The aim of ergonomics in manufacturing is to design workstations that encourage healthy work postures and maintain worker comfort and safety. Here are steps employers can take to minimize ergonomic hazards in their facilities.
Bending, twisting, turning and lifting heavy objects—these are common body movements for manufacturing workers, and they can result in painful injuries for a worker and, sometimes, costly periods of time away from work for recovery.
An injury related to this kind of work is called a musculoskeletal disorder (or MSD), sometimes also referred to as an “ergonomic injury.” It occurs when your body “uses muscles, tendons and ligaments to perform tasks, usually in awkward positions or in frequent activities which, over time, can create pain and injury,” according to the U.S. Bureau of Labor Statistics (BLS).
MSDs account for nearly 70 million physician office visits in the United States each year and around 130 million healthcare encounters, including outpatient, hospital and emergency room visits, according to research from the National Research Council and the Institute of Medicine.
Examples of the kinds of injuries caused include carpal or tarsal tunnel syndrome and other connective tissue disorders that result from overexertion or bodily reaction, according to the BLS. Overexertion and repetitive motion are the primary causes of these injuries.
Disabling workplace injuries cost U.S. businesses more than $59 billion annually, as they lead to time away from work, extended periods of recovery and workers’ compensation claims.
An effective ergonomics program reduces the risk of injury to your workers while maintaining or improving their health, leading to happier, healthier workers and fewer workdays lost to injuries and compensation claims. The idea is to design the job to fit the worker, not physically forcing the worker’s body to fit the job.
Solutions may include improving workstation design to minimize potential injuries, using flooring to minimize fatigue, or investing in help from robots and other technological innovations. Here are three solutions and best practices that can help improve ergonomics in your facility.
Other solutions may include organizer bins that minimize clutter around workstations and floor mats that reduce worker fatigue after long periods of standing, which both help to improve safety by reducing the possibility of injuries.
The most effective ergonomics programs consider the risks faced by each worker at his or her workstation. In the past, this has been achieved by hiring ergonomics experts to assess workplaces and train employees. But many companies do not have the budget required for this kind of training. Thankfully, simple, low-cost solutions are often available to solve problems.
As the Occupational Safety and Health Administration notes, many industries have successfully implemented ergonomic solutions in their facilities to minimize MSD injury risks.
These interventions have included “modifying existing equipment, making changes in work practices and purchasing new tools or other devices to assist in the production process,” OSHA says. “Making these changes has reduced physical demands, eliminated unnecessary movements, lowered injury rates and their associated workers’ compensation costs, and reduced employee turnover. In many cases, work efficiency and productivity have increased as well.”
Read more: Manufacturing Efficiency: 5 Ways to Maximize Shop Floor Space
