Ergonomics: Policy and Tactics

Combating cumulative trauma disorders (CTDs) is a long-term process that relies on continuous improvement. According to the Ohio Bureau of Workers’ Compensation (Ergonomics Best Practices for Manufacturing), you need a clear and well-supported policy combined with effective tactics to minimize the risk of CTDs in your workplace.

Policy

Begin by adopting policies that:

• Position ergonomic efforts as part of an overall goal of maintaining and preserving a healthy environment for all employees.
• Give ergonomic efforts the same level of importance as cost reduction, productivity, and quality assurance initiatives.
• Express an expectation of full cooperation by the workforce.
• Designate individuals known to get things done as ergonomic leaders.
• Secure the support of relevant labor groups, if applicable.
• Schedule meetings with employees to present and discuss policy and implementation plans.
• Set specific goals that give priority to jobs and areas with greatest risk.

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Tactics

Follow up with tactics that:

• Train the workforce to be more aware of risk factors for CTDs.
• Provide detailed instructions to those who will help lead the initiative or serve on committees.
• Bring in outside experts for consultation or program implementation, if necessary.
• Provide release time or other arrangements for employees involved in committees or other safety activities.
• Track and report results.
• Publicize key accomplishments.

Risk Factors

OSHA considers manual material handling the primary cause of compensable injuries in the U.S. workforce. The risk factors are common in such incidents, many of which occur at manufacturing worksites:

• Lifting heavy loads
• Carrying bulky loads or loads at a distance from the body
• Frequent lifting
• Bending the trunk, such as when lifting items from the floor or reaching into a bin
• Twisting the trunk
• Static loading, such as holding or carrying objects for long periods
• Pushing or pulling (especially pulling)

Of course, materials handling is only one of a number of tasks that put employees at risk of developing CTDs. Be sure to identify the specific risk factors in your workplace and the employees most at risk.

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Fixes

Risk factors can be reduced by several methods:

• Lift assist devices provide power to raise hoists, cranes, or manipulators. These are typically electric, hydraulic, or pneumatic.

• Transport devices can also reduce the need to lift, carry, push, or pull materials from one place to another. Strategies include the use of carts, conveyors, tugs, powered dollies, and forklifts.

• Powered hand tools with ergonomic design features can also help prevent CTDs in some jobs. When powered tools are used, the Ohio Bureau of Workers’ Compensation recommends trigger design and thumb activation, as well as features to dampen or isolate vibration. Tool handles should be at least 4 inches in length, and the handle diameter should be at least 1.5 inches. Handles should also be padded, nonporous, and nonconductive.

• Workstation design is a common cause of injuries, especially when employees clean, assemble, or pack parts. Prolonged standing on a hard surface can reduce blood flow in the legs, feet, and back, which leads to fatigue, and over time can cause an ergonomic injury. Reaching into bins or boxes for parts often causes stress on the back, shoulders, and wrists. Well-designed workstations include antifatigue floor mats, the option to sit or stand, and adjustable heights on work surfaces, bins, etc.

Tomorrow, we’ll feature highlights of the ergonomics program at Frito-Lay, where reducing CTD hazards has been a long-time priority.

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