Text For Citation: 02 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: (a) The hazard(s) of cumulative trauma disorder(s) due to re- peated hand, arm and wrist exertions during repetitive tasks and the resultant injurious effects of carpel tunnel syndrome, ten- dinitis, numbness of hands and arms and shoulder sprains and strains. Ergonomic evaluations were not performed to identify and subsequently modify such operations to reduce worker expo- sure. (1) In the molding department, molding machine operators were exposed to identified ergonomic risk factors, resulting in the developmen of cumulative trauma disorders caused by the repetitive tasks involved in the operation of the ma- chines including the carrying and stacking of tote bins, man- ual inspection and reaming of parts, and the use of sizing bars for funnel shaped part. (2) In the assembly department, assembly machine operators, including those at work stations #104, #153, #741, chrysler #604 and F100, were exposed to identified ergonomic risk fac- tors, resulting in the development of cumulative trauma dis- orders caused by the operation of single station and multiple station/turntable presses and other repetitive tasks in- volved. Additional stressors associated with this job in- clude the carrying of tote bins and the use of improperly sized hand tools. Among other methods, feasible abatement methods shall include: (1) Utilize ergonomic-engineering studies to identify the worker job asignments which have a prevalence of cumulative trauma disorders due to the repetitive tasks performed. De termine appropriate engineering and/or administrative con- trols to be implemented which will reduce the incidence of cumulative trauma disorders. (2) Develop a comprehensive education program which will provide information and training to employees and management regarding the general factors involved in cumulative trauma disorders, work practices for the repetitive tasks which will minimize the levels of mechanical forces applied and the num- ber of repetitive motion patterns and the introduction to work station and/or operation changes to be implemented. (3) Improve the medical services program to provide evalua- tion/examinations pertinent to worker medial nerve distribu- tion and muscular aberrations. The data obtained may be used to determine job assignment options for workers assigned to perform repetitive tasks either before assignment or subse- quent to surgical corrections. (4) Implement the above controls and establish an ongoing audit program to ensure the continued effectiveness of engi- neering, administrative and work practice controls selected. Emphasis shall be placed on the following ergonomic aspects identified as applicable to the operations listed above: (1) Molding department: (a) Removal of metal sizing bars (used for the moldings which have funnel type openings) from the edge of the work tables when not needed, and utilize cushioned edges for worker arm/elbow support(s). (b) Use of ergonomically designed workstations which include adjustable chairs equipped with back, seat and foot supports to provide proper postural support to the back, legs and shoulders. Ensure adequate clearance is provided for the operator(s) legs and thighs under the work table. (c) Modify the handles provided on the tote bins to provide a contoured gripping block or cut out and allow workers to use a hook grasp rather than a finger grip. (d) Implementation of work practice controls to limit the stacking of tote bins containing parts/materials so that the operator(s) do not lift above the shoulder and- /or provide combination roller conveyor/hydraulic table which would allow the operator(s) to keep the bins at the proper height for stacking. (2) Assembly department: (a) Evaluate the height of overhead two-hand controls used to operate presses #5, #213 and the press used for the 604 Chrysler subassemblies, to limit the operator(s) stretching their shoulders and arms above shoulder height to initiate the cycle. (Control location must meet the requirements of 1910.217 (c) for safe distance requirements.) Continue with the modification of press 2-hand controls from palm buttons to light beam con- trols. (b) Redesign the tool used for the manual spreading of glue on the 153 filter assembly line to reduce the flex- tion to the operator(s) wrist, pressure applied to the index finger and lateral extension of the elbow. As an interim measure, provide the workers with glue spreader tools that allow the spreading to be performed while the workers hand and wrist are in the neutral position. Provide a powered turntable that will rotate the metal filter pieces under the workers hand that performs the spreading. (c) Modify the dispensing port for the automatic glue application on the 153 filter assembly line so that it will spread the glue into the rexessed well of filter assembly and eliminate the need to manually spread the glue. (d) Modify the stacking shelves on presses #45, #41, #5, 153 and 741 assembly stations so that components for the parts to be assembled are at an angle to reduce the degree of flexion to the wrist when retrieving com- ponents. Positioned heights and angles should allow workers to handle materials with shoulder ectension angles of 45 degrees or less. (e) Develop a schedule which limits the number of work hour and/or maximum number of cycles at those stations which have been identified as having tasks involving a high degree or ergonomic risk factors. (f) Implement the use of ergonomically designed work stations which include adjustable chairs equipped with back, seat and foot supports to provide proper postural support to the back, legs and shoulders. Ensure that adequate clearance is provided for operator(s) legs and thighs under the worktable/worksurface. (g) Modify the handles on the tote bins used to carry components and finished products to provide a contoured gripping block, cut out or other arrangement which will allow the use a hook grasp rather than a finger grip. (3) Both Assembly and Molding departments: (a) Ensure the use of highly flexible proper fitting gloves. Offer gloves with high friction surfaces. The combination of proper fit and high friction gloves re- duces the hand/finger grip forces that workes need to exert when performing tasks. ABATEMENT SCHEDUEL Step 1 - Submit to the Area Director a written detailed plan of abate- ment outlining a schedule for the implementation to control employee exposure to undue rekpetitive motion trauma as refer- enced in this citation. This plan shall include at a minimum, target dates for the following: (a) Evaluation of the extent and cause of the hazard. (b) Evaluation of control measure options. (c) Selection of optional control measure(s). (d) Determination of control measure design. (e) Ordering and delivery of equipment and materials. (f) Installation of control measure(s). (g) Training of employees in proper operation and maintenance of control measures and procedures, and (h) Assurance of effective performance of such control mea- sures and procedures. Step 2 - Correction shall be completed by the implementation of such measures and procedures and their effectiveness at achieving compliance verified.