Author: christopher Harper

Using Ergonomic Equipment to Reduce Injury Rates

In our last post we talked about the challenges of managing a multicultural workforce in material handling, logistics, warehousing, fulfillment and other businesses. OSHA has reported higher than normal injury and on-the-job death rates for foreign-born Hispanic workers who comprise a growing segment of America’s hourly workforce. While language and cultural differences appear to be at the root of the problem, injury and death rates can be cut by using intuitive, ergonomically-designed, powered equipment to meet your material handling needs.

When communication is an issue, equipment that is easy to operate can improve training speed and reduce potential worker operation errors that can lead to injury. When controls are intuitively designed, communication gaps are narrowed further. What might not be grasped or fully remembered in verbal communication can be intuited by gesture or familiarity with similar equipment. This is not to say that a thorough training and safety program is not necessary, only that easy-to-operate equipment shortens the time between initial training and competent operation. Ergonomically-designed equipment is built around the worker, not the task, making it extremely user-friendly and an excellent choice in multicultural work environments.

Ergonomic material handling equipment that is electric or battery powered can further reduce injury and workplace death rates. In material handling situations, most injuries come from pulling, pushing or lifting loads and are the result of over-stretching or over-straining muscles. Powered equipment removes most of the need for heavy physical exertion from pulling, pushing and lifting tasks. By allowing the equipment to do the heavy lifting, so to speak, fewer situations are presented during the workday that might place workers at risk of injury.

To find out more about ergonomically-designed material handling equipment, visit the DJ Products website.

Michigan Proposes Ergonomic Regs to Curb Injuries

In response to concern about workplace injuries, Michigan plans to institute new state regulations targeting repetitive-stress job injuries. Under the proposed rules, employers would be required to offer ergonomic training and work to correct reported injuries. State regulators would have the power to punish employers for repeated worker injuries. Critics are concerned that the rules will place another financial burden on Michigan’s already struggling economy.

California is the only other state with similar regulations, despite the fact that repetitive-stress job injuries are estimated by OSHA to cost America more than $20 billion annually, or about one-third of the total workers’ compensation costs paid by employers. “It’s a significant issue, even though the standard is fairly minimal,” said Doug Kalinowski, director of MIOSHA. “It’s been very contentious.”

In 2001, repetitive-stress injury regulations proposed by federal regulators were estimated to cost employers $5 billion. Those regulations were blocked by Congress. Michigan’s Small Business Association is concerned that the costs of training and reporting procedures will place a significant burden on small businesses and make it harder for them to compete nationally. Larger companies that have ergonomics programs in place would be exempted under the proposed rules.

Manufacturers are similarly concerned. “It’s a pretty broad issue and there are a lot of costs involved,” noted Amy Show of the Michigan Manufacturers Association. “We don’t know what true costs are going to be until we know how strict the department is going to be in enforcing this.”

The proposed rules would only apply to general industry. Construction, agriculture, mining and domestic employment are specifically excluded. But the construction industry and labor representatives believe that if the rules are adopted, it will only be a matter of time before they are expanded to include construction. “There are many within the building trades, or ironworkers, that suffer from repetitive-motion injuries,” said William Borch, president of Ironworkers Local 25 in Saginaw, Michigan and one of the labor representatives who reviewed the proposed rules.

“The problem is that … these types of injuries are not an imminent danger [to life], even though they can be career-ending types of injuries and cause long-term pain and suffering,” Borch said. Considering the risk to workers, Borch felt the proposed rules provided minimum standards. “It doesn’t seem like a lot to ask,” he said.

Advocates of the proposed rules argue that the implementation of ergonomics creates a safer work environment, increases productivity, minimizes downtime and decreases workers’ compensation costs — all formidable inducements to embracing ergonomics.

Proactive Problem Solving Reduces Workplace Injuries

Reducing workplace injuries is every responsible business owner’s goal. Not only do you value your employees’ health and safety, but the cost of ignoring workplace safety — high medical, insurance, workers’ compensation and lost man-hour costs — can be staggering. It pays to be proactive in looking for potential injury-causing problems and coming up with ergonomic solutions that improve the fit between the work and the worker.

