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Euro pe an We e k f o r Saf ety

an d H eal th at Work

2000

PREVENTING MSDs IN PRACTICE

In order to encourage improvements,

http://osha.eu.int

especially in the working environment, as

regards the protection of the safety and

Turn your back on musculoskeletal disorders (MSDs)

health of workers as provided for in the

Treaty and successive action programmes

concerning health and safety at the

Work

workplace, the aim of the Agency shall be

to provide the Community bodies, the

Member States and those involved in the

field with the technical, scientific and

economic information of use in the field of

SYSTEMS AND PROGRAMMES

safety and health at work.

Health

and

Safety

for

Agency

European Agency

for Safety and Health

European

at Work

Gran Vía 33, E-48009 Bilbao, Spain

Tel. +34 944 794 360; Fax. +34 944 794 383 European Agency

Email: information@osha.eu.int for Safety and Health

at Work

European Agency for Safety and Health at Work

PREVENTING MSDs IN PRACTICE

Turn your back on musculoskeletal disorders (MSDs)

European Agency

for Safety and Health

at Work

A great deal of additional information on the European Union is available on the Internet.

It can be accessed through the Europa server (http://europa.eu.int).

Reproduction is authorised provided the source is acknowledged.

Printed in Spain

European Agency for Safety and Health at Work

Contents

1. INTRODUCTION .......................................................................................................... 5

2. PRACTICAL SOLUTIONS .............................................................................................. 9

2.1. Adapting a fork lift truck (Belgium) ............................................................... 10

2.2. Improved organisation of workstation for sewing of mattresses (Denmark) .... 14

2.3. Avoiding manual lifting by using a ’vacuum�? device to lift meat (Denmark) .... 16

2.4. An intelligent lifting device for loading a high frequency press (Germany) ...... 19

2.5. Improved seating and reduced lifting in garment manufacture (Greece) ......... 21

2.6. Automating removal of plastic from stainless steel parts (Spain) ..................... 23

2.7. Reducing manual efforts in factory loading tasks (Spain) ............................... 25

2.8. Removing repetitive tasks from the assembly of small components

(France) ....................................................................................................... 27

2.9. Technical devices to reduce manual handling and repetitive work in meat

packing (Italy) .............................................................................................. 30

2.10. Mechanical aids for handling glass panes (the Netherlands) ........................... 33

2.11. Redesign of tram driver’s position (Austria) ................................................... 36

2.12. Improving seating and ergonomics in factory quality control work

(Portugal) .................................................................................................... 39

2.13. Ergonomics programme for SMEs (Finland) ..................................................... 42

2.14. Ergonomics for junior schools (Sweden) ......................................................... 46

2.15. Introducing adjustable workstations on a packing production line

(United Kingdom) .......................................................................................... 48

2.16. Worker rehabilitation using voice recognition computer software

(United Kingdom) .......................................................................................... 51

3. ANNEXES ................................................................................................................ 55

3.1 Sources of further information ........................................................................... 56

3.2 Overview of practical examples .......................................................................... 57

European Agency for Safety and Health at Work

PRATICE

MSDs

PREVENTING

INTRODUCTION

Turn your back on musculoskeletal disorders

Background

Musculoskeletal disorders (MSD) are one of the most common work-related

ailments affecting millions of European workers across all employment sectors

at a cost of billions of euros to Europe’s economy. The disorders cover a broad

range of health problems. The main groups are back pain/injuries and work-

related upper limb disorders, commonly known as ‘repetitive strain injuries�?.

Lower limbs can also be affected. They are common across all employment

sectors and industries in all the Member States in the European Union. Once

they have occurred they can be difficult to treat and can result in permanent

pain and disability for the worker. However, much of the problem could be

Unless effective steps are

prevented or reduced by following existing health and safety regulations and

taken the toll of workers

guidance on good practice. Unless effective steps are taken the toll of workers

suffering will increase along

suffering will increase along with the costs to industry. Therefore many

with the costs to industry

employers want to know how to introduce effective measures in practice.

Sharing good practice

Across the European Union Member States a common set of directives aimed

at preventing health and safety risks in the workplace apply. An important role

of the European Agency for Safety and Health at Work is to gather and make

available information that will support and promote the prevention of work-

related ill health. This includes assisting and stimulating the sharing of

information to solve common problems.

This publication and the Agency’s web site aim to show that work-related

musculoskeletal problems can be solved in many ways. They provide real examples

of how companies and organisations have made interventions and sought to

reduce musculoskeletal disorders at work. Each type of industry and workplace has

its own conditions, that can also vary between Member States. Therefore work

practices and solutions to problems must be matched to the particular situation by

carrying out an assessment of the risks at the actual workplace concerned (see box

1). Nevertheless, many musculoskeletal problems are not unique and solutions can

be relevant and transferable across various sectors, types and sizes of enterprises.

Box 1.

