Ergonomic Evaluation of Workers at a Piston and Cylinder ... Evaluation of Workers at a Piston and Cylinder Liner Manufacturing Plant ... a report to the company and specifies needed

Ergonomic Evaluation of Workers at a Pistonand Cylinder LinerManufacturing Plant

Federal-Mogul

April 2008

National Institute for Occupational Safety and Health

Jessica Ramsey, MS

Judith Eisenberg, MD, MS

Health Hazard Evaluation Report HETA 2007-0124-3060

Lake City, Minnesota

DEPARTMENT OF HEALTH AND HUMAN SERVICES Centers for Disease Control and Prevention

Workplace Safety and Health

https://www.cdc.gov/niosh/hhe/reports

http://www.cdc.gov/niosh/hhe/

http://www.cdc.gov/niosh/hhe/

The employer shall post a copy of this report for a period of 30 calendar days at or near the workplace(s) of affected employees. The employer shall take steps to insure that the posted determinations are not altered, defaced, or covered by other material during such period. [37 FR 23640, November 7, 1972, as amended at 45 FR 2653, January 14, 1980].

Contents

RepoRt Abbreviations........................................................................ ii

Highlights.of.the.NIOSH.Health.Hazard.Evaluation............. iii

Summary............................................................................. iv

Introduction...........................................................................1

Assessment..........................................................................4

Results.and.Discussion........................................................6

Conclusions........................................................................10

Recommendations..............................................................11

References.........................................................................15

Appendix A Ergonomic.Evaluation.Criteria............................................16

Appendix B Factors.Comprising.the.Revised.NIOSH.Lifting.........Equation.............................................................................18

Appendix C Description.of.RNLE.Evaluation.of.712/713.Work........Center.................................................................................20

Appendix d Assumptions.for.Calculating.CLI.for.the.Current.Cycle...Time.Analysis.....................................................................23

ACknowledgments Acknowledgements.and.Availability.of.Report....................25

Health Hazard Evaluation Report 2007-0124-3060 Page �

ABBReviAtions

CLI Cumulativeliftingindex

HHE Healthhazardevaluation

LI Liftingindex

MSD Musculoskeletaldisorder

NIOSH NationalInstituteforOccupationalSafetyandHealth

OSHA OccupationalSafetyandHealthAdministration

RNLE RevisedNIOSHliftingequation

RWL Recommendedweightlimit

WMSD Work-relatedmusculoskeletaldisorder

Page �� Health Hazard Evaluation Report 2007-0124-3060

HigHligHts of tHe

niosH HeAltH

HAzARd evAluAtion

Health (NIOSH) received

at Federal-Mogul in

were asked to look at

The National Institute for Occupational Safety and

a union request for a health hazard evaluation

Lake City, Minnesota. An ergonomics evaluation was performed in March 2007. NIOSH investigators

potential ergonomic hazards among workers and make suggestions for workstation design.

What NIOSH Did ● Wetalkedtoworkersabouttheirworkandmedicalhistory.

Wealsotalkedtothemaboutpossiblework-related musculoskeletaldisorders.

● Wetalkedtotheplantchiropractoraboutinjuriesatthe plant.

● Wewatchedandtookvideosofjobsinthecastironfoundry, aluminumfoundry,pistonmachining,cylinderliner machining,andjointventureareas.

What NIOSH Found ● Wefoundthatworkersareexposedtoriskfactorsfor

developingmusculoskeletaldisorders.Theseriskfactors includehighforce,awkwardpostures,andrepetitivemotions.

● Wefoundthatworkersreportedmusculoskeletalpainor discomfortinthelowbackandshouldersfromheavylifting andawkwardpostures.

What Federal-Mogul Managers Can Do ● Managersshouldaddadjustableliftsandtablestoreduce

bendingandreaching.

● Managersshouldallowamplespacearoundmaterialstoreducereaching.

● Managersshouldtrainworkerstobeawareofunsafework practicesandlearntheearlywarningsignsofmusculoskeletal disorders.

What Federal-Mogul Employees Can Do ● Employeesshouldreportinjuriesandunsafeworkconditions

totheirsupervisors.

● Employeesshouldtakepartinsafetyandergonomicgroups.

● Employeesshouldtaketimetoworksafelyandliftproperly.

Health Hazard Evaluation Report 2007-0124-3060 Page ��

summARy

to a combination of risk

postures and repetitive

Most workers are exposed

factors for developing MSDs. Risk factors included awkward

motions. The use of adjustable tables and improved workstation design would reduce physical stresses and the risk of musculoskeletal injury.

OnJanuary30,2007,NIOSHreceivedanHHErequestfromthe InternationalBrotherhoodofBoilermakerstoevaluatepotential ergonomichazardsamongworkersattheFederal–Mogulpiston andcylinderlinerplantinLakeCity,Minnesota.Therequestwas promptedbyupcomingredesignofworkstationsandcells.

OnMarch8–9,2007,NIOSHinvestigatorsvisitedtheplantin LakeCity,Minnesota.OnMarch8,2007,NIOSHinvestigators (ergonomicspecialistsandaphysician)heldanopeningconference withmanagement,unionofficials,andtheon-sitechiropractor whoprovidesmedicalcaretotheemployees.Ergonomicspecialists touredtheplanttoobservespecificpistonmachining,cylinder linermachining,andfoundrytasks.Thephysicianinterviewed workersabouttheirmedicalstatusinaconfidentialsetting.On March9,2007,NIOSHinvestigatorsheldaclosingconferenceand providedpreliminaryrecommendations.

Theergonomicsevaluationindicatedthatmostworkerswereat riskfordevelopingMSDsfromawkwardposturesandrepetitive motions.Additionalriskfactorsinspecificareasincludedvibration andheavylifting.Ofthe26interviewedworkers,19reportedwork-relatedmusculoskeletalpainordiscomfortinthepreviousyear. Themostcommoncomplaintswerelowbackpainandshoulder pain.

Recommendationsforreducingtheriskofinjuryarecontained inthisreport,includinginstallingadjustablelifts,tables,andlift assists;andallowingadequatespacearoundpallets.

Keywords: NAICS 336350 (Motor Vehicle Transmission & Power Train Parts Manufacturing), pistons, cylinder liners, foundry, repetitive motions, work-related musculoskeletal disorders, ergonomics, prolonged walking and standing

Page �v Health Hazard Evaluation Report 2007-0124-3060

intRoduCtionOnJanuary30,2007,NIOSHreceivedanHHErequestfromthe InternationalBrotherhoodofBoilermakerstoevaluatepotential ergonomichazardsamongworkersattheFederal–Mogulpiston andcylinderlinerplantinLakeCity,Minnesota.Recentredesign ofsomeworkstationsintoworkcellspromptedtherequest.

