Pushmi-Pullyu Mentality Increases Workplace Injury

Remember the Pushmi-pullyu (push-me-pull-you) from Hugh Lofting’s Dr. Dolittle stories for children? It was an antelope with two heads, one on each end of its body. (In the popular Eddie Murphy movies, they used a llama.) Whenever the creature wanted to move, both heads would take off at once, pushing and pulling back and forth and going nowhere. Since pushing and pulling exert two of the greatest stresses on the body, the poor critter must have been in constant need of the good doctor’s chiropractic skills! That same Pushmi-pullyu mentality toward workplace task and equipment design can put your employees at serious risk of sustaining disabling musculoskeletal injuries.

Pushing, pulling, lifting and carrying tasks place a greater strain on the human body’s soft tissues — muscles and tendons — than any other tasks. These tasks are also universal to nearly all work environments. Wheeled carts, platforms or equipment must be loaded and unloaded and pushed and pulled through manufacturing plants, distribution centers, hospital corridors, grocery store aisles, hotel hallways, office buildings and retail establishments. Most jobs require at least occasional pushing, pulling, lifting or carrying; and many jobs require workers to spend their entire workday engaged in these activities, performing the same, repetitive movements hour after hour. The cumulative wear and tear on the body can lead to serious injury of soft tissues and eventual disability.

Too often tasks, work spaces and equipment aren’t designed to accommodate the natural differences in the size and physical capabilities of workers. A task performed first shift by a six-foot, 180-pound, 25-year-old male may be performed second shift by a five-foot three-inch, 130-pound, 45-year-old female and third shift by a five-foot seven-inch, 260-pound, 60-year-old male. Because work tasks and equipment are usually designed around a “standard” worker type — which, unfortunately, few workers match — most workers are forced to assume awkward postures while exerting force to complete work tasks. Serious, debilitating strains and sprains can result, particularly when these actions are repeated over time.

When soft tissues in the arms, shoulders, back and legs are injured, the tissues recover, though it may take some time. But repeated injury, particularly when it occurs before tissues have had time to fully recover, interferes with the body’s natural healing process, overwhelming the body’s ability to recover and leading to permanent, disabling injury. Such cumulative traumas are called musculoskeletal disorders. Also referred to as repetitive stress injuries and repetitive motion injuries, these serious, disabling strains and sprains cost U.S. businesses tens of billions of dollars each year.

Next time: Ergonomics; just what the doctor ordered.

Tips for Creating a Successful Ergonomics Program

Last time we talked about the financial and production benefits of implementing an ergonomics program (see our Nov. 24 post). A recent study on the bottom-line value of ergonomics showed a $4 savings for every dollar invested. Most businesses that purchase ergonomic equipment recoup their investment costs within the first year. The financial benefits alone make ergonomic equipment a shrewd investment in your future. But forward-thinking businesses that investment in ergonomics understand that they are also making a powerful proactive investment in the health, safety and retention of their workforce.

Creation of a successful ergonomics program requires three important elements, Mike Kind wrote recently in the New Hampshire Business Review:

Support of top management. To be successful, an ergonomics initiative must become part of your corporate culture and be thoroughly embraced and supported by top management. The introduction of an ergonomics program can be an excellent step toward creating a wellness-based focus in your organization, notes Kind.

Other wellness-centered activities include offering wellness training classes, scheduling health screenings and flu shots, providing healthier snacks and beverages in vending machines, sponsoring Weight-Watchers groups, offering gym membership discounts. Employers only stand to gain from sponsoring activities that promote a healthy workforce.

Established goals and measurable results. Any new initiative requires a bit of tweaking once it’s off the launch pad. Particularly in the early weeks of a launch, it’s important to conduct regular workplace assessments of a new ergonomics program to ensure that maximum efficiency and productivity are achieved. Close monitoring of employee complaints, injury reports, medical costs, workers’ compensation claims, absenteeism, lost man-hours and production results will provide the hard data needed to assess the success of your program and make any necessary changes.

Kind adds a word of caution: Don’t be surprised if you find an initial increase in incident reports. As employees learn about ergonomic issues, they are more likely to recognize the symptomatic causes of musculoskeletal complaints and report them. As your ergonomics program progresses and becomes an effective component of corporate culture, incidence reports will decrease significantly.

Next time we’ll discuss the importance of effective education, training and leadership in implementing a comprehensive ergonomics program in your workplace.

