Ergonomics: applying science to job design - includes related article - Cover Story

Prepared Foods, April, 1993

Reconfigured workstations and modified work procedures not only reduce injuries and illnesses, but improve worker morale, line efficiency, and product quality.

ENVIRONMENTALLY CORRECT--a term normally associated with the recycling, treatment, and disposal of wastes--may take on a new meaning in food plants as the workplace environment comes under increasing scrutiny and regulatory enforcement.

To operate "environmentally correct" facilities in the '90s, food companies are going to have to establish some type of ergonomics program to ensure the safety and well-being of their employees. While this may seem straightforward, the creation, implementation, and monitoring of an ergonomics program is not a simple procedure with easy-to-follow signposts.

Ergonomics, the study or science of job design, is in its formative stages. And like many other disciplines, ergonomics is not an exact science. "Two persons standing side-by-side doing identical tasks may develop very different cumulative trauma disorders (CTDs), or one worker may develop CTD symptoms while the other is unaffected," explained Rodger Bliese, senior ergonomics coordinator, The Hormel Foods Corp.

6000 JOBS ANALYZED

Founded in 1985, Hormel's ergonomic program is one of the most sophisticated and progressive in the food industry. At its headquarters in Austin, Minn., a corporate steering committee made up of vice presidents, safety directors, ergonomists, engineers, and managers oversees the ergonomic activities at 24 plants.

At the plant level, ergonomic committees consist of safety directors, engineers, supervisors, and hourly workers. "We support the plant committees through training, education, audio/visual aides, seminars, booklets, survey forms, an ergonomics newsletter, and a review of the programs," noted Bliese, a member of the corporate steering committee.

Surveying of workers and job analysis are key components of Hormel's program. "We conduct 'symptom surveys' to find out what parts of the body are working the hardest or are under the most stress," declared Bliese. "Committee members also perform actual tasks or simulate the jobs to uncover any problems. Videotaping is another method we employ to analyze worker movements."

To date, Hormel has studied more than 6000 jobs. Data collection includes postures, forces, repetitive motions, ambient conditions, etc. "Our extensive analysis enables us to identify those jobs that require immediate corrective action," stated Bliese. "About 90% of our remedial actions are relatively small in nature. They include engineering controls--workstand heights, conveyor positions, lighting, counterbalances on tools, lifting devices, mechanization and automation of manual operations, and redesigned handles for tools."

WORKER INVOLVEMENT

"The success of any ergonomics program depends on employee involvement and input from workers," declared Judi Freyman, director of safety, health, and environmental affairs, Armour Swift-Eckrich. "Unions have been very receptive to our ergonomics program because they understand the severity of the problems and want to work with us to seek solutions. Occasionally we get resistance from senior workers, who may not want to rotate jobs with workers having less seniority."

At Farmland Foods, suggestions from plant workers have led to numerous job modifications, workstation changes, and the building of custom-designed machines. One such machine--built by the in-house maintenance department--automatically pops open flat corrugated cartons. Performed manually in the past, this highly repetitive task was associated with CTDs.

WHERE TO START?

While many companies like Hormel, Farmland, and Armour Swift-Eckrich have well-established ergonomic programs, some food companies are probably in the early stages or have no formal program in place. For these companies, the number one ergonomics question is: "Where do I start?"

Published by the Department of Labor/OSHA, the "Ergonomics Program Management Guidelines For Meatpacking Plants" booklet provides an excellent framework for creating and managing safety procedures. While not a standard, the guidelines are applicable to all food manufacturing sectors.

(Editor's Note: On August 3, 1992, OSHA published an Advance Notice of Proposed Rulemaking on Ergonomic Safety and Health Management. According to the proposed rules, OSHA is considering the development of an ergonomic safety and health management standard covering general, maritime, construction, and agricultural industries. The comment period for this proposed rule ended February 1, 1993.)

"An ergonomics program starts with management commitment," declared Mike Fagel, corporate safety director, Aurora Packing Company. "Other key features include worksite analysis, hazard prevention and control, education and training, and medical management."

"Companies should review their OSHA 200 logs to determine which jobs have the most hazards or stressors," stated David J. Cochran, professor of industrial engineering, University of Nebraska-Lincoln, and a consultant to OSHA. "The jobs with the most hazards involving the most workers should be tackled first."