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Successful Applications of Ergonomic Principles to Loss Prevention . Vern Anderson, Ph.D., Coordinator Retail Trades Occupational Health CDC/NIOSH Mike Leiner Manager Store Safety Target Corporation. Two Acknowledgments for Leadership in Safety .

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Presentation Transcript
slide1

Successful Applications of Ergonomic Principles to

Loss Prevention

Vern Anderson, Ph.D.,

Coordinator Retail Trades

Occupational Health

CDC/NIOSH

Mike Leiner

Manager Store Safety

Target Corporation

two acknowledgments for leadership in safety
Two Acknowledgments for Leadership in Safety
  • 1. RILA recently signed a “Letter of Agreement” with the “Centers for Disease Control & Prevention” (CDC) and its Occupational Safety and Health Program CDC/NIOSH).
  • 2. The Loss Prevention Foundation (LPF), known for its Certification and Training for Loss Prevention also signed a “Letter of Agreement” with (CDC/NIOSH).
  • The purpose of both of these Letters of Agreement was to acknowledge the importance of workplace safety and to provide information on safety and health to their membership. In addition, the resources of CDC/NIOSH are committed to these same goals.
take away message
Take Away Message
  • Ergonomic is good business!
  • Correlates with business success
  • Adds value- provides competitive edge
    • Quality, efficiency, profitability
    • Controls costs (direct and indirect)

It’s the right thing to do

  • Protection of our most valuable resource: employees!

But, we can do more to protect our employees/customers.

purpose of our presentations
Purpose of our Presentations

.

We will show through examples how applying ergonomic principles can:

- improve productivity

reduceloss of property

reduce loss of work time

from preventable accidents

presentation outline
Presentation Outline
  • What you may not know about ergonomics.
  • Why be concerned about MMH injuries?
  • Examples of Good Work Practices
  • Example of Ergonomic Solutions
  • Costs and Loss Prevention Goals
  • Matching Solutions to Problems
safety and ergonomics
Safety and Ergonomics
  • Safety Activities: Phases (IAS)
    • Investigate –collect information
    • Analyze- assess and plan
    • Solve- develop solutions:
      • Training: Takes time, re-training needed
      • Administrative: Management decisions
      • Engineering: i.e., Ergonomic solutions
what you may not know about ergonomics
What you may not know about ergonomics.

.

Ergonomics is an engineering science to improve work efficiency

Ergonomics is about prevention through design.

what you may not know about ergonomics1
What you may not know about ergonomics

Ergonomics is about adapting work to fit your workforce: big or small*

Ergonomics is about how workers do their job and use tools (Logistics)

ergonomics some facts
Ergonomics : Some Facts
  • Put aside the notion that workplace ergonomics is only about injuries
  • Ergonomics makes good business sense:
  • Healthy people work better
  • Sick people perform poorly
because lifting injuries are important
Because Lifting Injuries are important

Some Facts to Consider: (Retail/Wholesale)

  • Affects 8-10% of workers yearly
  • Accounts for 21-36% of workplace injuries
  • Responsible for 33% -60% of workplace injuries costs
in short lifting related injuries
In short: Lifting Related Injuries

They represent the biggest single contributor to worker injury in the United States

...and the application of good ergonomic design and goodwork practices can substantially reduce those incidences.

problem all to common
Problem: All to Common

We can do better

what are our solutions
What are our Solutions?

Manual Materials Handling Jobs

Various Solutions:

Engineering Changes

“Hard Ergonomics”

Good Work Practices

“Soft Ergonomics”

training and administrative
Training and Administrative

Employees capabilities and Job Demands

Good Work Practices: Get Help

training and administrative1
Training and Administrative

Good Work Practice: Push instead of Pull

Cannot see ahead: Not Good.

training and administrative2
Training and Administrative

Good Work Practices:

Moving step stool into Van to stand on.

ergonomic study example height adjusted pallet jack
Ergonomic Study ExampleHeight Adjusted Pallet Jack

AFTER

BEFORE

Used a Height Adjustable Pallet Jack to elevate low boxes on pallet (bottom 1/3) to waist level when stocking on store floor, thereby reducing back bending & compressive forces on spine when cutting boxes open and lifting from pallets.

