Understanding and Eliminating Ergonomic Risks

Transcription

1 Understanding and Eliminating Ergonomic Risks Nathan Rucker, PhD, CPE Sagittal Systems, LLC 811 Clermont St Dallas, TX Agenda Framework for Success Ergonomics Injuries Ergonomics Risk Factors Eliminating Ergonomics Risks Applying Principles Fabrication areas Sub-fab Manufacturing Office environments 2 1

2 Framework for Success Understanding Ergonomics Risks 1. Knowledge of types of ergonomics injuries and the etiology 2. Understand ergonomic risk factors Eliminating Risks 1. Utilizing standard methodology to evaluate and prioritize risks and ROI 2. Target actions that are achievable rather than going for the homerun (small ball) 3. Evaluate risk reduction success 4. Highlight wins to key stakeholders and decision makers as both risk reduction and productivity gains 5. Use program effectiveness to drive further support and implementation 3 Ergonomics Injuries Cumulative Trauma Disorders Biomechanical trauma built up over time that usually results in an inflamed tendon or other soft tissue. Nerves Tendons Neurovascular Injuries lead to high WC cost and many days away from work. 4 2

3 Ergonomics Injuries Overexertion Exceeding the capacity of a group of muscles or other soft tissue resulting in strain or sprain. Common cause of back and shoulder injuries. Most common type of ergonomics injury. Muscle Soreness Exceeding the immediate capacity and endurance of muscles resulting in soreness and weaker muscles. Result of long work hours or performing a new task. Often leads to an overexertion injury. 5 Ergonomics Risk Factors FORCE REPETITION BIG 3 POSTURE 6 3

4 Force and Repetition + = Increased Risk for Injury 7 What about Posture Non-neutral postures can further increase the injury due to the increased compressive forces and friction placed on tendons at joints. The more weight or greater the muscle exertion the more stress placed on tendon. 8 4

5 Epidemiological Evidence Jobs with High Force and High Repetition are at an increased risk of contributing to the development of CTS Repetition is defined as cycle time less than 30 seconds or more than 50% of the time performing an exertion High force is defined as greater than ~10 lb of force per hand Strong evidence exist that a combination of risk factors leads to the development of MSDs 9 Posture as a single risk factor NO. Usually Body position + Low level exertions = Muscle Fatigue OR Un-natural posture + High Force = Overexertion 10 5

6 More Work Related Risk Factors Vibration Static postures Contact stress Extreme temperatures 11 Other Contributing Risk Factors ENVIRONMENT PSYCHOLOGICAL WORK LOAD (STRESS) 12 6

7 Personal Factors General health Surgical history Stress home Smoking Obesity Home and Sporting activities 13 Locations where you find risks Cumulative Trauma Disorders When person is assigned to one specific tool or set of tools with the same basic function Rarely seen in semiconductor manufacturing and production environments SEMI Design standards Industry and Employee Experience Ergonomic interventions Fabrication Sub-fab Manufacturing Office Metrology, Diffusion, Manual wet benches, Wafer starts No Not usually in the SEMI industry Yes 14 7

8 Locations where you find risks Overexertion High concern due to aging population, less conditioned work force, and smaller populations. Result of muscular fatigue and lack of muscular recovery Shift work or long work hours Material storage out of proper lifting range Large equipment requiring larger components with limited clearances Fabrication Sub-fab Manufacturing Office Maintenance tasks, Diffusion, Implant, Parts clean areas Generators, Pumps, Bottle Changes, Facilities activities Yes Lifting 15 Locations where you find risks Muscle soreness The work pace of many jobs in the fab is controlled by speed of the equipment Results in down time or time that is spent monitoring equipment Common in jobs that are static or are primarily sedentary Fabrication Sub-fab Manufacturing Office Metrology, Yield, Tool cleaning, Annual PM tasks Multiple activities Multiple activities Low back and neck 16 8

