When I worked at a production facility, I saw how certain job tasks and setups affected some workers—awkward postures and disorganized workstations often caused discomfort and risk of musculoskeletal disorders. These experiences highlighted the importance of conducting ergonomics assessments. By identifying and addressing the ergonomic risk factors, we were able to improve our workplace’s environmental health and safety (EHS), increase productivity, and enhance employee well-being.
In this article, I'll walk you through the ergonomic assessment process, sharing insights and practical steps to help you create a healthier work environment.
Key Takeaways
- Ergonomic risk assessment helps in creating work environments that promote safety, reduce injury risks, and improve overall efficiency.
- Qualitative tools like REBA and RULA help observe and assess postural risks, while quantitative tools such as the NIOSH Lifting Equation provide numerical data on physical demands.
- A structured approach ensures that all potential hazards are identified and addressed in an organized manner, leading to a safer and more comfortable workplace.
- Leveraging detailed checklists and adhering to OSHA guidelines enhances the thoroughness of your ergonomic assessment.
What Is An Ergonomic Assessment?
An ergonomic assessment is a systematic evaluation of a workplace to identify factors that might contribute to discomfort or injury. It involves analyzing how tasks are performed, the equipment used, and the overall work environment. The goal is to optimize these elements to enhance both comfort and long-term health, reducing the likelihood of strain or injury.
Why Perform an Ergonomics Assessment?
When the production facility I worked at conducted an ergonomic assessment, I saw several positive outcomes that made the effort worthwhile. Here are some of the specific results our facility achieved:
- Reduced Injury Rates: After implementing ergonomic solutions on the assembly line, we experienced a 40% decrease in musculoskeletal disorders (MSDs). Adjustments like better workstation heights and ergonomic tools minimized strain from repetitive tasks and heavy lifting.
- Increased Productivity: By optimizing the layout of our production floor and ensuring that tools and materials were within easy reach, our team’s efficiency improved, with workers spending less time navigating their stations and more time focused on their tasks.
- Lowered Costs: Fewer injuries meant lower medical costs and workers' compensation claims, and reduced expenses related to employee downtime and turnover.
- Enhanced Employee Satisfaction: Workers appreciated the improvements to their workstations and the company’s commitment to their well-being, which boosted overall morale.
Typically, ergonomic evaluations are carried out by professionals with expertise in occupational health, industrial engineering, or related fields. These individuals are trained to identify potential hazards and recommend practical solutions tailored to the specific needs of the workplace.
Types of Ergonomics Assessment Tools
In production facilities, the right ergonomic tools can uncover risks that might not be apparent through observation alone. These specialized tools, both qualitative and quantitative, allow for a systematic assessment of physical tasks, identify potential hazards, and find practical solutions that enhance both safety and productivity.
Rapid Entire Body Assessment (REBA)
REBA is a qualitative tool that evaluates whole-body postural risks associated with manual tasks. It assesses body positions, forceful exertions, types of movements, and grip to generate a risk score. Higher scores indicate a greater need for intervention.
In a production line assembling automotive parts, REBA can be used to evaluate a worker performing repetitive bending and lifting tasks. The analysis can help optimize workstation design or recommend assistive devices to reduce strain.
Rapid Upper Limb Assessment (RULA)
RULA focuses on the posture, force, and repetitive movements of the upper limbs, including the neck, shoulders, and wrists. A scoring system highlights areas requiring ergonomic changes. For example, for a worker operating a drilling machine, RULA can assess wrist and arm angles during operation. If scores indicate risk, ergonomic adjustments like repositioning the machine or adding arm supports can be suggested.
Snook Tables
Snook Tables are excellent for evaluating manual handling tasks, such as lifting, lowering, pushing, or pulling. They help determine the maximum recommended weights for different tasks by considering factors like the frequency of lifts and the height of the objects being handled.
In a warehouse, Snook Tables can assess the safe load weight for employees moving boxes. The results guide the implementation of lifting aids or limits on manual lifting weights.
NIOSH Lifting Equation
The NIOSH Lifting Equation is a mathematical tool used to determine safe lifting limits by considering variables such as the weight of the items, the frequency of lifts, and the distance the items are moved. For example, in a production facility, this equation can assess the lifting tasks performed by workers on the assembly line.
By inputting relevant variables, the NIOSH equation helps establish safe lifting guidelines. In one case, a facility redesigned certain lifting tasks to keep them within recommended limits, thereby reducing the risk of back injuries among workers.
