Risk Chapter 16: Ergonomic Risk Assessment Risk Assessments: Ergonomic Risk Assessment Objectives • Introduce Practical Ergonomic Risk Assessment Methods • Review Fundamental Ergonomic Risk Assessment Techniques • Present a Model for Practical Ergonomic Risk Assessment • Examine the Use of Techniques, their Strengthens and Limitations Introduction Ergonomic risk factors exist in almost all industrial and office work settings. Where there are manual tasks, ergonomic risks can generally be found; however, in many cases they are not recognized or assessed. Such risks can negatively impact employee safety and health, quality of products and services, production efficiency, employee morale and overall safety culture. The cost of ergonomic risks can be significant. Ergonomics and Design Ergonomics - the applied science of designing workplace demands and environment to accommodate human capabilities and limitation for well-being and optimum performance. The concept of designing in safety and ergonomic principles into the workplace continues to be emphasized and re-enforced by recent standards such as ANSI Z590.3-2011 and ANSI Z10-2012. Ergonomic Hazards Workplace ergonomic hazards can contribute to a number of negative effects. The most common and recognized impact is biomechanical and musculoskeletal stress to the worker. Workers exposed to ergonomic hazards such as prolonged repetitive motion, excessive force, awkward or static postures, compression, vibration and extreme temperature are at risk of developing work related musculoskeletal disorders (WMSDs). Ergonomic Hazards The accumulation of stress (also known as cumulative trauma) to the soft tissues such as muscles, nerves and blood vessels over time can cause serious and even permanent damage to the individual. Ergonomic hazards also contribute to ‘single-event’ incidents such as soft tissue strains, slips and falls, and ‘struck against’ objects. These hidden hazards can go unrecognized within the design of work areas, equipment, tools, or methods eventually causing workers to be injured from the exposure. Ergonomic Hazards Ergonomic hazards also include psychosocial stress or job stress. Psychosocial stress refers to the interaction of the worker and their work conditions. The term ‘work organization’ is often associated with this exposure. Ergonomic hazards related to system or product usability (poor ‘human factors engineering’) can contribute to human error. Ergonomic Risk Factors Indicators of ergonomic hazards are referred to as ergonomic risk factors, or stressors. These risk factors are conditions of a job process, work station, or work method that contribute to the risk of developing WMSDs, or other ergonomic hazard. These include forceful exertions, high repetition and duration, static or awkward postures, contact stress, vibration, poor lighting, and cold temperatures. Risk Factor Description Exerting force to complete a motion which requires an application of considerable contraction forces by the muscles, Forceful Exertions causing rapid fatigue. Motions include lifting, lowering, pushing, pulling, carrying, gripping, pinching, tossing. Performing repeated identical motions or multiple tasks where the motions of each task are very similar and involve the same Repetitive Motions muscles groups and tissues. Repetitive motions include assembly type tasks, keying, sorting, cutting, and finishing work such as sanding and buffing, and other similar activities. Positions of the body (limbs, joints, back) that deviate significantly from the neutral position while job tasks are being performed. Muscles do not work as efficiently in awkward Awkward Postures postures, and must exert more physical effort to accomplish the task. Awkward postures include elevated reach, shoulder abduction, head tilt, deviated wrist, and bent waist. Physical exertion held in the same posture or position throughout the exertion causing muscle fatigue. Also referred to as static Static Postures muscle loading, examples include gripping tools, holding arms out or up to perform tasks, or standing in one place for prolonged periods. Internal and external contact stress occurs from compression of soft tissues and blood vessels causing blood flow restriction and damage. Contact stress can occur from leaning on table edges, Contact Stress gripping handles, contact with hard surfaces, sitting in unpadded chairs, and internal rubbing of soft tissues against tendons and bones. Can also result when using a part of the body as a hammer or striking instrument. Vibration inhibits the blood supply to the affected body part and can lead to numbness, tingling, and damage of soft tissues. Localized vibration occurs when a specific body comes in contact with a vibrating object such as powered hand tools or Vibration equipment. Whole-body vibration occurs when standing or sitting in a vibrating environment (truck or heavy equipment operator) and when using heavy vibrating equipment such as a