Risk assessment

Before Good Practice information is applied, an assessment of the hazards

and risks present in the workplace should be carried out and reference made

to relevant national legislation.

A risk assessment is a careful examination of what could cause harm to

people, so that you can decide whether you have taken enough precautions

or need to do more to prevent harm. The aim is to make sure that no one gets

hurt or becomes ill. If a risk assessment is not carried out before implementing

good practice information, there is a danger not only that risks may not be

controlled but also that there may be wastage caused by misapplied resources.

Source: Agency website Good Practice area where more information about risk assessment and

good practice is available (see references at end of this publication)

European Agency for Safety and Health at Work

The practical examples

The 16 examples of good practice MSD prevention presented here are all award

winners in a European competition run as part of the European Week for Safety

and Health at Work 2000. The aim behind this European Agency initiative has

been to support the dissemination of good practice information about MSDs

and to increase the exchange of information about effective ways of prevention

and ‘practical solutions�? in Member States and at European level.

The winners come from 13 EU Member States and include small and medium-

sized enterprises, large companies, a trades union and a specialist safety and

health institute, operating in very different sectors.

Each example describes the nature of the problem, the solution applied and the

Each example describes the

results. It is hoped the cases will give those in the workplace an idea of what is

nature of the problem, the

achievable. It is not meant to be definitive or provide detailed technical

solution applied and the

guidance. Not all elements of all cases were successful and these short

results

summaries present the best features to demonstrate what can work in practice

and the process to achieve it. Some of the enterprises developed their own

solutions using their own expertise. Others found it useful and cost-effective to

use consultants with expert knowledge and practical experience in investigating

MSD problems. The majority included the involvement of employees and their

representatives to determine the problems and try out solutions. This is crucial

to success as they have first hand experience of the work situation. Some

initiatives were initiated by trade union organisations. A table at the end lists

the title of the example, source of problem, industry and intervention.

Risk prevention

It is hoped that these examples will be of practical use to others. Good practice

is about taking effective action to tackle the root cause of the problem. Every

organisation is different so for an existing solution to be used by another

organisation, it has to be adapted to their particular circumstances. The

European directives on safety and health at work and national legislation to

implement them and supporting guidelines set out the approach to take (see

box 2). The Agency website provides links to information about these directives

and to national sites providing information about their legislation, guidelines

and also national good practice solutions. Various reports and factsheets giving

further information about MSD risks and their prevention are available from the

Agency website, as well as more examples of Good Practice and advice about

how to use them. See ‘references and sources of further information�? section.

Turn your back on musculoskeletal disorders

European prevention approach

�? Avoid MSD risks;

�? evaluate MSD risks that can not be avoided;

�? combat the MSD risks at source;

�? adapt the work to the individual, especially the design of workplaces, the

choice of work equipment and the choice of working and production

methods, with a view, in particular, to alleviating monotonous work and

work at a predetermined work-rate and to reduce their effect on health;

�? adapt to technical progress;

�? replace the dangerous by the non-dangerous or less dangerous;

�? develop a coherent overall prevention policy which covers technology,

organisation of work, working conditions, social relationships and the

influence of factors related to the working environment;

�? give collective protective measures priority over individual protective

measures

�? give appropriate instructions to workers.

Based on “Framework�? Directive 89/391 article 6.2 (5)

Acknowledgements

The Agency relied upon its network of ‘Focal Points�? in the Member States

(competent authorities, or bodies nominated by them, responsible for

occupational safety and health) to nominate good practice examples for the

Agency award scheme. We would like to thank them and the winning

organisations for their help in the production of this publication.

European Agency for Safety and Health at Work,

November 2000

European Agency for Safety and Health at Work

PRATICE

MSDs

PREVENTING

PRACTICAL SOLUTIONS

Turn your back on musculoskeletal disorders

2.1 ADAPTING A FORKLIFT TRUCK

IDEWE

Interleuvenlaan 58

3001 Leuven

Belgium

Contact: Mr Dirk Delaruelle

Tel: + 32 16 390 428, Fax: + 32 16 400 236

Email: dirk.delaruelle@idewe.be

Ta s k

Unloading lorries and storage of packages on pallets in a warehouse

Problem

A forklift truck is used to unload lorries. Standard packages of bags of

polyethylene and polypropylene granules are stacked on pallets. The pallets are

then transported and stacked in a large warehouse.

Forklift truck drivers had reported various work-related neck and back problems

to the company medical physician. A survey of mental and physical stress in the

materials handling department, supplemented by data from conversations

between individual employees and the physician, showed that full-time forklift

truck driving was the most stressful job in this department. An ergonomic analysis

was made of the work and the driver’s cab. The ground was uneven, consisting

of ‘Stelcon�? elements, with the result that drivers were continuously exposed to

major shocks and jerks. For safety reasons the loaded forklift trucks were driven

in reverse. Thus, the shocks were absorbed with the body turned. The driver’s seat

was not provided with springs. This resulted in further back strain. The forklift

used turned out to have an especially low cabin structure to enable the containers

to be loaded. Increased pressure of work in this department also needed to be

resolved by organisational measures. Technical and safety aspects were also

regarded as important objectives that needed improving

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European Agency for Safety and Health at Work

Solution

IDEWE, an external authority for prevention and protection, implemented this

project at Borealis Beringen.

