The Job Improvement Process

Transcription

1 Simple, Straightforward and Systematic Ergonomic Risk Reduction The Job Improvement Process Josh Kerst, CPE, CIE Vice President and Ergonomics Engineer

2 Objectives Describe a simple process to evaluate work for human capabilities - Find It» Work strain avoidance - forces and postures that are overly fatiguing» Higher fidelity job assessment tools as needed Eliminate non-value added activities Fix It» Worker compatible machines - simple, highly reliable, and easily improved» Workstation geometry & proper equipment Reduce risk to control loss Check for Success» Ultimate waste of human capital.» Reduced hassle and safer work environment» Describe a web-based solution library

3 Business Reality 101 In today s business climate initiatives must deliver measurable value in the short to medium term. Its about job improvement not just analysis.

4 Ergonomic Process Structure Identify and improve workplace conditions that reduce exposure to ergonomic risk factors.

5 Simplify the Process PDCA becomes

6 Using the Right Tool for the Job The Tools

7 Launching Point Use a simplified approach to launch or invigorate the process. Provide tools that are easy to understand and focus on improvement not analysis Use a multi-level team approach Make changes that are:» High Visibility» High Impact

8 Launching Point Use a simplified approach to launch or invigorate the process. Provide tools that are easy to understand and focus on improvement not analysis Use a multi-level team approach Make changes that are:» High Visibility» High Impact Occurs RAPIDLY with a focus on Improvement

9 Kaizen Event to RAPID Event Adopted the method developed to foster continual improvement within Toyota Production System Designated using a define block of time Cross functional team that focuses on finding and fixing issues to:» Unlock talents & abilities of employees,» Make decisions at the lowest level, in quickest time by people who know the best solution. Benefits:» Accelerate improvement» Improve productivity» Gain time, space and labor savings» Collapse lead time and gain management support» Reduce WIP and scrap» Labor relations improvement

10 What s the Team s Purpose To make rapid, simple improvements to the ergonomic conditions of the workplace that improve the safety, productivity, and quality of life of our employees. Launch an initiative to allow the ergonomic process to gain a visible foothold at this site.

11 Use current deployments L E A N D M A I C E R G O LEAN DMAIC ERGO Silos of Knowledge Integrated Approach

12 Get the Right SWAT Team Represent skills, abilities, & organizations on participative team :» Operators/employees» Maintenance, Engineering, Facilities» Supervisors, Managers» Health & Safety» Lean Production Officer, Six Sigma Green/Black Belts Commitment to time & contribution based on roles» Leaders» Team players» Social and personable» Practical» Enthusiastic» Like to work towards change» Dedicated to improvement Empowered by management and accountable for results

13 Hit List

14 Find the Postures

15 Simple tool Horizontal Distance Elbows Out Butts Up

16 Perspective changing Hit List Find It Horizontal Distance Wash Rag Contact Fix It Comfort Zone Don t Give Me Static

17 Find the POSTURE Washrag Elbows Out Shoulders too high/low Hungry Head Butts Up Horizontal Distance Sit vs. Stand Twist and Shout Contact Bad Vibes

18 Apply the Appropriate RULE Keep it straight Keep elbows at sides Keep it in the comfort zone Keep it in sight Keep it above the knees Keep it close Is it right for the task Keep it in line with the spine Don t lean on the machine Don t hold it

19 Document it to CHECK FOR SUCCESS Completed Improvements Within 30 days Within 60 days Within 90 days

20 Tools Used

21 RAPID Form DOCUMENT IT Page 1 Job Information Page Mulch Plug 110 February 10, 2003 Day Greeneville, TN Line 110 Bob, Mary, Cam Job Information

22 RAPID Form DOCUMENT IT Root Cause Using tool at improper heights Inserting bolts into unit at high heights N/A N/A Total of Yes Knees in contact with table edges 3

