summary report: participative ergonomics for manual tasks ... · summary report: participative...
TRANSCRIPT
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
Workplace Health and Safety Queensland, Department of Justice and Attorney-General
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry PN10990 Version 1. Last updated April 2011.
Acknowledgments The project discussed in this report was implemented on behalf of Workplace Health and Safety Queensland (WHSQ) by Tracy Consulting Services Pty Ltd, a Brisbane-based ergonomics consulting firm. WHSQ would like to thank Tracy Consulting as well as the organisations that participated in the project, specifically:
One Steel Australian Tubemills
Neumann Steel
Everhard Industries
Monadelphous Engineering
Moffat
Bradken
Hastings Deering
TJM Products
Russell Minerals
Century Yuasa Batteries.
© The State of Queensland (Department of Justice and Attorney-General) 2011
Copyright protects this document. The State of Queensland has no objection to this material being reproduced, but asserts its right to be recognised as author of the original material and the right to have the material unaltered.
The material presented in this publication is distributed by the Queensland Government as an information source only. The State of Queensland makes no statements, representations, or warranties about the accuracy or completeness of the information contained in this publication, and the reader should not rely on it. The Queensland Government disclaims all responsibility and all liability (including, without limitation, liability in negligence) for all expenses, losses, damages and costs you might incur as a result of the information being inaccurate or incomplete in any way, and for any reason.
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
Table of contents
Acknowledgments................................................................................................................................2 Executive Summary .............................................................................................................................4 Introduction..........................................................................................................................................6 Manufacturing sector workers compensation data ..............................................................................6 PErforM program.................................................................................................................................6 Participative ergonomics......................................................................................................................7 Project participants...............................................................................................................................7 Outcomes .............................................................................................................................................8 Future action ........................................................................................................................................9 Appendix 1: Risk assessments and controls ......................................................................................10
Monadelphous................................................................................................................................10 Everhard Industries ........................................................................................................................11 Bradken ..........................................................................................................................................14 Russell Mineral Equipment............................................................................................................15 Century Yuasa Batteries.................................................................................................................16 Hastings Deering............................................................................................................................17 Moffat.............................................................................................................................................18 Neumann Steel ...............................................................................................................................19 One Steel ........................................................................................................................................19
Appendix 2: Examples of controls implemented...............................................................................20
Monadelphous................................................................................................................................20 Everhard .........................................................................................................................................22 TJM Products .................................................................................................................................23 Bradken ..........................................................................................................................................24 Russell Mineral Equipment............................................................................................................25
3
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
4
Executive Summary This report provides a summary of a pilot project conducted over 12 months in 2010 by Workplace Health and Safety Queensland (WHSQ) in the manufacturing industry. The project involved assisting a sample of manufacturing organisations to implement the Participative Ergonomics for Manual Tasks (PErforM) program for manual tasks risk management. The PErforM program is a simplified manual task risk management program that involves facilitating workplace-based teams to devise manual tasks solutions for high risk manual tasks.
The project was funded by a grant from the WHSQ Small Business program and led and implemented on behalf of WHSQ by Tracy Consulting Services Pty Ltd, a Brisbane based ergonomics consulting firm.
Tracy Consulting Services assisted 10 manufacturing organisations (five metals manufacturing and five machinery manufacturing organisations) to implement the PErforM program. The participating organisations ranged from medium to large in size and were located in both urban and regional areas.
The objective of this project was to build capacity within the manufacturing industry to manage manual tasks risks. Specifically, this project aimed to:
pilot and evaluate the implementation of the PErforM program
identify barriers and enablers in this industry sector
develop case studies to share with industry.
The metal and machinery manufacturing sub sectors were selected for the project due to their high number of workers compensation claims for musculoskeletal disorders. The manufacturing industry had not been exposed to the PErforM program prior to this project.
The PErforM project was successfully implemented in the manufacturing sector. This project was a substantial undertaking that resulted in significant manual task risk reduction measures being implemented in nine out of the ten participating organisations. All organisations intend to integrate the PErforM program into their system for manual task risk management.