A multidisciplinary project group was set up. The engineer from the Materials

Handling department directed the project. Various operators from the Materials

Handling department ensured participative input.

In addition to the participation of Borealis’s in-house prevention department,

Determining the ergonomics

the company doctor and the ergonomist from IDEWE �? the external prevention

solution also involved the

authority �? and an employee of Barlow Handling (a company that sells, hires out

use of anthropometric data

and adapts forklift trucks) also took part in it. of the drivers and

recommendations to

The subjective views and experiences of the Materials Handling workers were

propose changes to the cab

already known from the survey and the conversations with the company

physician. The ergonomists used this data and ergonomic analysis of the

existing situation and forklift truck, (based on the “NOVA�? checklist) to assess

the situation. The project group then formulated ergonomic recommendations.

Determining the ergonomics solution also involved the use of anthropometric

data of the drivers and recommendations to propose changes to the cab.

First the ground surface in the warehouse was replaced by a soft asphalt

covering.

Since no forklift truck could be found on the market that fulfilled all the

ergonomic safety and technical specifications, it was decided to adapt an

existing forklift truck. A prototype forklift was built and carefully evaluated

during trial phases, with adjustments to the design being made throughout this

process:

�? visibility when driving forwards was ensured by raising the entire cabin

structure. This also enabled tall drivers to sit upright;

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Turn your back on musculoskeletal disorders

�? the driving seat has been set lower in relation to the base-plate;

�? a shorter seat base prevents circulation to the thighs from being cut off. The

driving seat is equipped with new springs, cushioning vibrations and acting

as shock absorbers;

�? the levers are within easy reach and can now be operated while maintaining

good posture;

�? the switch controlling driving direction has been moved so that it can now be

operated from the steering wheel;

�? improved lumbar support and the amended design of the seat back makes

sitting more comfortable;

�? the seat and controls can be adjusted to suit the driver;

�? in order to increase productivity, it was decided to implement the design with

a double pallet fork, so two pallets can be lifted at the same time.

The ergonomist provided instructions to project group members on their use

and driver training for these new forklifts, for example individually adjusting the

driver’s cab, in order to make the working position as ergonomically effective as

possible and in order to be able to work efficiently. The instructions and

working procedures were incorporated into work guidelines or standard

operating procedures. Comments from drivers resulted in some changes being

made.

Results

Reduction in work-related health problems in forklift truck drivers:

�? it is now very rare for there to be a need to drive backwards, as forward

visibility has been greatly improved;

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European Agency for Safety and Health at Work

�? exposure to vibrations and shocks have been reduced by the new ground

covering;

�? increase in operator participation as a result of participative approach.

Reduction of costs:

�? the eight adapted forklift trucks are hired at an increased rental cost, but the

increased productivity has resulted in savings (Hire costs BEF 1 600 000 a

year; an annual profit of BEF 7 200 000 as a result of increased productivity

and a BEF 5 600 000 net annual profit).

�? 80% gain in storage and order picking.

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Turn your back on musculoskeletal disorders

2.2 IMPROVED ORGANISATION OF

WORKSTATION FOR SEWING OF

MATTRESSES

Carl Thøgersen A/S, (Huma)

Bredgade 187/Fabriksvej 13

7760 Hurup Thy.

Denmark

Contact: Mr Peter Petersen

Tel: +45 9795 1655 �? Fax: +45 9795 3255

Ta s k

Sewing mattresses.

Problem

The working position was fixed and employees had to make numerous twisting

back movements when handling large mattresses during sewing. Foot pedal

controls were also causing problems. There were a high number of complaints

of health problems regarding MSD like pains in back, neck and shoulders.

Sickness absence was between 7 and 10%.

Solution

A comprehensive action plan was developed to combat monotonous repetitive

A comprehensive action plan

work in the company. The Danish Regional Preventive Services took part in the

was developed to combat

process, contributing advice on the development of technical solutions for

monotonous repetitive work

example.

in the company

Initially a new platform for workstations which could be lowered or raised to

allow employees to sit or stand up while working was introduced. The control

pedal system was altered and careful attention given to working space

requirements. Employees may now alternate between standing up for half the

day and sitting down the other half while sewing the large mattresses. This also

provides some variety.

Despite the changes the problems with the control pedals continued, causing

some operators to rest on one hip. Therefore further technical changes were

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European Agency for Safety and Health at Work

introduced including

the use of automatic

sewing machines.

