Ergonomics Processes: Implementation Guide and Tools for the Mining Industry PDF
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IC 9509 INFORMATION CIRCULAR/2009 Ergonomics Processes Implementation Guide and Tools for the Mining Industry Department of Health and Human Services Centers for Disease Control and Prevention National Institute for Occupational Safety and Health Information Circular 9509 Ergonomics Processes: Implementation Guide and Tools for the Mining Industry By Janet Torma-Krajewski, Ph.D., Lisa J. Steiner, and Robin Burgess-Limerick, Ph.D. DEPARTMENT OF HEALTH AND HUMAN SERVICES Centers for Disease Control and Prevention National Institute for Occupational Safety and Health Pittsburgh Research Laboratory Pittsburgh, PA February 2009 This document is in the public domain and may be freely copied or reprinted. Disclaimer Mention of any company or product does not constitute endorsement by the National Institute for Occupational Safety and Health (NIOSH). In addition, citations to Web sites external to NIOSH do not constitute NIOSH endorsement of the sponsoring organizations or their programs or products. Furthermore, NIOSH is not responsible for the content of these Web sites. All Web addresses referenced in this document were accessible as of the publication date. Ordering Information To receive documents or other information about occupational safety and health topics, contact NIOSH at Telephone: 1–800–CDC–INFO (1–800–232–4636) TTY: 1–888–232–6348 e-mail: [email protected] or visit the NIOSH Web site at www.cdc.gov/niosh. For a monthly update on news at NIOSH, subscribe to NIOSH eNews by visiting www.cdc.gov/niosh/eNews. DHHS (NIOSH) Publication No. 2009–107 February 2009 SAFER • HEALTHIER • PEOPLE™ Contents Acknowledgments Abstract I. Introduction: Ergonomics and Risk Management Basic Elements of Ergonomics Risk Management Processes Participatory Ergonomics Evolution of Risk Management Processes II. Ergonomics Processes: Case Studies Bridger Coal Co. Badger Mining Corp. Vulcan Materials Co. Lessons Learned Summary III. Process Effectiveness Bridger Coal Co. Badger Mining Corp. Vulcan Materials Co. IV. Implementation Tools Tool A: Risk Factor Report Card Tool B: Musculoskeletal Discomfort Form Tool C: General Risk Factor Exposure Checklist Tool D: Ergonomics Observations Tool E: Handtool Checklist Tool F: Manual Tasks Risk Assessment Tool G: Ergonomics Task Improvement Form Tool H: Risk Factor Cards Tool I: Ergonomics Sticker for Mining Industry V. Training Introduction Ergonomics and Mining: Ensuring a Safer Workplace – Training for Management Ergonomics and Risk Factor Awareness Training for Miners Ergonomics Observations: Training for Behavior-based Safety Observers References Appendix – Ergonomics Processes: Beyond Traditional Safety and Health Programs Acronyms and Abbreviations Used in This Report ACGIH American Conference of Governmental Industrial Hygienists BBS behavior-based safety CARE Corrective Action Request for Evaluation GAO General Accounting Office MSD musculoskeletal disorder MSHA Mine Safety and Health Administration NDL no days lost NFDL nonfatal days lost NIOSH National Institute for Occupational Safety and Health OSHA Occupational Safety and Health Administration PPE personal protective equipment S&H safety and health SHE safety, health, and environmental Acknowledgments The authors thank the many organizations who helped to demonstrate that ergonomics can be integrated with existing safety and health programs to improve working conditions for their employees. Specifically, we thank Paul Gust, Kean Johnson, and Pat James of Bridger Coal Co.; Marty Lehman, Mellisa Stafford, Linda Artz, and Don Seamon of Badger Mining Corp.; and Dick Seago, Mike Junkerman, Andy Perkins, Truman Chidsey, Chris Hipes, Bryan Moore, Jeff Black, Tim Watson, and Philip Phibbs of Vulcan Materials Co. The authors thank the many current and former researchers and technicians with the National Institute for Occupational Safety and Health (NIOSH) who assisted with the implementation of the three ergonomics processes: Bridger Coal Co. Process - Kim C. Gavel, Launa Mallett, Fred Turin, Rich Unger, Charlie Vaught, and William Wiehagen; Badger Mining Corp. Process - Pauline Lewis and Sean Gallagher; and Vulcan Materials Co. Process - Kelly Baron and Susan Moore. Additionally, several NIOSH researchers participated in the development of the process implementation tools and training described in this document. We extend our appreciation to Jeff Welsh and Jonisha Pollard for assisting with the development of the Risk Factor Cards; Susan Moore for assisting with the development of the Hand Tool Checklist; Bill Porter for graphic modifications to the Risk Factor Checklist and Ergonomics Observations Form; E. William Rossi for graphic support in developing posters and stickers; and Al Cook, Tim Matty, and Mary Ellen Nelson for their assistance in the design, fabrication, and testing of interventions. ERGONOMICS PROCESSES: IMPLEMENTATION GUIDE AND TOOLS FOR THE MINING INDUSTRY By Janet Torma-Krajewski, Ph.D.,1 Lisa J. Steiner,2 and Robin Burgess-Limerick, Ph.D.3 Abstract Research has shown that an ergonomics process that identifies risk factors, devises solutions to reduce musculoskeletal disorders (MSDs), and evaluates the effectiveness of the solutions can lower worker exposure to risk factors and MSDs and improve productivity. A review of the Mine Safety and Health Administration (MSHA) injury/illness database indicated that 46% of illnesses in 2004 were associated with repetitive trauma and 35% of nonfatal lost days involved material handling during 2001– 2004. Even though these statistics show that MSDs significantly