Building Your Ergonomics Program: Risk and Injury Prevention Rachel Michael, CPE, CHSP Principle Consultant Rachel.Michael@bsigroup.com BSI Group EHS Services and Solutions
Introduction Rachel Michael MS, CPE, CHSP Principle Consultant Past President of Board of Directors- BCPE National Ergonomics Conference Co-Chair This presentation will focus on ergonomics programs affecting the workforce. However, similar principles may be applied to product/end user design.
Ergonomics Definitions Ergonomics is a body of knowledge around human ability, human limitation and human characteristics relevant to design. Ergonomic design is the application of that knowledge to the design of tools, systems and environments for safe and efficient use.
Ergonomics Programs Background 1993 Ergonomics Programs for Meatpacking proposed by OSHA 1997 California adopts CCR5110 known as the ergonomics program standard 2000-2003 Washington State Ergonomics Rule in place 2001 (63 days)- Federal OSHA Ergonomics Program Standard Attempted in MI, NC and NYC (largely related to schools) Best practice in many industries and organizations
Ergonomics Programs An ergonomics program is a defined way for an organization to address how ergonomics (a body of knowledge about human abilities, human limitations and human characteristics relevant to design) is utilized in that organization.
Ergonomics Programs Most programs typically encompass the following elements, though specific operations may need additional elements: Management Commitment Hazard Identification and Abatement Employee Training and Program Involvement Medical Management Sustainability
Ergonomics Programs These programs are largely different from Employee Health and Safety Programs as they are almost exclusively performance based rather than specification based. Understanding this different, we ll learn, is key to continued success.
Ergonomics Programs Current State Review To help organizations understand how their ergonomics programs measure up to others and how these programs are structured, Aon plc. conducted a survey of OSH and ergonomics professionals about the function and effectiveness of ergonomics programs. The survey addressed several questions: Who is responsible for ergonomic programs? What drives ergonomic efforts? What is the experience with third-party vendors? What metrics are used, and are they effectively measuring efforts and success?
Ergonomics Programs Current State Review One of the more impactful findings was the contrast between what metrics the larger organization felt measured their ergonomics efforts and what metrics the program managers felt would be most meaningful. Most companies reported using trailing indicators, such as metrics collected for mandatory reporting, to measure their ergonomics efforts. But when asked which metrics were most valuable for measuring their ergonomics efforts, companies rated these lagging indicators much lower, instead citing task analysis scores and discomfort/symptom reports as the most valuable tools for measuring ergonomic efforts.
Why Are Your Ergonomics Efforts not Getting Desired Results?
Why Are Your Ergonomics Efforts not Getting Desired Results? Ergonomics programs have an even higher rate of failure than traditional safety programs. In addition to these obstacles, ergonomics programs can also be challenged with: A management belief of a low risk of regulatory involvement. Being the only performance based program amongst other specification based programs. Employed staff does not have skill set and cannot adequately review potential third parties. Viewing ergonomics programs as a function of only health and safety and not part of overall company culture or goals.
Why Are Your Ergonomics Efforts not Getting Desired Results? If the ergonomics program does not tie into design it is better described as an injury response program Activities may be designed, or aligned more closely, with injury response rather than prevention (PT on the job, coaching around bad design)
Why Are Your Ergonomics Efforts not Getting Desired Results? Root causes are poorly investigated and a single root cause is attributed such as employee awareness or employee training A focus on employee reliant controls A poor understanding of mechanics of injury and how to look at root causes
ROI From Ergonomics Programs Several reviews of the effectiveness of ergonomics interventions have provided useful estimates (Department of Labor and Industries [DLI], 2000;) as part of a review of the effectiveness of various accident prevention programs, evaluated two comprehensive ergonomics programs and found an average 49.5% reduction in accidents.
ROI From Ergonomics Programs As part of a regulatory Cost- Benefit Analysis a team of economists and ergonomists from the Washington DLI estimated the benefits of ergonomic interventions by evaluating the literature on actual ergonomic programs in the workplace. A total of 63 reports and publications on the success of ergonomic programs were evaluated and determined to be of sufficient quality for determining rule effectiveness.
