Ergonomics: A Waste of Money or Worth The Investment?
In this episode, Joe and Jen debate if making changes based on ergonomic evaluations are worth the money, and how to get a return on any ergo projects. If you're wondering if JHAs, JSAs, and Ergo assessments are worth the time and effort, this one is for you!
This video is intended for educational purposes. solutions offered are not designed to take the place of an attorney, and should not be taken as legal advice. It is recommended that viewers consult a safety consultant or an occupational safety legal team to navigate their specific circumstances. For educational purposes, videos may show the inside of manufacturing facilities, including meat and poultry production facilities, commercial farming, feed milling, and petrochemical facilities. Images shown may depict individual lines and show employees working in their daily jobs, however these visuals may not be suitable for all audiences. Viewer discretion is advised.
The episodes focus is on ergonomics in manufacturing facilities, specifically meat and poultry production facilities, meat industry further processing facilities, commercial farming, and petro chemical industries is sometimes sidelined. Joe and Jen provide specific examples from industries like poultry processing, where high turnover and physically demanding work lead to frequent ergonomic-related injuries. They stress the importance of ramping up new hires to reduce these risks and suggest that poor ergonomics may even contribute to turnover itself.
A key theme in the discussion is expanding the traditional understanding of ergonomics. Rather than focusing solely on tasks like knife handling or palletizing, the hosts encourage listeners to think more broadly about ergonomic challenges. This could include the strain of long shifts spent standing or sitting, repetitive motions, awkward working conditions, or poorly designed workspaces. They also touch on how environmental factors—extreme heat or cold, for example—can exacerbate ergonomic risks.
Joe and Jen also examine how improperly fitted personal protective equipment (PPE) can lead to ergonomic problems. PPE such as gloves, hard hats, or boots that don’t fit correctly can cause discomfort and even injuries. Jen, in particular, shares her experience as a woman in the workforce, highlighting how much of the PPE is designed for men and often ill-fitting for female employees, leading to discomfort and potential hazards.
Another major topic is the importance of Return on Investment (ROI) when implementing ergonomic solutions. Joe suggests that businesses often hesitate to invest in expensive ergonomic equipment or redesigns, but by focusing on improvements that provide measurable cost savings—such as reducing injury rates and improving productivity—it's easier to justify the expense. Jen adds that ergonomic improvements can also address turnover issues, as high-turnover roles often correlate with ergonomic challenges. Automating repetitive, physically demanding tasks is one solution they propose.
The hosts also talk about evaluating "work design" from an ergonomic perspective, which involves looking beyond the individual task to the overall workflow. For example, a worker might not just be standing or sitting in one spot; they may be moving around an area, stepping over obstacles, or twisting awkwardly. Addressing these hidden risks can lead to significant ergonomic improvements and cost reductions in terms of injuries and maintenance.
Key Takeaways:
Ergonomics Is Often Overlooked: When businesses are under pressure, ergonomic improvements are frequently postponed, yet neglecting them leads to higher injury rates and long-term costs.
New Hires at Risk: In physically demanding industries like poultry processing, new hires are particularly vulnerable to ergonomic injuries, especially if proper work hardening and ramp-up processes are not followed.
Broaden Ergonomic Understanding: Ergonomics isn't just about repetitive tasks; it involves the entire work environment, including awkward movements, environmental factors, and poorly designed equipment.
PPE and Ergonomics: Ill-fitting PPE can cause significant ergonomic problems, especially for women or other employees whose body types differ from the "standard" sizing used for most PPE.
ROI of Ergonomic Solutions: Investing in ergonomic solutions can deliver a solid ROI by reducing injuries, improving productivity, and even lowering turnover in high-risk roles.
Work Design Matters: Ergonomic assessments should include the broader context of the worker’s environment, not just isolated tasks.
Fatigue Increases Risks: Ergonomic risks increase toward the end of a shift when workers are fatigued, making tasks like lifting heavy hoses more dangerous.