ergonomic study example self leveling cart deli bakery
Ergonomic Study ExampleSelf-Leveling Cart Deli/Bakery

Tested a spring-loaded customized self-leveling cart to reduce the bending and stooping required to load/unload flat-bed carts and the forces on the back /spine

ergonomic study example results
Ergonomic Study Example: Results

Spring Self leveling cart : Deli/Bakery

  • Strong positive usability feedback and highly recommended (2 associates)
  • Back, Shoulder, & Knee discomfort ↓dropped ≥ 30% (2 associates)
  • Productivity ↑increased 1.9% (delivery time) = 5.3 min. savings/day

BEFORE

AFTER

ergonomic results example deli bakery
Ergonomic Results Example: Deli Bakery

BEFORE

AFTER

  • Also Positive usability feedback and recommended (1 associate)
  • Reported Low Back discomfort ↓ 29% (1 associate)
  • Productivity ↑ 9.2% (transport time) = 6.2 min. savings/day(1 associate)

Tested Battery powered adjustable cart to reduce carrying & Lifting

findings from ergonomic studies
Findings from Ergonomic Studies
  • Adjustable carts allowed products to be placed at waist level
    • Reduced -bending down to floor level
    • More workers were able to do this job
    • Did not affect productivity
  • Workers liked the cart
    • Reported less back fatigue
    • Easy to use - felt to be more productive
    • Liked cart maneuverability
injuries from manual lifting tasks
Injuries from Manual Lifting Tasks
  • Sprains/strains–muscles, ligaments, tendons
  • Chronic pain affecting joints
  • Disc injuries of the back or neck
  • Compression of peripheral nerves
  • Soft tissues disorders bruises
  • Compression of blood circulation
what you don t want
What you don’t want.

Musculoskeletal Disorders

  • Median number of lost work days
    • 5 days for all workers with any injury
    • 25 days for workers with MSDs
  • Average cost per injury
    • $1,100 for all other cases
    • $10,800 for an MSD
  • MSDs tend to have
    • Longer durations
    • Longer treatment time
    • Greater work disability
sales to cover costs

Accident Costs

1% Profit

2% Profit

3% Profit

$ 1,000

$ 100,000

$ 50,000

$ 33,000

$ 5,000

500,000

250,000

167,000

500,000

$ 10,000

1,000,000

333,000

$ 25,000

2,500,000

1,250,000

833,000

$100,000

10,000,000

5,000,000

3,333,000

It is necessary to sell an additional $250,000 in products or services to pay the cost of $5,000 annual losses

SALES TO COVER COSTS*

$250,000

$ 5,000

*

mmh example 1 deli bakery
MMH Example 1. Deli/Bakery
  • Task 1. Breakdown pallets
  • Task 2. Transfer to work area
  • Task 3. Restock coolers/freezers

Intervention Tested

mmh example 1 intervention s pring loaded custom cart
MMH Example 1: Intervention Spring Loaded Custom Cart

After

Before

Trial a spring-loaded customized self-leveling cart to reduce the bending and stooping required to load/unload flat-bed.

mmh example 1 intervention results summary self leveling cart
MMH Example 1: Intervention Results Summary: Self-leveling Cart
  • Ergo risk reduced from HIGH to Moderate (Back) for heaviest weights
  • Ergo risk reduced from Moderate to Low(Back) for average weights
  • Strong positive usability feedback and highly recommended)

BEFORE

AFTER

Lift to/from bottom 1/3 cart

slide35

MMH Example 1: Ergonomic Results

HIGH Risk

BEFORE

54 lb wt. lifted

Compressive Force ↓ 58%

(1000 lb ↓)

LOW Risk (borderline)

AFTER

54 lb wt. lifted

mmh example 2 deli bakery meat prep
MMH Example 2: Deli/Bakery/Meat Prep
  • Task 1. Carrying multiple boxes
    • From Coolers/freezer in Deli/Bakery
    • To Meat Preparation

Intervention Tested

mmh example 2 intervention adjust high lift cart
MMH Example 2: Intervention: Adjust High-Lift Cart