Ergonomics: Just What the Doctor Ordered

Pushing, pulling, lifting and carrying tasks place a greater strain on the human body’s soft tissues — muscles and tendons — than any other workplace tasks. Universal to nearly every work environment, these tasks are the source of musculoskeletal injuries that annually cost U.S. businesses tens of billions of dollars. Fortunately, most of these injuries are preventable. The debilitating and disabling strains and sprains that annually plague millions of U.S. workers can be largely prevented with the adoption of ergonomic practices and the use of ergonomically-designed equipment.

Workers come in all shapes and sizes, but work tasks and equipment are usually “one size fits all.” Most workplace musculoskeletal injuries occur when workers are forced to adapt their bodies to fit the task or equipment, torquing their bodies into awkward postures that increase stress on muscles and tendons. For example, when pushing, pulling or maneuvering a heavy wheeled cart, a worker must exert significant force to overcome rolling resistance. While handholds designed to assist in force delivery may be at the correct level for an average-sized male, even an averaged-sized female worker will have to stretch and strain to move the cart, placing undue stress on back, leg, shoulder and arm muscles. The risk of musculoskeletal injury is great when worker and equipment are not a perfect fit.

Ergonomics is the science of fitting the equipment or task to the capabilities of the worker to prevent musculoskeletal injury. Ergonomically-designed equipment, like the powered carts and movers designed and manufactured by DJ Products, takes into account a host of variables that affect worker production and efficiency. The type of task, force required, worker gender and diversity, optimal handhold height, distance, and frequency of the task must all be considered in the design of ergonomic equipment.

DJ Products is a major innovator in the design and manufacture of ergonomic solutions to material handling situations. Our ergonomically-designed electric and motorized carts, tugs and movers eliminate the strains and pains associated with manually pushing and pulling heavy carts, equipment or materials in a wide variety of industrial and retail environments. Our products are less costly, smaller and more maneuverable than traditional electric equipment used to move carts and equipment on production floors and in warehouses. Our battery-powered walk-behind movers provide maximum operator control and safety while offering superior maneuverability, even in narrow or tight spaces like busy hospital corridors and crowded grocery aisles. As a leading manufacturer of ergonomic powered carts and movers, DJ Products has built a reputation for developing ergonomic solutions to unique and specialized customer material handling challenges. Contact our ergonomic sales engineers today for an evaluation of your ergonomic needs.

Successful Ergonomics Program Requires Strong Leadership

With President-elect Obama and a Democratic Congress poised to enact tough ergonomic standards within the next year, we’ve been discussing the financial, production and personnel benefits of implementing an ergonomic program (see our Nov. 24 & 26 posts). Being proactive in creating a wellness-focused corporate climate will enhance your ability to compete in the future. Implementation of a strong ergonomic plan and a move to ergonomically-designed equipment has been proven to increase production efficiency and decrease healthcare costs.

The success of a comprehensive ergonomics plan is dependant upon the support of top management, the creation of demonstrable goals and measurable results, and, most critically, the provision of effective employee education and training coupled with strong program leadership.

Effective education, training and leadership. Thorough education and onsite training of employees is critical to the success of a new ergonomics program. Education about the features and processes of a new ergonomics initiative must be backed up with onsite training.

As workers become familiar with new features and practice new processes, the provision of adequate onsite supervision is critical. Workers need time to learn new skills and procedures and change long-established habits. Continuous supervision not only reinforces raining, but reveals areas that require adjustment. Ask your employees for input. People who perform the tasks often spot potential problem areas in new procedures and provide keen insight into productive solutions.

In an article published in New Hampshire Business Review, Mike Kind also recommends selecting a “champion” to spearhead a new ergonomics initiative. Designating a person with clear oversight over the program facilitates implementation of the original initiative and subsequent revisions. It creates a clear chain of command easily accessible by both management and workers. It centralizes the dissemination of information and collection of review data, improving analysis quality and speed.

A recognized industry leader in the design and production of ergonomically-designed material handling equipment, DJ Products provides a useful Ergonomic Load Calculator on our website. Created to assist ergonomic and health and safety professionals in designing ergonomic programs, our free calculator estimates the amount of horizontal force necessary to move wheeled loads. By inputting vital data about your specific application, including floor condition, terrain, footing, load weight and transport distance, our Ergonomic Load Calculator calculates the specific needs of a given application.

DJ Products’ ergonomic specialists are also available to assist you in evaluating your ergonomic needs. We’re the experts in finding creative solutions to ergonomic issues in the workplace. Give us a call today and let us help you position your business for the future.