OnMarch8–9,2007,NIOSHinvestigatorsvisitedthepiston andcylinderlinerplantinLakeCity,Minnesota.OnMarch8, 2007,NIOSHinvestigators(ergonomicspecialistsandaphysician) heldanopeningconferencewithmanagement,unionofficials, andtheon-sitechiropractor.Ergonomicspecialiststouredthe planttoobservepistonmachining,cylinderlinermachining,and foundrytasks.TheNIOSHphysicianinterviewedworkersabout theirmedicalstatusinaconfidentialsetting.OnMarch9,2007, NIOSHinvestigatorsheldaclosingconferenceandprovided preliminaryrecommendations.

Process Description

TheLakeCity,Minnesotaplantwasfoundedin1868asacast ironfoundry.Machiningofcastironpistonsbeganin1939,and productionofaluminumpistonsstartedin1948.Theplantbegan productionofcylinderlinersin1983.Federal-MogulPowertrain SystemsacquiredtheLakeCityplantin1998andestablished Federal-MogulTPLiners,Inc.in1999.AtthetimeoftheNIOSH evaluation,theplanthadapproximately500employeesand 350,000squarefeetoffloorspace.Currentworkperformedon-siteincludescastironfoundryoperations,aluminumfoundry operations,pistonmachining,cylinderlinermachining,andajoint ventureoperation.

Cast Iron Foundry

Approximately75peopleworkinthecastironfoundry.Workers inthisareausehoistsandcranestoperformsomematerial handlingtasks.However,theyarerequiredtomanuallylift50– poundbagsofrawmaterials,andmanuallyplacethefinalproduct inbasketsaccordingtosize.Workersalsogrindcastingswhenthe tumblerdoesnotremovealltheexcessmaterial.


intRoduCtion (Continued)Aluminum Foundry

Approximately30peopleworkinthealuminumfoundry.This areaislessautomatedthanthecastironfoundry.Dependingon thesizeofthepartproduced,thealuminummoldstationshave variousmanipulatorsandliftassists.However,operatorsmanually pourthealuminumintothemoldatsomestations.Otherstations havemanipulatorstohelpholdtheladlewhilepouring.Forsome products,theworkerremovestheproductfromthemoldusing pliersandplacesitonaconveyorthattransportsthepartfromthe moldstationintoabasket.Otherstationsareequippedwithalift thatpicksupthepartandplacesitonaconveyor.Workersinthe aluminumfoundryusehammerstoreleasetheproductfromthe moldandtobreakoffexcessmetalfromtheproduct.

Piston Machining

Approximately80peopleworkinpistonmachining.Workers machinealuminumpistoncastingstosizeandspecificationsin thisarea.Theyremoverough,forgedpistonsfromawirebasket, millthemonaseriesoflathes,andplacethefinishedproductin eitherawirebasketoracardboardbox.Thepistonmachiningarea usedtobeinlineforsinglepieceflow:oneworkerwouldmachine anentirewirebasketofpistonsonaparticularlathebefore transferringtoanotherlatheuntilallmachiningwascomplete. Recently,thecompanyimplemented“leanmanufacturing”and movedtowardaworkcellformat:agroupofworkersrunsan entirewirebasketofpistonsthroughtheseriesoflathes,andthe finalproductisplacedineitherawirebasketoracardboardbox. AsofMarch2007,thecompanyhadcreatedfourworkcellsin thepistonmachiningarea.NIOSHinvestigatorsobservedpiston machiningtasksinboththeoldandnewworkstationdesigns, whichwerelocatedinoneoftheareasofprimaryconcernfor WMSDrisk.

Cylinder Liner Machining

Approximately180peopleworkincylinderlinermachining. Workersmachinecastironlinerstofinishedproductspecifications inthisarea.Thecompanyhaslinerworkcenters,buttheyare notstandardized.Recently,followingacycletimeanalysisofan area,twoworkcellswerecombinedintoaworkcenter(712/713)

Page � Health Hazard Evaluation Report 2007-0124-3060

intRoduCtion (Continued) toimproveworkflow.Thiswasanotherareaofprimaryconcern regardingriskforMSDs,andNIOSHinvestigatorsobserved thecombinedtasksinthe712/713area.Thisareaiscapableof machiningboththeLakeCitycastings(madein-house,requiring boring)andMexicocastings(madeinMexico,pre-bored).Two differentcastingsaremachinedatthesametime;oneworkersruns allthemachines.Inthisarea,theworkerretrievesroughforged cylinderlinersfromapallet.Theworkerthenmillsthelinerona seriesofboresandlathes,checksitforcalibration,andplacesitin awirebasket.

Joint Venture

Approximately90peopleworkinthejointventurearea.Thisarea isaresultofanagreementforajointventurebetweenFederal– MogulandTeikokuPistonRingCo.,Ltd.Althoughthisarea hasadifferentplantmanager,Federal–Mogulisresponsiblefor environment,health,andsafetyfortheentirefacility,including theJointVenturearea.Centrifugalsystemscreatelongtubes thatarecuttosizetoproduceahighvolumeofcastironliners. Automatedmachininglinesoperateside-by-side,andworkers manuallyhandlematerialsonlyduringgaugingandinspection.

Onsite Employee Health Clinic

Acontractedchiropractorwithindustrialergonomicstraining staffstheon-siteemployeehealthclinic2daysperweek.The chiropractorexaminesemployeeswhoreportsymptomsand evaluatestheirworkstations.Basedupontheseresults,hewrites areporttothecompanyandspecifiesneededlightdutywork restrictions.Thechiropractorrefersemployeesforfurther evaluationtoaphysicianifthemusculoskeletalsymptomspersist.

Ergonomic and Safety Committees

Eachproductiondepartmenthasasafetyteam.Theseteams addresssafetyandergonomicissuesonaweeklybasis.Theteams arecross-functional,composedofmanagement,engineers,union operatorsandunionsafetyrepresentatives.Theplantsafetyand ergonomiccommitteeconsistsofaunionsafetyrepresentative fromeachproductiondepartmentandtheEnvironment,Health, andSafetyCoordinator.Thisteammeetsonamonthlybasis.