Developing a proactive plan to reduce workplace injuries is a four-step process:

  1. Observe and question
  2. Set priorities
  3. Implement improvements
  4. Follow up

1. Observe and question.

Look for clues to possible problem areas in available statistical data. Check injury reports for patterns that indicate higher injury rates for certain tasks or in certain areas. OSHA logs, worker reports and complaints, absence rates, and workers’ compensation reports are good starting points. Ask if your workers’ compensation insurance carrier provides workplace assessment surveys as part of their risk-management services.  

Look at production reports for bottleneck areas. Check quality control reports for poor quality product or service. Problems can indicate areas where workers are having difficulty completing tasks effectively under current conditions. The root cause of such problems is often poorly designed equipment or task procedures.

Spend some time following the entire process of your business from start to finish. Pay particular attention to areas highlighted by the data review. Observe the way workers do their jobs. Watch for risk factors such as awkward postures, repetitive motions, forceful exertions, pressure points or extended periods spent in the same position. Watch for signs of worker discomfort or pain such as self-restricting movements, efforts not to move certain body parts or massaging hands, arms, legs, necks or backs. Pay attention to unnecessary handling and duplication of material or product movement.

Look for ways in which workers have modified standard procedures to make it easier to do their work, including modifications to tools, equipment, workstations or task performance. Talk to managers but also talk to the workers who actually perform the tasks. Ask workers how they would change the work process, operations, tools or equipment to make their jobs less physically demanding and more efficient. You’ll get a clear idea of what isn’t working and may get some excellent suggestions for improvement.

Continued next time

The Cost of Ignoring Ergonomics

Back in industry’s dark ages, equipment was designed to do a task without much thought to the comfort or safety of the worker who would be operating it. Back injuries, tendonitis, carpal tunnel syndrome and other stress and repetitive motion injuries were an aggravating and often debilitating part of the job. The toll wasn’t just on the workers, industry paid a price in decreased productivity, poor product quality, increased medical and workers’ compensation costs, low morale and high absenteeism. The annual price tag for workplace injury and illness is estimated at $171 billion.

That’s a pretty hefty price tag considering that America spends about $170 billion a year on cancer and $164 billion on cardiovascular disease, the country’s two biggest killers. According to an American Medical Association study, each year in America there are 6,500 deaths from workplace injuries and more than 60,000 deaths from workplace-related diseases. Non-fatal workplace injuries number 13.2 million annually with 862,000 illnesses. That’s a staggering price in human suffering and industry dollars. The total cost of workplace injuries is nearly equal to the combined annual profits of America’s 20 largest companies.

But that’s just part of the picture. Workers’ compensation claims already cost American businesses $60 billion annually, according to the U.S. Department of Labor. More than 50% of those claims are for back injuries from lifting, pulling, pushing and straining, says the National Council on Compensation Insurance. In fact, workplace back injuries, which involve lengthy and costly treatment, affect more than 1.75 million workers each year, according to the Bureau of Labor Statistics. Add in the estimated time-lost cost per injury of $26,000 per incident and the prevention of a single injury can result in an immediate savings of $26,000.

This staggering cost and the desire to provide American workers with healthier and safer working conditions gave rise to ergonomics and the beginning of a radical change in the way industry approaches equipment design.

Next time: The rise of ergonomics in industrial design.

ANSI Upholds Construction Ergonomic Standard

The American National Standards Institute recently upheld its adoption of ergonomic standards in the construction industry. Rejecting an appeal by the Construction Industry Employer Coalition to withdraw adoption of the approved voluntary consensus standard on the reduction of musculoskeletal problems (ANSI/ASSE A10.40-2007), ANSI reaffirmed the importance of ergonomic design and safe practices in preventing injuries to construction workers.

