Transcript Slide 1

Ergonomic Risk Reduction Process
Long Beach P&DC
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
The End
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Long Beach P&DC
Core Team Mission
We are fully committed, through the co-operation of APWU, NPMHU, OSHA, and
USPS, to an on-going employee driven ergonomic risk reduction process that will
reduce ergonomic risks at the Long Beach P&DC. Our goal is to identify risks that can
cause wear and tear on the human body known as Musculoskeletal Disorders (MSDs).
We will make every effort to eliminate or reduce those risks thus improving the quality
of life for our fellow employees, at home and in the workplace.
We will achieve our mission through:
- Changes to the workplace based on task analysis, individual needs, and
suggestions from employees
- Proactively implementing changes to improve safety, comfort, and function
in all work areas
- Educating employees on effective ways to reduce ergonomic risks
- Emphasizing communication, training, employee feedback and participation
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
“Working Together to Make a Difference”
On April 20, 2006 the Long Beach P&DC became the 108th
postal facility to adopt the Ergonomic Risk Reduction
Process (ERRP). Since then, the ERRP Site Core Team
has been seeking ways to prevent, reduce or eliminate
risks factors encountered by employees as they perform
their daily tasks. The Teams have conducted training,
acquired new equipment and modified work methods in
the effort to reduce Musculoskeletal Disorders (MSDs).
With the support of the Plant Manager, Mail Processing,
Maintenance, IPS and fellow employees the Core Team
achieved the goals set forth by HQ ERRP.
In recognition of their accomplishments, the Core Team
celebrated their 1 year anniversary on April 24th with a
luncheon hosted by Plant Manager David Shapiro.
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Long Beach P&DC
MSD RECORDABLE INCIDENTS YTD
FY 2002-2007
FY07, 3
FY06, 14
FY02, 26
FY05, 17
FY03, 16
FY04, 23
FY02
FY03
FY04
FY05
FY06
FY07
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Long Beach P&DC
WORK HOURS
2007 WK HRS
2006 WK HRS
2005 WK HRS
2004 WK HRS
2003 WK HRS
2002 WK HRS
1334604
1904633
1739212
1667313
1718626
1778049
2007
INCIDENTS
2006
INCIDENTS
2005
INCIDENTS
2004
INCIDENTS
2003
INCIDENTS
2002
INCIDENTS
R23
0
2
1
2
5
7
R2
1
6
9
8
7
14
R910
1
2
2
0
1
2
R9
0
3
5
10
1
2
MSD Reportables [009 080 081 090 091 100 101
110 111 120 121]
11
24
24
27
28
33
MSD Recordables [excludes 'N','NX','NY' & 'NZ']
3
14
17
23
16
26
H/L
0
3
9
13
10
9
LWD [R23 R910]
1
4
3
2
6
9
RWD [R2 R9]
1
9
14
18
8
16
#1) From eFlash reports
FINANCE # 054483 LONG BEACH P&DC
INJURIES
ILLNESSES
[080 081]
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Long Beach P&DC
2007
2006
2005
2004
2003
2002
#2) TOTAL Reportable I&Is
27
53
52
59
71
62
#3) TOTAL Recordable I&Is
14
29
32
38
28
34
MSD Rate
0.45
1.47
1.95
2.76
1.86
2.92
Handling & Lifting Rate
0.00
0.32
1.03
1.56
1.16
1.01
Lost Work Day Rate
0.15
0.42
0.34
0.24
0.70
1.01
Restricted Work Day Rate
0.15
0.95
1.61
2.16
0.93
1.80
RECORDABLE:
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Long Beach P&DC
It doesn’t always take rocket
science to fix a problem!
Some of our simple household
and recreational items make
great solutions…………….
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Stuck again! Why bend
and reach?
When you can simply
push with a boat
hook!
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Some tools are very
versatile!
Boat hooks are one of
them!
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Help, I’ve fallen and I
can’t get up!
Now this does the trick!
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Spotlight - Sack Wrench
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Rodney Fajardo, a mail processor approached the Tour 3 Core
Team with his idea for a tool to facilitate opening priority
pouch clasps. He had modified a small 3” box wrench.
A task analysis was conducted and the risk factors identified:
Forceful motion of the fingers, hand and wrist
Awkward posture of the fingers, hand and wrist
Repetitive motion of the fingers, hand and wrist
Fatigue of the fingers and hand
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After “brainstorming”, we elected to try the same solution and
researched where to purchase a sufficient quantity.
Upon communicating with other ERRP sites, we discovered
Postal Products had a “sak wrench” available. Michele
Paturzo, our Field Coordinator sent us samples for review.
The “sak wrench” did not meet all of our needs and we
decided to develop our own design.
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Samples > Concept > Prototypes
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Communication > Contacts > Estimates
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After selecting the design, Melvin Jones created a prototype.
We contacted our Maintenance Dept. who was not able to produce them
for us in house.
We researched where and how we could acquire the quantity we needed.
Patty Roberts, Site Coordinator for Minneapolis/TWC recommended a
company they had used for previous projects; Quality Tool Mfg.
We determined where the sack wrenches were needed and how many we
needed to order.
We contacted Quality Tool and sent them our prototype, a belt and clasp,
and a .mpg file demonstrating the purpose of the sack wrench.
Estimates
Postal Products
$3.50 approx. each
$5.67 approx. each w/plasticoat
Quality Tool Mfg.
$3.57 each
$3.67 approx. each w/plasticoat
(dipped by Team)
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Prototypes > Selection
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Final product
Quality Tool Mfg.
Sack wrench - $3.57
Eezer grip - $ .40
Cost $3.97 each
75 wrenches - $267.75
125 grips - $55.00 including S/H
Total cost - $322.75
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Before and After
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
More success stories
The following photos represent successful
projects from each Tour
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Before and After
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Before and After
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Before and After
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Before and After
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Before and After
ERRP Leadership Training – July 2007
Ergonomic Risk Reduction Process
Before and After
ERRP Leadership Training – July 2007