The project also resulted in an enhancement to the PErforM training materials. The evaluation stage provided key learnings for the WHSQ implementation of the PErforM program.
The project demonstrated that the PErforM risk assessment tool can be applied across a wide range of manual tasks within the metal and machinery manufacturing sub-sectors. There was no significant variation with respect to the size of the manufacturing organisations, the location of the organisation, or the particular sub-sector. The critical enablers for the successful implementation of the PErforM program were identified as:
selecting and mentoring a committed site champion
management commitment and support for the program including the implementation of controls
actively engaging the workforce in the process
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
5
embedding the PErforM program within existing health and safety systems.
WHSQ plans to undertake the following activities that will build on the learnings from the project:
Investigate methods for providing ongoing support and coaching assistance to organisations implementing the PErforM program, eg use of external consultants, electronic media (webinars/pod casts/video conferencing/email updates), forums and networks.
Publish and promote the case studies.
Develop additional resources to support the implementation of the program in a variety of industries, including developing cost-benefit material that can be included in training.
Publish the PErforM resource package on the WHSQ web site.
Provide PErforM ‘train the trainer’ training to industry as well as OHS/ergonomics professionals, industry associations and unions.
Evaluate the sustainability of the PErforM program in the participating organisations at six and twelve months post project completion.
Promote and support the implementation of the PErforM program in other industries.
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
6
Introduction This report provides a summary of a pilot project conducted over 12 months in 2010 by Workplace Health and Safety Queensland (WHSQ) in the manufacturing industry. The project involved assisting a sample of manufacturing organisations to implement the Participative Ergonomics for Manual Tasks (PErforM) program for manual tasks risk management. The PErforM program is a simplified manual task risk management program that involves facilitating workplace-based teams to devise manual task solutions for high risk manual tasks. The metal and machinery manufacturing sub-sectors were selected for the project due to their high number of workers’ compensation claims for musculoskeletal disorders. The manufacturing industry had not been exposed to the PErforM program prior to the commencement of the project.
The intent of this project was to explore the use of a participative approach to manual task risk management within the manufacturing industry. This was facilitated by coaching and mentoring provided by ergonomics consultants. The objective was to build capacity within the manufacturing industry to manage manual tasks risks. Specifically, this project aimed to:
pilot and evaluate the implementation of the PErforM program
identify barriers and enablers in this industry sector, and
develop case studies to share with industry.
The project was implemented on behalf of WHSQ by Tracy Consulting Services Pty Ltd, a Brisbane based ergonomics consulting firm. It was conducted over 12 months during 2010.
Manufacturing sector workers compensation data The manufacturing industry has the highest non-fatal claims rate of all industries, with 55% of these claims being for musculoskeletal disorders (MSD).1 In 2006-07, the sheet metal product manufacturing and machinery equipment sub-sectors were identified as having one of the highest MSD claims experience within the manufacturing industry.
PErforM program The PErforM program is a simplified manual task risk management program based on the premise of the worker being the expert. It involves training workers to identify and assess manual task risks in their work tasks as well as generate control ideas to reduce the risks.
The PErforM program was developed by WHSQ in conjunction with the University of Queensland and Curtin University of Technology. The program is based on participative ergonomics, an internationally recognised approach for managing manual task risks.
Scientific research has demonstrated that PErforM has a positive effect on decreasing manual tasks risks. A significant reduction in manual task injury risks, as assessed by WHSQ Inspectors, was
1 Based on claims that last more than seven days (Queensland Employee Injury Database, Office of Economic and Statistical Research).
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
7
reported for workplaces receiving the PErforM intervention.2 PErforM has been used in industries including mining, civil construction, aged care, food processing and timber.
Participative ergonomics The participative approach to manual tasks risk management relies on maximising the involvement of workers as task experts. Workers are taught how to identify and assess high risk manual tasks and develop appropriate control measures.