Initially one machine

was tested in the

factory and 16 have

been bought since

then. The new

machines allow

operators to move

more freely while

sewing large items.

and this has created

considerable

satisfaction among

employees.

Results

�? Effect with regard to absence due to illness: a drop from 7-10% to 1%;

�? efficiency has increased by 30-35%;

�? employees more satisfied for example with greater freedom of movement

when carrying out the work;

�? work is continuing on improving the workstations. Plans include the testing

of height-adjustable platforms from where the mattresses may be taken for

sewing without the operator having to bend her back;

�? the process and solution chosen is also suitable for other companies.

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Turn your back on musculoskeletal disorders

2.3 AVOIDING MANUAL HANDLING USING

A VACUUM DEVICE TO LIFT MEAT

Slagteriselskabet DANISH CROWN a.m.b.a.

Andreas Steenbergs Plads

8700 Horsens

Denmark

www.danishcrown.dk

Contact: Mr Tommy Jensen

Tel: +45 7562 3100; Email: thj@danishcrown.dk.

Contact: Ms Lisbeth Jungdal

Tel: +45 7633 8841; lisbeth.jungdal@foedevare-bst.dk

Ta s k

Manual handling of heavy loads of meat at high frequency in a meat processing

and preparation factory.

Problem

Back disorders are particularly common among Danish meat workers. 64% of

men and 56% of women throughout the industry have back symptoms at least

twice a year (compared to an average of 45% men suffering pains in the lower

part of the back at least once a year-according to figures from a major Danish

study, DIKE 1989).

Heavy slabs of meat had to be manually lifted at high frequency. Several

workplaces required the lifting of approximately 10 tons an hour per employee

using inappropriate movements.

Solution

A specially designed vacuum lifting device or ‘meat magnet�? was developed for

lifting slabs of meat. It consists of a horizontal vacuum lifting unit, a vacuum

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European Agency for Safety and Health at Work

suction device and a pneumatic control unit. The operator places the suction

device on the meat slab and a vacuum is created between the device and the

item, so it can be lifted and held automatically for transport. By activating an

open/close valve on the right hand side, the meat item may be raised and

lowered without any heavy physical effort on the part of the operator.

Several other lifting relief measures have also been introduced. The work

process is also part of a job rotation scheme and work is in progress to develop

better scope for job rotation, ‘knife-free days�? and other technical and job

organisational initiatives.

To help in the training in the use of the ‘meat magnet�? and to help share the

The involvement of

idea across the meat industry a professional video was developed. It has been employee prevention

shown at divisional meetings in several companies within the meat processing representatives and the

industry and used for teaching at meat processing and technical colleges. participation of all

employees played a crucial

The involvement of employee prevention representatives and the participation

part in developing a

of all employees played a crucial part in developing a successful solution. The

successful solution

project was carried out with the assistance of the external Occupational Health

Service, who made regular visits, working with a special project group from

within the company and with the involvement of the company’s joint

prevention committee. Care was taken to keep employees in the division

informed of progress throughout the project. Employee prevention

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Turn your back on musculoskeletal disorders

representatives were involved in early testing of the meat magnetic lifting aid.

All staff had the opportunity to discuss the project and test the ‘meat magnet�?.

Results

The effects have been many and varied:

�? the ‘meat magnet�? has eliminated the need for heavy lifting without

increasing the speed;

�? nearly all the employees report that the equipment is suited to the task and

60% find that using the equipment reduces work stresses on the lower back,

upper back, shoulders, elbows, left wrist, hand and fingers;

�? no employees have experienced an increase in repetitiveness and about half

experience less repetitiveness;

�? fewer employees are seeking physiotherapeutic treatment for lower back

pains;

�? more older employees, men and women, and those with symptoms of

premature physical wear, can manage the work;

�? training and retaining new employees has become easier;

�? many good ideas put forward by employees for technical innovations and

work organisation have been implemented;

�? the interest in participating in activities aimed at improving the working

environment has increased;

�? daily interaction between staff has improved. Working with others including

on new initiatives to improve the working environment has improved, for

example in relation to both attitudes and practical issues such as setting

budgets;

�? the idea has spread across the sector and now various different ‘magnets�?

have been developed for lifting other meat items.

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European Agency for Safety and Health at Work

2.4 AN INTELLIGENT LIFTING DEVICE FOR

LOADING A HIGH-FREQUENCY PRESS

Wilkhahn

Wilkening + Hahne GmbH+Co

Fritz-Hahne-Straße 8

D-31848 Bad Münder

Germany

Contact: Mr Kerstan von Pentz

Tel.: +49-504-2999-0 Fax: +49-504-2999-226

e-mail: info@wilkhahn.de

Ta s k

Table manufacture in the furniture industry: gluing solid wood bandings onto

table tops using a high-frequency press.

Problem

Manual lifting of heavy, unmanageable loads requiring physical strength and

with corresponding bad posture was causing health problems especially

regarding MSD.