Assessment NIOSHinvestigatorstouredthefoundry,assessingmachining taskstoobservetheprocessesofcastironmolding,aluminum molding,machiningpistons,andmachiningcylinderliners.They alsoobservedtasksinthejointventurearea.Specificjobsinthe pistonmachiningandcylinderlinermachiningareaswereselected forevaluationbaseduponconversationswithmanagementand laborrepresentativesregardingtherecentredesignofthesework areas.AppendixAcontainsadescriptionoftheergonomics evaluationcriteriatheinvestigatorsused.NIOSHinvestigators recordeddigitalvideos,measurementsofworkstationheights,and measurementsofreachdistancestodocumentthetasksperformed bytheworkers.TheyrefferedtotheWashingtonStateCaution ZoneChecklistregardinghandandarmvibrationexposure [WashingtonStateDepartmentofLaborandIndustries2008].The investigatorsusedtheRNLE[Waters1994]toassessthephysical demandsofliftingtasksinthecylinderlinermachiningarea.A fulldescriptionofthecomponentsoftheRNLEisprovidedin AppendixB.Inbrief,theequationprovidesRWLandLIfor aliftingtask,givencertainliftingconditions.TheRWListhe weightthatcanbehandledsafelybyalmostallhealthyworkersin theseconditions.TheLIistheratiooftheactualloadliftedtothe RWL.TaskswithanLI>1.0mayplaceanincreasingnumberof individualsatriskoflowbackinjury,andtaskswithanLI>3.0 poseariskofbackinjuryformostworkers.Liftingtaskswithan LI ≤ 1.0 pose little risk of back injury for most workers. The key to interpretingtheriskofinjuryforagivenLIistounderstandhow injuriesincreaseastheLIincreases.Across-sectionalepidemiologic studyconductedbyNIOSHindicatedthatastheLIincreasedfor 204workersperforming50differentliftingjobsinfourdifferent industrialfacilities,theprevalenceofreportedbackpainalso increased[Waters1999].Theprevalenceofbackpainlastinga weekormorewashighestforworkersperformingliftingjobsin the 2 < LI ≤ 3 category, nearly twice that of workers in non-lifting jobs. The risk of injury for jobs in the 1 ≤ LI ≤ 2 category was higherthanfornon–liftingjobsbuttheincreaseinriskwasnot significantduetosmallsamplesize.Themainconclusionofthe studywasthatwhilemoredataareneeded,thebestapproachto injurypreventionistodesignjobsforworkersthatresultinLIs ≤ 2.

AllcurrentemployeesofFederal–Mogulhadbeeninvitedto participateinconfidentialinterviewspriortothesitevisit. NIOSHinvestigatorsprovidedadvancednotificationregarding theHHEmedicalinterviewstoboththemanagementandunion fordisseminationtotheemployeesseveralweeksbeforethesite


Assessment (Continued) visit.Aninterviewschedulewaspreparedjointlybytheunionand managementaheadofthesitevisit.Workerswereaskedquestions abouttheirjobandiftheyhadanymusculoskeletalpainover thepastyearthattheythoughtmightbework–related.Ifthey reportedpainoverthepreviousyear,additionalquestionswere askedregardinglocationofpainandtasksassociatedwiththe pain.Employeeswerealsogiventheopportunitytovoiceanyother healthandsafetyrelatedconcernsregardingtheirworkatFederal– Mogul.


Results And disCussionCast Iron Foundry

Variousareasofthecastironfoundryposerisksfor musculoskeletalinjury.Atthebeginningofthecastironprocess, workersmanuallylift50–poundbagsofrawcarbonandsilicato makebatchesofiron.Eachbatchrequiresliftingfourbags(200 pounds);approximatelysevenbatchesarepreparedpershift, totaling28bags(1120pounds).Palletsofrawmaterialsareplaced directlyonthefloor.Extendedreaches,especiallywhenliftingthe lastrowofmateriallocateddirectlyonthefloor,exacerbatethe potentialfatiguefromhandlingthelargeamountofweight.

Anotherareathatposesamusculoskeletalriskisattheendof thecastironprocess.Workerssorttheproductintowirebaskets accordingtosize.Thecurrentlayout(Figure1)requiresworkersto twisttoplaceproductsintothebaskets.Also,thewirebasketsare notheightadjustable,requiringworkerstoreachintothebasket whenplacingthebottomrowsofproduct.

Conveyor of finished product

X X X

Basket 1 Basket 2 Basket 3

Figure 1. Current layout of sorting cast iron products (X represents a worker’s location)

Attheendoftheconveyorline,workersgrindpiecesnot adequatelyremovedbythetumblerattwostations.Onestation’s layoutwasaresultofsuggestionsfromapreviousNIOSHHHE [NIOSH1995].Parts–inandparts–outbaskets,withtiltlifts,are locatedoneithersideofthegrindingstation.Theparts-inbasket stillposesariskformusculoskeletalstresstothebackdueto extendedreachesintothebasket.Theworkerisalsopotentially exposedtohand-armvibration,duetousingapneumaticvibrating toolduringtheworkday.


Results And disCussion Aluminum Foundry(Continued) Themajorstressorsobservedinthisareaarefromthestatic awkwardposturesofthehands,wrists,andarmsastheworkers pouraluminumfromtheladleintothemold.Staticpostureand strengthrequiredtoslowly,carefullypourthealuminumcauses stressonthewristsandhands.Anotherstressfuljobelementwas removingthealuminumpistonfromthemoldwithpliersand placingthepistononaconveyor.Automationwouldremovethese stressors;however,moststationsarenotautomated,andthese stepsarestillperformedmanually.

Piston Machining

Themajormusculoskeletaljobstressorsobservedforpiston machiningweretotheupperlimbsandback.Theinitialliftfrom thewirebasketoftenrequiredextendedreaches.Thereachvaried fromstationtostationandproducttoproduct.Incomingbaskets atthebeginningofpistonmachiningcellsdidnothaveadjustable lifttables.Musculoskeletalfatigueduetothetotalamountof weighthandledbytheoperatoreachdayexacerbatedthestressof extendedreaches.Theendofthemachininglinewhereworkers placedthefinishedproductintowirebasketsorcardboardboxes hadthesameextendedreachstressor.Outgoingbasketsandboxes attheendofpistonmachiningprocessdidnothaveadjustablelift tables.However,onestationdidhavethecardboardboxraised onawheeledcart.Thispositionstillrequiredtheworkertoreach whenplacingthefirst/bottomrowofproductintotheboxorto walkaroundtothefarcornerandstillreachdownintothebox.A fewoftheworkcellswereequippedwithshadowboardsthatheld toolsneededtochangediesandworkonthemachines.Thesehad replacedtraditionaltoolboxesthattookupspaceandrequired workerstobenddowntoretrievepartsandtools.However,several stationsstillhadtoolboxes.

Cylinder Liner Machining

ManagementaskedtheNIOSHinvestigatorstoevaluatethe recentlycombined712/713cylinderlinerworkcenter.The twoworkcellswerecombinedtoimproveworkflow;however, managementwasconsideringrearrangingtheworkdueto concernsaboutexcessivewalkingbetweenthemachines.During


Results And disCussion theweekoftheNIOSHsitevisit,theworkerinthecellwas (Continued) machining“Mexico”castings.Theareawasequippedwithatilt table,butitcouldnotbeusedwiththeMexicocastingsbecause theyarriveattheplantstackedandshrink–wrapped(theparts wouldfalloverifthecurrenttilttablewasused).LakeCity castings,theothercastingstypicallymachinedinthisarea,are madein-houseandcanbetransportedthroughtheplantinwire basketsthatcanusethecurrenttilttable.