9 Identifying jobs with ergonomic risk Cumulative Trauma Disorders Various tools including Strain Index, RULA, TLV-Hand Activity Level Early reporting leads to identifying jobs and task that could potentially lead to cumulative injuries Benchmark with other semiconductor companies Overexertion Assess tasks with material handling analysis tools NIOSH Lifting, Psychophysical, Biomechanical models Employee surveys 17 Identifying jobs with ergonomic risk Muscle Soreness Discomfort surveys Assess jobs or maintenance task that require static unneutral postures Review jobs and compare with data for time to fatigue based on body position Determine rest allowances based on level of work RPE surveys to determine exertional demands and then assess time to fatigue 9 18

10 Eliminating ergonomic risks 1. Score jobs according to risks 2. Determine potential solution 3. Calculate ROI Do not forget to include productivity gains Ergonomics is a discipline of Industrial Engineering 4. Attack simple solutions first or those that offer the most bang for the buck Not all solutions have to be perfect or high cost. Implementing some changes or eliminating a single risk factor can often significantly reduce the overall risks. 19 Phase of Ergonomics Program Growth Short Term Long Term Loose focus and struggle to find and implement solutions Quick growth by eliminating easy to solve problems. Mature Program Someone spearheads the effort and progress is again realized. Simple Complex 20 10

11 Semiconductor Examples 21 Wafer Fabrication Product Loading, Controls & Monitors, Product Storage 22 11

12 Wafer Fab Solutions Modify workstations to accommodate a range of users Standardized method to safely handle cassettes Keep WIP and other storage between knees and shoulders with heavier Modify tool load stations to promote good hand/wrist postures Replace loading tool designs with more ergonomically designed tools Ensure adequate clearances 23 Maintenance Tasks Heavy Lifting and Poor Postures? 24 12

13 Other Fab Related Tasks 25 Maintenance and Other Tasks Solutions Follow recommendations from suppliers Purchase lifting assist Ensure adequate work space around tools Limit static work positions and bad postures Train on the importance of changing body positions Ensure personnel understand their limits Partner with suppliers to develop solutions Benchmark with other companies to share solutions 26 13

14 Manufacturing 27 Manufacturing Solutions Tooling and Fixtures Integrate ergonomics design and lean principles for equipment and manufacturing process Lifting aids and work positioners Proper material storage Pre-fabrication or kit materials Training for employees Facility design 28 14

15 Office Ergonomic gadgets do not replace proper set-up or translate to ergonomics success. Pay close attention to laptop usage in conference rooms and during travel. 29 Office Solutions Teach basic workstation set-up principles Purchase ergonomics chairs Many great solutions from reputable furniture companies available at low costs (i.e. Haworth) Encourage breaks Eliminate printers from workstations forcing people to get up and move Controls lighting; both external and internal 30 15

16 Ergonomics Program Benefits Reduced Injuries Reduced Waste and Scrap Increased Productivity Increased comfort and morale 31 Conclusion Consider all potential risks when talking with employees an performing assessments Usually employee will perform a task using the quickest method Develop solutions with employee involvement Work with other companies to develop or share solutions Small changes and improvement is better than NO improvement Ergonomics solutions must increase productivity 32 16

17 Additional General Information 33 General methods to limit/reduce risks Cumulative Trauma Disorders Insure work areas meet SEMI S8 Promote job rotation and cross training for employees Development and use of ergonomic hand tools Limit time of holding or carrying equipment by provide material handling equipment Automation system Carts 34 17

18 General solutions to limit/reduce risk Overexertion Standardized heights and guidelines for material storage Limit lifting and provide lifting tools where necessary Provide appropriate hand tools T handles Power drivers Instruct employees on the basics of recognizing a potential situation where overexertion might occur 35 General solutions to limit/reduce risk Muscle Soreness Programs to generate more movements Stretching programs and incentives Wellness programs Job rotation and cross training JHA s and job coaching identifying proper methods to perform tasks Shoe program Stretching 36 18