23 Wash Rag FIND IT

24 Keep it Straight FIX IT

25 Wash Rag FIND IT

26 RAPID Form DOCUMENT IT Improvement Ideas Operator Interview - Lower height of fixture to improve -working Lower height heights of fixture to improve heights - Use in-line tool, rather than pistol -grip Use tool in-line tool, rather than pistol grip tool - Install platform for operators - Tilt part to improve part orientation

27 RAPID Form DOCUMENT IT -Lifting heavy parts -Using tool for long periods of time - Hands/Wrists sore from using tool - Back from lifting parts - Feet/Legs tired from standing on concrete -Investigate floor use all of day proper tools -Install operator platforms Operator Interview - Anti-fatigue matting - Gloves for using tool - Store parts off the ground

28 RAPID Form DOCUMENT IT Immediate and Long-Term Fixes - Install platform for operators - Provide an in-line tool - Install workstation padding Elbows Out Washrag Contact !!!

29 Find It Fix It Ergonomics

30 Find It Fix It Problem» Working at fixed height work table is difficult for different height operators Solution» Attached hydraulic legs so units goes up and down

31 What About Results? Changes that improve the workplace A record of improvements (Before/After Photos) Plans for longer term improvements ( days) Presentation of our process, results and plans to site management

32 Some Examples

33 DOCUMENT Check for Success IT Completed Improvements Long term engineering controls» Within 30 days» Within 60 days» Within 90 days Assign responsibility Presented to site management team

34 Event Results 22 Manufacturing Locations 6-18 people teams (Avg. 8) 4-5 day events operations evaluated immediate changes made ($0-600) additional changes planned in days 22 Ergonomics Teams established Create a pull for more training more involvement

35 Project Elements: RAPID Team Event Ergonomics Event Scorecard

36 Project Elements: RAPID Team Results

37 Results Breakthrough improvements in:» Health & Safety measures» Productivity/work flow Sustainable impact in the immediate to short term Sustainable ergonomics team Scalable to other sites and business groups and proof of concept

38 Keys to success Simplified Approach Team Approach (be selective) Skill Development (training) Develop infrastructure (process model) Demand and expect results Harness the enthusiasm Simply put. Can you create a workplace that allows your people to work better

39 When to Use / Limitations Hit List When to Use the Simplest Methods» When the level of necessary detail about the job is low and/or» When off-the-shelf solutions or skilled in-house resources are readily available Limitations of the Ergonomics Hit List» Does not provide measurable (quantitative) risk exposure» Typically a posture driven model

40 Using the Right Tool for the Job The Tools

41

42 Risk Factors " Increase the probability of a certain outcome " Do not guarantee that a certain outcome will occur " Assist in the job improvement process by identifying root causes

43 Ergonomic Job Analysis Observation Discomfort Survey Risk Factor Survey

44 Completing the Risk Factor Survey Step 2 Pin Press Orangeburg, SC 22A Assembly 1st A47 Hinges!!!!!!!!!!!!!!!!!!!! ! S

45 Scoring the BRIEF Low, Medium, or High

46 When to Use / Limitations of the BRIEF When to Use the BRIEF Survey When a high level of detail is necessary and/or When readily available off-the-shelf solutions are not feasible Limitations of the BRIEF Survey Designed to analyze a job with specific tasks that are repeated throughout a cycle

47 The BRIEF Exposure Scoring Technique The BEST BRIEF Survey Body Area Scores BRIEF Physical Stressors Scores BEST Job Risk Factor Score Time Exposure Multiplier BEST Job Hazard Score

48 The Completed BEST Completed BEST Pin Press Orangeburg, SC 22A Assembly 1st A47 Hinges

49 From Simple to Detailed Simplified Approach All some or none options for analysis Web-based and password Instant infrastructure (process model) Share results

50 The BRIEF Exposure Scoring Technique Priorities Low Medium High Very High Priority Low Medium High Very High

51 Web-based Job Improvement Tool

52 On-line Solution Database

53 Suite of Risk Assessment Tools

54 Built-in Improvement Process Mapping

55 Search and Reapply

56

57 Human Performance Ergonomics Improvement Accelerated