Participative ergonomics uses the expertise of:
workers – who bring their knowledge of the job or task
management – who provide support for the process and the implementation of controls
facilitators/‘champions’ – who support and drive the process within the organisation.
The advantages of using a participative approach include:
development of effective controls that target the key risk factors associated with manual tasks, and are designed for the work requirements and the workers
workers have a greater sense of ownership, a say in their workplace, and a commitment to use the controls once they are implemented.
Project participants The 10 selected metal and machinery manufacturing organisations were:
Metal manufacturing sector:
One Steel Australian Tubemills
Neumann Steel
Everhard Industries
Monadelphous Engineering
Moffat.
Machinery manufacturing sector:
Bradken
Hastings Deering
2 Straker, L., Burgess-Limerick, R., Pollock, C, Egeskov, R., (2004), “A randomized and controlled trial of a participative ergonomics intervention to reduce injuries associated with manual tasks: physical risk and legislative compliance”, Ergonomics, Vol 47, No. 2, pgs 166-188.
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
8
TJM Products
Russell Minerals
Century Yuasa Batteries.
Outcomes The project demonstrated that the PErforM program could be implemented in the manufacturing industry as nine out of the ten participating organisations successfully implemented the program. All organisations reported that they planned to continue using the program.
The organisations reported that prior to participating in the pilot program they did not systematically assess their manual tasks risks. They said the PErforM program has given them a framework for managing these risks. Several case studies will be published as a result of the project, highlighting how the organisations controlled their manual tasks risks as well as made productivity gains. A summary of the tasks assessed during the project are provided in Appendix 1 and examples of controls implemented are provided in Appendix 2.
The project identified a number of barriers and enablers that impacted on the organisation’s ability to implement the PErforM program. These were as follows:
Key enablers:
Management commitment: Management support for the program was critical.
Identifying a suitable site champion: Having a suitable site champion in place was critical to the success of the program.
Coaching from the ergonomics consultant: All organisations reported that coaching from the ergonomics consultant was invaluable and most said it was unlikely they would have experienced the success they did without the coaching support.
Risk assessment tool: Organisations said the risk assessment tool was simple, portable and easy for all members of the workforce to use. The program found that workers could be trained to use the PErforM tool regardless of position, background, education, ethnicity or language barriers. Most workers felt that the tool’s ‘bodymap’ personalised the process.
Broad workforce engagement: Workforce engagement promoted communication between workers and management.
Ease of integration into health and safety systems: PErforM was easily integrated into an organisation’s existing health and safety systems. All organisations intend to expand the program across their business beyond the life of the project.
Key barriers:
Lack of management commitment: Management support for implementing the PErforM program and its processes was generally easy to obtain. However, some organisations would have benefited from greater management support and ‘presence’ throughout the entire process.
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
9
Lack of succession planning for site champions: Turnover of site champions impacted on the program.
Limited skills and knowledge: Prior to commencing the project, some organisations had limited knowledge and lacked a systematic approach for manual tasks risk management. Some organisations required assistance with action planning and developing business cases in order to obtain management approval for controls.
Worker perceptions: Some workers needed to be encouraged to participate as the program involved a different approach than they were used to.
Manufacturing pressures: The realities of the manufacturing environment, such as tight timeframes, low profit margins and a focus on productivity, impacted on the time and resources allocated to the PErforM program.
Future action WHSQ plans to undertake the following activities that will build on the learnings from the project:
Investigate methods for providing ongoing support and coaching assistance to organisations implementing the PErforM program, eg use of external consultants, electronic media (webinars/pod casts/video conferencing/email updates), forums and networks.
Publish and promote the case studies.
Develop additional resources to support the implementation of the program in a variety of industries, including developing cost-benefit material that can be included in training.
Publish the PErforM resource package on the WHSQ web site.
Provide PErforM ‘train the trainer’ training to industry as well as OHS/ergonomics professionals, industry associations and unions.
Evaluate the sustainability of the PErforM program in the participating organisations at six and twelve months post project completion.
