Ergonomics

1. PURPOSE: Many traditional work injuries occur suddenly, as a result of a specific incident. Cumulative trauma disorders (CTD's), on the other hand, develop gradually over a period of weeks, months, or even years. Many injuries of this type may be caused by prolonged stress of a particular body part, often compounded by awkward body postures. Because of the extensive use of hands, arms, wrists, shoulders, legs and back to perform manipulative work, CTD's frequently manifest themselves in these portions of the body. It is often difficult to distinguish between the occupational and nonoccupational factors which contribute to the development of CTD's. It is also difficult to control non-work related activities of each associate. However, it is possible to establish workplace controls to protect the health and safety of the associates from CTD's. The objective of this program is to identify approaches to control of CTD's, to recommend activities involved in the control and to comply with the proposed OSHA Ergonomic Standard. 2. SCOPE: This policy applies to all AbcAssociates in the performance of all work related tasks. 3. DEFINITIONS: A. Cumulative Trauma Disorder (CTD): A health disorder arising from repeated bio-mechanical stress, repetitive motion injury, usually resulting in injury to the tendons, tendon sheaths, and related bones muscles, and nerves of the hands, wrists, back, legs, elbows, shoulders, and neck. B. Ergonomics: An interdisciplinary field concerned with adapting the workplace to meet the physical and mental capabilities of the worker. C. Ergonomic Team: Those responsible for identification and correction of ergonomic hazards in the workplace. This team includes health, safety, personnel, supervisors, engineers and the

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associates. Each participants responsibilities are noted in section 7. of this document.

4. CONTROL APPROACHES: A. Worksite Analysis - recognize and correct hazards

Worksite analysis involves identification of significant body motions such as bending, twisting, reaching, and lifting; mechanical stressors such as pressure points on hands, legs and fingers and vibration; forceful exertion dependent on the objects weight, shape, friction generated use of gloves, repetition and the associate's experience; environmental factors such as noise, heat, cold and lighting to name only a few. Observation of tasks being performed and associate and supervisor interviews can provide the bases for worksite analysis. Red flags indicating that ergonomic problem exist include:

Associate complaints and concerns Poor task performance Frequent breaks Absenteeism Modifications to equipment or tools Identification of those risk factors noted above, (significant body motions, mechanical stressors etc.) Injury Engineering Controls

B.

Ergonomics is a multi-disciplinary field concerned with adapting the workplace to meet the physical and mental capabilities of the worker. The process engineer, industrial engineer, design engineer, safety engineer and the operations supervisor all must be involved in process design, storage and retrieval and materials flow to ensure that all ergonomic issues are addressed.

Ideally, ergonomic concerns should be addressed before:

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equipment is purchased or modified procedures are established or modified process flows are established or modified change in product is initiated facility's delivery systems are installed or modified associate selection new tools are purchased or old tools modified storage and retrieval systems are installed or modified

A proactive program that addresses ergonomic concerns will ensure a harmonious interaction between the worker and the work site thus reducing the likelihood of the existence of CTD causing hazards. Engineering controls include but are not limited to the following:

Automate the job to eliminate hand movements, force and high frequency tasks Design jobs where both hands can be used

Positioning of the work and worker to eliminate awkward postures - reduce extreme and repetitive body motions at full range of motion, (i.e. reaching, bending, twisting, standing)

Make workstations and seating adjustable to allow for changes in postures Reduce force needed to do tasks and to eliminate repetition Round off surface edges to avoid pressure points Locate parts within easy reach Provide adequate lighting for the work being done Angle or tilt work toward the worker to avoid bending of neck and back Use counterweight to support heavy hand tools

C. Administrative Controls

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Not every ergonomic solution demands an engineering change or consideration. However, it is important to note that the proactive engineering review process will often times be the most beneficial method of CTD control in the long run. When engineering considerations are not feasible, administrative controls can be implemented. These controls include but are not limited to:

Reduction in task frequency Rotation of workers between different types of jobs using different muscle groups

Alternate hands, if possible, so that the job is not performed primarily with one hand or the other

Have gradual break-in periods, especially for new associates and for new techniques

Train workers in correct work methods. Educate them about the nature of the problem and how to best eliminate the problems

Train management and supervisors about the problems, and in what the correct response to the affected associate should be

Avoid machine pacing Avoid incentive pay scales Expand the work content of the job

Seek medical advise as to appropriateness of job placement exams, work-site exercise and stretching programs, the use of wrist rests, etc.