The worker’s tasks include laying the solid wood bandings and table tops in the

high-frequency press, supervising the pressing process and removing the

complete table top. On average 80 table tops are completed each shift. The

workers had to load the high-frequency press manually. This involved them

lifting the table tops weighing approximately 40 kg from the freight lorry,

carrying them, placing them in the press and removing them. Manual loading

was only possible with two workers because of the size of the panels, so

another worker had to be deployed solely for the loading process.

The manual loading was causing strain on the spine, due to the weight of the

table top, the detrimental body-posture (e.g. bending with the weight) whilst

placing the panel in the press or removing it and the frequency of the lifting and

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Turn your back on musculoskeletal disorders

carrying process. The repeated lifting, carrying and setting down tasks took

place approximately 200 times per shift.

Solution

A mechanical lifting device was introduced so it is no longer necessary to move

A mechanical lifting device heavy loads manually. It uses a vacuum system and intelligent control device to

uses a vacuum system and

hold the tabletop in a suspended position. The use of the vacuum to hold the

intelligent control device to

tabletop means it can be easily moved. An electronic measuring gauge records

hold the tabletop in a

the weight of the panel and the electronic controls enable the panel to be

suspended position

suspended. The worker can move the suspended panel in any direction without

expending energy. Workers were actively involved in decisions the

implementation of this solution

Results

�? Reduction of time lost due to sickness;

�? improved efficiency of work processes;

�? cost savings as the direct result of innovation approx. �? 16,000 p.a.

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European Agency for Safety and Health at Work

2.5 IMPROVED SEATING AND REDUCED

LIFTING IN GARMENT MANUFACTURE

FANCO S.A.

Industrial District of Komotini,

Postal Code 69100 Komotini

Greece

Contact: Mr Ioannis Iatrakis, Mr K Tsepelidis

Tel: +301 (0)531-98513

Fax: +301 (0)531-98595

Ta s k

Textile industry - sportswear manufacture. Production work and transportation

of goods within the factory in the tailoring division and printing and dyeing

division.

Problem

The work in the tailoring division, printing and dyeing division involved

prolonged periods sitting in a static position and constantly lifting or pulling The work involved

loads. An increase in health problems and absenteeism had been noted, prolonged periods sitting in

especially related to MSD. Some machines were operated by pedals that were a static position and

uncomfortable to use. Very large and heavy metal trolleys were being used to constantly lifting or pulling

transport goods in the factory, which required intense muscular effort and loads

strain on the part of the employee.

Solution

The company has taken the following steps to help tackle these problems:

�? use of new adjustable seating which provides the worker with much better

support and also allows them to adjust their body position when working;

�? adjusting the pedals of the machines to suit the employee;

�? replacing the heavy trolleys by installing a mechanical system of rolling, raised

shelves (Schonenberger system) for the purpose of placing, transporting and

storing items to be tailored;

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�? increasing the use of other lifting devices such as fork-lifts, hand-operated

pallet-bearing machinery;

�? training employees in the correct lifting methods and the use of the lifting

devices;

�? training employees in other work tasks so a rotation system can be used to

move them between different tasks. The aim of this is to reduce both physical

and mental strain and allow employees to move from one work area and

atmosphere to another.

�? moving older and more susceptible employees to lighter work posts;

�? carrying out regular health surveillance to help check for problems and that

solutions are working;

�? creating a pleasant and spacious room for rest and recreation with a canteen.

Results

�? Decrease of musculoskeletal problems;

�? decrease in average of days off;

�? improvement of productivity.

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European Agency for Safety and Health at Work

2.6 AUTOMATIC REMOVAL OF PROTECTIVE

PLASTIC FROM STAINLESS STEEL

PARTS

FAGOR Electrodomésticos, S.Coop.

20500 Arrasate (Gipuzkoa),

Garagartza Auzoa, 39

20500 Arrasate (Gipuzkoa)

Spain

Contact: Mr Iñaki Bordes Zorrozua

Tel: +34 943 77 92 27

Fax: +34 943 79 68 91

e-mail: ibordes@fagorelectrodomesticos.com

Ta s k

Removal of plastic protective covering from stainless steel parts in dishwasher

production and ‘stamping�?.

Problem

Plastic covering is used to protect the stainless steel used in the production and

assembly of household appliances from getting scratched, marked etc. The There is a risk of MSD such

operation to remove the plastic from the stainless steel part has until now been as tendinitis in the forearm

performed manually. The from the repetitive effort

worker begins from one point involved in the movement

and pulls it back, so that by required to do this task

performing circular

movements all the plastic is

removed. There is a risk of

MSD such as tendinitis in the

forearm from the repetitive

effort involved in the

movement required to do this

task.

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Turn your back on musculoskeletal disorders

Solution

The Department of Stamping

Engineering, the section in

which stainless steel is worked,

had for some time been

examining how to avoid the

manual performance of this

operation. As a machine or

tool for this purpose could not

be found in use elsewhere, so

it was decided to design one,

which removes the plastic

semi-automatically.