Promote and support the implementation of the PErforM program in other industries.
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
10
Appendix 1: Risk assessments and controls Outlined below is a summary of the tasks, controls and status of the completed risk assessments for each of the participating sites, as at December 2010. Organisations varied in their ability to complete the proposed six risk assessments.
Monadelphous Task Status Risk controls identified Implementation
Handling gas and oxy bottles
Training and assessment completed
Controls developed and implemented
Completion of reticulated gas supply to workshop
Modified two-wheel hand trolley to move bottles
Training
Gas supply automated – has reduced manual handling of gas and oxy bottles in the workshop by 85%
Two-wheel hand trolley built and implemented to handle all other bottles
Using oxy cutting torch when working on rotators
Training and assessment completed
Controls developed and implemented
Design and fabricate a holder for the welding gun or welding torch
Training
Adjustable stand built and implemented to hold oxy cutting torch
Storage and handling of coiled wire boxes
Training and assessment completed
Controls developed and implemented
Design and fabricate a stand or table to store the coiled wire boxes on to eliminate bending and awkward postures
Training
Storage table built and implemented within tool store
Storage and handling of tools and equipment from the tool store
Training and assessment completed
Controls developed and implemented
Reorganise store to include racking and shelving
Store items at appropriate heights to eliminate bending and awkward postures
Store reorganised including appropriate racking and design to minimise manual handling
Handling plate steel on the horizontal profile cutter
Training and assessment completed
Controls developed and implemented
Purchase a profile cutter
Consider smaller plate steel and better access around cutting platform
Outsource
Cost-benefit analysis undertaken on profile cutter – unable to be purchased at this time
Smaller plate steel being used
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
11
Handling plate steel through guillotine
Task that had previously been risk assessed was revisited using PErforM tool
Flat bed feeder table has been fitted with multi-directional roller ball bearings facilitating movement of plate steel
Magnetic handle grips used to move steel through guillotine
Significant manual handling risk reduction confirmed using these modifications and controls
Everhard Industries Task Status Risk controls identified Implementation
Using the hydrabend press
Training and assessment completed
Controls developed and implemented
Cabinet panels to be imported in a ready to assemble state, which will eliminate the need to press any flat steel into shape
Cabinet panels are now imported ready to assemble; use of the hydrabend press has been eliminated
Spot welding cabinets
Training and assessment completed
Controls developed and implemented
Cabinet panels to be pop riveted together rather than spot welded
A new jig with more manoeuvrability to be provided to hold the panels in place whilst being riveted together; the jig position will not be limited by the position of the spot welding machine so awkward postures will be eliminated
Cabinet panels are now pop riveted together
New jig to hold panels has been implemented
Powdercoating steel cabinets
Training and assessment completed
Controls developed and implemented
No manual task risks identified using the PErforM tool
Task has been eliminated due to importation of ready-to-assemble powder coated panels
Packing laundry tubs
Training and assessment completed
Controls developed and implemented
Install an adjustable height packing bench on this line
Increase rotation between tasks in this area
Improve work process flow by positioning plastic bags and empty cartons in a more accessible location
Regular maintenance of counter balance and swing arm to which the staple gun is attached
Packing table implementation pending
Increased staff rotation implemented
Work process flow improved by reorganising storage of cardboard and plastic
Improved maintenance of counter balance swing arm for staple gun
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
12
Loading trucks Training and assessment completed
Controls developed and implemented
Limited manual task risks identified using the PErforM tool
No elimination or design controls identified – aim is to palletise the cartons and then forklift them onto the trucks.
Administrative controls – continuing education and manual task risk awareness training.