Oneworkerperformedallofthetasksinthe712/713workcenter (24movements,17lifts,0.5liftsperminute).Thisconsistedof lathingtwocylinderlinerssimultaneously,transportingeachliner fromthepalletthroughtheseriesofmachines,andplacingitin theoutgoingwirebasket.Managementalsoprovidedtwoproposed cycletimeanalysesthattheywereconsideringimplementing. Proposal#1had32totalmovementsand23lifts(0.33liftsper minute);proposal#2had32totalmovementsand19lifts(0.44 liftsperminute).AdescriptionoftheRNLEevaluationperformed onthe712/713workcenterisprovidedinAppendixC.CLIs werecalculatedwithrespecttothecurrentcycletimeanalysis,the proposedcycletimeanalysesprovidedbymanagement,andforthe individualcells(9liftsfromthecurrentcycletimeanalysis,0.5lifts perminute)(Table1).Anexampleoftheassumptionsthatwere madeforcalculatingtheliftingindicesforthecurrentcycletime analysisareprovidedinAppendixD.

Everyliftingjobtaskevaluatedinthisareaexceededthe recommendedLIof1.0,butnonesurpassedanLIof3.0, consideredhazardousfornearlyallworkers.Bothoftheproposed cycletimeanalyseshadhigherCLIsthanthecurrentcycletime analysis.TheCLIfortheindividualcellwasmuchlower(almost half)thanthecombinedworkcenter.Thecurrentandproposed cycletimeshadLIsbetween2.1and2.8,indicatinganelevatedrisk of injury as compared to jobs that have an LI ≤1.0.

Notethatthecalculationoftheliftingindexdoesnottakeinto

Table 1. CLIs for Cylinder Liner 712/713 Work Center

Layout options CLIs

Current cycle time analysis 2.1 Proposal #1 cycle time analysis 2.8

Proposal #2 cycle time analysis 2.8

Individual work cell analysis 1.1


Results And disCussion considerationthefatigueassociatedwiththeamountofwalking (Continued)requiredinthe712/713workcenterduringtheshift.Togeta betterindicationofthestressassociatedwiththisjob,ametabolic analysis(includingheartrate)wouldberequired;thiswasbeyond thescopeoftheHHE.

Joint Venture

Themajormusculoskeletalstressorobservedinthejointventure areawasshoulderextensionduringthegaugingprocess.Transfer ofthepartintothegauginginstrumentrequiredthattheworkers extendtherightshoulderduetotheworkstationdesign.In addition,thebinfordefectivepieceswaslocated7to10feet behindtheworker,sotheyhadtotossthepartbehindthemusing theirlefthand,whichcausedextremeleftshoulderextension.The repetitivemotionofbothoftheseshoulderposturesmaycause painanddiscomforttotheseworkers.

Employee Interviews

Allbutoneofthe26employeesinterviewedweremale.The averageageoftheseemployeeswas45.5yearswitharangeof23 to65years.TheaveragedurationofemploymentatFederal-Mogul was19years.Participantscamefromallareasofthefacilitywith 11fromthecylinderlinermachiningarea,7fromthepiston machiningarea,3fromthealuminumfoundry,2fromthecast ironfoundry,2fromthejointventurearea,and1whoworked throughouttheplant.Only6%(26/445)ofworkersinthe areasevaluatedwereinterviewed.Thiswasaconvenienceand notarandomemployeesample.Theemployeeswereselected forinterviewjointlybythemanagementandunioninorder tominimizedisruptionoftheproductionlinebutstillinclude employeeswhohaddisparateopinionsonworkplaceconditions.

Seventy-threepercent(19/26)ofparticipantsreportedhaving musculoskeletalpainordiscomfortinthepreviousyearthat theybelievedwasassociatedwiththeirwork.Themostcommon complaintswerelowbackpainandshoulderpainthatemployees associatedwithliftingheavypartsandhavingtobendatodd angles.Inthelast2years,workerscompensationhaspaidnine claimsforlowerbackstrain/sprain;nineclaimsforshoulder strain/sprain;andoneforcarpaltunnelsyndrome.


Results And disCussion (Continued) Allbutoneemployeereportedroutinelyworkingmorethan

40hoursperweek.Thecompanyhadacompulsoryovertime policyrequiringworking10hourseachdayinsteadof8hours duringtheworkweek,workingfourconsecutiveSaturdaysbefore havingoneoff,andworkingeveryotherSunday.Thispolicywent intoeffectwhenordersbecamebackloggedtoprovidetimely shippingtocustomers.Employeesmentionedthatthispolicy hadalsobecomemorefrequentlyusedduetoreductionsinthe workforceatFederal-Moguloverthelastfewyears.Employees reportedincreasedfatigueandmusculoskeletalpainduringthe 6–and7–dayextendedovertimeworkweeksascomparedtoa 5–dayworkweek.Althoughhoistsandotherlift-assistdeviceswere availableatsomeworkstations,severalemployeeswerereluctant tousethemoutofconcernthatthedevicewoulddamagetheir product.

ConClusionsOn-siteassessmentsandinterviewsattheFederal–Mogulplant arethebasisforthefollowingconclusions.Mostworkersatthe plantareexposedtoacombinationofconcurrentriskfactorsfor developingupperextremityMSDs:awkwardpostures,repetitive motions,heavyloads,andinadequaterecoverytimeduetothe compulsoryovertimepolicy.Theproblemswithworkstationdesign thatplaceworkersatriskforMSDinjuriesincludenon–adjustable workstationsandlackofspaceforcompletingthejobtasks.

MostmusculoskeletaldisordersreportedduringtheNIOSH medicalinterviewsandinworkerscompensationclaimsinvolvethe upperextremityandlowback.

Page �0 Health Hazard Evaluation Report 2007-0124-3060

ReCommendAtionsThepreferredmethodofcontrollingergonomicshazardsisto provideengineeringcontrols.Engineeringcontrolsinvolvemaking changestoworkstations,tools,andequipment.Engineering controlsarepreferablebecausetheyeliminatethehazardatthe source.Administrativecontrolsaredesignedtolimitworkers’ exposurestohazardousconditionsandcanbeusedtemporarily untilengineeringcontrolsareimplemented.Inaddition,changes inworkpracticescanalsosignificantlyreduceriskfactorsfor developingMSDs.Trainingishelpfulinallowingemployeesto participateintheprocessofidentifyinghazardsandmakingjob modifications.

Engineering Controls

Generalrecommendationsthatwouldeliminateorsignificantly reducephysicalstressesinindividualareasarelistedbelow.

Cast Iron Foundry 1. Provideadjustableturntablesthatpneumaticallyliftand

rotatethebagsofrawmaterialsandbasketsoffinished productsotheyarealwaysclosesttothebodywhen lifting.Theheightofthe“workingrow”ofbagsshouldbe approximately30"abovetheground[Watersetal.1994]. Theliftshouldbedesignedsuchthattheoperatorcanstand ascloseaspossible.