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5. MEDICAL MANAGEMENT SYSTEM: An effective medical management program for cumulative trauma disorders is essential to ensure early identification, evaluation and treatment of signs and symptoms of CTD's, to prevent their recurrence and to aid in their prevention. Local Medical Services personnel may participate as a team member of the AbcErgonomic Team. They will:

provide early medical evaluation and referral, treatment and rehabilitation for CTD's,

with Safety and Health, conduct periodic, systemic walk through to remain knowledgeable of operations and work practices, to maintain close contact with associates, to identify risk factors for CTD's as part of the Ergonomics Team,

follow established protocols for evaluation, treatment, and followup of workers the signs and symptoms of CTD's,

6. TRAINING AND EDUCATION: The purpose of a training and education program is to ensure that associates are sufficiently informed about the ergonomic hazards to which they are exposed so that each associate will be able to actively participate in their own protection. A training program has been developed for all associates, supervisors engineers, health care personnel and managers. This program includes the following: A.

GENERAL TRAINING: overview of potential risks of illness and injury causes and early symptoms means of prevention treatment overviews prevention exercises

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a video of site specific ergonomic hazards

an explanation of the associates, and the employers responsibilities reporting procedures for hazard identification for early intervention

handout for future reference JOB SPECIFIC:

B.

Initial orientation and hands on training for the specific tasks to be undertaken. Identification of good ergonomic practices, materials storage, proper tool use, proper glove fit, good posture, and proper materials handling techniques.

Individual specific evaluation of work stations for appropriate heights

C.

PROGRAM FOR EVALUATING EFFECTIVENESS:

Injury and ergonomic complaint data is tracked on a monthly basis.

Each complaint is logged and follow-up is conducted to ensure the appropriateness and effectiveness of the intervention strategy.

Work practices are periodically observed by the Site Safety and Health Manager

Associates are periodically evaluated as to their understanding of ergonomic principles.

7. RESPONSIBILITIES: A.

The Safety and Health Manager is responsible for:

providing the initial training to all managerial and supervisory personnel. This training includes: the definition of ergonomics, the supervisor's role, hazard evaluation/recognition, workplace
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design practices, high risk tasks, high risk associates, high risk postures and posture demands, causes of pain associated with body mechanics, material handling, specific exercises, and control practices.

Communication and associate education Participation as a member of the Ergonomics Team by providing technical support for control of ergonomic concerns. Ensuring compliance with OSHA recording requirements, Upper management is responsible for:

B.

support of the overall Ergonomics Program and for those programs that support good ergonomic practices such as, Equipment Approval Signoff Procedure, Materials Handling Policy and supervisory training, for engineering dedication and sound materials handling practices.

programs to implement task redesign and subsequent training programs that receive continuous support in order to control ergonomic injuries.

and for periodically reviewing of the program's effectiveness. The Process, Design and Industrial Engineer are responsible for:

C.

ensuring that sound ergonomic principals are used during the selection, installation and operations of the processes and equipment. Not only does process equipment need ergonomic consideration but office areas, facilities equipment and all workstations should be critiqued. Good workplace and workstation design will help reduce worker fatigue, exertion and muscleoskeletal disorders that can result in awkward postures and static loads. Good ergonomics design can also increase the efficiency and productivity of an operation,

for participating as a member of the Ergonomics Team,

and that engineering changes do not adversely impact the operations or safe task performance.

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D.

Supervisors are responsible for: educating all associates in good ergonomic practices, providing tools that are ergonomically designed, providing materials handling devices best suited for the task, providing training in correct operation of tasks, hazard evaluations, addressing associates complaints and concerns

referring these associates to the Safety and Health Manager for early intervention where such guidance is required, providing personal protective equipment that is suitable for the task and for the fit of the associate (i.e. appropriate glove size)

for discouraging the use of medical devices such as back braces, supports and wrist braces without providing medical supervision and training in the proper use. Medical devices of the above noted nature are only to be implemented when engineering controls and management controls are not feasible and must only be used as a short term control method,

participating as a member of the Ergonomics Team,

selection of associates who are physically and mentally suited for each assigned task, so the at the tasks can be performed safely, and for development of programs for task redesign and development of subsequent training programs for continuing effort in order to achieve maximum injury control.

E.

The associate is responsible for: hazard recognition, bringing concerns to the supervisor before medical intervention is needed,

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adherence to safe work practices and proper equipment operations,

proper use of materials handling devises that are provided.

insistence on training in task performance, use of tools and equipment before task undertaking,

participating as a member of the Ergonomics Team,

and bringing to the supervisor's attention equipment, procedural, or materials handling changes that have been implemented that adversely impact the associate.

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