Weighing the Options

Functional equipment operated by quality employees is pretty much the lifeblood of the material handling industry.  Unfortunately, with the state of the economy over the course of the last couple years, many warehouses and distribution centers are operating with outdated and broken down equipment that is hampering their employee’s productivity and putting them at risk of injury. Some owners feel that equipment upgrades simply aren’t in the budget, but at the same time they constantly have to pay for costly repairs on the machines that they are using and losing time and money when equipment is down.  If all of the repairs and lost income from delays over the course of a year were tallied, odds are that the sum would far outweigh the cost of an equipment upgrade.

Upgrading outdated material handling equipment in favor of the safer, more reliable and more efficient powered carts from DJ Products will have many benefits, both immediate and long term, which will far outweigh the initial one time investment of the purchase.

The material handling equipment from DJ Products is ergonomically designed to be among the safest equipment that your employees can use, this helps to ensure that your employees avoid many of the injuries often associated with manual material handling.  You’ll also get unparalleled reliability, with carts that can operate strong for an entire shift on a single charge with no worries at all about failure.

Healthy employees and reliable equipment will dramatically increase your operational productivity, this will allow you do satisfy more customers and do so in a quicker fashion.  Equipment that can help to keep your employees healthy and allow you to fulfill customer orders more quickly will pay for itself in no time, regardless of the cost of the initial investment.

2010 Applied Ergonomics Conference Slated for March

Scheduled for March 22-25, the 2010 Applied Ergonomics Conference (AEC) to be held in San Antonio, Texas is slated to be North America’s biggest and most impressive gathering of ergonomics experts, applications and equipment providers. What sets AEC apart from other ergonomic conferences is its emphasis on the practical application of ergonomic principles and discoveries to real world industrial problems. This is not an esoteric meeting of high-brow academics, though you’ll find the more practical of their ilk in attendance. This is a working man’s conference. A meeting of industrialists, ergonomic experts and others involved in day-to-day efforts to improve the health and safety of American workers through the application of ergonomics to real world problems.

 The 2010 AEC conference will be held at the Marriott San Antonio Hill Country Resort and Spa with early registration discounts available through January 15, 2010. Ergoweb is offering a special 50% discount to its followers until this Friday, December 18 on registrations for the conference and host hotel. (Click here for registration form and more information from ErgowebM [Expired].)

Keynote speakers scheduled include Y. Ian Noy, vice president and director of Liberty Mutual Research Institute for Safety, and Guy Fragata, senior advisor for Ergonomics Patient Safety Center of Inquiry. Multiple educational tracks and numerous informational exhibits by leaders in the ergonomics industry will also be featured at the conference.

As a leader in the design and manufacture of ergonomically-designed material handling equipment, DJ Products is intimately involved in solving daily ergonomics problems in a wide variety of U.S. industries including manufacturing and heavy industry, hospitality, hospital and health care, automotive and commercial retail. We understand the critical need for ergonomic systems and ergonomic material handling equipment that protects the health and safety of American workers. To find our more about our full line of ergonomic motorized carts and tugs, visit the DJ Products website.

Ford Using ‘Avatar’ Technology to Improve Auto Ergonomics

Ford is using Hollywood’s latest special effects gimmick to help design its cars and make them more ergonomic and driver friendly. You may have heard of motion-capture technology where a person’s body is hooked up to a slew of sensors that record individual muscle movements. It’s the revolutionary technology behind Hollywood director James Cameron’s sleek blue beings in the holiday movie hit Avatar. Ford Motor Co. has started using the same motion-capture technology to tweak the ergonomic design of its cars.

Since the early 1900s time-motion studies of ergonomics pioneers Frank and Lillian Gilbreth to movie-maker Cameron’s impressive high-tech sensors, industrial designers have been studying how workers move their bodies to accomplish different work tasks in an effort to create more efficient designs. Greater productivity may have been the early goal, but concern for worker health and safety has become an equally motivating challenge, one that gave birth to the field of ergonomics.

“Just like in the movies, we hook people up with sensors to understand exactly how they move when they are interacting with their vehicles,” Gary Strumolo, Ford manager of research and engineering, told Motor Trend magazine in a recent online article (click here to read the Motor Trend article and see pictures of the process). “Once we have all that motion captured, we create virtual humans that we can use to run thousands of tests that help us understand how people of all sizes and shapes interact with all kinds of vehicle designs. It’s an incredibly efficient way of engineering tomorrow’s vehicles.”