jackhammer. Exposure to excessive cold while performing work tasks causing restricted blood flow and loss of dexterity and sensitivity. The Cold Temperature risk of soft tissue damage is increased when exposure to cold is combined with other risk factors, such as vibration or contact Ergonomic Risk Factors Ergonomic risk factors tend to be synergistic in their effect. Individually, an ergonomic risk factor may not contribute a notable risk, however, when two or more risk factors are combined, the risk of biomechanical stress leading to a WMSD can be significantly increased. Establishing an Ergonomics Assessment Process A standardized method of assessing ergonomic risks should be established, including appropriate ergonomic risk assessment tools, user training. Process steps include: • Identify existing jobs/tasks with ergonomic risks • Assess, prioritize and track ergonomic risk factors • Select and implement effective control measures • Prevent new ergonomic risks from being introduced into the workplace • Support continuous improvement with team-based problem solving Assessing Ergonomic Risk Standard risk assessment techniques are generally not designed to detect ergonomic risk factors to the level necessary. Tools discussed in this text such as Job Hazard Analysis (JHA), Preliminary Hazard Analysis (PHA), Failure Mode and Effects Analysis (FMEA) are used to identify and evaluate multiple types of hazards and risks on a broader scale. Ergonomic hazards are sometimes recognized in JHAs, PHAs, and FMEAs, however, these hazard analysis and risk assessment methods are unable to pinpoint, analyze and assess detailed ergonomic risk factors. For this, a more targeted risk assessment tool is needed. Assessing Ergonomic Risk Upon recognizing the potential for an ergonomic hazard, a tool designed to specifically detect and assess ergonomic risk factors is required. Ergonomic risk assessment tools (ERATs), of which there are many, are used to detect and assess existing risk factors on a micro-level. The systematic sequence of applying a standard risk assessment followed by an ergonomic assessment is useful in identifying, assessing, and controlling ergonomic risks to the degree necessary. Assessment Tool Application Body Segment Type Complexity
OSHA Screening General Industry Whole Body Qualitative Low
Tool Repetitive Tasks Checklist WISHA Checklist General Industry Whole Body Qualitative Low Repetitive Tasks Checklist ACGIH TLV for General Industry Trunk Qualitative Moderate Lifting Lifting Tasks Table ERAT General Industry Upper Extremities Qualitative Moderate Repetitive Tasks Spreadsheet RULA General Industry Upper Extremities Semi-quantitative Moderate Repetitive Tasks Trunk Worksheet REBA General Industry Whole Body Semi-quantitative Moderate Repetitive Tasks Worksheet Snook Tables General Industry Trunk Semi-quantitative Moderate Manual Handling Table ACGIH TLV for Office Settings Upper Extremities Semi-quantitative Moderate Hand Activity Hand Work Worksheet NIOSH Revised General Industry Trunk Quantitative Moderate Lifting Equation Manual Handling Formula Strain Index General Industry Upper Extremities Quantitative Moderate Hand Work Worksheet Energy Expenditure General Industry Upper Extremities Quantitative High Prediction Program Manual Handling Trunk Software University of MI 3D Static Strength General Industry Trunk Quantitative High Prediction Model Manual Handling Lower Extremities Software University of MI Ergonomics Improvement Process Similar to initiatives involving quality, Lean, and operational risk management systems, the ergonomics process should be managed as an ongoing, integrated and sustainable process of continuous improvement. Ergonomics Improvement Process Identify Jobs • To begin, the most obvious place to start is with loss history. Jobs or tasks that have a history of MSD incidents in both frequency and severity should be made a priority. • Often times, information from employees can be most helpful in identifying high risk jobs. Employee feedback, reported concerns and discomfort surveys should be used in selecting problem areas. • Workplace observations by the ergonomics team or other trained personnel are a good source of information. Modifications made to chairs, tools and other workplace items are a ‘red flag’ indicating a need further investigation. Ergonomics Improvement Process Assessment Tools • Qualitative Tools - Qualitative tools are most commonly used and are good for screening jobs. Most are manual or Excel based. • Semi-quantitative Tools - Semi-quantitative tools generally require more expertise in their application. Typically, semi-quantitative tools are targeted for specific applications and risk factors such as lifting, hand work, or body region. • Quantitative Tools - A third group of tools are called quantitative assessment tools which are typically used to perform more in-depth analysis. As a result, quantitative tools require a higher degree of user training, knowledge and skill. Ergonomics Improvement Process Assessment Tool Application Body Segment Type Complexity
