Ergonomic Design Review (EDR) –Implementing a Comprehensive Process

2006 Applied Ergonomics Conference

Eli Lilly and Company

• A leading innovation-driven pharmaceutical corporation

• Founded in 1876

• Corporate headquarters in Indianapolis, Indiana

• Approximately 43,000 employees around the world

Eli Lilly and Company

Lilly global presence

R&D facilities in 9 countriesManufacturing sites in 14 countriesProducts sold in 143 countries

Eli Lilly and Company

The Lilly Ergonomics Process

We have come a long way….

…but have many opportunities to improve

The Challenge

• Numerous large capital facility projects annually

• Very dynamic industry – needs are constantly changing

• Budget and timelines are key focus

• Design partners and in-house engineers possess modest ergo knowledge

The Challenge

How do we

integrate ergonomics into our new and

renovated facilities???

painlesslypainlessly

Lilly Lilly Ergonomic Ergonomic

Design Review Design Review ProcessProcess

Design Design Review Review

Procedure and Procedure and Checklist Checklist

ToolTool

TrainingTraining

Internal Internal Ergonomic Ergonomic

Engineering Engineering StandardStandard

Lilly Lilly Gate Review Gate Review

ProcessProcess

Lilly HS Gate Review Process

Key to the EDR for large cap projects

Gate 1 Trigger for EDR

Basic / Conceptual Design Review ChecklistBasic / Conceptual Design Review Checklist• 17 general questions about possible ergo issues• Answers reviewed by project team to decide if EDR is

needed.

EDR at EDR at approx. 30% approx. 30%

of basic of basic engineeringengineering

Conducting the EDR

1.1. Assemble your team:Assemble your team:• Design firm representative• User representative(s)• Lead project engineer• Local HS representative• Ergonomics professional (optional)• Administrative assistant

Conducting the EDR

2. Preparation and scheduling:2. Preparation and scheduling:• Divide project into logical portions

– Don’t try to do too much in one review!

• Schedule approx. 4 hours per review• Provide drawings to team at least one week in advance• Use 3D computer modeling if available• Ensure access to other experts during the review

The EDR Checklist (Prompt list)

Use to guide and Use to guide and prompt the teamprompt the team• 12 Sections• 50 Sub-sections• Over 200 prompts

Select and complete Select and complete only those that applyonly those that apply

The EDR Checklist (Prompt list)

Review each questionReview each question

Is the design OK?Is the design OK?

Does the item need to be Does the item need to be specified in the design?specified in the design?

Recommendations?Recommendations?

EDR Checklist - content

• Waste Handling• Lighting and Inspection

• Ventilated Workstations• Scales and Scanners

• Flow Racks & Shelving• Laboratory Design

• Case Forming, Labeling, and Packaging

• HMIs, Office Design, and Seated Workstations

• Maintenance and Cleaning• Manual Material Handling, Carts & Industrial Trucks

• Standing Work Heights and Reaches

• Clearances and Layout

The EDR Checklist (Prompt list)

Summarize and prioritize all Summarize and prioritize all recommendationsrecommendations

Assign responsible individuals Assign responsible individuals and set specific target datesand set specific target dates

Document the outcome of each Document the outcome of each recommendation.recommendation.

Training

Lilly developed a 1-day EDR training course geared toward project and process engineers

Content includes:1. Introduction to basic design principles

– heights, reaches, seated and standing workstations, NIOSH lifting equation, etc.

2. The EDR process and introduction to the checklist3. Practice in small groups doing actual EDRs

Not designed to make them experts, but gives them the ability to understand and participate in the process.

Ergonomic Engineering Standard

Standard created to establish a baseline ergonomic baseline ergonomic design expectationdesign expectation

Closely mirrors the content covered by the EDR checklist

Helps ensure consistency from project to project

Clearly articulates Lilly’s ergo criteria to our external design partners.

Primarily geared toward large facility projects, but can be used for small local site projects

Summary – helpful hints

• Have a system to trigger an EDR (e.g. gate review)

• Assemble an effective team

• Use a database or checklist to ensure the proper questions are asked during the EDR

• Document and track progress on recommendations

• Train engineers and others on how to do an EDR

• Create an ergo engineering standard to serve as the backbone of the entire process