
• Training
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Establishing an ERA Process Topic Who Objectives Delivery Updates
Managing the Process Part 1
GMs, Plant Managers Coordinator
• Understand process
• Responsibilities • Goals
Internal Every 3 years
Ergo for Engineering Design
Engineers Maintenance Tooling
• Ergo design guidelines
• Assessment tools • Software
Internal or outside approved vendor
Every 3 years
Ergo Awareness
Operators Supervisors
• Understand process
• Responsibilities • ID risk factors and
controls
Internal Every year
Ergo Committee
Ergo Committee
• Assessment tools • Problem solving
Internal Every year
Example
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Establishing an ERA Process
• Scope/context
• Goals/Objectives
• Responsibilities
• Training
• Resources
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Establishing an ERA Process
• Scope/context
• Goals/Objectives
• Responsibilities
• Training
• Resources
• Process Steps
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Design Concept
Preliminary Design
Detailed Design
Build or Purchase
Commission (Install and Debug)
Production Maintenance
Decommission
ANSI Z590.3
PtD guidance for “Life-cycle” assessments
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Ergonomic Risk Assessment Process
Establish
Analyze
Ergonomic Improvement
Process
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Ergonomic Risk Assessment: Where to Start?
Loss History Incident Data OSHA logs Worker’s Compensation Information
Employees Input & Feedback Surveys
Workplace Observations Visual Cues Job Analysis/Risk Factors
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Performing an Assessment
Set Goal Select Tool
ID Team Gather
Data Record
Data Analyze
Data Develop Findings
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• Relative Risk Measure
• Baseline & Benchmarking Measure
Risk Factors
• Team Assessments
• Create Ownership Involve
Employees
• Prioritize and Rank
• Target Efforts Provide
Guidance
Set Goals for Assessment
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Ergonomic Risk Assessment Process
Establish
Analyze
Prioritize Ergonomic
Improvement Process
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Prioritize
• Numerical Scores and corresponding Risk Ratings (RPN)
– Exposure base
• Recordable Incidents and Reports of Discomfort
– Hot Spots
– Potential problems
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Ergonomic Risk Assessment Process
Establish
Analyze
Prioritize
Implement
Ergonomic Improvement
Process
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Implement
• Identify Effective Controls
– Ergo committee brainstorming
– Use Hierarchy of Controls
1. Engineering
2. Administrative
3. Work Practices
• Select Effective Controls
– Communicate with employees
• Implement Controls
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Ergonomic Risk Assessment Process
Establish
Analyze
Prioritize
Implement
Follow-up
Ergonomic Improvement
Process
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Follow-up
• Verify Controls are Correctly Implemented
• Obtain employee feedback
• Formal Review after break-in period
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Ergonomic Risk Assessment Process
Establish
Analyze
Prioritize
Implement
Follow-up
Measure
Ergonomic Improvement
Process
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Measure
• Short Term and Long Term Metrics
– Lagging Long Term Measures
• ergo incidents rates & DART rates
• Employee complaints
– Proactive Short Term Measures
• # of Assessments performed
• RPN reductions
• Ergo training
• Ergo assessments of new operations/MOC
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Ergonomic Risk Assessment Process
Establish
Analyze
Prioritize
Implement
Follow-up
Measure
Communicate Ergonomic
Improvement Process
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Communicate
• Communication at all levels
• Collect employee feedback on ergo conditions regularly
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Application
• General Industry
• Manual Handling
• Repetitive Tasks
• Hand Work
• Office / VDTs
Body Segment
• Upper Extremities
• Lower Extremities
• Trunk
• Whole Body
Selecting the Right Tool
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Assessment Tool Application Type Body Segment
WISHA Checklists General Industry Repetitive Tasks
Qualitative •Whole Body
ANSI Z365 Tool General Industry Repetitive Tasks
Qualitative •Upper Extremities •Trunk
MI Energy Expenditure Prediction (EEP)
General Industry Manual Handling
Quantitative
•Upper Extremities •Trunk
Strain Index Office Settings Hand work
Quantitative •Upper Extremities
Hand Activity TLV Office Settings Hand work
Semi-quantitative •Upper Extremities
RULA General Industry Repetitive Tasks
Semi-quantitative •Upper Extremities •Trunk
Snook Tables General Industry Manual Handling
Semi-quantitative •Trunk
NIOSH Revised Lifting Eq. General Industry Manual Handling
Quantitative
•Trunk
REBA General Industry Repetitive Tasks
Semi-quantitative •Whole Body
MI 3D SSP Software General Industry Manual Handling
Quantitative •Trunk •Lower Extremities
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Qualitative Tools
• Commonly used
• Good for screening jobs
• Manual or Excel based
– OSHA Basic Screening Tool
– WISHA Checklists
– ACGIH TLV for Lifting
– ANSI Z365 Tool
– NIOSH Checklists and others
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OSHA Basic Screening Tool
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WISHA
Calculators
• Lifting Operations
• Hand/Arm Vibration
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ACGIH TLV for Lifting
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Semi-Quantitative Tools
• More focused
• Specific risk factors/body regions
– RULA
– REBA
– Snook Tables
– ACGIH TLV for Hand Activity
– Utah Back Compression
– others
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Quantitative Tools
• Require training/knowledge
• In depth analysis
– NIOSH Revised Lifting Equation
– MI 3D Static Strength Prediction Model
– Strain Index
– Dynamic Work Analysis
– Static Work Analysis
– others
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NIOSH Revised Lifting Equation
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Michigan 3D Static Strength Prediction Model
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Ergo “Hot Spots” Simple Color-coding System
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Ergonomic Action Plans
Team Solutions Cost/Benefit & ROI Assignments and Responsibilities Track Performance / Risk Scores