ROI From Ergonomics Programs The observed average reduction in number of WMSD injuries was 50%, while the average reduction in WMSD costs was 64%. The literature search also revealed a decrease in the severity of WMSD injuries that were reported after implementation of ergonomic programs, as seen in the reduction in days per injury and cost per claim.
ROI From Ergonomics Programs A GAO review of ergonomics programs from 5 major employers found these efforts resulted in a 36-91 percent reduction in workers compensation costs.
ROI From Ergonomics Programs Utility Company: Injuries reduced by 60% $162,000 annual cost reduction 9:1 dollar benefit to cost ratio for ergonomics program Noticeable improvement in worker productivity and morale A Long-term Care Facility: Premiums dropped from $1.5 million to $770,000 Lost work days fell from 573 to 12 over four years. Automobile Manufacturer: Injuries on chassis line reached $1,458,000 in 1996 from 54 incidents 1997 injury costs reduced to $945,000 1998 costs reduced to $486,000 Food Distribution Company: Injury and illness costs dropped more than 45%. Back injuries down from 76 to 21 in first year.
Ergonomics Programs In The Office Office Specific Ergonomics Program Standards apply in global geographies- same features Office ergonomics programs can be benefitted by large scale purchasing power and standardized equipment and set up. Computer based workforce can ease logistics in implementation of computer based training. Reference ANSI/HFES 100 Human Factors Engineering of Computer Workstations
Ergonomics Programs In The Office Pitfalls include poor administration of funding and consistency. Good faith attempts to do the right thing can lead to subpar equipment purchases, leakage of funds and insufficient adherence to true medical accommodation. Poor furniture selection and IT set up must be addressed in comprehensive programs and future budget planning.
Ergonomics Programs In The Office A robust office ergonomics program can address challenging issues such as: Me-too-ism Home based employees Standing opportunities Alignment with EEOC and ADAAA and protection from claims in these areas Reviewing work relatedness
Case Studies- Integrating Ergonomics into Design Aerospace Manufacturer
Case Studies- Integrating Ergonomics into Design
Case Studies- Integrating Ergonomics into Design Ford Motor Company has a long history with ergonomics and human factors.
Case Studies- Integrating Ergonomics into Design
Case Studies- Integrating Ergonomics into Design
Case Studies- Integrating Ergonomics into Design
Summary Ergonomics programs have now been in place in industry for almost 30 years. While there are many modalities to failure and a lack of sustainability, persistent organizations consistently and continually see a clear financial return on investment.
Summary Ergonomics program are largely performance, rather than specification, based and thus may see greater performance from close alignment with departments other than traditional employee health and safety.
Summary Ergonomics programs should be in place first to direct activities such as employee training, hazard assessment, workstation design and equipment selection. Comprehensive ergonomics programs have a long and proven history of financial success and positive ROI.
Additional References NIOSH Publication 91-117(1997). Elements of an ergonomics program. A 114-page primer based on extensive practical experience accumulated by NIOSH that defines key elements of an effective ergonomics program including reference levels or guidelines to determine whether a certain workplace and job demand may pose a risk of a musculoskeletal disorder. GAO August 1997 Report to Congress: Worker Protection- Private Sector Ergonomics Programs Yield Positive Results 2016. 2015 Safety Management Function: Current State of Ergonomics Programs an Aon Global Risk Consulting Report. Journal of Safety Research 39 (2008) 339 344.
Additional References Occupational Safety and Health Administration [OSHA] (1999). Ergonomics program, proposed rule: Appendix III-B.Washington, DC: U.S. Department of Labor. Ohio Bureau of Workers' Compensation [BWC] (2002). Ergonomics best practices manuals.columbus, OH: Author Accessed October 3, 2005 from https://www.ohiobwc.com/employer/forms/publications/nlbwc/safehyg- Pubs1.asp?txtCID=57033220. Department of Labor and Industries [DLI] (2000). Cost-benefit analysis of the ergonomics standard. Olympia, WA: Author. Aon 2015 Safety Management Survey Report: Ergonomics Programs. http://www.aon.com/forms/2016/2015-safety-management-survey.jsp
Thank You for Your Time and Attention Q & A? Rachel.Michael@bsigroup.com