Hand Grip and Insertion Force
Measuring the force required to grip and insert objects can highlight tasks that may cause hand and wrist strain. In production environments where workers operate power tools and handle small components repeatedly, excessive force can lead to conditions like carpal tunnel syndrome. By using hand grip dynamometers and insertion force gauges, facilities can quantify the effort required for these tasks.
How to Perform an Ergonomic Assessment?
Conducting an ergonomics assessment involves a structured approach to identify and mitigate risks in the workplace. Here’s a breakdown of the process:
1. Review Existing Data
As you can see in the image above, the first step is to gather and examine existing information related to workplace injuries and productivity. This includes analyzing injury reports, worker compensation claims, and any previous ergonomics assessments to identify common issues and trends. For example, if data shows a high number of back injuries, it indicates a need to focus on lifting practices and workstation setups.
2. Gather Subjective Data
Next, it's important to collect feedback directly from employees to gain insights that numbers alone might miss. This can be done through surveys, questionnaires, interviews, and focus groups where workers share their discomfort experiences and suggest areas for improvement. In the production facility where I worked, employees reported frequent wrist pain, which prompted an evaluation of their tool usage and hand positions.
3. Choose Tools
Selecting the appropriate ergonomic assessment tools is essential for a thorough evaluation. Depending on the tasks and environments, both qualitative tools like REBA and RULA and quantitative tools such as the NIOSH Lifting Equation and hand grip measurements are chosen so that risk factors are accurately identified. This selection ensures that all aspects of workplace ergonomics are effectively assessed.
4. Assess Data and Prioritize Risk
With the collected data, the next step is to analyze and prioritize the ergonomic risk factors. This involves comparing the data against safety standards and guidelines to identify high-risk areas that need immediate attention. For instance, if the NIOSH Lifting Equation reveals that certain lifting tasks exceed safe limits, those tasks become a priority for intervention.
5. Craft a Plan to Implement Mitigation
Once the risks are prioritized, a plan is developed to mitigate them. This involves designing solutions such as adjusting workstations, introducing ergonomic equipment, or modifying work processes based on the identified risks. In our facility, addressing excessive lifting led to redesigning certain tasks and introducing mechanical aids, which helped reduce the physical strain on workers.
6. Write a Report
The final step is to document the entire assessment process and the recommended actions in a comprehensive report. This report outlines the identified ergonomic risk factors, provides clear and actionable recommendations, and includes an implementation plan with timelines and assigned responsibilities. A detailed report serves as a roadmap for executing changes and tracking improvements over time, ensuring that the ergonomic evaluation leads to lasting positive outcomes.
Identifying Workplace Ergonomic Risk Factors
Below is a summary of the Occupational Safety and Health Administration (OSHA) Ergonomic Risk Factor Guide, which categorizes optimal work positions, moderate stress, and severe stress for various body parts and positions commonly evaluated during an ergonomics assessment:
|
Body Part / Position |
Optimal Work Position |
Moderate Stress |
Severe Stress |
|
Head and Neck |
Neutral posture with the head aligned with the spine, looking straight ahead, 0° to 10° |
Slight forward or sideways head tilt, 10° to 15° |
Extreme neck flexion, extension, or lateral bending, 15° to 20° |
|
Elbow Angle |
Elbows bent between 90° and 105° |
Elbow angles between 105° and 120° |
Elbow angles between 120° and 135° |
|
Elbow Abduction |
Minimal abduction with elbows close to the body, 0° to 10° |
Elbow abduction between 10° and 20° |
Elbow abduction greater than 20° |
|
Wrist Flexion |
Neutral wrist position, 0° to 15° |
Wrist flexion between 15° and 30° |
Wrist flexion greater than 30° |
|
Wrist Extension |
Neutral wrist position, 0° to 15° |
Wrist extension between 20° and 35° |
Wrist extension greater than 35° |
|
Hip/Lower Back Flexion |
Neutral spine with hips bent at approximately 0° to 5° |
Hip flexion between 5° and 10° |
Hip flexion between 10° and 15° |
|
Reaching |
Minimal reaching with tools and materials within easy reach. Male: 10” to 15”, Female: 8” to 12” |
Male: 15” to 20”, Female: 12” to 16” |
Male: 20” to 25”, Female: 16” to 20” |
|
Task Height |
Work surfaces at or slightly below elbow height when standing or sitting. Male: 36” to 39”, Female: 35” to 38” |
Male: 39” to 41”, Female: 38” to 40” |
Male: 41” to 43”, Female: 40” to 42” |
|
Workstation Height |
PRECISION WORK Male: 40” to 44”, Female: 38” to 42” |
SMALL, LIGHT WORK Male: 36” to 38”, Female: 34” to 36” |
LARGE, HEAVY WORK Male: 30” to 36”, Female: 28” to 34” |
Using this table as a reference during an ergonomics assessment can help identify areas where adjustments are needed to improve workplace ergonomics.
