|
Countless
numbers of companies and work sites have embraced ergonomics beyond
what was asked of them. Strategies vary from simple to complex, but has
the return been worth the investment? The Occupational Safety and
Health Administration (OSHA) has compiled case after case exemplifying
companies who have presented a problem, an ergonomic solution, and the
success of the solution with some impressive results. This article will
focus on companies making changes to address Repetitive Stress/Strain
Injury (including Carpal Tunnel Syndrome), Repetitive Motion Injury,
and Cumulative Trauma Disorder.
- Advanced Filtration Systems
Inc. in Illinois looked closely at a job that was resulting in many
Carpal Tunnel Syndrome (CTS) diagnoses in their employees, 2 of who
required surgery. Their filter inspection process required employees to
use an extended pinch grip and turn their wrists to manually manipulate
and inspect filter items coming off a chain conveyor. Aside from the
conveyor, the process was completely manual. By implementing robots and
a different conveyor, the process became 95% automated. The results? No
Carpal Tunnel Cases had been reported since the change at the time of
report. Additionally, the product defect rate decreased and employee
morale increased significantly. This change earned the company an award
from the Director of OSHA’s Region V office along with publicity and
recognition in the written media.
- Sun Microsystems, Inc. in
California experienced a high number of Repetitive Motion Injuries
(RMIs) in employees in the early ‘90s. By 1993, the disability claims
were around 300. Reeling from the cost of the claims and loss in
productivity, the company purchased ergonomic equipment and furniture
as well as implemented training and workstation assessments to
employees who requested them. As a result, despite major growth in
number of employees, between 1993 and 2002, the number of claims
dropped from 300 to 50. The total cost that had exceeded $1.5 million
in 1992 dropped to less than $100,000 in 2002. Additionally, the
average cost to close a disability claim of a work-related
musculoskeletal disorder went from over $12,000 in '92 to $2500 in '02.
- Duracell, located in Georgia,
recognized that Cumulative Trauma Disorders (CTDs) were a whopping 35%
of their recordable injuries over a 4-year period. Setting a goal to
reduce CTDs by 50%, the company formed a committee to tackle the
problem. After much research of data and cost, the committee
implemented improvements including automation, work height adjustments,
redesign of workstations, ergonomic furniture, and several other
solutions. By using these methods and maintaining a comprehensive
ergonomics program, Duracell reduced CTD incidents by 90% and total
accident rates by 81%.
- Siemens VDO Automotive in
Michigan found that 43% of their 250 office workers were complaining of
CTDs in their back, shoulders, elbows, and fingers. Evaluating each
workstation, Siemens provided ergonomic support for chairs and computer
workstations, training on ergonomics and back safety, and frequent
exercise breaks. Two years after the implementation, not a single
CTD-related lost time incident had occurred. They estimated a savings
of 20,000 hours per year that had previously been lost to doctor
visits, time off, and pain.
- Blue Cross Blue Shield of
Kansas reported 103 CTD-related claims in 1991 costing over $500,000.
The company shifted its entire focus on employee health and made nearly
30 changes. Some of them include: purchasing ergonomic furniture and
accessories, ongoing education of employees on ergonomics, installing
health stations, designing and building equipment necessary for
workstation comfort when such equipment can’t be found, and exercise or
stretch programs. By 2002, CTD/RSI claims had fallen from 103 to 52,
resulting in cost plummets from $526,000 to $137,000.
The most
aggressive and successful programs are ongoing and involve leadership,
hazard analysis and control, follow-up, training, and even working with
nurses or physical therapists to manage early symptoms of RSIs or CTDs.
Workstation analysis and education are consistent in ergonomic
improvements. Overall, the results are dramatic and positively affect
the number of claims reported, productivity, and employee morale.
|
