Requested File

Simple, Straightforward and Systematic
Ergonomic Risk Reduction
The Job Improvement Process
Josh Kerst, CPE, CIE

Vice President and Ergonomics Engineer
Applied Ergonomics Conference
2004 Humantech, Inc
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

2004 Humantech, Inc
Business Reality 101
In todays business climate initiatives must

deliver measurable value in the short to
medium term.
Its about job improvement not just
analysis.

2004 Humantech, Inc
Ergonomic Process Structure
Identify and
improve
workplace
conditions that
reduce exposure
to ergonomic risk
factors.

2004 Humantech, Inc
Simplify the Process
PDCA becomes

2004 Humantech, Inc
Using the Right Tool for the Job
The Tools

2004 Humantech, Inc
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

2004 Humantech, Inc
Launching Point
Occurs
Provide tools
that are easy to understand
RAPIDLY
and focus on improvement not analysis
Use a with
multi-level a
teamfocus
approach
Make changes that are:
on
Improvement
Use a simplified approach to launch or
invigorate the process.
High Visibility
High Impact

2004 Humantech, Inc
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

2004 Humantech, Inc
Whats the Teams 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.
2004 Humantech, Inc
Use current deployments
L
E
A
N
D
M
A
I
C
LEAN
E
R
G
O
Silos of Knowledge
ERGO
DMAIC
Integrated Approach

2004 Humantech, Inc
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

2004 Humantech, Inc
Hit List

2004 Humantech, Inc
Find the Postures

2004 Humantech, Inc
Simple tool
Horizontal Distance
Elbows Out
Butts Up
2004 Humantech, Inc
Perspective changing
Hit List
Find It
Horizontal Distance
Wash Rag
Contact
Fix It
Comfort Zone
Dont Give Me Static

2004 Humantech, Inc
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
2004 Humantech, Inc
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
Dont lean on the machine
Dont hold it
2004 Humantech, Inc
Document it to CHECK FOR SUCCESS
Completed Improvements
Within 30 days
Within 60 days
Within 90 days

2004 Humantech, Inc
Tools Used

2004 Humantech, Inc
RAPID Form
DOCUMENT IT
Page 1 Job Information Page
Mulch Plug
February 10, 2003
Greeneville, TN
Line 110
Bob, Mary, Cam
110
Day
Job
Information

2004 Humantech, Inc
RAPID Form
Root Cause
DOCUMENT IT
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
2004 Humantech, Inc
Wash Rag
FIND IT

2004 Humantech, Inc
Keep it Straight
FIX IT

2004 Humantech, Inc
Wash Rag
FIND IT

2004 Humantech, Inc
RAPID Form
Improvement
Ideas
Operator
Interview
DOCUMENT IT
- Lower height of fixture to improve

- working
Lower height
of fixture to improve
heights
working 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

2004 Humantech, Inc
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
-Investigate
use
proper tools
concrete
floor
allof
day
-Install operator platforms
Operator
Interview
- Anti-fatigue matting
- Gloves for using tool
- Store parts off the ground

2004 Humantech, Inc
RAPID Form
DOCUMENT IT
- Install platform for operators
Immediate and
Long-Term Fixes
- Provide an in-line tool

- Install workstation padding
Elbows
Out
Washrag
Contact
90
60
30
!
!
!

2004 Humantech, Inc
Find It
Fix It Ergonomics

2004 Humantech, Inc
Find It
Problem
Working at fixed height work
table is difficult for different
height operators
Fix It
Solution
Attached hydraulic legs so units
goes up and down

2004 Humantech, Inc
What About Results?

Changes that improve the workplace
A record of improvements (Before/After Photos)
Plans for longer term improvements (30-60-90 days)
Presentation of our process, results and plans
to site management

2004 Humantech, Inc
Some Examples

2004 Humantech, Inc
Check for Success

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

2004 Humantech, Inc
Event Results
22 Manufacturing Locations
6-18 people teams (Avg. 8)
4 - 5 day events
14-30 operations evaluated
13-50 immediate changes made ($0-600)
22-59 additional changes planned in 3090 days
22 Ergonomics Teams established
Create a pull for more training more
involvement
2004 Humantech, Inc
Project Elements: RAPID Team Event
Ergonomics Event Scorecard