Unloading shipping containers
Task that had previously been risk assessed was revisited using PErforM tool
Design a purpose-built platform to raise the level of the worker to facilitate unloading higher cartons
Stack pallets to a height to facilitate appropriate handling techniques from purpose built platform
Investigate a mobile conveyor to transport cartons from shipping container to outside, then stack on a pallet for mechanical removal
Increase staff rotation
Implementation pending
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
13
TJM Products
Task Status Risk controls identified Implementation
Unloading containers
Training and assessment completed
Controls developed and implemented
Palletise fit kits
Palletise bull bars
Fit kits have been palletised
Bull bars to be palletised in future
Loading and unloading bars from etch line
Training and assessment Completed
Controls developed and implemented
Build 250mm high ramp to elevate workers to etch line and eliminate above-shoulder reach
Prototype ramp trialled successfully
New ramp is being built in-house and will be installed
Loading up fit kit table from mount bin
Training and assessment completed
Controls developed; yet to be implemented
Build half cage frame to sit mount bin at correct height not at floor level
Controls yet to be implemented
Assembling plastics to sports bars
Training and assessment completed
Controls developed; yet to be implemented
Lower assembly table legs by 200mm
Buy retractable pulleys to hold air drills
Controls yet to be implemented.
Shrink-wrapping Training and assessment completed
Controls developed; awaiting approval from management before implementing
Purchase a shrink wrap tunnel
Quote obtained for purchase of shrink wrap tunnel – management decision pending
Lifting bars onto pallets
Training and assessment completed
Controls developed; awaiting approval from management before implementing
Purchase an automated conveyor ramp in conjunction with shrink wrapper
Quote obtained for purchase of automated conveyor ramp – management decision pending
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
14
Bradken Task Status Risk controls identified Implementation
Oxy cutting of scrap
Training and assessment completed
Controls developed and partially implemented
Automation
Move alloy bins
Hose support
Redesign work area
Redesign lance holder
Alloy bins have been moved, hose support implemented and lance holder redesigned. All working well
Plumbing for gas being re-routed to complete controls
Pouring of molten metal
Training and assessment completed
Controls developed and partially implemented
Change to bottom pour ladles
Install a permanent air/electrical driven motor
Remote operation of air/electrical driven motor
Supply retractable hose
Provide air driven motors at all stations
Training
Retractable hoses and air driven motors have been implemented and trialled at one station, with good results
Quotes to be obtained for purchase of all motors
Training has been completed with new work method statement
Fettling furnaces Training and assessment completed
Controls developed and partially implemented
Purchase a mini Brokk excavator
Supply retractable air hose
Investigate a cargo style net to collect bricks/slag and remove this with overhead crane
Investigate different styles of chisels
Investigate different styles of jackhammers
Training, investigate air-fed helmets and anti-vibration gloves
Retractable air hoses have been implemented
Mini Brokk has been trialled and funding applied for
Specific training completed
Bagging of alloys and throwing into furnace
Training and assessment completed
Controls developed and partially implemented
Alloys to be pre-packaged by supplier in 10kg bags
Build a frame to hold bag whilst filling with alloys
Design drawn up
Rebuilding of electrodes
Assessment pending
Assessment pending Assessment pending
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
15
Russell Mineral Equipment Task Status Risk controls identified Implementation
Removing scrap steel from profile cutter and placing in recycle bin
Training and assessment completed
Controls developed and implemented
Design and fabricate a new forklift assisted tipping bin
New tipping bin fabricated and implemented – has significantly reducted manual handling requirements and risks
Stacking mig wire rolls
Training and assessment completed
Controls developed and implemented
Reduce roll size
Design and fabricate mig welding wire storage racks
Roll size reduced
Mig welding wire racks fabricated and installed – all lifting and stacking is now performed at waist height and with smaller loads and forces
Shovelling slag from under profile bed into waste bin
Training and assessment completed
Controls developed and implemented
Install a more portable profile bed (lifted by overhead crane) to ensure easy access when cleaning up metal slag
More portable profile bed installed that is lifted out of the way using the overhead crane, facilitating easy cleaning of slag and the elimination of awkward postures