In the new design of the workstation, the operator will feed the machine with

parts which are still in their plastic covering, raising the edge of the plastic

slightly, the machine will then remove the plastic leaving the machine to do the

rest.

The machine’s functioning mechanism is basic and consists of pincers closing on

the raised edge of the plastic and pulling it back in a regular way. Feeding the

part into the machine is not done directly but on a bedplate which allows one

to be fed in and the finished one to be removed. The removed plastic is then

collected in a container located in the lower part of the machine, which is easily

extractable.

Results

�? Elimination of an established risk from a repetitive manual task;

�? the evaluation of the outcome and benefits is ongoing.

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European Agency for Safety and Health at Work

2.7 REDUCING MANUAL EFFORT IN

FACTORY LOADING TASKS

Henkel Ibérica, S.A.

Factoría de Montornés del Vallés

Vial Norte N.1

08170, Montornés del Vallés

Barcelona

Spain

Contact: Mr Jordi Cruz

Tel: +34 93 290 4178

Fax: +34 93 290 4181

email: jcruz@henkel.e

Ta s k

Loading industrial detergent sacks of finished goods on pallets, loading solid

raw materials for industrial detergents into mixers, loading raw materials for

industrial adhesives into mixers.

Problem

This company produces a variety of chemical products including cleaning

agents and adhesives. MSD risks from various tasks involving the manual

handling of heavy loads such as barrels, sacks, etc. were identified, including

the adoption of forced postures, creating problems of absenteeism and possible

poor industrial relations. The worst problems were in the industrial detergents

and industrial adhesives production area involving tasks such as putting heavy

sacks of industrial detergent onto pallets, loading solid industrial detergents

into mixers, loading industrial adhesives into mixers and into crushers.

Solution

Specialised assistance was engaged in order to make a joint ergonomic study of

the workstations affected. Based on this study, the main initiatives taken were:

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�? comprehensive analysis of

each of the workstations

(including use of the

“NIOSH lifting equation�?

and the limits proposed by

ISO/CD 11226) and

introduction of prevention

measures based on this

analysis;

�? mechanisation to avoid

manual handling of loads

(Vacuum-action bag

manipulators);

�? redesign of the workstation

to avoid forced postures;

�? specific training for

employees involved in each

of the workstations;

�? education and awareness

raising e.g. display of

information posters at the

workstations involved etc.

Results

50% decrease in worker

absenteeism caused by �? 50% decrease in worker absenteeism caused by musculoskeletal disorders,

musculoskeletal disorders, following introduction of the corrective and preventive measures;

following introduction of the �? improvement in work relations, due to decrease in absenteeism;

corrective and preventive �? benefits due to the improvement of working conditions include the increase

measures in employee satisfaction and the improvement in working atmosphere.

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European Agency for Safety and Health at Work

2.8 REMOVING REPETITIVE RISKS FROM

T H E A S S E M B LY O F S M A L L

COMPONENTS

ESSWEIN

Les Ajons

B.P. 167

85002 La Roche Sur Yon Cédex

France

Contact: Mr Cyrille Paquiet

Tel 02.51 36 55 55 Fax 02.51.36.56.53

Ta s k

Small component assembly line work during production of electrical domestic

goods

Problem

Esswein is an industrial branch of the BRANDT Group, specialising in the

production of dishwashers, washing machines and tumble dryers. Production

line operators carry out a whole range of operations to assemble and install

small components and sub-assemblies: frame and motor components, internal

components, electrical circuits, etc. All these operations entail a large number

of very precise positioning, assembly, screwing and clipping operations. It was

found that the upper limbs of operators were under constant stress as a result

of time constraints, precise and repetitive movements and different levels of

exertion at different workstations. The number of work-related MSD was on the

increase and new cases had increased by a factor of nine over five years.

The different activities concerned were giving rise to a range of MSD problems

on all the production and assembly lines.

Risks arising from the movements performed

�? stresses on the wrists and elbows in the case of clipping, insertion of wiring

and screwing;

�? stresses on the shoulders due to the height at which operations had to be

performed at some workstations.

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Risks connected with the forces exerted

�? weight of tools;

�? weight and bulk of the components to be handled.

Risks arising from the repetitive nature of movement sequences

�? work on assembly lines, with tasks divided into repetitive sequences always

requiring the same movements.

Organisational and relational problems

�? little rotation between workstations;

�? working areas not geared towards co-operation;

�? overloading of supervisors and workshop methods.