The appeal by a coalition of five construction trade associations was the latest attempt to derail the ANSI standard approved last year. The coalition first appealed the ergonomic standard during hearings held in May 2007. An appeals panel found those complaints to be without merit, a decision supported by the American Society of Safety Engineers, and the standard was formally approved on July 23, 2007. Shortly thereafter, the coalition filed the formal appeal that was just rejected.

“We are pleased with ANSI Board of Standards Review’s decision to uphold the approval and publication of the A10.40 standard, said ASSE VP James Smith, CSP.” At ASSE we are committed to the protection of people, property and the environment and this standard is an excellent step in protecting workers from injury and in helping to create safer and more healthy workplaces.”

“National consensus standards, such as A10.40, reflect the insights of the final users and the opinions of professionals who work at all levels of public and private sectors in technology development, safety and health, manufacturing, training, financial analysis, personnel and academia,” said A10 Committee Chair Richard King, CSP, CRSP. “This balanced perspective enables standards to be crafted in a manner that benefits and protects standard users.”

Help Workers Beat the Heat

The dog days of August aren’t here yet but the nationwide heat wave means it’s time to review heat safety tips to prevent heat exhaustion and heat stroke. When workers don’t work in temperature controlled environments, heat can take a toll on workers’ health, cause production to suffer and even be life-threatening when workers and managers do not take proper precautions to manage heat stress.

Sweat is the body’s cooling system. As air passes over the body, it evaporates sweat, cooling the body. But during hot weather, particularly if the humidity is high, sweating can’t keep up. Body temperature rises faster than sweating can cool it down. When body temperatures get too hot, heat illness and even death can occur. Older, overweight and pregnant workers are most at risk of heat illnesses, which include:

  • Heat rash where the skin becomes irritated from excessive sweating. Tightly fitting clothing can exacerbate heat rash and the individual’s discomfort.
  • Heat cramps are painful muscle pains or spasms, generally in the abdomen and legs, brought on by exertion or exercise during prolonged exposure to high temperatures. Heat cramps are often the first sign that the body is not coping with high temperatures.
  • Heat exhaustion occurs when body fluids are lost through heavy sweating and not replaced. In an effort to cool the body, blood flow to the skin is increased, drawing it away from vital organs and causing mild shock. Heat exhaustion is evidenced by extreme lethargy, heavy sweating, rapid breathing and a fast, weak pulse. If not treated, it can lead to dangerous heat stroke.
  • Heat stroke (also called sun stroke) is a life-threatening condition indicating that the body’s natural cooling mechanism has completely broken down and ceased functioning. Body temperatures can rise above 106 degrees Fahrenheit, high enough to cause brain damage. Sweating stops and the skin becomes dry to the touch. The individual’s pulse begins to race, becoming strong and rapid. Heat stroke victims can become dizzy, particularly dangerous if they are operating equipment. If untreated, unconsciousness, permanent brain damage and death can follow.

Next time: Preventing and treating heat injury

Boat and Trailer Sales Made Easier with a Trailer Mover

The most common method for moving a boat or other piece of equipment that requires a trailer is by way of a vehicle with a trailer hitch.  In a confined showroom or on the crowded lot of a dealership, this method of getting a trailer from one location to another isn’t always possible.  In dealerships where the equipment must be moved around in tight quarters, a piece of equipment like the Trailer Mover from DJ Products is essential to increase efficiency and reduce the risk of injury.

The lightest boats and RVs can be far too heavy to safely attempt to maneuver manually.   Even in situations where multiple employees are on hand to try and strong arm a boat or trailer, serious injuries could occur.  The only way to safely get a boat or trailer from one location to another without using a motor vehicle is with a properly designed piece of equipment like the Trailer Mover.

The Trailer Mover is much smaller and easier to maneuver than most other trailer pullers available.  This gives employees the ability to quickly and easily navigate the confines of a crowded showroom without accidents that could cause unnecessary damage to other boats or RVs.

Avoiding workplace injuries and keeping the product in good condition are two of the biggest keys to success in any dealership.  Having a properly designed piece of equipment to move boats and trailers is the perfect solution for keeping employees and the boats and RVs safe in a high volume, fast paced dealership.  The Trailer Mover is an affordable and easy to use piece of equipment that can help dealership owners save money on worker’s compensation claims and repair costs for damaged equipment.

