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

Section 5(a)(1) of the OSHAct 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 the hazards associated with working in the Blowmold Department, of repetitive hand, wrist, and finger operations which could result in injuries including, but not limited to tendinitis, carpal tunnel syndrome, and repetitive strain injuries of the shoulders, elbow and wrist in that: (a)Employees working on machine #14 manufacturing the HB 76 Hub Assembly were exposed to the known hazards of: (1) frequent elevated and extended reaches; (2) forceful thumb exertions when pushing the hub into the wheel unit; and, (3) long periods of standing. Some feasible means to control these hazards are: ¿1! Lower and relocate employees in relationship to all work items so that reach elevations and distances can be limited to ergonomically desirable levels. Reaches should be no higher than about mid-chest to shoulder height and limited to no more than 16 to 17 inches. ¿2! Provide employees with a press which will apply the pressure to push the parts together. ¿3! Develop and enforce work/rest schedules. Generally, a minimum of a 15-minute rest break at least every two ¿2! hours is required. (b)Employees working on machine #19 manufacturing kiddie links were exposed to the known hazards of: (1) frequent forceful finger exertions; (2) elevated and extended reaches used to place items in the flamer, retrieve items from the main conveyor, and to access flash waste bins; and, (3) long periods of sitting. Some feasible means to control these hazards are: 1) Provide a tool to separate the product from the flash. If this task must be performed by hand, develop a work rotation which will permit frequent periods of time spent at tasks which do not require repeated finger exertions; 2) Relocate employees in relationship to all work items such that reach elevations and distances can be limited to ergonomically desirable levels. Reaches should be no higher than about mid- chest to shoulder height and limited to no more than 16 to 17 inches; 3) Provide a chair that conforms to proper ergonomic principles; 4) If gloves are worn during manipulations (b)(1) above, they must fit properly. They must provide for maximum tactile sensitivity while also providing for a maximum coefficient of friction between the hand and the load surface. (c)Employees working at machine #20 manufacturing the steering wheel with bellows were exposed to the known hazards of: (1) Frequent torso flexions with the arms extended to the side of the body to obtain materials from the catch basket at the end of the conveyor; (2) Repeated, extended and elevated reaches to accessmaterials from the supply conveyor, to access squeakers from the supply box, and to place flash into the discard area; and (3) Repeated finger and thumb force with the wrist in a deviated posture and with rotation of the forearms. Some feasible means to control these hazards are: 1) Lower the work table such that employees can sit on a regular chair instead of an elevated stool. An elevated area should be provided to catch items coming off the belt, such as a shelf at the end of the conveyor or an item to provide elevation on which the current catch basket could be placed. The work table and conveyor catch area should be aligned in such a manner that employees can access materials without repeatedly flexing the torso; 2) Reduce the distance employees must reach to perform assembly tasks. Move the conveyor discharge area closer to employees. Tilt supply boxes and reposition discard areas so that employees do not need to reach above shoulder height to access items. Move the flash discard box down next to the employee and tilt the squeaker box toward the employee to reduce the number of elevated reaches. The work table should be lowered so that employees are in higher orientations and can access items while maintaining ergonomically desirable postures; and 3) Develop a jig to place the bellows in, so that the flash ends can be cut off instead of pulled apart. Redesign the squeaker assembly and steering wheel such that pieces are glued or screwed together rather than snapped into place, develop a rotation scheme so a minimum amount of time is spent performing strenuous finger actions. (d)Employees working on machines #24 and #25 manufacturing revealers were exposed to the known hazards of: (1) Repeated, extended and elevated reaches with the elbows abducted away from the torso to access revealers for flaming; (2) Repetitive reaches behind the body to place finished revealers into boxes; (3) deviations of the wrist while exerting finger force to the flaming device. Some feasible means to control these hazards are: 1) Reduce the distance employees must reach to perform assembly tasks; move the finish boxes closer to the employee and tilt them so that employees can have adequate access while limiting their reaches to ergonomically desirable distances and elevations; recess the supply boxes into the work table to reduce the severity of elevated reaches; 2) Redesign the workstation so that employees have access to the boxes to be packed without reaching behind themselves, move the packing box closer to employee or instruct the employee to rotate around in their seat so they are facing the packing box before materials are loaded into it; and 3) The head or handle of the flaming device should be bent such that the task can be accomplished while the wrist is maintained in a neutral posture. This device should have the nozzle adjusted to reduce the deviation of the wrist. Each task using the device should be analyzed to determine proper alignment necessary to minimize wrist deviation. (e)Employees working on machine #18 manufacturing 9" forks were exposed to the known hazard of repeated depressions of the activation button on the flaming tool. One feasible means to control this hazard would be to modify the current torch or provide new torches whose activation mechanism is a bar or lever rather than a button. (f)Employees working on machine #10 manufacturing the fitness walker platform were exposed to the known hazard of repeated use of finger force with the wrist in a deviated posture to use a straight in-line knife for manually cutting the center section out of molded products. Some feasible means to control these hazards are: 1) Develop a router type device which could be used to perform all trim operations; and 2) Instruct employees to use a power grip if a straight in-line knife is to be used. ABATEMENT NOTES: The following are among other feasible and acceptable abatement methods to correct these hazards: (1)Proper engineering design of the job, work stations, and equipment so that the work can be performed independent of specific worker characteristics and techniques, evaluating and modifying as necessary. A qualified ergonomic consultant should conduct this evaluation, seeking employee input. Jobs should be classified as to the nature and extent of exertion. (2)Instituting administrative controls, including the following: a)Training new employees in safe work techniques b)Working with minimum strain on the body and minimizing the application of forces with the fingers c)Job rotation and job enhancement, allowing for as much variation as possible in the distribution and frequency of musculoskeletal activity d)Adequate mandatory rest breaks e)Implementation of an exercise program (3)Hiring of a properly trained ergonomic consultant to assist in an analysis of all jobs, training employees and implementing therecommendations made. (4)Implementing a medical management program to monitor employees and prevent early symptoms from progressing to