Even during a slow economy, manufacturers must still take all necessary precautions to ensure that their workers stay protected from injuries and disorders resulting from the repetitive use of improper manufacturing processes. Fortunately, by initiating preventative practices and selecting ergonomically designed tools, employers can help lessen their exposure to citation and liability. A complicated and costly issue Ergonomics is the science of fitting job functions to the physical capabilities of the human body. Without proper ergonomics on the production floor, employees can be subject to musculoskeletal disorders when a mismatch arises between the physical capacity of workers and the physical demands of their occupation. Jobs that involve reaching, bending over, using continuous force, working with vibrating equipment and doing repetitive motions pose a particular risk for developing injuries and disorders. To protect workers from injuries caused by over-extension, repetitive motions, and unnatural postural positions, OSHA has traditionally relied on existing powers to issue monetary fines to employers. The General Duty clause, Section 5, paragraph (a) (1), of the OSHA Act of 1970 states that an employer is responsible to provide a safe and healthy workplace for their employees. Absent a specific standard, such as in the case of ergonomics, OSHA can still cite an employer using that section. Not only is the federal government empowered to cite manufacturers, but also Section 18 of the Act encourages individual states to develop and operate their own job safety and health programs. Aside from the threat of fines from federal and state agencies, manufacturers also must bear the brunt of increasing worker's compensation costs and man-hour production losses. Manufacturers have much to gain by assuming a proactive position. Reducing worker fatigue can improve both morale and production line consistency while reducing absenteeism, and lowering worker's compensation costs. Viable strategies to improve ergonomics The old adage, "An ounce of prevention is worth a pound of cure" has never rung truer than for the case of preventing ergonomic injuries in the first place. Since preventing ergonomic injuries relies primarily in fitting job tasks to a worker's physical ability, all prevention programs must begin with the interface between the worker and the production tools and equipment. Yet, high-output production runs common to today's manufacturing environment present a challenge, since most hand tools, for instance, are designed for only occasional use. Repetitive injuries become much more likely under such conditions. Typically what happens, is everything starts fine at the beginning of a shift," notes Brad Mountz, President & CEO of Mountz Inc., and a San Jose, California-based torque tool supplier for over 40 years. "In the case of an electric or pneumatic tool that an operator must use for eight hours a day, the worker might have it in his or her hand for three to four hours before fatigue sets in. Then, as the shift goes on, the worker starts to exhibit bad habits: not sitting up straight, not having the tool at the right plane or not maintaining a firm grip. This is when injuries occur and production mistakes take place." However, the optimal design of workstations and tools, along with the use of mechanical assists, can go a long way toward reducing the incidence of injury while improving production processes. For example, Mountz offers a line of "EZ-Glider" torque reaction arms specifically designed to reduce repetitive motion injuries by absorbing the weight and torque reaction of hand tools such as electric and pneumatic screwdrivers. By duplicating biomechanical ranges-of-motion normal to the human body, such ergonomic assists reduce joint stress. Mountz' linear arms, for instance, can sustain a maximum torque of over 73 lbf.ft. Fielding the recoil forces that the human wrist normally absorbs, an anti-rotating clamp prevents torque-arm rotation. An available extended arm shaft expands the working range of the linear arm, thus reducing rotator cuff and similar shoulder injuries. Articulated torque arms, with the ability to bend and rotate like an elbow, provide a 360-degree range, allowing quick rundown of multiple fasteners. These flexible arms accept a variety of tools including pistol grips, angle nutrunners, and inline electric screwdrivers up to 73 lbf.ft of torque. (more) To reduce stress on the human body even further, Mountz has servo-assisted torque arms that automatically lower the driver. Operators push a trigger and pneumatic action glides the driver downward, improving accuracy and consistency with secure perpendicular movements. "Our goal in developing any new tool is to evaluate its ergonomic aspects by seeking input from employers and employees alike," continues Mountz. "For example, workers have told us that an egg-shaped handle, with two different tactile materials, leads to a more comfortable grip. We also started making handles with a larger diameter than in the past; from 1" to 1-3/4." We found that if the surface area has a larger grip, the operator is less likely to squeeze as hard. This can reduce the likelihood of wrist injuries." The availability of ergonomically optimized devices puts all manufacturers on notice that they have the means to meet the "general duty" standard imposed by the U.S. Department of Labor. Conceivably, if someone used a tool repeatedly and developed carpal tunnel syndrome as a result, and if there was a way to change that tool to improve the way that employee was having to work with that tool, yet OSHA re-inspected and the change was not made to correct the problem, then OSHA could cite the employer. An ergonomic mindset helps ensure safer conditions Besides the proper selection of ergonomically correct tools and workstations, manufactures should adopt enterprise wide programs that increase the awareness of ergonomics within administrative offices as well as on the production floor. A successful ergonomic system incorporates employee participation that includes discussion across all levels and directions of an organization. It's recommended to avoid the one-size-fits-all approach. Every ergonomic concern requires its own evaluation, ideally performed by a person competent in such issues. When indicated, control measures should be designed to eliminate ergonomic stresses specific to the results of the evaluation. Finally, effective follow-up mechanisms must be provided. - Form a permanent safety committee - Perform a job safety analysis for every job - Perform routine inspections, even if no hazards have been reported - Immediately correct any deficiencies; and conduct an accident investigation for each incident, even "near misses." Ergonomics is more than just treating a stress injury as an isolated occurrence," advises Brad Mountz. "If you have an operator who complains of a sore wrist, numb fingers or tired shoulders, then resolving just that individual's problem is a very short-sighted solution. Eventually, every operator doing that same or similar job is going to experience the same symptoms. You might as well solve the problem across the board." The productivity bonus An organizational mindset that embraces the prevention of ergonomic injuries does more than decrease exposure to government fines and worker's compensation cost increases; it can benefit the productivity of a manufacturer. "It's important to keep the big picture in mind," emphasizes Mountz. "Look at your operators as proponents of your business. Anything you can do to make them comfortable will improve the productivity of your business in the long run." Prevention of ergonomic injuries now an economic necessity Manufacturers wishing to survive in the coming years must fully embrace preventative measures to ergonomic injuries. The issue is not going away. Fortunately, efforts to reduce injuries are often rewarded with increases in the bottom line. Under such light, manufacturers can view ergonomic standards as a boon, not bane. Eliminating ergonomic hazards increases productivity, quality, profits, and the country's ability to compete on a global level. About Mountz, Inc. San Jose, California based Mountz Inc. produces a wide variety of torque tools, including torque analyzers, torque testers, torque sensors, torque wrenches, electric screwdrivers, torque screwdrivers, torque multipliers, assembly tools, screw counters, balancers and special torque applications. Over the last 40 years, Mountz Inc. has proven its in-depth knowledge of torque solutions by consistently developing and producing as well as marketing and servicing highly sophisticated, cutting-edge tools. Mountz Inc., known among members of the industry as the nation’s premier torque tool supplier, is an ISO 9001 registered and ISO 17025 accredited company. Mountz Inc. offers tools that comply with ISO6789:2003 and are constructed from high quality materials, engineered for superior reliability and safety and backed by a standard warranty. For more information website at www.etorque.com # # # # #
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