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Success with Ergonomics
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Honda of America Mfg., Inc. |
| State: |
Ohio |
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| Company: |
Honda of America Mfg., Inc.
Marysville, OH |
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| Industry: |
Auto Manufacturing – SIC Code: 3711 |
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| Associates: |
12,500 |
Success Brief: Associates new to the
Assembly Department complained that the orientation training was inadequate. A
Team comprised of representatives from the Safety, Production, Medical and
Wellness Departments revised the existing training to focus on four separate
areas and continue twice as long. To date the training has increased safety,
quality and productivity and improved annualized savings of Honda of America
(HAM).
The Problem
The Assembly Department at the HAM East Liberty (Ohio)
Plant received complaints of muscular aches, pains and soreness caused by the
performance of unfamiliar physical tasks from new associates (both new to the
Company and new to the Department) during their first 90 days.
The existing 5-day new hire orientation training was divided daily into two
parts: half was learning safety fundamentals in the classroom, and half was
shadowing an experienced production associate. Only one hour of the week was
devoted to work simulation in a test-build or laboratory environment where
associates learned how to hold tools, tighten fasteners, install small parts,
etc.
A Team, comprised of members from the Safety, Production, Medical and Wellness
Departments analyzed the deficiencies in the existing orientation training and
discovered that while it incorporated safety policies and procedures in the
classroom, it did not provide hands-on instruction for using assembly tools and
equipment that would lead to safe job performance. In addition, it did not
physically prepare new associates for the rigors of their new work environment.
Plus, it provided only general information and minimal training to help new
associates understand job tasks, safe work methods, and proper techniques.
Finally, follow-up activity to ascertain whether or not the associates were
proficient and competent at their new assignments was minimal.
The Solution
After analyzing the existing 5-day orientation training, the Team developed and
implemented an expanded 10-day new hire orientation program to be completed
before new associates started their jobs in the Assembly Department. In addition
to the previous classroom training and work simulation, the new orientation
program includes physical conditioning and on-the-job training. Like sports camp
prior to the season, the physical conditioning program “work hardens” new hires
by devoting 20 hours to build their endurance and cardiovascular abilities,
flexibility, range of motion, and strength. In addition, a work simulation
segment teaches associates the best techniques and postures for, as well as the
potential hazards of, the tasks they will perform (e.g., tightening nuts and
bolts and using powered tools, equipment and other assist devices). The
on-the-job training portion allows associates to demonstrate that they know the
steps of their new job processes. Periodic follow-up sessions occurring at least
once a week (or more frequently if the new associate reports any problems or
concerns) between a Team member and new associate during his/her first 90 days
ensure that the progress of the new associate is reviewed, safe work methods are
reinforced, and concerns of the new associate are addressed.
The Impact
As a result of the implementation of the new orientation
training, the associates at HAM’s Assembly Department meet the physical
requirements of their assignments and demonstrate safer work techniques and
awareness of job hazards. The Department has observed a 40-percent reduction in
incidents occurring during the first 90 days of the new associates’ assignments.
Quality and productivity measures have improved, and initial annualized net
savings for HAM have reached $341,000. This figure includes injury cost
avoidance plus quality and productivity savings less the cost to implement the
improved orientation program, which includes the cost of procuring training
equipment plus the labor costs for both the trainers and the trainees. The
projected cost to expand the program to all plants is $900,000, which is on
target as this program has been slowly introduced to other plants/departments.
The complete full implementation at all plants is expected by June 2010. The
savings once the program is expanded to all plants is projected to be
approximately $3,000,000 (injury cost avoidance plus any quality and
productivity enhancements less the projected program costs) for the first year;
the projected cost savings for the following year is expected to decrease
reflecting the approximately 50-percent reduction in injuries during the first
90 days of a new hire's assignment as demonstrated in the data from the first
year that this program has been in effect. This project earned the Team the
Applied Ergonomics Conference Committee Ergo Cup award in Training and Education
in March 2008.
Source: Team of
associates from the East Liberty Plant, Honda of America Mfg., Inc. (June 2009)
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