2004 Humantech, Inc
Project Elements: RAPID Team Results

2004 Humantech, Inc
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

2004 Humantech, Inc
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
2004 Humantech, Inc
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
2004 Humantech, Inc
Using the Right Tool for the Job
The Tools

2004 Humantech, Inc

2004 Humantech, Inc
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

2004 Humantech, Inc
Ergonomic Job Analysis

Observation
Discomfort Survey Risk Factor Survey

2004 Humantech, Inc
Step 2
Completing the Risk Factor Survey
Pin Press
9-12-02
Assembly
Orangeburg, SC
1st
!
!
3
22A
A47 Hinges
!
2

2004 Humantech, Inc
Scoring the BRIEF
Low, Medium, or High

2004 Humantech, Inc
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

2004 Humantech, Inc
The BRIEF Exposure Scoring Technique
BRIEF Survey
Body Area Scores
The BEST
BRIEF Physical
Stressors Scores
BEST Job Risk

Factor Score
Time Exposure Multiplier
BEST Job
Hazard Score

2004 Humantech, Inc
The Completed BEST

Pin Press
9-12-02
Assembly
Completed BEST
Orangeburg, SC
1st
22A
A47 Hinges
31
2
33
0.8
26.4

2004 Humantech, Inc
From Simple to Detailed

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

2004 Humantech, Inc
The BRIEF Exposure Scoring TechniquePriorities
10
Low
20
30
Medium
40
High
50
70
60
Very High
Priority
Low
Medium
High
Very High
0-9
10 - 29
30 - 49
50+

2004 Humantech, Inc
Web-based Job Improvement Tool

2004 Humantech, Inc
On-line Solution Database

2004 Humantech, Inc
Suite of Risk Assessment Tools

2004 Humantech, Inc
Built-in Improvement Process Mapping

2004 Humantech, Inc
Search and Reapply

2004 Humantech, Inc

2004 Humantech, Inc
Human Performance Ergonomics

Improvement Accelerated
www.humantech.com

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Simple, Straightforward and Systematic

Ergonomic Risk Reduction

The Job Improvement Process

Josh Kerst, CPE, CIE

Eliminate non-value added activities Fix It

Reduce risk to control loss Check for Success

Applied Ergonomics Conference

Business Reality 101

In todays business climate initiatives must

Applied Ergonomics Conference

Ergonomic Process Structure

Applied Ergonomics Conference

Simplify the Process

Applied Ergonomics Conference

Using the Right Tool for the Job

Applied Ergonomics Conference

Applied Ergonomics Conference

Applied Ergonomics Conference

Kaizen Event to RAPID Event

Applied Ergonomics Conference

Whats the Teams Purpose

Use current deployments

Applied Ergonomics Conference

Get the Right SWAT Team

Commitment to time & contribution based on roles

Empowered by management and accountable for results

Applied Ergonomics Conference

Applied Ergonomics Conference

Find the Postures

Applied Ergonomics Conference

Applied Ergonomics Conference

Find the POSTURE

Apply the Appropriate RULE

Document it to CHECK FOR SUCCESS

Applied Ergonomics Conference

Applied Ergonomics Conference

Page 1 Job Information Page

Applied Ergonomics Conference

Applied Ergonomics Conference

Applied Ergonomics Conference

Applied Ergonomics Conference

- Lower height of fixture to improve

Applied Ergonomics Conference

-Lifting heavy parts

- Hands/Wrists sore from using tool

Applied Ergonomics Conference

- Install platform for operators

- Provide an in-line tool

Applied Ergonomics Conference

Applied Ergonomics Conference

Applied Ergonomics Conference

What About Results?

Applied Ergonomics Conference

Applied Ergonomics Conference

Check for Success

Applied Ergonomics Conference

Project Elements: RAPID Team Event

Ergonomics Event Scorecard

Applied Ergonomics Conference