Sliding the plan scanning board on profiler
Training and assessment completed
Controls developed and implemented
Source lighter and stronger material for plan scanning board and use rollers to reduce friction and slide into position
Lighter and stronger material is now use for plan scanning board and rollers are used to facilitate the sliding of the board into position, allowing for easy setup of plans prior to commencing profile cutting
Removing tape from painted components/parts sitting on pallets on the ground
Training and assessment completed
Controls developed and implemented
Fabricate tables to suitable heights to perform task
Provide seating
Tables fabricated and installed
Seating provided
Has resulted in significant improvements to working posture
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
16
Moving LPG bottles
Training and assessment completed
Controls developed and implemented
Purchase new gas trolleys
Training of safe handling of gases
New adjustable gas trolleys have been purchased and workforce trained - has significantly reduced load handling as a result of using mechanical aids
Century Yuasa Batteries Task Status Risk controls identified Implementation
Labelling wet Batteries
Training and assessment completed
Controls developed and implemented
Controls not yet reassessed
Automated lifting equipment, adjustable pallet stand
Bridging conveyor, overhead height controller
Access to both sides of the pallet
Training
Job rotation
Automated
Capping batteries
Training and assessment completed
Better (thicker) fatigue matting
Improved footwear
Trial a step
Investigate design of vent plugs
Mechanise process
Vacuum system for loading vent plugs
Training
Optional job rotation
Controls identified have not progressed to completion
Loading battery filler
Training completed
Assessment underway
Four operators involved in the process of loading the batteries onto the acid filler conveyor – reviewed showed that all four operators complete the task differently
Further review will be undertaken for the operators to develop a standard practice in conjunction with the development of other controls to assist with the completion of the task
Pending
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
17
End of line plate take-off
Training and assessment to be completed
To be completed To be completed
Tekmax loading Training and assessment to be completed
To be completed To be completed
Cast on Training and assessment to be completed
To be completed To be completed
Hastings Deering Task Status Risk controls identified Implementation
Hitch/lynch pin modification to lathe
Training and assessment completed
Controls developed; implementation pending
Hitch/lynch pin modification designed and manufactured
Hitch/lynch pin manufactured and installed with good effect
Tightening a lathe chuck
Training and assessment completed
Controls developed and implemented
Fit soft jaws to manual lathes
Develop a stand work procedure for tightening a lathe chuck
Controls successfully implemented
Moving cylinder trolley around the workshop and wash bay
Training and assessment completed
Controls developed; awaiting implementation
Purchase a motorised tug to move cylinder trolley around the workshop to reduce the risk of injury to staff postures
Awaiting costing and implementation
Risk assessment of honer used on internal diameter of cylinder
Training and assessment completed
Controls developed and implemented
Purchase and install an inertia reel that will attach to the grinder to reduce force on upper body
Purchase an adjustable bench for use when angle grinding internal surface of cylinder
Purchase anti-vibration gloves when operating the grinder on the cylinders
Anti-vibration gloves purchased and implemented. Awaiting costing and approval for other controls
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
18
Moving a 208lt drum from the compound
Training and assessment completed
Controls developed; awaiting implementation
Manufacture and install a rail at back of the oil compound
Rail has been manufactured and installed with good effect
Welding head onto cylinder
Training and assessment completed
Controls developed; awaiting implementation
Manufacture a motorized system to be attached to the hydraulic bay welding stand
Manufacture an adjustable system for the roller work bench
Purchase anti-vibration gloves for use when operating needle gun
Anti vibration gloves have been purchased
Other controls are being costed prior to implementation
Moffat Task Status Risk controls identified Implementation
Handling prover frames
Training and assessment completed
Controls developed; implementation pending
Purchase overhead cranes
Use magnets to attach prover frames to the overhead crane
Proposal has been put to management regarding the purchase of two new overhead cranes and lifting magnets
Capital expenditure to be raised in January 2011
Lifting large moulder cassettes out of jigs
Training and assessment completed
Controls developed; implementation pending
Purchase overhead cranes