Boat Sales Made Easier with a Trailer Mover

Spring is here and the weather is heating up and that means one thing for boat dealers – the chance for more sales.  Fisherman, divers and folks who just love to relax out on the open water are all more likely to be looking to head out boat shopping now that the weather is more suitable for those activities.

While an increase in sales is certainly welcome in any business these days, increased activity on the lot could pose some issues for a boat dealer that isn’t prepared with the appropriate equipment.  Boats are easy to transport when they are hooked to the back of your truck, but dealer lots are often far too cramped for employees to be able to use a full sized vehicle for maneuvering stock. 

A piece of equipment like the trailer mover from DJ Products can instantly make the task of moving new and used boats around the lot faster, safer and easier.  The small frame size and tight turning radius of the trailer mover make it a very convenient option for navigating cramped and crowed lots.  The trailer mover is very easy to control which could result in a dramatically reduced risk of accidents on the lot.  This helps to keep valuable employees safe from injury and valuable inventory free from damage.

Using a trailer mover on a lot also allows employees to easily and safely rotate stock when new inventory comes in.  This means that lot owners can constantly put the most desirable boats directly where prospective customers will be sure to see them.

In order for a boat dealer to keep up with increases in traffic and to maximize profits in the process there needs to be a safe and effective means available for moving inventory.  A piece of equipment like the trailer mover will instantly make a boat lot safer and allow employees to adequately and attentively serve any customer that walks through the door.

Moving an Airplane Can Be a Solo Mission with an Aircraft Tug

From the paper airplanes you made as a child to taking a cross-country flight, the ability to see something soar through the air is quite a thrill. When an airplane flies, part of the reason it is able to stay up in the air is that the air moving over the top of it is going at a faster speed that the air that is moving below the plane.

An airplane is a remarkable and rather expensive piece of equipment. For that reason, you can’t just use any old machine to move an airplane around. DJ Products’ airplane tugs make it possible for one person to safely and easily maneuver aircraft in a tightly stacked hanger or staging on a ramp. While you wouldn’t think of moving a plan on your own, you can do so with our aircraft tug. Just like flight, that is nothing short of amazing! One person can push or pull an aircraft that weighs in at up to 35,000 pounds with one of our aircraft tugs.

Our airplane tugs have a smooth acceleration and braking system. And the quiet electric motor means that the person operating the airplane tug will not be distracted by noise and can concentrate fully on the task of getting the aircraft from point A to point B.

While we focus on providing ergonomically correct, safe, and cost effective solutions to transport some of your most important products, we have a lighter side too. You can customize your aircraft tug or aircraft tow with a custom logo if you wish. There is no reason that your equipment can’t be useful, safe, and fun all at the same time.

Trailer Movers: Small Products that Make a Big Difference

The DJ Products Trailer Mover is a little piece of equipment that can do big things.
You don’t need something the size of a trailer to move a trailer. What you do need is a material handling solution that has been ergonomically designed to prevent the pain and strain that may otherwise occur when someone tries to move a trailer on their own or with the wrong equipment.

It can be tempting to think that you or one of your employees can just move a trailer a short distance but taking on such as task can cause more damage than you may realize. First, overextending the body when you manually lift and move a trailer from one location to another can cause significant strain on the body…the kind of strain that may seem to go away, only to flare up later. Second, trying to move a trailer, boat, or RV without adequate equipment may cause damage to whatever is in the surrounding area. You can overestimate the amount of control you have over large objects and not realize until it is too late that you did not have the grip or space needed to really maneuver something as large and as heavy as a trailer.

Our TrailerCaddy trailer mover can push or pull an RV, a camper, an equipment trailer or a boat. It is less bulky than traditional electric trailer puller products and offers increased control in tight areas. You can use our trailer mover to move a trailer or boat across a parking lot or just a short distance in a showroom.