Transcript ERGONOMICS FOR WELDERS

Ergonomics in Welding
An overview of WMSDs* hazardous
exposures and solutions
*Work-related musculoskeletal disorders
What will You learn
• Identify WMSDs hazardous
exposures in welding jobs
• Propose solutions for hazardous
exposures
• Find further information about
ergonomics in welding operations
Hazards
Welding operations are necessary in many
industries such as construction,
manufacturing, maintenance, etc.
Welding has several hazardous conditions for
women and men in these jobs.
Hazards
Common hazards found in welding are:
inhaling metals fumes,
eye exposure to welding arc light (UV, visible),
foreign objects in eyes,
burns,
noise,
cuts, bruises, etc.
WMSD Hazards
Welding also includes musculoskeletal disorders
(WMSD) hazards such as:
awkward body postures,
lifting heavy equipment or materials,
static postures for prolonged periods,
awkward postures of the wrist, etc.
WA State-funded compensable claims 1994-2004
Welders, Cutters, Solderers
By Nature of Injury
Other
13%
Sprains account for
more than 1/3 of the
compensable claims
among welders in the
State of Washington.
Some of those could
be caused by
hazardous WMSD
exposures.
Neural
5%
Sprains
32%
Ill-Def
Symptoms
9%
Hearing loss
11%
Fracture/
Dislocation
14%
Contussion/
Cut/
Scratches
16%
WA State-funded compensable claims 1994-2004
Welders, Cutters, Solderers
By Body Part
The back, neck and
shoulder together with
the arm and hand
regions make up more
than one half of the
injuries among welders
in Washington State.
Preventive efforts
should therefore focus
on those body parts
among welders at your
workplace.
Other
15%
Back/Neck/
Shoulder
28%
Ears
11%
Foot/
Leg
20%
Hand / Arm
26%
Welding is a strenuous occupation involving
work in awkward postures and handling
heavy equipment, usually with a high degree
of sustained stress to arm and shoulders.
Consequences of a poor working environment
• Absences due to injury or illness
and the transfer of welders to
other tasks
• Overtime for replacement
workers. Welders are skilled
employees
• High employee turnover
• Increased training and
supervisory time
• Reduced productivity and quality
WMDS hazards most common in welding
OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT
• Rigorous manual precision
requirements
– High degree of uniformity
• Awkward and static postures
– Difficult work position
• Heavy lifting, difficult material
handling
– Heavy objects, heavy welding
equipment
• Repetition
– High work intensity
Hazard Elements
Duration (how long?)
Frequency (how often?)
Intensity (how hard?)
Common postures adopted in welding
Working in
front
Working at
ground level,
precision work
Working at
ground
level
Working at
ground level,
confined space
Working
above the
shoulders
Working above
shoulders,
confined space
‡From: Torner et al, 1991
Awkward postures in welding
Severe torso flexion
Torso twisting
Kneeling, squatting
Bent wrists
Neck flexion/extension
Shoulder flexion/abduction (separation)
The goal of a healthy work environment
To simplify the welding performance for the
welder and reduce the physical load during
the work
•Automate physically demanding or
repetitive jobs
•Expand the work content of welders
(provide flexibility between jobs)
– Multi-skilled workers who are able to
perform different tasks within a group)
The Real World
• Often cost, ease of maintenance, space
considerations drive the design process
• When hazards can’t be engineered out,
using best practices is the alternative
• Examples of good design: providing
opportunities for adjustments, providing
different sizes, using good planning to
eliminate unnecessary work
Possible Ergonomic Improvements
Heavy Lifting
•
•
•
•
•
•
Manipulators
Lighter welding
equipment, easier to
handle
Using lighter cables
with low stiffness
Use cable supporting
devices
(balancers)
Utilize overhead
hoists
Utilize lifting and
turning tables
Ergonomic improvements
Awkward Postures
•
•
•
•
•
Position work between
waist and shoulder,
when possible
Lifting tables
Motorized positioning
devices
Use welding guns with
swivels and designed
for use in both hands
Work stool
Ergonomic improvements
Team lifting helps
reduce heavy,
awkward lifting of
equipment and
materials.
AFTER
BEFORE
From: SIMA San Diego Ergonomics Program
Ergonomic improvements
To reduce working
with the back bent at
ground level, any
work table will help
to adopt a safer
posture
AFTER
BEFORE
From: Shipyard Ergonomics, 2003
Ergonomic improvements
Pre-assembly and
material handling
equipment helps reduce
unnecessary lifting or
any other kind of
manual material
handling
Ergonomic improvements
This rotational clamp
for pipe helps reduce
awkward postures for
the neck, shoulders
and arms.
Ergonomic improvements
Tables for welding
and transport reduce
manual lifting,
carrying of heavy
materials.
The tables also have
wheels.
Ergonomic improvements
Welding leads on
pulleys help reduce
heavy and awkward
lifting, static postures
for long periods.
Ergonomic improvements
Robotic automation, are
also feasible solutions to
highly repetitive motions
with the arms and
hands. May also reduce
the exposure to fumes.
Possible Consequences
Not implementing
some or all these
ergonomics guidelines
may result in the
following…
Work-related musculoskeletal disorders
They are cumulative
(occur over
time and not a result of a single incident):
•Often occur when the
physical demands of work
cause wear and tear
•Involve soft tissues such
as muscles, tendons,
ligaments, joints, nerves,
blood vessels
Work-related musculoskeletal disorders
They are not acute injuries such as:
•Broken bones
•Cuts
•Slips
•Falls
•Trips
•Motor vehicle accidents
•Being struck by or
caught with objects
Common disorders among welders
• Back injuries
• Shoulder pain/loss of range of motion
• Tendinitis/Bursitis
• Reduced muscle strength
• Carpal tunnel syndrome
• White finger
• Knee joint diseases
The Ergonomics Cycle
Management
Support
The ergonomics cycle
provides with an
organized way to
start your
ergonomics effort.
Employee
Involvement
Problem
Identification
Evaluate
progress
Solution
Implementation
Training
Address
Injuries
Credits
The technical contents of this
slideshow are based upon the
presentation developed by
Ninica Howard, MS, CPE,
research ergonomist with the
SHARP program at the
Washington state Dept. of
Labor and Industries.
More resources
•Shipyard Ergonomics for purchase at Shipbuilders Council of America at
www.Shipbuilders.org
•NIOSH’s Ergonomic Interventions in the Building, Repair, and
Dismantling of Ships
•SHARP Program
•Easy Ergonomics. A practical approach for improving the workplace OR
OSHA & CAL OSHA Services. www.cbs.state.or.us/osha/pdf/pubs/3347.pdf
•On WMSD hazardous exposures visit the WISHA webpage at:
www.lni.wa.gov/Safety/Topics/Ergonomics
•Example Template of an accident prevention program :
•www.lni.wa.gov/Safety/Basics/Programs/Accident
•Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas
Bank
•You may also write us at:
•[email protected]
Thank you