2. Useormodifythealternatelayout(Figure2)toeliminate twisting.Thebasketsarealsonotadjustableandrequire reachingintothebasket.Placebasketsonadjustabletables toeliminateexcessivebendingwhenplacingpiecesonthe bottomrow.

X X X

Conveyor of finished product

Basket 1 Basket 2 Basket 3

Figure 2. Proposed layout for sorting cast iron products (X represents a worker’s location).


ReCommendAtions (Continued) 3. Reducevibrationexposurebyprovidingtoolswith

lowvibrationfrequencies,properlymaintainingtools, schedulingrestbreakstoallowforrecovery,andalternating worktaskswithothertasksthatdonotinvolvevibration exposure.

Aluminum Foundry 1. Provideazero-balancehoisttosupporttheladlewhen

pouringaluminumintothemolds;someworkstations alreadyhavethisequipment.

2. Provideazero-balanceliftdevicetoremoveproductfrom themoldsandeliminatetheuseofpliers,whichcause awkwardwristpostures.

Piston Machining 1. Provideadjustableturntablesthatpneumaticallyliftand

rotatethebasketsofproductsotheyarealwaysclosestto thebodywhenlifting.Theheightofthe“workingrow” ofproductshouldbeapproximately30"abovetheground [Watersetal.1994].Theliftshouldbedesignedsuchthat theoperatorcanstandasclosetothebasketaspossible.

2. Reducematerialhandlingbyconstructinggravityfeed conveyorstomovepistonsfromonestationtoanother.

3. Providezero-balanceliftdevicestomoveheavierpistons fromonestationtoanother.NIOSHinvestigatorsobserved afewofthesedevicesinvariousareas.Incorporatingthem inmoreareaswouldreducemanualmaterialhandlingand riskofupperlimbandlowbackpainandinjuries.

4. Replaceremainingtoolboxeswithshadowboardsto eliminatebendingtoretrievetoolsandparts.

Cylinder Liner Machining 1. Provideadjustableturntablesthatpneumaticallyliftand

rotatethebasketsofproductsotheyarealwaysclosestto thebodywhenlifting.Theheightofthe“workingrow”of productshouldbeapproximately30"abovetheground [Watersetal.1994].Theliftshouldbedesignedsuchthat theoperatorcanstandasclosetothebasketaspossible. Reducingthereachdistancebyadjustingtheheightofthe basketwillreducetheLI.


ReCommendAtions (Continued) 2. Splitthe712/713areabackintotwoindividualjobsto

minimizetheriskoflowbackpainandinjury.Thislayout hadthelowestCLIofalltheproposedlayouts.

Joint Venture 1. Providecontainer-handlingturntablesthatpneumatically

liftandrotatecontainerssothatcylinderlinersarealways closesttothebodywhenlifting.Theheightofthe“working row”oflinersinthecontainershouldbeapproximately30" abovethegroundand10"orlessawayfromthebody.The containerliftshouldbedesignedsuchthattheoperatorcan standasclosetothecontaineraspossible.Theliftshould alsoaccommodatethevarietyofcontainersusedinthe plant(pallets,wirecontainers,cardboardboxes)without spillingmaterial(suchastilttablesthatcannotbeusedwith palletizedmaterials).

2. Redesigntheworkstationbyaddinganextensiontothe workstationtoreorienttheworkerandeliminateshoulder flexionwhenperforminggaugingtasks.

3. Redesigntheworkareatorelocatethescrapcontainerand eliminateshoulderextensionwhenthrowingscrapintothe container.

Administrative Controls

Theeffectivenessofadministrativechangesinworkpracticesfor controllingMSDsdependsonmanagementcommitmentand employeeacceptance.Regularmonitoringandreinforcement arenecessarytoensurethatcontrolpoliciesandprocedures arenotcircumventedinthenameofconvenience,schedule,or production.Anadvantageofadministrativecontrolsisthatthey canbeimplementedquicklyandeasilywithoutcapitalexpense. However,becauseadministrativecontrolsdonoteliminate thehazard,theyshouldbeconsideredtemporarysolutions forcontrollingexposuresuntilengineeringcontrolscanbe implemented.Administrativecontrolrecommendationsforall processes/areasincludethefollowing:

1. Rotateworkersthroughseveraljobswithdifferentphysical demandstoreducethestressonlimbsandbodyregions.


ReCommendAtions (Continued) 2. Equipallareaswithanti-fatiguematsand/orfootreststo

preventmusclefatigue,lowbackpain,andstiffnessinthe neckandshouldersfromprolongedstanding.

3. Schedulemorebreakstoallowforrestandrecovery. Reassessthecompulsoryovertimepolicytoallowweekend recoverytimemoreconsistently.

4. Broadenorvaryjobcontenttooffsetcertainriskfactors (i.e.,repetitivemotions,staticandawkwardpostures).

5. TrainemployeestorecognizeWMSDsandinstructthemin workpracticesthatcaneasethetaskdemandsorburden.

Work Practices

Changesinhowworkersperformspecifictaskscanalso significantlyreducerisksofMSDs.Developingstandardsand operatingproceduresareafewwaystoachievethisgoal.

1. Trainworkerstoslidematerialsfromthecenterofa containertotheedgebeforelifting.Whenreachingor movingpistons,cylinderliners,andbagsofmaterialsto orfromthecenterofacontainerorpallet,workersshould slidethepieceintoposition,ratherthanreachingand placingpiecesinorfromthecenter.

2. Trainworkerstousetwohandswhenhandlingpistonsand cylinderlinersfromthebeginningtotheendofthework cycle.

3. Trainworkerstoavoidhandpinchpostureswhen transportingpistonsandcylinderlinersfromone workstationtoanother.

4. Trainworkerstousezero–liftassistdevicesproperly,and audituseofthedevices.

5. Keepequipmentwellmaintainedandinproperworking order.


RefeRenCes NIOSH[1995].Hazardevaluationandtechnicalassistancereport: AEGoetz,LakeCity,MN.Cincinnati,OH:U.S.Department ofHealthandHumanServices,PublicHealthService,Centers forDiseaseControlandPrevention,NationalInstitutefor OccupationalSafetyandHealth,NIOSHHETAREPORTNO. 94–0040–2496.

WashingtonStateDepartmentofLaborandIndustries[2008]. Ergonomicsevaluationtools.[http://www.lni.wa.gov/Safety/ Topics/Ergonomics/ServicesResources/Tools/default.asp].Date accessed:January2008.

WatersTR,Putz-AndersonV,GargA[1994].Applications manualfortherevisedNIOSHliftingequation.Cincinnati, OH:U.S.PublicHealthService,CentersforDiseaseControl andPrevention,4NationalInstituteforOccupationalSafetyand Health,DHHS(NIOSH)Publication94–110.