OSHA Screening General Industry Whole Body Qualitative Low
Tool Repetitive Tasks Checklist WISHA Checklist General Industry Whole Body Qualitative Low Repetitive Tasks Checklist ACGIH TLV for General Industry Trunk Qualitative Moderate Lifting Lifting Tasks Table ERAT General Industry Upper Extremities Qualitative Moderate Repetitive Tasks Spreadsheet RULA General Industry Upper Extremities Semi-quantitative Moderate Repetitive Tasks Trunk Worksheet REBA General Industry Whole Body Semi-quantitative Moderate Repetitive Tasks Worksheet Snook Tables General Industry Trunk Semi-quantitative Moderate Manual Handling Table ACGIH TLV for Office Settings Upper Extremities Semi-quantitative Moderate Hand Activity Hand Work Worksheet NIOSH Revised General Industry Trunk Quantitative Moderate Lifting Equation Manual Handling Formula Strain Index General Industry Upper Extremities Quantitative Moderate Hand Work Worksheet Energy Expenditure General Industry Upper Extremities Quantitative High Prediction Program Manual Handling Trunk Software University of MI 3D Static Strength General Industry Trunk Quantitative High Prediction Model Manual Handling Lower Extremities Software University of MI Ergonomics Improvement Process Assessment Team • Ergonomic risk assessments are best performed by a cross-functional team of trained and qualified members. Such teams should include users/operators, production, quality, skilled trades, maintenance, and SH&E professionals. • Safety committees which have a diverse and experienced group can be used in this process. • A qualified ergonomics coordinator that is proficient in workplace ergonomics and risk assessment to guide the team is essential. Ergonomics Improvement Process Performing the Assessment • Ensure there are adequate resources and time allotted to perform assessments. Equipment such as digital cameras and measuring tapes can be useful in gathering and documenting data for analysis. • Other instruments such as light meters, sound level meters, infrared thermometers, force gauges, and goniometers may be needed. • During the assessment, it is advised that the assessor verify that the selected job is being performed at its typical capacity or rate, and representative of its normal operation. Ergonomics Improvement Process The ergonomic risk assessment process involves three basic steps: 1. Identify and collect data a. Obtain operator input and involvement b. Observe task cycles and identify task details c. Collect digital video and photos of tasks, operator interactions for further analysis d. Collect data regarding work area, materials, tools, and environment 2. Analyze data a. Analyze collected data to understand the nature and types of ergonomic risk b. Use selected ergonomic risk assessment tool inputs to determine level of risks 3. Evaluate a. Evaluate severity, likelihood, and exposure/duration of each risk b. Input resulting risk factor in the assessment tool Ergonomics Improvement Process Identifying Corrective Measures • Jobs with high risk scores require immediate corrective measures to reduce the identified risk factors. • The ergonomics team should be involved in identifying and developing effective ergonomics solutions. Brainstorming can be used to identify potential improvements and controls that will reduce ergonomic risk. • The team must understand and use the Hierarchy of Controls concept to select the most effective controls measures. This often requires some use of cost/benefit analysis and return of investment calculations to select feasible control measures and help persuade decision makers. Ergonomics Improvement Process Implementing Measures • Before any changes are initiated, affected workers should be made aware of what will take place, why it is necessary, and when it will take place. • Any special training needed by workers to use the controls effectively, should be provided prior to the implemented changes. • Workers should be included in the process of selecting ergonomic interventions to create buy-in and ownership. Ergonomics Improvement Process Verify and Refine • Soon after implementation, the ergonomics team and engineering personnel should meet with affected operators to verify the measures are working properly. • There may be need for fine tuning certain applications, or complete overhaul in rare cases. • Operator feedback or concerns about ease of operation, comfort, speed, etc. should be collected to identify any needed adjustments or corrections. • After a sufficient break-in period, a more in-depth review of the new control measures and their effectiveness should be made. Ergonomics Improvement Process Communicate Results • Results from the assessment must be tracked, measured and communicated for the process to be effective. • The organization’s ergonomics team should establish short term and long term metrics that demonstrate