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

Applied Ergonomics Conference

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.

Applied Ergonomics Conference

2004 Humantech, Inc

Ergonomic Process Structure

Identify and
improve
workplace
conditions that
reduce exposure
to ergonomic risk
factors.

Applied Ergonomics Conference

2004 Humantech, Inc

Simplify the Process

PDCA becomes

Applied Ergonomics Conference

2004 Humantech, Inc

Using the Right Tool for the Job

The Tools

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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.
Applied Ergonomics Conference
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

Applied Ergonomics Conference

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

Applied Ergonomics Conference

2004 Humantech, Inc

Hit List

Applied Ergonomics Conference

2004 Humantech, Inc

Find the Postures

Applied Ergonomics Conference

2004 Humantech, Inc

Simple tool
Horizontal Distance

Elbows Out

Butts Up
Applied Ergonomics Conference
2004 Humantech, Inc

Perspective changing

Hit List

Find It
Horizontal Distance
Wash Rag
Contact

Fix It
Comfort Zone
Dont Give Me Static

Applied Ergonomics Conference

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
Applied Ergonomics Conference
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
Applied Ergonomics Conference
2004 Humantech, Inc

Document it to CHECK FOR SUCCESS

Completed Improvements
Within 30 days
Within 60 days
Within 90 days

Applied Ergonomics Conference

2004 Humantech, Inc

Tools Used

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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
Applied Ergonomics Conference
2004 Humantech, Inc

Wash Rag

FIND IT

Applied Ergonomics Conference

2004 Humantech, Inc

Keep it Straight

FIX IT

Applied Ergonomics Conference

2004 Humantech, Inc

Wash Rag

FIND IT

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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

!
!
!

Applied Ergonomics Conference

2004 Humantech, Inc

Find It

Fix It Ergonomics

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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

Applied Ergonomics Conference

2004 Humantech, Inc

Some Examples

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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
Applied Ergonomics Conference
2004 Humantech, Inc

Project Elements: RAPID Team Event

Ergonomics Event Scorecard

Applied Ergonomics Conference

2004 Humantech, Inc

Project Elements: RAPID Team Results

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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
Applied Ergonomics Conference
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
Applied Ergonomics Conference
2004 Humantech, Inc

Using the Right Tool for the Job

The Tools

Applied Ergonomics Conference

2004 Humantech, Inc

Applied Ergonomics Conference

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

Applied Ergonomics Conference

2004 Humantech, Inc

Ergonomic Job Analysis

Observation

Discomfort Survey Risk Factor Survey

Applied Ergonomics Conference

2004 Humantech, Inc

Step 2
Completing the Risk Factor Survey

Pin Press
9-12-02

Assembly

Orangeburg, SC
1st

!
!
3

22A
A47 Hinges

!
2

Applied Ergonomics Conference

2004 Humantech, Inc

Scoring the BRIEF

Low, Medium, or High

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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

Applied Ergonomics Conference

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+

Applied Ergonomics Conference

2004 Humantech, Inc

Web-based Job Improvement Tool

Applied Ergonomics Conference

2004 Humantech, Inc

On-line Solution Database

Applied Ergonomics Conference

2004 Humantech, Inc

Suite of Risk Assessment Tools

Applied Ergonomics Conference

2004 Humantech, Inc

Built-in Improvement Process Mapping

Applied Ergonomics Conference

2004 Humantech, Inc

Search and Reapply

Applied Ergonomics Conference

2004 Humantech, Inc

Applied Ergonomics Conference

2004 Humantech, Inc

Human Performance Ergonomics

Improvement Accelerated

www.humantech.com