WatersTR,BaronSL,PaicitelliLA,Anderso,VP,SkovT,Haring-SweeneyM,WallDK,FineLJ[1999].Evaluationoftherevised NIOSHliftingequation:across-sectionalepidemiologicstudy. Spine24(4):386–395.


Appendix A: eRgonomiC evAluAtion CRiteRiA

ThetermMSDsrefertoconditionsthatinvolvethenerves,tendons,muscles,andsupportingstructures ofthebody.WMSDsareamajorcomponentofthecostofwork-relatedillnessintheUnitedStates.A substantialbodyofdataexistsprovidingstrongevidenceofanassociationbetweenMSDsandcertain work-relatedfactors(physical,workorganizational,psychosocial,individual,andsociocultural).The multifactorialnatureofMSDsrequiresadiscussionofindividualfactorsandhowtheyareassociated withWMSDs.Thereisstrongevidencethatworkinggroupswithhighlevelsofstaticcontraction, prolongedstaticloads,orextremeworkingposturesinvolvingtheneck/shouldermusclesareatincreased riskforneck/shoulderMSDs[NIOSH1997].Thereisalsostrongevidencethatjobtasksthatrequire acombinationofriskfactors(highlyrepetitious,forcefulhand/wristexertions)increaseriskforhand/ wristtendonitis[NIOSH1997].Lastly,thereisstrongevidencethatlow-backdisordersareassociated withwork–relatedliftingandforcefulmovements[NIOSH1997].Anumberofpersonalfactorscanalso influencetheresponsetoriskfactorsforMSDsincluding:age,gender,smoking,physicalactivity,strength, andanthropometry.Althoughpersonalfactorsmayaffectanindividual’ssusceptibilitytooverexertion injuries/disorders,studiesconductedinhigh-riskindustries,showthattheriskassociatedwithpersonal factorsissmallcomparedtothatassociatedwithoccupationalexposures[NIOSH1997].

Inallcases,thepreferredmethodforpreventing/controllingwork-relatedmusculoskeletaldisordersis todesignjobs,workstations,tools,andotherequipmenttomatchthephysiological,anatomical,and psychologicalcharacteristicsandcapabilitiesoftheworker.Undertheseconditions,exposurestotask factorsconsideredpotentiallyhazardouswillbereducedoreliminated.

ThespecificcriteriausedtoevaluatethejobtasksatFederal–Mogulwereworkplaceandjobdesigncriteria foundintheergonomicsliteratureandrecommendationsforacceptableliftingweightsasdeterminedby theRNLE[Waters1994].

Workstationdesignshoulddirectlyrelatetotheanatomicalcharacteristicsoftheworker.Sinceavarietyof workersmayuseaspecificworkstation,arangeofworkheightsshouldbeconsidered.Baseduponfemale/ male50thand95thpercentileanthropometricdata,workstationheightsshouldbewithinarangeof27.6" tonohigherthan60"[Kroemer1989].Theseheightscorrespondtoknuckleandshoulderdimensionsof U.S.civilians,age20to60years.

Handandarmvibrationistransmittedtoworkershandsandarmsbycontactwithavibratingsource. Toolscommonlyusedinindustry,suchasgrinders,sanders,andjackhammers,areallsourcesof vibration.Handandarmvibrationsyndromeischaracterizedbyexposuretolevelsofvibrationthat leadtosymptomssuchasnumbnessandtingling,blanchingofthefingers,andcarpaltunnelsyndrome [Chengaluretal.2004].Itisrecommendedthatexposuretomoderatehandandarmvibrationfromhand toolsbelimitedtonomorethantwohourstotalperday,aspertheWashingtonStateCautionZone Checklist[WashingtonStateDepartmentofLaborandIndustries2008].Ifthevibrationvalueforthetool isknown,acalculatorforhandandarmvibrationisalsoavailableintheWashingtonStateHazardZone Checklist[WashingtonStateDepartmentofLaborandIndustries2008].


Appendix A: eRgonomiC evAluAtion CRiteRiA (Continued)

TheRNLEisatoolforassessingthephysicaldemandsoftwo-handedliftingtasks.Theequationprovides arecommendedweightlimitandliftingindexforaliftingtask,basedupontheliftingconditions[Waters 1994].TheRNLErecommendswheninitiatingaliftthattheverticalheightofthehandsabovethefloor shouldbe30".Aheightof30"abovethefloorisconsidered“knuckleheight”foraworkerofaverage height.TheRNLEalsostatesthatinidealliftingconditions,themaximumrecommendedweightlimitis 51pounds.Therefore,aworkershouldnotliftanythingover51poundswithoutassistancefromanother workerorusingaliftassistdevice[Waters1994].Inbrief,theequationprovidesRWLandLIforalifting task,givencertainliftingconditions.TheRWListheweightthatcanbehandledsafelybyalmostall healthyworkersinsimilarcircumstances.TheLIistheratiooftheactualloadliftedtotheRWL.Tasks withaLI>1.0mayplaceanincreasingnumberofindividualsatriskoflowbackinjuryandtaskswithaLI >3.0poseariskofbackinjuryformostworkers.

References

ChengalurSN,RodgersSH,BernardTE,eds.[2004].Kodak’sergonomicdesignforpeopleatwork.2nd ed.Hoboken,NJ:JohnWiley&Sons.

KroemerKHE[1989].Engineeringanthropometry.Ergonomics32(7):767–784.

NIOSH[1997].Musculoskeletaldisordersandworkplacefactors:acriticalreviewofepidemiologic evidenceforwork-relatedmusculoskeletaldisordersoftheneck,upperextremity,andlowback.U.S. DepartmentofHealthandHumanServices,U.S.PublicHealthService,CentersforDiseaseControland Prevention,NationalInstituteforOccupationalSafetyandHealth,(DHHS)PublicationNo.97–141.

WashingtonStateDepartmentofLaborandIndustries[2008].Ergonomicsevaluationtools.[http://www. lni.wa.gov/Safety/Topics/Ergonomics/ServicesResources/Tools/default.asp].Dateaccessed:January 2008.

WatersTR,Putz-AndersonV,GargA[1994].ApplicationsmanualfortherevisedNIOSHlifting equation.Cincinnati,OH:U.S.PublicHealthService,CentersforDiseaseControlandPrevention, NationalInstituteforOccupationalSafetyandHealth,DHHS(NIOSH)Publication94–110.


