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AMERICAN RAILWAY ENGINEERING & MAINTENANCE OF WAY ASSOCIATIONAMERICAN RAILWAY ENGINEERING & MAINTENANCE OF WAY ASSOCIATION

Safety Initiatives to Reduce Sprains & Strains Injuries

Maintenance Team #40

Jay GilliamDirector Safety

Union Pacific Railroad


FRA Reportable InjuriesFRA Reportable InjuriesAAR Group A Engineering AAR Group A Engineering DeptsDepts

(AMTK, BNSF, CSX, NS, UP)(AMTK, BNSF, CSX, NS, UP)

769 733

523 482

1000100911071057

0

200

400

600

800

1000

1200

1400

1998 1999 2000 2001 2002 2003 2004 2005PROJ

Source: FRA Website


FRA Reportable Injury RatesFRA Reportable Injury RatesAAR Group A Engineering AAR Group A Engineering DeptsDepts

(AMTK, BNSF, CSX, NS, UP)(AMTK, BNSF, CSX, NS, UP)

1.861.62

1.39

2.40

2.71

2.35

2.50

1.98

0.00

0.50

1.00

1.50

2.00

2.50

3.00

1998 1999 2000 2001 2002 2003 2004 2005YTD

Source: FRA Website


Railroads vs Other IndustriesRailroads vs Other IndustriesFRA & OSHA Reportable RatesFRA & OSHA Reportable Rates

0

2

4

6

8

10

1997 1998 1999 2000 2001 2002 2003

ConstructionTransportation and Public UtilitiesAll IndustryAAR Group A Engr Depts

Source: Department of Labor Bureau of Labor Statistics


Percentage of Sprains & StrainsPercentage of Sprains & StrainsEngineering DepartmentEngineering Department

47% 49%42% 42% 43%

34%

41%37%

45%42%43%40%

0.00

0.10

0.20

0.30

0.40

0.50

0.60

BNSF CP CSX NS UPRR ALL

2003 2004


Primary Causes of Sprains & StrainsPrimary Causes of Sprains & Strains

Slips, Trips & FallsLifting (Overexertion)Body Positioning/Work ProceduresUse of Tools (Hand & Power)Contact with Object or Equipment


BNSF % CPR % CSX % NS % UP % All RR %

Back 22 15.00% 44 27.50% 37 26.00% 12 32.00% 62 17.22% 177 23.54%Finger/Hand 27 18.00% 28 17.50% 6 4.00% 8 21.00% 49 13.61% 118 14.82%Ankle/Foot 20 14.00% 15 9.37% 15 10.00% 4 11.00% 25 6.94% 79 10.26%

Shoulder/Neck 20 14.00% 4 2.50% 12 8.00% 4 11.00% 27 7.50% 67 8.60%Wrist/Arm/Elbow 13 9.00% 22 13.75% 5 3.00% 1 3.00% 36 10.00% 77 7.75%


Slip/Trip/Fall 21 14.00% 27 16.88% 38 27.00% 11 29.00% 78 21.67% 175 21.71%Struck by Material 3 2.00% 32 20.00% 8 5.00% 9 24.00% 51 14.17% 103 13.03%

Hand Tools 37 25.00% 13 8.12% 22 15.00% 2 5.00% 36 10.00% 110 12.62%Handling Material/Equip 51 35.00% 15 10.00% 9 24.00% 40 11.11% 115 16.02%Vehicles/Equip Collision 22 15.00% 6 3.75% 12 8.00% 2 5.00% 33 9.17% 75 8.18%


Sprain/Strain 59 40.00% 68 42.50% 60 42.00% 17 45.00% 134 37.22% 338 41.34%Bruise/Contusion 13 9.00% 17 10.62% 15 10.00% 3 8.00% 93 25.83% 141 12.69%Cut/Laceration 32 22.00% 38 23.75% 36 25.00% 8 21.00% 58 16.11% 172 21.57%

Fracture 28 19.00% 8 5.00% 18 12.00% 8 21.00% 20 5.56% 82 12.51%

Highest Percentage of Injuries by Category (2004)

Injuries by Body Part

By Activity

Nature of Injuries

% of Inc % of Rep % of Rep % of Inc



% of Rep

% of Rep

% of Rep

Mixed

Mixed

Mixed


Current Safety Initiatives to Current Safety Initiatives to Reduce Sprains & StrainsReduce Sprains & Strains

Eliminate or Automate Tasks Tool ImprovementsEquipment Improvements Process & Training Improvements


Eliminate or Automate TasksEliminate or Automate TasksHerzog Plus Ballast TrainsMagnets on Boom Equipment to Handle OTM and Remove ScrapOff/On-Track Equipment to Unload OTMBulk Loading Spikes and Anchors


Tool ImprovementsTool ImprovementsHand ToolsHydraulic ToolsMechanical Production Machines


Tool ImprovementsTool Improvements (cont.)(cont.)


Equipment ImprovementsEquipment Improvements

Hy-Rail Transportation VehiclesMechanized Production Track MachinesSpecialized Machinery Mechanical Lifting Devices (Cranes & Lifts)


Equipment Improvements Equipment Improvements (cont.)(cont.)


Process ImprovementsProcess ImprovementsWeekly Safety Audits Ergonomic Awareness:

– Static Muscles and Movements– Safety Guidelines on Tasks

Ergonomic Assessment and Task Program – Currently using CBT Models – Developing Web-Based Model

Stretch/Flex/Prevent - Fatigue Prevention and Neutral Body Positioning


Process Improvements Process Improvements (cont.)(cont.)Walking Program & 3 Point ContactDesign Review Process with Supply & Engineering prior to purchase ensuring Equipment, Vehicles, & Tools utilize an Ergonomic Model.Storage Boxes on Vehicles - Waist High to Eliminate Stooping and BendingTraining Improvements - CBT for Operator Familiarization of OEM Instructions


Process ImprovementsProcess Improvements (cont.)(cont.)Rail Relay Track Materials Laid Out and Scrap Removed in Same Window as Gang is Working (Rail, Plates & OTM)Job Briefings - Total Safety Focus Tool of Month Demonstrations Eliminate Stumbling Hazards on Trucks


Opportunities for ImprovementsOpportunities for ImprovementsHandling Tie Plates in Production GangsInstalling & Removing Rail Anchors or Clips by Hand (Mattweld Tool - NS)Lightweight Portable DerailsUse of Robotics for Highly Repetitive Tasks1-Man Rail Puller


SummarySummaryRailroads Continue to Reduce Personal Injuries while Sprains & Strains Continue to be about 40% of All Injuries

Railroads Spend Millions Annually on Equipment and Tools to Reduce Injuries

Railroads Must Continue to Partner with Equipment Manufacturers to Design Out Potential Hazards

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