Tag: safety

Ergonomics Can Significantly Decrease Worker Injuries

Material handlers and laborers suffer more injuries and illnesses than construction workers, truck drivers or, indeed, any other category of workers, according to the U.S. Department of Labor. Material handlers and laborers miss more work days and therefore cost U.S. businesses more money in lost man-hours and higher insurance and healthcare costs than any other worker class.

Numerous studies have proved that ergonomically-designed equipment and systems can significantly decrease worker injury. Many manual tasks necessary during the handling of materials require repetitive motions — pushing, pulling, bending, lifting and carrying — that place undue strain on the human body. These actions can result in sprains, strains, back pain and other musculoskeletal injuries. Back pain is by far the most commonly reported workplace injury in the material handling industry. Treatment is generally lengthy and expensive, gobbling up the lion’s share of healthcare and workers’ compensation costs.

The implementation of an ergonomics program can significantly reduce injuries and their associated costs while improving productivity and worker morale. The Material Handling Industry of America (MHIA) has published a 68-page booklet of tips for improving ergonomics in the material handling industry. Click this link to download MHIA’s free Ergonomic Guidelines for Manual Material Handling. For more information on ergonomically-designed electric and motorized carts, pushers and tuggers, visit the DJ Products website.

Next time we’ll share some of MHIA’s best tips for improving ergonomics in the material handling industry and reducing worker injury and its associated costs.

Electric Tuggers Improve Ergonomics in Material Handling

Improving the ergonomics of material handling decreases worker injuries, improves workplace efficiency and leads to a healthier bottom line. Medical costs, insurance premiums, workers’ compensation payments and lost man-hours soar when ergonomics are ignored. Material handling is one of the most injury-intensive industries, according to the U.S. Department of Labor. Every effort you make to fit the demands of work tasks to the capabilities of your workers (i.e., ergonomics) will decrease costs and ultimately improve profit margins.Material handling requires many actions that can result in serious and expensive musculoskeletal injuries. Repetitive motions, awkward postures and the application of force as workers lift, push, pull, carry and handle materials create daily opportunities for injury. Attention to ergonomics in designing tasks, workspaces and equipment can dramatically decrease the physical demands and injury potential of many material handling activities.Carrying and lifting are the two actions that present the greatest potential for worker injury when handling materials. Today we’ll address tips for ergonomic carrying; on Friday, we’ll share tips for lifting ergonomically.Carrying tasks place stress on the back and shoulders and create contact pressure on the shoulders and hands. When repeatedly strained or overstressed, the effort and force needed to carry materials can cause injury. To decrease injuries caused by carrying, follow these suggestions:

  • Eliminate unnecessary carrying.
  • Minimize the distances materials must be carried and use electric tuggers to carry materials over longer distances.
  • Organize work tasks so that physical demands and work pace increase gradually as muscles warm up.
  • Rotate workers or alternate carrying with non-carrying tasks to prevent overstraining the body and give muscles a chance to rest between efforts.
  • Wear properly fitting gloves to improve grip stability.
  • Reduce load weights and test loads for stability and balance before carrying.
  • Slide, push or roll materials. These actions place less stress on the body than carrying.
  • Use conveyors, slides or chutes to move materials.
  • Use electric tuggers to transport heavy loads.

Is Absenteeism Hurting Your Bottom Line?

The nation’s 300 largest employers reported in a 2007 survey by research firm CCH Inc. that absenteeism costs their businesses more than a quarter million dollars annually in direct payroll costs. Add in lost revenue from lower productivity and unscheduled absences can have a significant negative impact on a business’ bottom line. In these recessionary times, absenteeism can make already slim profits disappear.

Only a third of all work absences are due to illness, said Susan Frear, director of education for the Dallas office of the Society for Human Resource Management. “The rest of the absences are related to having to be someplace else or they just don’t feel like coming in. So a lot has to do with the culture of the place.”

Changes in management style or corporate procedures can make a significant difference in absenteeism rates. “Take a hard look at the climate,” suggests Barb Ashbaugh, owner of Ashbaugh’s Trade Secret, a performance management company. Authoritarian managers “who make employees feel it’s their way or the highway” cause higher levels of absenteeism, Ashbaugh noted. Companies that count “occurrences” instead of individual days absent encourage employees to sneak in a couple of extra days off, warned Nancy Glube, an Atlanta human resources executive.

Retail giant J.C. Penney Co. is trying a new approach that shows promise for both large and small businesses. With 1,500 workers calling in “sick” and another 1,200 out on disability each day, Penney executives were concerned about the impact of growing absenteeism rates on the company’s profit margin. This fall they began project PowerLine. When an employee is absent for 3 days, the PowerLine team swings into action. They communicate with the employee to determine the nature of the absence and whether the employee qualifies for health insurance, workers’ compensation or short-term disability benefits. The team notifies store and department managers and insurance carriers and sends the employee the appropriate forms to complete. Daily absenteeism rates have dropped dramatically.

What has made the PowerLine program so successful in such a short time is the constant follow-up that continues until the employee returns to work. “I’ve found that when someone goes out on disability, that person undergoes a significant event in their life,” said Penney’s benefit manager Jim Cuva, “and if no one checks on them to see how they’re doing, they could stay out longer than necessary.” The PowerLine program is Penney’s way of “letting them know we care.”

Employees who know they’re valued work harder, are more productive and are absent less frequently. Making the effort to create a positive work environment can positively impact your bottom line. On Monday, we’ll talk about how implementing ergonomic practices in your workplace can improve worker morale, decrease worker injury and boost your bottom line.