BEFORE

AFTER

Testing a battery powered height adjustable high-lift cart to eliminate the manual carry and transport multiple boxes.

mmh example 2 results summary high lift cart lift
MMH Example 2 Results Summary: High Lift Cart Lift

BEFORE

AFTER

From cooler to prep table

BEFORE

AFTER

mmh example 2 intervention results high lift cart
MMH Example 2 Intervention Results High Lift Cart

BEFORE

AFTER

Lift-transfer into

prep sink

BEFORE

AFTER

mmh example 3 grocery stockers
MMH Example 3. Grocery Stockers
  • Task 1. Stocking Goods on Grocery Floor
        • Canned Goods/Sauces

Height Adjustable Pallet Jack

Intervention Tested

mmh example 3 interventions tested
MMH Example 3 Interventions Tested

AFTER

BEFORE

Test a Height Adjustable Pallet Jack to elevate low boxes on pallet

mmh example 3 interventions tested1
MMH Example 3: Interventions Tested

BEFORE

AFTER

Trial of a Height Adjustable Pallet Jack to elevate low boxes on pallet

mmh example 3 results summary
MMH Example 3 Results Summary:

BEFORE

AFTER

Height Adjustable Pallet Jack

mmh example 4 grocery stockers
MMH Example 4. Grocery Stockers
  • Task 1. Stocking Goods on Grocery Floor
        • Canned Goods/Sauces

Intervention Tested

mmh example 4 intervention stock roll cart
MMH Example 4 Intervention Stock & Roll Cart

AFTER

BEFORE

Trial / investigate feasibility of height adjustable “Stock and Roll” cart to support & transfer multiple cases to aisle locations.

mmh example 4 interventions tested
MMH Example 4 Interventions Tested

AFTER

BEFORE

Test/ investigate feasibility of height adjustable “Stock and Roll” cart to support & transfer multiple cases to aisle locations.

mmh example 4 results summary
MMH Example 4: Results Summary:

AFTER

BEFORE

AFTER

  • Ergo risk reduced from HIGHto Low(Whole Body) for carrying cases to shelf
  • Ergo risk reduced from HIGHto Moderate (Shoulder, Arm/Elbow, Hand/Wrist) for static holds of cases and stocking shelves(canned goods)

Carry & stock cases of goods on aisle shelves

examples additional interventions tested
Examples: Additional Interventions Tested

BEFORE

AFTER

Trial a Push-Button Height Adjustable Cart (battery powered) to minimize back bending

examples additional interventions tested1
Examples: Additional Interventions Tested

AFTER

BEFORE

List Price: $2,395

Trial a Push-Button Height Adjustable Cart (battery powered) to minimize back bending

examples additional interventions examined
Examples: Additional Interventions Examined

BEFORE

AFTER

Trial a Height Adjustable Pallet Jack to elevate low boxes on pallet to waist level when unloading

examples additional interventions examined1
Examples: Additional Interventions Examined

AFTER

BEFORE

Trial a Self-Leveling Cart (spring-loaded) to minimize back bending required to palletize

take away message repeated
Take Away Message Repeated
  • Ergonomic is good business!
  • Correlates with business success
  • Adds value- provides competitive edge
    • Quality, efficiency, profitability
    • Controls costs (direct and indirect)

It’s the right thing to do

  • Protection of our most valuable resource: employees!

But, we can do more to protect our employees/customers.

a new research initiative
A New Research Initiative

CDC Campaign to Assist Businesses Maintain A Healthy Workforce in the Retail/Wholesale Trades

Focus on Manual Materials Handling:

“We can and need to do better!”

niosh uc sponsored purpose
NIOSH/UC Sponsored Purpose:

Manual Materials Handling Workshop

“Matching Solutions to Problems”

October 11-12, 2011

Hyatt Regency, Cincinnati, Ohio

Participants:

Practitioners/researchers

Industry/safety/loss prevention representatives

Manufacturers/vendors of MMH equipment

Contact: Vern Putz Anderson, NIOSH

vep1@cdc.gov, 513-533-8319

Purpose:

Develop engineering solutions for high risk

manual materials handling (MMH) jobs in Retail, Wholesale, and Warehousing (RWW) Industries