contribute to occupational illnesses and injuries in the U.S. mining industry, few mining companies have implemented an ergonomics process. Despite the many unique challenges in the mining environment, three mining companies partnered with the MSD Prevention Team at the National Institute for Occupational Safety and Health’s Pittsburgh Research Laboratory to demonstrate that an ergonomics process could be systematically implemented and effectively integrated with existing safety and health programs. Because these three mining companies were very different in organization, culture, and size, the ergonomics processes had to be modified to meet the needs of each company. A description of how these three companies applied ergonomics and the tools and training used to implement their processes is given. Prior to discussing the case studies, general information on the elements of an ergonomics process is provided. 1Lead Research Scientist, Pittsburgh Research Laboratory, National Institute for Occupational Safety and Health, Pittsburgh, PA. 2Team Leader, Musculoskeletal Disorder Prevention Team, Pittsburgh Research Laboratory, National Institute for Occupational Safety and Health, Pittsburgh, PA. 3Associate Professor in Occupational Biomechanics, School of Human Movement Studies, The Univer- sity of Queensland, Brisbane, Australia. YELLOW INSERT SHEET Section I Introduction: Ergonomics and Risk Management Ergonomics is the scientific discipline concerned with the understanding of interactions among people and other elements of a system to optimize their well-being and overall system performance [IEA 2008]. This is generally accomplished by applying ergonomic principles to the design and evaluation of manual tasks,1 jobs, products, environments, and systems, ensuring that they meet the needs, capabilities, and limitations of people. When integrated with safety and health programs, ergonomics can be viewed as a third leg of a three-pronged risk management approach to reduce musculoskeletal disorder (MSD) rates. Safety focuses on hazards that may result in traumatic injuries, industrial hygiene concentrates on hazards that may cause occupational disease, and ergonomics addresses risk factors that may result in MSDs and other conditions, such as vibration-related illnesses. By applying ergonomic principles to the workplace with a systematic process, risk factor exposures are reduced or eliminated. Employees can then work within their abilities and are more efficient at performing and completing tasks. The benefits of applying ergonomic principles are not only reduced MSD rates, but also improved productivity and quality of life for workers. The purpose of this document is to provide information on implementing a successful ergonomics process that is part of the organizational culture. Section I describes the basic elements of the process and then discusses the importance of employee participation in the implementation of the process. Also included in this section is information on the evolution of risk management as it applies to an ergonomics process. A model developed for safety and health risk management defines five stages, ranging from a pathological stage to a generative stage— from a stage that attributes safety problems to employees to one that involves all employees in risk management at multiple levels with the goal of promoting the well-being of employees. Section II describes how three mining companies implemented ergonomics processes, including lessons learned. Interventions implemented by the mining companies are presented in Section III, along with information on changes to discomfort levels at one of the companies. Section IV describes various tools used when implementing the processes, while Section V focuses on 1Manual tasks are tasks that involve lifting, pushing, pulling, carrying, moving, manipulating, holding, pounding, or restraining a person, animal, or item. 1 training, including a presentation for management that promotes the value of ergonomics processes. The tools presented in Section IV and the management presentation contained in Section V are provided as electronic files on the CD included with this document. Basic Elements of Ergonomics Risk Management Processes Successful ergonomics risk management processes have several elements in common. The process starts with establishing an understanding of the task and interactions that occur between the worker and equipment, tools, work station used to complete the task, and work area/environment in which the task is conducted. Managing risks associated with manual tasks requires identifying risk factor exposures. If the exposures cannot be eliminated, the degree and source of risk requires assessment. Potential controls or interventions are then identified, evaluated, and implemented to reduce the risk as far as reasonably practical. The ultimate aim of an ergonomics risk management process is to ensure that all tasks performed in workplaces can be performed with dynamic and varied movements of all body regions with low to moderate levels of force, comfortable and varied postures, no exposure to whole-body or hand-arm vibration, and breaks taken at appropriate intervals to allow adequate recovery. Element 1: Identifying Risk Factor Exposures During Manual Tasks Identification of risk factor exposures should include consultation with employees, observation of manual tasks, and/or review of workplace records. Employees should be asked what they think is the most physical part of their job or what task is the hardest to do. Conditions that could potentially indicate risk factor exposures include the following: 2
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