the effectiveness of the ergonomic risk assessment process. • As with any successful risk assessment model, the ergonomic risk assessment process should involve stakeholders from beginning to end. As goals are achieved, the organization should celebrate, recognize and reinforce involved stakeholders. Ergonomic Risk Assessment Tool (ERAT) - A Practical Assessment Tool One of many quick screening and assessment tools available is the Ergonomics Risk Assessment Tool (ERAT). ERAT was developed by the authors (Lyon, Popov), and is based on the draft ANSI Z365 Ergonomics Checklist that was part of the “Management of Work-Related Musculoskeletal Disorders Accredited Standards Committee Z365 Working Draft” withdrawn in 2003. Ergonomic Risk Assessment Tool (ERAT) - A Practical Assessment Tool ERAT is limited to the assessment of ergonomic risk factors impacting the upper extremities, and is appropriate for office work, and assembly type work environments. The Initial Assessment (IA Worksheet) is used to develop a baseline risk score and action level with possible control measures to reduce risk factor scores. The Post-Controls Assessment (PCA Worksheet) is used after the Initial Assessment and implementation of control measures to establish a current risk factor score. Ergonomic Risk Assessment Tool (ERAT) - Initial Assessment Ergonomic Risk Assessment Tool (ERAT) - Post Control Assessment Job Task: Evaluator: Dept: Date: Job Task: Evaluator: Dept: Date: Duration of Task Duration of Task Risk Factor <1 1-4 >4 Score Comments Risk Factor <1 1-4 >4 Score Comments hour hours hours N/A hour hours hours N/A Repetition Enter Only One Score Repetition Enter Only One Score Every few minutes 0 0 1 Every few minutes 0 0 1 Every few seconds 0 1 3 Every few seconds 0 1 3 Lifting Enter Only One Score Lifting Enter Only One Score 5 to 15 lbs. 0 0 1 5 to 15 lbs. 0 0 1 15 to 30 lbs. 1 1 2 15 to 30 lbs. 1 1 2 30 to 50 lbs. 2 2 3 30 to 50 lbs. 2 2 3 Over 50 lbs. 3 3 3 Over 50 lbs. 3 3 3 Push/Pull Force Enter Only One Score Push/Pull Force Enter Only One Score Easy 0 0 1 Easy 0 0 1 Moderate 0 1 2 Moderate 0 1 2 Heavy 1 2 3 Heavy 1 2 3 Carry > 10 feet Enter Only One Score Carry > 10 feet Enter Only One Score 5 to 15 lbs. 0 0 1 5 to 15 lbs. 0 0 1 15 to 30 lbs. 0 1 2 15 to 30 lbs. 0 1 2 Over 30 lbs. 1 2 3 Over 30 lbs. 1 2 3 Postures Score Each Postures Score Each Head Tilt 0 1 2 Head Tilt 0 1 2 Shoulder Reaching 0 1 2 Shoulder Reaching 0 1 2 Flying Elbow 0 1 2 Flying Elbow 0 1 2 Bent wrist/pinch grip 0 1 2 Bent wrist/pinch grip 0 1 2 Bend or twist waist 0 1 2 Bend or twist waist 0 1 2 Environmental Score Each Environmental Score Each Noise 0 1 2 Noise 0 1 2 Lighting/Glare 0 1 2 Lighting/Glare 0 1 2 Impact/compression 0 1 2 Impact/compression 0 1 2 Vibration/power tool 0 1 2 Vibration/power tool 0 1 2 Excessive Pace 0 1 2 Excessive Pace 0 1 2 Extreme Temperature 0 1 2 Extreme Temperature 0 1 2 Action Level Total 0 Action Level Total 0 Action Level 1 Total score of 10 or less - may require further analysis Action Level 1 Total score of 10 or less - may require further analysis Action Level 2 Total score of 11 - 22 - requires intervention in near future Action Level 2 Total score of 11 - 22 - requires intervention in near future Action Level 3 Total score of 23 - 36 requires immediate intervention Action Level 3 Total score of 23 - 36 requires immediate intervention Hierarchy of Ergonomic Risk Controls Method Phase/Application Control Examples Effectiveness
Prevent entry of hazard into
Conceptual Stage workplace by design through Avoidance High Design/Redesign selection of technology and work methods.
Existing Processes Eliminate hazard by changes in
Elimination High Redesign design, equipment and methods
Substitute materials, sizes, weights
Moderately Substitution Existing Processes and other aspects to a lower High hazard severity or likelihood
Administrative Practices and changes in work practices, training, Moderately Controls Procedures job enlargement, job rotation, rest Low breaks, work pace
Reduce impact of hazard to
Personal employee by use of protective Protective Workers Low equipment and materials such as Equipment vibration attenuation gloves Conclusion Ergonomic hazards and latent conditions to some degree exist in almost all work systems and can be missed in standard risk assessment efforts. Many organizations uncertain of the ergonomic risk levels in their operation or the impact it has on the business, have a significant opportunity for improvement. For an organization to improve its ability to manage ergonomic hazards, an effective ergonomic risk assessment process is needed to reduce risks to an acceptable level. For organizations that have yet to implement an ergonomics process, it is an opportunity for SH&E professionals to help the business decision makers understand and recognize the value of reducing ergonomic risk, and guide them in establishing a process. Keeping it simple, yet effective is a key to success.