Appendix B: fACtoRs CompRising tHe Revised niosH lifting

equAtion

Calculation for Recommended Weight Limit (RWL)

RWL = (LC) x (HM) x (VM) x (DM) x (AM) x (FM) x (CM)

LC = Load Constant

HM = Horizontal Multiplier

VM = Vertical Multiplier

DM = Distance Multiplier

AM = Asymmetric Multiplier

FM = Frequency Multiplier

CM = Coupling Multiplier

U.S. CUSTOMARY 51 lbs

(10/H)

(1-(0.0075|V-30|))

(0.82+(1.8/D))

(1-(0.0032A))

(from Table B1)

(from Table B2)

Where:

H = Horizontal location of hands from midpoint between the ankles Measured at the origin and the destination of the lift (inches)

V = Vertical location of the hands from the floor Measured at the origin and destination of the lift (inches)

D = Vertical travel distance between the origin and the destination of the lift (inches)

A = Angle of asymmetry – angular displacement of the load from the sagittal planeMeasured at the origin and destination of the lift (°)

Duration is to be defined to be: ≤ 1 hour; ≤ 2 hours; ≤ 8 hours Assuming appropriate recovery allowances


123456789101112131415

Appendix B: fACtoRs CompRising tHe Revised niosH lifting

equAtion (Continued)

Table B1. Frequency Multiplier (FM) for the Revised NIOSH Lifting EquationWork Duration Frequency � 1 Hour Lifts/min � 2 Hours � 8 Hours

V < 30Ǝ V � 30Ǝ V < 30Ǝ V � 30Ǝ V < 30Ǝ V � 30Ǝ 0.2 1.00 1.00 0.95 0.95 0.85 0.85 0.5 0.97 0.97 0.92 0.92 0.81 0.81

0.94 0.94 0.88 0.88 0.75 0.75 0.91 0.91 0.84 0.84 0.65 0.65 0.88 0.88 0.79 0.79 0.55 0.55 0.84 0.84 0.72 0.72 0.45 0.45 0.80 0.80 0.60 0.60 0.35 0.35 0.75 0.75 0.50 0.50 0.27 0.27 0.70 0.70 0.42 0.42 0.22 0.22 0.60 0.60 0.35 0.35 0.18 0.18 0.52 0.52 0.30 0.30 0.00 0.15 0.45 0.45 0.26 0.26 0.00 0.13 0.41 0.41 0.00 0.23 0.00 0.00 0.37 0.37 0.00 0.21 0.00 0.00 0.00 0.34 0.00 0.00 0.00 0.00 0.00 0.31 0.00 0.00 0.00 0.00 0.00 0.28 0.00 0.00 0.00 0.00

>15 0.00 0.00 0.00 0.00 0.00 0.00

Table B2. Coupling Multiplier (CM) for the Revised NIOSH Lifting Equation

Couplings V < 30Ǝ Coupling Multipliers

V � 30Ǝ Good 1.00 1.00Fair 0.95 1.00Poor 0.90 0.90


Appendix C: desCRiption of Rnle evAluAtion of 712/713 woRk CenteR

Followingacycletimeanalysisofonecylinderlinermachiningarea,managementcombinedthe712and 713areasintooneworkcenter.Thisresultedintwodifferentcastingsbeingmachinedatthesametime; allthemachinesarerunbyoneworker.FigureC1depictsthelayoutofthe712/713workcenterduring thesitevisit.Roughforged“Mexico”cylinderlinerswereretrievedfromapallet.TheMexicolinerwas milledonaseriesofmachinesthenplacedinawirebasket.Theareaisalsocapableofrunning“Lake City”cylinderliners;thoseareretrievedfromawirebasket,andmustbeboredbeforeproceedingthrough thesameseriesofmachinesandthenplacedinawirebasket.Liftsperformedduringthecurrentcycle timeanalysisaredescribedinTableC1.Managementalsoprovidedtwoproposedcycletimeanalyses thattheywereconsideringimplementing.Proposal#1had32totalmovementsand23lifts(TableC2); proposal#2had32totalmovementsand19lifts(TableC3).WhencalculatingtheRNLE,threevertical locationswereused:lowpallet/cage,middlepallet/cage,andhighpallet/cage.Measurementsforeachof thethreelocationsweremadeduringthesitevisit.Itwasassumedthatwhenacylinderlinerwasremoved fromthehighpalletlocation,itwouldbeplacedinalowwirebasketlocation,i.e.,eachfullpalletrequired anemptywirebasket.

DeburrDeburr

Bore

Side Side

Part 1 Part 2

Pallet Part 1

Pallet Part 2

Lathe

Part 1

Mill

Part 1

Lathe

Part 2

Mill

Part 2

Basket Part 2

Basket Part 1

713 712

Figure C1. 712/713 Work center layout during NIOSH site visit.

Page �0 Health Hazard Evaluation Report 2007-0124-3060

Appendix C: desCRiption of Rnle evAluAtion of 712/713 woRk CenteR (Continued)

Table C1. 712 and 713 Current Cycle Time Analysis 712 side 713 side

Cycle # Task Cycle # Task 1 Castings to lathe table 14 Part to 713 lathe 2 Unload lathe 15 Unload lathe 3 Load lathe 16 Load lathe 4 Cycle start lathe 17 Cycle start lathe 5 Part to mill 18 Part to mill table 6 Unload mill to table 19 Unload mill 7 Load mill from table 20 Load mill 8 Cycle start mill 21 Cycle start mill 9 Milled part to deburr 22 Part to deburr table 10 Unload deburr 23 Unload deburr to finished 11 Load deburr 24 Walk to 712 castings 12 13

Cycle start deburr Walkto713castings

17 lifts (highlighted) Total man cycle time = 1.76 min/part

Table C2. 712 and 713 Proposal #1 Cycle Time Analysis 712 side 713 side

Cycle # Task Cycle # Task 1 Castings to bore 18 Part to 713 bore 2 Unload bore to both sides 19 Unload castings to both sides 3 Load bore both sides 4 Cycle start bore 5 Bore part to lathe 6 Unload lathe 7 Load lathe 8 Cycle start lathe 9 Part to mill 10 Unload mill to table 11 Load mill from table 12 Cycle start mill 13 Milled part to deburr 14 Unload deburr 15 Load deburr 16 Cycle start deburr 17 Walk to 713 castings

20 Load both sides 21 Cycle start bore 22 Bore part to lathe 23 Unload lathe 24 Load lathe 25 Cycle start lathe 26 Part to mill table 27 Unload mill 28 Load mill 29 Cycle start mill 30 Part to deburr table 31 Unload deburr to finished 32 Walk to 712 castings

23 lifts (highlighted) Total man cycle time = 2.81 min/part


Appendix C: desCRiption of Rnle evAluAtion of 712/713 woRk CenteR (Continued)

Table C3. 712 and 713 Proposal #2 Cycle Time Analysis 712 side 713 side

Cycle # Task Cycle # Task 1 2 castings to bore 17 Walk to lathe 2 Unload bore to both sides 23 Unload lathe 3 Load bore both sides 24 Load lathe 4 Cycle start bore 25 Cycle start lathe 5 Bore parts to lathe 26 Part to mill table 6 Unload lathe 27 Unload mill 7 Load lathe 28 Load mill 8 Cycle start lathe 29 Cycle start mill 9 Part to mill 30 Part to deburr table 10 Unload mill to table 31 Unload deburr to finished 11 Load mill from table 32 Walk to castings 12 Cycle start mill 13 Milled part to deburr 14 Unload deburr 19 lifts (highlighted) 15 Load deburr Total man cycle time = 2.24 min/part 16 Cycle start deburr


