To: Company: From: Fax: Phone: Date: Project#: Pages:

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1 Consultants in Ergonomics To: Company: From: Fax: Phone: Topic: Date: Project#: Pages: Pricing Proposal Engineering Proposal Walter; As per our meeting on July 13, 2004, here are the ergonomic engineering options for your consideration. In the meeting we identified 15 potential operations that may need to be evaluated. Pricing is based on those 15 operations. Samples of the engineering and physical demands analysis can be found in the appendices. Pricing is for professional fees only. Travel expenses will be billed separately as stated in the attached conditions form. Option 1: Conduct Initial Assessment Initial Assessment: 15 $ each... $9, Includes a rudimentary task analysis and is the beginning point for each engineering or work method improvement - Evaluate task demands relative to Ergonomics and define the current acceptability of the task/workstation combination in terms of flow, error potential aspects of the design, and risk factors for Work Related Muscular Skeletal Disorder (MSD s) - Documentation of physical demands of the operation (Appendix B) Option 2: Human Performance Engineering Solutions Engineering solutions: 15 $3, each... $45, Includes task analysis, Quantified statement of risk - Lift/Lower, Push/Pull and carrying analysis, Recommendations to address opportunities - Ergonomic risk reduction by recommendation - Prioritized project action plan, with vender phone numbers and cost - Video record of each operation analyzed - Documentation of physical demands of the operation 1

2 Option 3: Workstation Concept Design Support Drawings support: 15 $ each... $7, Includes concepts drawings of proposed workstation changes - Critical dimensions to illustrate recommendations Option 4: Productivity Analysis: 15 $ each...$7, Documentation of current cycle time - Productivity impact listed by ergonomic recommendation - Statement of overall impact on operation (Appendix A) Option 5: On-site Preliminary Design Review Present and review: 1 day on $1,000.00/day... $1, Review report with ergonomics team - Discuss solutions presented - Develop project plan with timelines and responsibilities Option 6: Daily Consulting Activities Site visits or Daily consulting... $1,200.00/day - Perform facility review and document ergonomics issues - Discuss with site personnel potential solutions - Deliver report with prioritization of issues and potential solutions - Perform consulting activities as requested by the site - Perform project management tasks (find and meet with vendors, cost analysis, etc.) I will be returning to the office September 21 in the meantime feel free to call my associate if you wish to discuss the proposal before then. Once we have confirmed the project, I can propose a project schedule to efficiently meet your needs. Regards, Telephone: Fax: 2

3 APPENDIX A Sample Engineering Review 3

4 "Bumper Install" Task Description The bumper install operation was studied at the Ford Plant. The purpose of this job is to install the rear bumper, weighing 70 pounds, onto the 2003 F150. Two associates were observed performing the following tasks. Workstation Preparation Install brackets Install bumper Final assembly Associates are scheduled to work eight hours per day, and production take time is one vehicle per nine minutes. The associates rotate to other assembly operations every four hours. This report evaluates each of these tasks individually and provides recommendations for ergonomic and efficiency improvements. A risk assessment, using the REBA survey, a lifting analysis, using the NIOSH Lifting Equation, as well as a work methods analysis, using Motion Time Measurement were performed. Proposed Workstation Redesign The proposed workstation is a combination of individual recommendations that have the greatest impact on ergonomic risk and cycle time. Each of the recommendations is discussed in detail later in the report, with illustrations where required. These recommendations are listed below, with corresponding page numbers listed in parentheses. For the Bumpers operation, the proposed workstation redesign includes: Automatic Hoist Settings (7) Flexible Task Lighting (18) Adjustable Height Cart (8) Pulse/Auto Shut-Off Drivers (19) Lift, Rotate Table (9) Tool Wrap (20) Light Activation Sensors (10) Move Cord (21) Lower Hoist Control (11) Flags on Hoist Ramp (13) Improved Anti-Fatigue Matting (22) Box Cutter (24) Mirror Above Hoist (14) Parts Apron/Tool Belt (25) Right Angle Tool (15) Move Hoist Control to Driver Side, Rear of Vehicle (26) Swivel Hose Coupling (16) Smaller Hoist Ramp (17) Hoist to Lift and Align Bumper (27) These recommendations will significantly reduce or eliminate all major risk factors (see table below) and could reduce the overall cycle time of 4.4 minutes by 1.1 minutes, or 25.0%, to 3.3 minutes. Projected REBA Score Reduction Current Projected Reduction

