ergonomic risk reduction process errp leadership training – july 2007 long beach p&dc

Ergonomic Risk Reduction Process

ERRP Leadership Training – July 2007

Long Beach P&DC



The End



Core Team MissionCore Team Mission

We are fully committed, through the co-operation of APWU, NPMHU, OSHA, and We are fully committed, through the co-operation of APWU, NPMHU, OSHA, and USPS, to an on-going employee driven ergonomic risk reduction process that will USPS, to an on-going employee driven ergonomic risk reduction process that will reduce ergonomic risks at the Long Beach P&DC. Our goal is to identify risks that can reduce ergonomic risks at the Long Beach P&DC. Our goal is to identify risks that can cause wear and tear on the human body known as Musculoskeletal Disorders (MSDs). cause wear and tear on the human body known as Musculoskeletal Disorders (MSDs). We will make every effort to eliminate or reduce those risks thus improving the quality We will make every effort to eliminate or reduce those risks thus improving the quality of life for our fellow employees, at home and in the workplace. of life for our fellow employees, at home and in the workplace.

We will achieve our mission through:We will achieve our mission through:

- Changes to the workplace based on task analysis, individual needs, and - Changes to the workplace based on task analysis, individual needs, and suggestions from employeessuggestions from employees- Proactively implementing changes to improve safety, comfort, and function- Proactively implementing changes to improve safety, comfort, and function in all work areasin all work areas- Educating employees on effective ways to reduce ergonomic risks- Educating employees on effective ways to reduce ergonomic risks- Emphasizing communication, training, employee feedback and participation- Emphasizing communication, training, employee feedback and participation

Long Beach P&DC



“Working Together to Make a Difference”

On April 20, 2006 the Long Beach P&DC became the 108th postal facility to adopt the Ergonomic Risk Reduction Process (ERRP). Since then, the ERRP Site Core Team has been seeking ways to prevent, reduce or eliminate risks factors encountered by employees as they perform their daily tasks. The Teams have conducted training, acquired new equipment and modified work methods in the effort to reduce Musculoskeletal Disorders (MSDs).

With the support of the Plant Manager, Mail Processing, Maintenance, IPS and fellow employees the Core Team achieved the goals set forth by HQ ERRP.

In recognition of their accomplishments, the Core Team celebrated their 1 year anniversary on April 24th with a luncheon hosted by Plant Manager David Shapiro.



Long Beach P&DC

MSD RECORDABLE INCIDENTS YTD FY 2002-2007

FY02, 26

FY07, 3

FY06, 14

FY05, 17

FY04, 23

FY03, 16

FY02 FY03 FY04 FY05 FY06 FY07



Long Beach P&DCWORK HOURS 2007 WK HRS 2006 WK HRS 2005 WK HRS 2004 WK HRS 2003 WK HRS 2002 WK HRS

#1) From eFlash reports 1334604 1904633 1739212 1667313 1718626 1778049

FINANCE # 054483 LONG BEACH P&DC

2007 INCIDENTS

2006 INCIDENTS

2005 INCIDENTS 2004 INCIDENTS

2003 INCIDENTS

2002 INCIDENTS

INJURIES

R23 0 2 1 2 5 7

R2 1 6 9 8 7 14

ILLNESSES

R910 1 2 2 0 1 2

R9 0 3 5 10 1 2

MSD Reportables [009 080 081 090 091 100 101 110 111 120 121] 11 24 24 27 28 33

MSD Recordables [excludes 'N','NX','NY' & 'NZ'] 3 14 17 23 16 26

H/L [080 081] 0 3 9 13 10 9

LWD [R23 R910] 1 4 3 2 6 9

RWD [R2 R9] 1 9 14 18 8 16



Long Beach P&DC

RECORDABLE:

MSD Rate 0.45 1.47 1.95 2.76 1.86 2.92

Handling & Lifting Rate 0.00 0.32 1.03 1.56 1.16 1.01

Lost Work Day Rate 0.15 0.42 0.34 0.24 0.70 1.01

Restricted Work Day Rate 0.15 0.95 1.61 2.16 0.93 1.80

2007 2006 2005 2004 2003 2002

#2) TOTAL Reportable I&Is 27 53 52 59 71 62

#3) TOTAL Recordable I&Is 14 29 32 38 28 34



It doesn’t always take rocket science to fix a problem!

Some of our simple household and recreational items make great solutions…………….

Long Beach P&DC



Stuck again! Why bend and reach?

When you can simply push with a boat

hook!



Some tools are very versatile!

Boat hooks are one of them!



Help, I’ve fallen and I can’t get up!

Now this does the trick!



Rodney Fajardo, a mail processor approached the Tour 3 Core Team with his idea for a tool to facilitate opening priority pouch clasps. He had modified a small 3” box wrench.

A task analysis was conducted and the risk factors identified:Forceful motion of the fingers, hand and wristAwkward posture of the fingers, hand and wristRepetitive motion of the fingers, hand and wristFatigue of the fingers and hand

After “brainstorming”, we elected to try the same solution and researched where to purchase a sufficient quantity.

Upon communicating with other ERRP sites, we discovered Postal Products had a “sak wrench” available. Michele Paturzo, our Field Coordinator sent us samples for review.

The “sak wrench” did not meet all of our needs and we decided to develop our own design.

Spotlight - Sack Wrench



Samples > Concept > Prototypes



Communication > Contacts > Estimates

After selecting the design, Melvin Jones created a prototype. We contacted our Maintenance Dept. who was not able to produce them

for us in house. We researched where and how we could acquire the quantity we needed. Patty Roberts, Site Coordinator for Minneapolis/TWC recommended a

company they had used for previous projects; Quality Tool Mfg. We determined where the sack wrenches were needed and how many we

needed to order. We contacted Quality Tool and sent them our prototype, a belt and clasp,

and a .mpg file demonstrating the purpose of the sack wrench.

EstimatesPostal Products Quality Tool Mfg.

$3.50 approx. each $3.57 each$5.67 approx. each w/plasticoat $3.67 approx. each w/plasticoat

(dipped by Team)



Prototypes > Selection



Final product

Quality Tool Mfg.

Sack wrench - $3.57Eezer grip - $ .40

Cost $3.97 each

75 wrenches - $267.75125 grips - $55.00 including S/H

Total cost - $322.75



Before and After



More success stories

The following photos represent successful projects from each Tour



Before and After

ergonomic risk reduction process errp leadership training – july 2007 long beach p&dc

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