Ergonomics Process Consulting - Lessons Learned at a Large Midwest Manufacturer

Abstract

An ergonomics process was created at a large Midwest manufacturing plant that included a unique combination of known best practices for ergonomics programs, behavior-based safety principles, and post-injury management principles. A four-phase consulting process (Discovery, Design, System Up, and System Check) was used to assist the client in tailoring a process to its culture. The process resulted in the formation of six teams, the creation of a steering committee, and the development of a document that describes all aspects of the process. The client's loss frequency rate was reduced by 16% and loss cost rate was reduced by 43% during the first year. Several “lessons learned” were noted during this project. These include: job evaluation tools for supervisors need to be very simple and brief, ergonomics processes may reduce losses sooner than expected, all Cumulative Trauma Disorder (CTD) injuries should be investigated using the referral process created, common tracking forms should have been developed during Design, and job improvement follow-up needed better tracking.