Ergonomic Assessment Checklist
While OSHA hasn't established a comprehensive ergonomic assessment standard applicable to all workplaces, it provides valuable resources and recommendations to help employers address common risk factors effectively. One tool is the Ergonomic Assessment Checklist, which covers various aspects such as workstation layout, tool design, task rotation, and employee training.
Below is a comprehensive checklist template based on OSHA's guidelines, tailored to help you systematically evaluate various aspects of your work environment:
| Section | Details |
|---|---|
| Date | |
| Activity Assessed | |
| Organization | |
| Point of Contact | |
| Personnel Observed | |
| Building/Location | |
| Room/Area | |
| Risk Rating (Circle) | High / Medium / Low |
| Risk Factors | |
| 1. Diagnosed repetitive stress injuries (e.g., carpal tunnel, tendinitis)? | Yes / No |
| 2. Complaints about ergonomic issues from employees? | Yes / No |
| 3. High-repetition tasks (e.g., 100+ repetitions/hour or 2,000+ per day)? | Yes / No |
| 4. Routine tasks involving heavy lifting (>20 lbs repetitively or >50 lbs occasionally)? | Yes / No |
| 5. Tools forcing work outside neutral positions for extended periods? | Yes / No |
| 6. Awkward head or neck positions for prolonged durations (e.g., 1-3 hours)? | Yes / No |
| 7. Awkward back angles (e.g., hunched or bent) maintained for extended periods? | Yes / No |
| 8. Awkward elbow angles or extreme force application for extended periods? | Yes / No |
| 9. Awkward wrist flexion or extension for extended periods? | Yes / No |
| 10. Extreme reaching distances or work at awkward heights for prolonged durations? | Yes / No |
| 11. Regular use of high-impact tools (e.g., riveters, impact wrenches)? | Yes / No |
| 12. Regular use of high-vibration tools (e.g., grinders, sanders)? | Yes / No |
| 13. Workstation height concerns (e.g., too high or low)? | Yes / No |
| 14. Tasks performed at extreme heights or depths for extended periods? | Yes / No |
| 15. Additional ergonomic concerns or observations? | Yes / No |
| Evaluation Explanation | |
| Question Number(s) | |
| Activity Description | |
| Risks Identified | |
| Observations/Notes | |
| Signatures | |
| Name of Assessor | |
| Name of Reviewer | |
By following OSHA's recommendations, employers can create safer workspaces that not only comply with regulatory expectations but also enhance overall productivity and employee well-being.
Ergonomics Assessment FAQs
How do you solve ergonomic problems?
Ergonomic problems are solved by identifying risk factors through assessments, and then implementing practical solutions like adjusting workstation designs, introducing ergonomic tools, providing training on proper body mechanics, and scheduling regular breaks to reduce repetitive strain.
How does ergonomics affect employees' work performance?
Good ergonomics enhances work performance by reducing fatigue, discomfort, and risk of musculoskeletal disorders, which leads to increased focus, performance, and job satisfaction. Poor ergonomics, on the other hand, can result in lower productivity and higher absenteeism due to injuries.
What is the proper working height?
The proper working height varies depending on the task. For most standing work, the surface should be at elbow height, approximately 36 to 46 inches for tasks requiring precision, or lower for tasks requiring downward force.
When a task requires a lot of force, what kind of hazard could that present?
Tasks requiring excessive force can lead to ergonomic hazards such as muscle strain, joint stress, and overexertion injuries, especially to the back, shoulders, and wrists.
What are the symptoms of poor ergonomics?
Symptoms of poor ergonomics include fatigue, muscle pain, stiffness, numbness, tingling, reduced range of motion, and long-term issues like repetitive strain injuries (RSIs) or work related musculoskeletal disorders (MSDs).
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