Appendix d: Assumptions foR CAlCulAting Cli foR tHe

CuRRent CyCle time AnAlysis

Table D1. Current Cycle Time Analysis [low/empty pallet and high/full wire basket] Lift # 1 2 3 5 6 7 9 10 11

VHW 11

o 20 o 22

Hd 12 Vd 30 A 0 C fair F 0.5

Duration 8

11 12 47 12 30 0

fair 0.5 8

11 12 30 12 47 0

fair 0.5 8

11 12 30 12 30 0

fair 0.5 8

11 12 40 12 30 0

fair 0.5 8

11 12 30 12 40 0

fair 0.5 8

11 12 30 12 30 0

fair 0.5 8

11 11 12 12 36 30 12 12 30 36 0 0

fair fair 0.5 0.5 8 8

Table D1. Current Cycle Time Analysis (continued)Lift # 14 15 16 18 19 20 22 23

VHW 11

o 20 o 22

Hd 12 Vd 30 A 0 C fair F 0.5

Duration 8

11 12 47 12 30 0

fair 0.5 8

11 12 30 12 47 0

fair 0.5 8

11 12 30 12 30 0

fair 0.5 8

11 12 40 12 30 0

fair 0.5 8

11 12 30 12 40 0

fair 0.5 8

11 12 30 12 30 0

fair 0.5 8

11 12 36 20 46 0

fair 0.5 8

Table D2. Current Cycle Time Analysis [middle pallet/middle wire basket]Lift # 1 2 3 5 6 7 9 10 11

VH

W 11 Ho 20 Vo 33

d 12 d 30

A 0 C fair F 0.5

Duration 8

11 12 47 12 30 0

fair 0.5 8

11 12 30 12 47 0

fair 0.5 8

11 12 30 12 30 0

fair 0.5 8

11 12 40 12 30 0

fair 0.5 8

11 12 30 12 40 0

fair 0.5 8

11 12 30 12 30 0

fair 0.5 8

11 11 12 12 36 30 12 12 30 36 0 0

fair fair 0.5 0.5 8 8


Appendix d: Assumptions foR CAlCulAting Cli foR tHe

CuRRent CyCle time AnAlysis (Continued)

Table D2. CurrLift #

ent Cyc14

le Time 15

Analysis 16

(contin18

ued) 19 20 22 23

W 11 11 11 11 11 11 11 11 Ho 20 12 12 12 12 12 12 12 Vo 33 47 30 30 40 30 30 36 Hd 12 12 12 12 12 12 12 20 Vd 30 30 47 30 30 40 30 33 A 0 0 0 0 0 0 0 0 C fair fair fair fair fair fair fair fair F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

Duration 8 8 8 8 8 8 8 8

Table D3. Current Cycle Time Analysis [high/full pallet and low/empty wire basket] Lift # 1 2 3 5 6 7 9 10 11

W 11 11 11 11 11 11 11 11 11 Ho 20 12 12 12 12 12 12 12 12 Vo 46 47 30 30 40 30 30 36 30 Hd 12 12 12 12 12 12 12 12 12 Vd 30 30 47 30 30 40 30 30 36 A 0 0 0 0 0 0 0 0 0 C fair fair fair fair fair fair fair fair fair F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

Duration 8 8 8 8 8 8 8 8 8

Table D3. CurrLift #

ent Cyc14

le Time 15

Analysis 16

(contin18

ued) 19 20 22 23

W 11 11 11 11 11 11 11 11 Ho 20 12 12 12 12 12 12 12 Vo 46 47 30 30 40 30 30 36 Hd 12 12 12 12 12 12 12 20 Vd 30 30 47 30 30 40 30 22 A 0 0 0 0 0 0 0 0 C fair fair fair fair fair fair fair fair F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

Duration 8 8 8 8 8 8 8 8

VH

W = Weight lifted (pounds) Ho = Horizontal height of lift at origin (inches) Vo = Vertical height of lift at origin (inches)

d = Horizontal height of lift at destination (inches)d = Vertical height of lift at destination (inches)

A = Asymmetry (degrees)C = CouplingF = Frequency (lifts per minute)


ACknowledgements And

AvAilABility of RepoRt TheHazardEvaluationandTechnicalAssistanceBranch(HETAB) oftheNationalInstituteforOccupationalSafetyandHealth (NIOSH)conductsfieldinvestigationsofpossiblehealthhazards intheworkplace.Theseinvestigationsareconductedunderthe authorityofSection20(a)(6)oftheOccupationalSafetyand Health(OSHA)Actof1970,29U.S.C.669(a)(6)whichauthorizes theSecretaryofHealthandHumanServices,followingawritten requestfromanyemployersorauthorizedrepresentativeof employees,todeterminewhetheranysubstancenormallyfound intheplaceofemploymenthaspotentiallytoxiceffectsinsuch concentrationsasusedorfound.

HETABalsoprovides,uponrequest,technicalandconsultative assistancetofederal,state,andlocalagencies;labor;industry;and othergroupsorindividualstocontroloccupationalhealthhazards andtopreventrelatedtraumaanddisease.Mentionofcompany namesorproductsdoesnotconstituteendorsementbyNIOSH.

ThisreportwaspreparedbyJessicaRamseyandJudithEisenberg ofHETAB,DivisionofSurveillance,HazardEvaluationsand FieldStudies(DSHEFS).Ergonomicfieldassistancewasprovided byDanielHabes.DesktoppublishingwasperformedbyRobin Smith.EditorialassistancewasprovidedbyEllenGalloway.Health communicationassistancewasprovidedbyStefanieEvans.

Copiesofthisreporthavebeensenttoemployeeandmanagement representativesatFederal-Mogul;andtheOSHARegionalOffice. Thisreportisnotcopyrightedandmaybefreelyreproduced.The reportmaybeviewedandprintedfromthefollowinginternet address:http://www.cdc.gov/niosh/hhe.Copiesmaybepurchased fromtheNationalTechnicalInformationService(NTIS)at5825 PortRoyalRoad,Springfield,Virginia22161.


Below is a recommended citation for this report: NIOSH [2008]. Health Hazard Evaluation Report: Ergonomic evaluation of workers

OH: U.S. Department of Health and Human Services, Public Health Service, Centers for Disease Control and Prevention, National Institute for Occupational

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E-mail: [email protected]

or visit the NIOSH web site at:

For a monthly update on news at NIOSH, subscribe to NIOSH eNews by visiting

Safety and health at work for all people through research and prevention.

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Safety and Health, NIOSH HETA No. 2007-0124-3060.

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