Text For Citation: 01 Item/Group: 001 Hazard: ERGONOMIC

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to: Assemblers in the Flav-R-Savor, Foodwarmer and Booster Departments were required as part of their jobs to use tools,(e.g., screw- driver, nut driver, drills, etc.) and perform repetitive motions in postures that resulted in finger, hand, wrist and arm stressors that caused numerous incidents of cumulative trauma disorders to the musculoskeletal system. (a) Assembler - Flav-R-Savor - repetitively using these tools with fingers, wrists and hands and arms to assemble wire harnesses, motors upper units, cabinet doors, cabinets and wiring that are all components of food-warming ovens. (b) Assembler - Foodwarmer - repetitively using these tools with fingers, wrists, hands and arms to assemble cover plates, wire guard assemblies, end plates, elements and screens that are all components of food-warming lamps (Glo-Ray). (c) Assembler - Booster - repetitively using these tools with fingers, wrists, hands and arms to assemble control box assemblies, tanks and housing cabinets that are all components of Booster water heaters. Amond other methods, one feasible and acceptable abatement method to correct this hazard is the implementation of an ergonomics management program consisting of the following four elements: 1. Worksite analysis to recognize and identify existing repetitive motion hazards in the workplace. This analysis should include development and use of an ergonomic check- list and employee questionnaire. Periodic surveys of the workplace shall be conducted at least annually to evaluate work practices and engineering controls. Employee parti- cipation in the ergonomic program should be encouraged through a mechanism such as a safety committee. 2. Medical management which includes accurate recordkeeping of cumulative trauma disorder (CTD) injuries. The program should address early recognition, evaluation, and referral of CTD cases. Systematic worksite review by the medical team should also be included in the program. 3. Training and education for exposed employees, including methods to evaluate the effectiveness of the training. Re-training should be done annually, or as operations change. Training should address hazards associated with the job, the risks of the driller and sorter operations, and how to prevent CTDs. A supervisors' training program should also be implemented to allow recognition of repetitive motion hazards and to reinforce the employer's ergonomics program. 4. Hazard prevention and control which includes engineering, work practice, and administrative controls. a. Administrative controls are implemented which reduce the duration, frequency, and severity or exposure to repetitive motion hazards. These controls may include job rotation and reduction of repetitions. b. Work practice controls are implemented which include proper work techniques and new employee con- ditioning. Examples of work practice controls applicable in this workpalce include: i. Maintain a reasonable work pace, and ii. Rotate employees to jobs with less stressors. c. Engineering controls are designed by a qualified ergonomist and may include workstation redesign. The goal of this program should be to make the job fit the person and to reduce the frequency of repetitive movements. Examples of engineering controls applicable to this workplace include: OPERATIONS Flav-R-Savor 1. Wire Harness Assembly a. elevate work table to waist height or tilt the table and allow employee to do job in a sitting position. b. use an overhead suspended in line screw/nut driver with an anti-torque device. c. use a ball type driver with ratchet. 2. Cabinet Door Assembly a. adjust height of work station to waist level (this allows the hands to be halfway between waist and armpit). b. position door in a vertical position to allow vertical tapping or use a foot pedal operated press. c. use a suspended anti-tongue screwdriver. d. control size tolerances by establishing better quality control through use of jigs. 3. Flav-R-Savor Upper Unit Assembly a. rotate unit 90 degrees so work can be done from top to bottom. b. use suspended anti-torque driver. c. use motor driver inline nut driver that is counterbalanced to reduce torque. d. use a drill to cut hole, a mallet to set pieces and a cold press to push part into place. 4. Flav-R-Savor Motor Assembly a. provide a fixture to allign motors so that the spin axis is vertical. b. adjust table height to waist level so employ- ee can stand erect while working. c. use suspended anti-torque tool. 5. Flav-R-Savor Cabinet Assembly a. use a roller to install rubber stripping. b. keep parts closer to assembly area - maybe through use of a portable cart. c. instruct employee to keep cabinet closer to his body. 6. Flav-R-Savor Conveyor - Final wine assembly a. provide a fixture to lower assembly into oven. b. use suspended anti-torque tool 7. Food Warmer - End Plates a. place end plates in a vertical position and rotate 90 degrees. b. adjust table to proper employee height (hand position halfway between waist and armpits). c. use suspended anti-torque tool. 8. Food Warmer - Cover Plate and Wire Guards a. adjust table to proper height. b. use a power crimping tool. c. provide fixture to hold wire end and part together. d. use suspended tools. e. use ergonomically designed handles on tools and use shorter bladed screwdrivers. 9. Food Warmer - Assembly a. adjust conveyor to proper height. b. use suspended tools. c. provide a collar on present tool at the bottom of the cylinder for increased grip and power transmission. d. always use suspended tool when working on the horizontal. 10. Food Warmer - Special Order Area a. use suspended tools. 11. Booster - Small Assembly a. instruct employees to pull ratchet lever toward body rather than across it. b. adjust tables to proper height. c. use suspended tools. d. don't use handheld screwdriver in a stab grip. e. keep work area at distance so work can be performed with 1/2 arm extension or less. 12. Booster - Tank Assembly a. redesign pipe fitting tool with an opposed handle that extends from the top or the side. b. rotate unit on assembly line 90 degrees, instruct worker to make bolt and screw con- nections from one side with hands close to the body, then do other side from other side of conveyor.