Use magnets to attach moulder cassettes to the overhead crane
Proposal has been put to management regarding the purchase of two new overhead cranes and lifting magnets
Capital expenditure to be raised in January 2011
Lifting small moulder cassettes out of jigs
Training and assessment completed
Controls developed; implementation pending
Purchase overhead cranes
Use magnets to attach moulder cassettes to the overhead crane
Proposal has been put to management regarding the purchase of two new overhead cranes and lifting magnets
Capital expenditure to be raised in January 2011
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
19
Neumann Steel Task Status Risk controls identified Implementation
Raising coiled wire into position for guillotine
Training and assessment completed
Controls developed; being costed for implementation
Pneumatic hoist to raise wire coils into position
Pneumatic mechanical solution being costed for implementation
64 manual tasks have been assessed using the PErforM tool across all sections of the plant
Training and assessment completed Controls developed and implemented for 28 of the tasks
Focus has been on design and engineering controls for 28 of the 64 tasks assessed
Further controls on remaining tasks to be systematically explored and implemented over time
Specific details not available at time of report
One Steel Task Status Risk controls identified Implementation
No tasks assessed using the PErforM tool due to withdrawal from the project
OneSteel will continue to use the PErforM tool internally outside the scope of the project
Training of site champion completed
Training of workgroup completed
No risk assessments completed
Tasks to be assessed by One Steel independently of project program
N/A
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
Appendix 2: Examples of controls implemented
Monadelphous Monadelphous achieved great success with the PErforM project and has been selected as one of the case studies. Monadelphous both undertook new risk assessments and completed other manual handling projects they already had in process.
Tasks selected included handling oxy bottles; using the oxy cutting tool when working on rotators; handling plate steel in the guillotine and horizontal profile cutter; and the storing and handling coiled wire and tools.
When handling gas and oxy bottles, the particular hazards identified using the PErforM tool were:
daily handling of oxy bottles by every boilermaker/welder
manual handling risks of high forces, poor coupling and awkward postures due to pallet height created risks of dropping bottles and possible crush injuries.
2 3 1 4 5
Figures 1-5: Figures 1 and 2 depict the new trolley designed to fit to the height of the pallet. Figures 3-5 show the reticulated gas system.
Controls identified by the workgroup were eliminating the handling of the bottles by reticulating the gas/oxy supply to the workshop; and implementing design changes to the existing two-wheel trolley.
20
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
These controls were supported by management and implemented at a cost of approximately $80 000 for the reticulation system and $100 for the modification of the two-wheel trolley. The outcome is that 75% of all the oxy/gas used on-site is now delivered in bulk and reticulated throughout the workshop. The remaining 25% of bottles are handled by the redesigned trolley. These controls have removed all of the hazardous manual handling components associated with performing this task. As well as improving safety, the site reported substantial productivity gains as there has been less downtime due to changing bottles.
Other controls implemented focused on the handling of plate steel for the guillotine. Fabricating and implementing a stand with multiple ball bearings allowed simple movement of the steel plate across its surface using magnetic hand grips.
6 7 8
Figures 6-8: Figure 6 shows the steel plate stand with multiple ball bearings allowing simple movement of plate steel. Figure 7 is a single ball bearing on the stand. Figure 8 is the magnetic hand grip used to move the plate steel across the stand
Monadelphous also fabricated a mig welder stand that is fully adjustable vertically and horizontally. It is used when welding on the rotators to clamp and hold the welder in position. This has eliminated much of the static working postures, forceful gripping and awkward postures associated with this task.
9 10 11 Figures 9-11: Mig welder stand
21
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
Figure 12: Reorganised tool store
Reorganising the tool store at the Monadelphous’s Gladstone workshop and installing a storage table for coiled wire boxes removed the awkward postures that occurred when manually handling these items.
12
Everhard Everhard selected the following manual tasks to be assessed as part of the PErforM project: using the Hydrabend press spot welding cabinets powder coating steel cabinets packing laundry tubs, loading trucks unloading shipping containers.