Solution

The project arose from discussions over a number of years about MSD

The solutions involved a prevention in the enterprise. These discussions paved the way for the

whole range of changes to

introduction of a range of measures in the appliance production and assembly

improve work and

departments.

workstations and to improve

the whole process of

The solutions were developed through discussion and participation of the

ensuring good ergonomics

workers and their union representatives.

by integrating it into

management activities They involved a whole range of changes to improve work and workstations and

to improve the whole process of ensuring good ergonomics by integrating it

into management activities:

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European Agency for Safety and Health at Work

�? mechanised assistance with screwing: changes in the positioning of tools in

many screwing stations and changes to their conditions of use in order to

reduce levels of exertion;

�? assistance with component handling;

�? introduction of variable height workstations;

�? training in new skills and tasks and incentives for task rotation, following

ergonomic studies of the respective constraints of the various individual

stations;

�? organisational work changes to tackle psychosocial risk factors that can

exacerbate the probability of the onset of MSDs (e.g. poor work relations and

tensions) including improved communication with operators and reacting to

their complaints;

�? training for technicians in methods of analysing and finding solutions for

MSD risks;

�? integration of the use of ergonomic and biomechanical criteria into the

design of new workstations from the outset. The complete redevelopment of

a production line provided an opportunity to take account of MSD issues

right from the design stage;

�? involvement and steering of schemes by the unit directors, including enabling

ergonomic aspects to be taken into account in management decisions.

Supervisory staff have been trained on how to take account of working

conditions in their decisions;

�? creation of a range of working parties, with

employee participation, in order to analyse

and redevelop workstations.

Results

�? All these measures, introduced over a

number of years and still in progress, have

curbed the rise in MSDs and substantially

improved working conditions;

�? many bio-mechanical risk factors have been

eliminated: repetitive movements reduced,

improved working postures, lower levels of

exertion;

�? there is now systematic inclusion of

ergonomic criteria in the design of new

workstations. Increased attention is paid to

ergonomics, MSD prevention and working

conditions in all management decisions;

�? there has also been a marked improvement

in the social climate.

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2.9 TECHNICAL DEVICES TO REDUCE

MANUAL HANDLING AND REPETITIVE

WORK IN MEAT PACKING

Aziende USL Modena e ASL Mantova

P.zza Ospedale

41012 Carpi

Italy

Contact: Dr Rinaldo Ghersi

Tel: +39 059 659937

Fax: +39 059 659903

email: r.ghersi@ausl.mo,it

Ta s k

Various tasks related to meatpacking including moving, cutting, cleaning and

collecting of animal parts in pork meat production.

Problem

Studies show that workers in the meat sector suffer from a high rate of back

disorders and the company had noticed a high rate of various MSD problems.

The main problem involved manual handling of heavy loads of meat, including

whole pig carcasses, at high frequency. Several workplaces required the lifting

of heavy loads by the employee using awkward movements. For example

twisting and turning whilst holding the load; manoeuvring loads at a height

with the arms fully stretched above the head; carrying and supporting heavy

carcasses and meat joints across one shoulder. Other tasks involved very forceful

and awkward movements to cut the carcasses, often whilst supporting the load

manually at the same time. Identified risks included: carrying, pulling, pushing

and holding heavy loads, often in static positions; repetitive movements; poor

indoor climate; the danger of injury from using sharp instruments and devices

for cutting; high physical workload.

Solution

Manual handling of loads and repetitive movements were reduced by using

semiautomatic and automatic machines and systems for the high risk tasks and

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European Agency for Safety and Health at Work

also making changes to working

procedures and by doing so avoiding

the need for the workers to carry out

these high risk tasks.

For example the following changes

were introduced:

�? a machine operated meat joint

cutter with integral protective

gauntlet, with the load of the meat

supported by a ceiling hung

support;

�? automated movement of carcasses

through the factory, suspended

from the ceiling, to eliminate

manual carrying over the shoulder.

Carcasses now move automatically

between process areas and are

suspended at the correct working

height;

�? automated cutting open of ceiling

suspended carcasses, eliminating a

forceful cutting task and manual

support of the load;

�? automatic removal of intestines

weighing 25 Kg, before done

manually involving an awkward

twisting movement whilst holding

the heavy intestines;

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�? automated ‘unhooking�? the carcasses from the ceiling to place on a

Carcasses now move

horizontal conveyer;

automatically between

�? in shoulder jointing section further automation to support the load and to

process areas and are

open and cut the meat;

suspended at the correct

�? mechanical lowering of pieces of meat to be processed;

working height

�? the suspension of the carcasses from the ceiling has also improved the

working postures of those carrying out inspections of the meat.

Results

An evaluation has shown:

�? reduced manual handling of loads;

�? reduced accident rate;

�? elimination of risks especially regarding MSD.

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2.10 MECHANICAL AIDS FOR HANDLING

GLASS PANES

ARBOUW

P.O. Box 8114

1005 AC Amsterdam

Netherlands

Contact: Mr Henk van der Molen

Tel: +31 20 580 5580

Fax: +31 20 580 5555

email: vdmolen@arbouw.nl

Ta s k

Glazing industry: transport and positioning of glass window panes.