5 Time (minutes) Takt Time 4.4 Current Cycle Time 3.3 Proposed Cycle Time Summary of Cycle Time Impact A summary table of recommendations is provided identifying the cycle time reduction from recommendation implementation. Recommendation Task Addressed Projected Cycle Time Savings 1 Automatic Hoist Settings 41.8 seconds 2 Adjustable Height Cart 1.3 seconds 3 Lift and Rotate Table 0.6 seconds 4 Light Activation Sensors 1.3 seconds 5 Lower Hoist Control 0.6 seconds 19 Parts Apron/Tool Belt 4.4 seconds 20 Move Hoist Control to Driver 17.5 seconds Total Cycle Time Savings 67.5 seconds (1.1 minutes) Summary of Lifting Impact A summary of recommendations that address lifting concerns, as calculated with the NIOSH lifting equation, is provided below identifying the impact on the recommended weight limit (RWL). The current RWL for lifting 50 percent of the 60 pound bumper (30 pounds) to the vehicle height of 68 inches is 15 pounds with a lifting index (LI) of 2.0, placing a percentage of the work force at risk of injury from performing this lift. Recommendation Recommended Weight Projected Lifting Index 1 Automatic Hoist Settings 30.3 pounds Hoist to Lift and Align Bumper Manual lifting of bumper is eliminated N/A 5

6 Evaluation of Recommendations The recommendations described above have been rated according to impact and ease of implementation. The numbers in the following figure correspond to those used in the Summary of Recommendations table. The recommendations in Region 1 reduce the task REBA score by one or more points and require few resources to implement. The recommendations in Region 2 require few resources to implement and represent reductions in risk. However, these ideas alone will not reduce the REBA score for the applicable tasks. The recommendations in Region 3 reduce the REBA score by one or more points, yet require several resources to implement. Those recommendations in Region 4 require several resources or involve other process to implement and do not affect the REBA score. Recommendations Recommendations are provided and have been rated according to impact and ease of implementation. Each recommendation is described by one of the following four regions. Region 1: These recommendations decrease the task REBA score (reduce risk) for one or more body areas by one or more points with minimal resource requirements. Implementation timeline is projected at 30 days or less with a projected cost of less than $2,000. Region 2: These recommendations may not change the task REBA score; however, they represent significant reductions in risk. The recommendations in this category can be implemented by associates or supervisors within 30 days with a projected cost of less than $2,000. Region 3: These recommendations decrease the task REBA score for one or more body areas by one or more points, but either the time to implement is greater than 30 days or the projected cost is in excess of $2,000. The recommendations in this category are usually assigned to engineering or management. Region 4: These recommendations may not impact the task REBA score and require many resources to implement. These ideas are best left for the development of a new facility or installment of a new line. Vendor, cost, and phone information is provided for each recommendation, where applicable. HIGH IMPACT DIFFICULT TO IMPLEMENT Region 3 Region 1 EASY TO IMPLEMENT Region 4 Region 2 LOW IMPACT 6

7 Region 1 Automatic Hoist Settings Task(s) Addressed: Risk Factor(s) Addressed: Finger press 10 sec., Wrist extension sec., Full elbow extension, Shoulder raised sec., Neck sideways Cycle Time Reduction: 41.8 seconds Use programmed hoist settings to reduce the duration of risk postures while holding down the lever and to reduce reaching and twisting while watching the vehicle move. As the associate presses the lever, he or she monitors the vehicle height, causing elbow extensions, shoulder raising, and neck turning. If the controls were programmed with a preset lift height, the associate would only need to activate the control once, without static pressing or monitoring. While the hoist is moving, the associate is free to perform other preparation activities, saving 41.8 seconds. Having multiple level settings may allow the associates to install the bumper at a lower setting and secure the bumper at the higher setting. The maximum height to install the bumper is 48 inches above the standing surface. This increases the RWL from 15 pounds to 30.3 pounds, placing the majority of the working population at nominal risk from performing this lift. To accommodate this loading height, the following preset hoist settings would be necessary. Ground Level (0 inches) Bumper Load Level (15 inches) Bumper Secure Level (35 inches) 7

8 Adjustable Height Cart Task(s) Addressed: Risk Factor(s) Addressed: Full elbow extension, Neck bent 20, Back bent 20, sideways, Stand on 1 leg Cycle Time Reduction: 1.3 seconds Vendors: Grainger (503) Vestil Manufacturing (800) Southworth (800) Lafis Material Handling Group (800) Fredon Handing, Inc. (800) Cost: $500 Provide the associates with an adjustable height cart to reduce extended reaching and back and neck bending while retrieving parts. Currently, the height of the cart is 31 inches, causing the associates to assume high risk arm, neck, and back postures while retrieving components and tooling. An adjustable height cart allows the associates to raise or lower the cart based on their individual anthropometry. The recommended range of heights for the cart is 33 to 37 inches above the standing surface. Raising the part and tool retrieval height could lead to a cycle time reduction of 1.3 seconds. 8