Figure 13: The Hydrabend press
The Hydrabend press is used to bend plate steel in order to form panels for laundry tub assembly. This task, along with the need to later powdercoat the panels, has been eliminated by directly importing ready-made powder coated panels for assembly. 13
Figure 14: Assembling laundry tub panels
The assembly of laundry tub panels (previously performed by welding at floor level) has been replaced with pop rivets. The panels are now assembled on raised stands using supported spring-loaded pop rivet guns.
14
22
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
Everhard are strong supporters of PErforM and have commenced rolling the tool out into the concrete moulding area of their business.
TJM Products TJM Products undertook six quality risk assessments with a motivated team of employees. The tasks selected included: unloading shipping containers loading and unloading bull bars from the etch line loading up fit kit table from the mount bin assembling plastics to sports bars shrink wrapping objects lifting bars onto pallets. Often TJM’s raw components arrive in tightly packed shipping containers from China. Unpacking the shipping containers involves manually intensive work with significant forces and awkward postures. To solve this problem, employees produced a mock-up palletised solution that can be moved in and out of the shipping containers by forklift, particularly when stacking bullbars. Management then travelled to China and successfully influenced the supply chain when packing the fit kits. The issue regarding the bull bars has not yet been resolved. Before
15 16 After
Figures 15 to 18: TJM Products’ process for unloading shipping containers before and after implementing PErforM.
17 18
23
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
Another task assessed was the shrink wrapping of all objects produced at TJM. This task is manually intensive and involves awkward postures and forceful gripping actions to control the heat gun; and has the additional safety risks of molten plastic burns and fire. After using the PErforM risk assessment tool, a business case has been made to management for purchasing a shrink wrap tunnel capable of handling all objects with mechanical loading and unloading.
19 20
Figures 19 and 20: Manual shrink wrapping
Employees were also involved in manually lifting 45 kg bullbars onto hooks on the etch line, prior to spraying and coating. A number of solutions were considered (many were cost prohibitive) so employees decided to trial a raised platform to improve working postures and forces as an interim measure. A raised ramp and platform is now being built and installed by TJM. 21 22 Figures 21 and 22: Lifting bullbars onto the etch line
Bradken Bradken assessed four of the six identified manual tasks during the project, including oxy cutting scrap steel; pouring of molten metal; cleaning of the fettling furnaces; and bagging of alloys and throwing into the furnace. The controls implemented included: retractable hose and lance supports re-plumbing gas supplies trials of retractable and air driven motors when pouring molten metals the trial of a mini excavator for the cleaning of the fettling furnaces.
24
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
The last task was selected as one of the case studies for further distribution across the manufacturing sector as an outcome of the project.
Before
23 After
24 25 Figures 23-25: Figure 23 shows typical work associated with clearing the fettling furnace. Figures 24 and 25 show the control using the remote controlled excavator.
Russell Mineral Equipment Russell Mineral Equipment (RME) completed six manual task risk assessments including removing scrap steel from profile cutters; stacking mig wire rolls; sliding the plan scanning board on the profiler; removing tape from painted components; and moving LPG bottles. A range of controls were implemented including: influencing suppliers to reduce wire roll sizes installing a modified profile cutting bed that can be lifted by overhead crane to facilitate
cleaning underneath using a lighter weight material and rollers to facilitate the movement of the scanning board on
the profile cutter installing adjustable work tables and seating for the operators when removing the painting tape purchasing gas adjustable trolleys for moving oxy bottles. Most notably, RME designed and fabricated a scrap steel removal system that was installed on each of their profile cutters. Located adjacent to the profile cutting bed, the scrap steel falls into the new skips, which are picked up by forklift, taken to the industrial waste bin and through a hinged tipping mechanism and slid into the scrap steel into the bin. Implementing these scrap steel skips has eliminated all manual handling from this task.
25
Summary report: Participative Ergonomics for Manual Tasks (PErforM) Program within the Manufacturing Industry
Before
26 27
After
28
Figures 26-28: Figure 26 shows work on the profile cutter; figure 27 shows a worker shovelling profile pieces into the scrap bin; figure 28 shows the new scrap steel bin.
26