We may not have lithe blue aliens darting around our manufacturing plant, but DJ Products has long been a leader in the design and manufacture of ergonomic material handling carts and tugs. Long before James Cameron and Ford started sticking wired sensor pads on test subjects, DJ Products was investigating and studying how the body moved and applying it to material handling design. Nice to see the rest of the world starting to catch up!

Get Things Moving with DJ Products’ Vehicle and Heavy Equipment Pushers

DJ Products makes ergonomic equipment to help transport a variety of heavy loads—even if that load is something that is also used in transport.
If your cart, car, or piece of equipment has all straight wheels or is on a rail, then the there are ergonomic products that can help solve material handling applications where no turning is required, or an operator will turn the wheels while a CarCaddy pushes from behind, as in the case of pushing a bus down an assembly line.

Car and Vehicle Pusher: While our car pushers have industrial applications, they can also be used to move a stalled vehicle. The front push pad of the vehicle pusher can help preserve the paint and the look of stalled vehicle.

Trailer Mover, Puller or Pusher: Our powered trailer movers are not as bulky as traditional puller products. They can push or pull RVs, campers, boats or equipment trailers. This is a perfect solution when a trailer is being moved down an assembly line, in a show room or at a trade show.

Paper Roll Pusher, Spool Pusher: This can help you move large rolls of paper, fabric or rubber. It is designed to move heavy objects that roll.

Equipment Pusher, Equipment Puller: These can eliminate the stress and strain associated with moving heavy equipment. One of our cart movers can push or pull cars up to 50,000 lbs., while a powered trailer dolly can lift tongue up to 15,000 lbs.

You can take the time to find a specific electric cart pusher on our website, or call our Sales Engineers for a recommendation on your proper solution.

Hospitals: Help Your Staff Treat Summer Injuries

Summertime and the livin’ is easy…people like to spend time outside, getting into summer sports and being more active. We all hope for the best but we know that an increase in activity increases the chances of injury. For this reason, hospitals need to stay on alert and be ready for patients who arrive and need help after a baseball game, water skiing, a race, or an impromptu tumble down a hill.

During the summer, you need all of your staff ready to work and assist. You will want your employees ready to work and not injured themselves from attempting to hurry while transporting supplies needed for patients that arrive with injuries. DJ Products makes powered carts including a Powered Dirty Linen Cart, Powered Housekeeping Cart and a Motorized Clean Linen Wire Cart that can keep work moving efficiently and allow employees to navigate tight corners safely.

Our products can also reduce the chance that your employees will experience muscle strain or musculoskeletal injuries as they push or pull carts with heavy loads through hospital corridors. All of our products are battery powered “walk-behind units” that allow for better operator control than traditional wheeled carts. Because of this operating flexibility, our electric cart movers can be used in more applications than standard material handling equipment.

Check out our products online and if you have questions, you can call our Sales Engineers at 800-686-2651 and ask for a recommendation on your proper solution. One of our Sales Engineers will be more than happy to explore custom applications where our base products match primary criteria.

Making the Responsibility Revolution Work for You

Hand in hand with the “go green” movement, the “responsibility revolution” is changing the way Americans shop. Everyone from the companies that supply your parts and materials to the end product consumer is watching how corporations use resources and interact — with the local community and the world at large. Ethical consumerism is on the rise and savvy business owners are paying attention.

An outgrowth of our raised consciousness about the interrelationship of environmental systems, people are paying more attention to how companies are interacting socially with their environment. It’s not enough these days to decrease your carbon footprint and lower your energy consumption, people expect a certain level of social responsibility from the companies they buy from and invest in. The marketplace is replete with examples of companies that have suffered for their lack of social consciousness. Nike attacked for unfair overseas labor practices. Wal-Mart boycotted for unfair labor practices at home. Rabid consumer groups have been quick to call attention to practices they find unethical, tarnishing corporate reputations, forcing management changes and even putting companies out of business.

Smart corporations are working to demonstrate to consumers that they care about the planet and the people they share it with. Implementing a strong ergonomic program and switching to ergonomic equipment that protects the health and safety of your workers is one immediate step companies can take to show their concern for others. Many Americans are looking for improvement and changes in their own back yards. Using local suppliers, contracting with local transport firms, supporting local events and charities, improving the lives of the people you hire — both on the job and off — these actions speak louder than words. They show people that you are a responsible corporate partner in their community and an asset in their daily lives.