Problem

Manual handling problems were occurring in the horizontal and vertical

transport of window panes and in the positioning of window panes. This was

giving rise to serious back, neck and arm disorders. Examining the accident and

sickness absence records confirmed the extent of the problem: the sick leave at

the start of the project was 16.7 % and the disability rate (one year sick leave)

was 5.5 % which is very high.

Most window panes weigh well in excess of 50 kg and panes weighing

between 100 and 200 kg are quite common. (While typical lifting

recommendations quote maximum weights for manual handling of 25 kg).

Besides heavy loads there were problems of transporting the large, unwieldy

panes across difficult and uneven surfaces, including outdoors on building site

terrain. The existing transport cart weighed 45 kg, far too much for easy

working. Besides the weight they were also difficult to handle and manoeuvre

and the wheels often unsuitable, especially on construction sites where

transport ways can be muddy or sandy for example.

Surveying and health surveillance of employees revealed more about the nature

of complaints. More than 75% of the glaziers had complaints about the

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physically demanding aspects of their work. The rate of associated ill health

problems was well above the norms in the construction sector, a sector that has

high rates of manual handling related ill health problems. The problems were

greatest for the back, but significant for other parts of the body as well. For

example, prevalent complaints were: to the back 28% (compared to

construction industry rate of 23%); neck complaints 23%; shoulders 27%;

elbow 14 %; wrist 9%; hand/fingers 10%; hip 11%; knee 22%.

Solution

The companies involved worked with the ARBOUW Institute to develop the

solutions. New working methods and mechanical aids were developed to avoid

as far as possible the need for the glaziers to carry out any manual handling in

the pane transportation and mounting process altogether.

A mechanical hoist mounted on a truck means that a glass pane can be loaded

and unloaded without physical strain. The hoist can be easily folded out. The

hoisting lasts almost one minute longer than manual loading and unloading.

However one worker can now do the job, while previously for most window

panes at least two workers were necessary.

Two tools for horizontal transport were developed: a new lightweight cart,

A new lightweight cart,

weighing 25 kg, can stand loads of 200 kg and can easily be handled by one

weighing 25 kg, can stand

person. The wheels can be changed for different situations. For transport over

loads of 200 kg and can

even floors, a mini-cart in the shape of a roller skate was designed.

easily be handled by one

person An easy to use vertical transport aid can lift a pane up to the third floor of a

building. The lifting device can be used in combination with a transportable

scaffold to provide a stable platform. The physical strain is low, since there is no

manual lifting. A special device prevents the hazard of the grip of the vacuum

lifting device slipping through leakage of the vacuum.

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European Agency for Safety and Health at Work

Results

�? Elimination of manual handling is possible and practically feasible;

�? 13% to 59% of the glaziers are now using one or more of these mechanical

aids;

�? improved working between and within companies: the exercise involved

three different companies and the participatory process led to real

collaboration between all involved in the three companies as well as in their

branch organisations;

�? economic costs/benefits: qualitative assessments showed a break-even or

productivity gain with the new working methods.

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2.11 REDESIGNING TRAM DRIVER’S

WORKING POSITION

Wiener Linien GesmbH & Co KG

Erdbergstrasse 202

A-1030 Vienna

Austria

Contact: Ing. Franz Kaida

Tel: +43/1/7909-17390

Fax: +43/1/7909-17390

email: franz.kaida@wienerlinien.co.at

Ta s k

Driving public transport trams

Problem

Wiener Linien GmbH & Co KG, the Vienna Transport Authority, is Austria’s

largest local transport company, carrying more than 700 million subway, tram

and bus passengers each year. The tram division operates 570 eight- and

twelve-wheel low-floor tramcars and trailer trucks, and employs 1,400 drivers.

The company was concerned about the possible high health risks to drivers of

operating old trams, resulting in time off work due to illness and early

retirement on health grounds. The reasons identified included strain on the

musculoskeletal and motor system, stress, irregular hours and poor climatic

conditions inside the vehicle.

The design of the driving positions in the old vehicles (529 units) required the

driver to adopt constricted postures and perform repetitive activities such as

button operation to open and close doors, etc., resulting in extreme strain on

the musculoskeletal and motor system.

In order to be ready to brake at any time, the driver of a moving tram had to

have his right hand on the ‘gritting�? lever and his thumb on the ‘rail brake�? lever.

The length of the two levers meant that the right arm usually has to be held

fully extended or slightly bent. At the same time, the left hand was being used

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European Agency for Safety and Health at Work

to operate the stop/start lever. The driver had to use additional pressure to

operate the ‘dead man’s handle�?. These requirements meant that the driver

was forced to work in constricted postures with twisting of the torso. The

drivers also had to use their feet to operate three pedals (dip switch, bell and

solenoid brake).

In addition, at the start of their work shift many drivers found that they did not

have time to adjust their seats, leaving them in the position used by the previous

driver, as they were difficult and complicated to alter. This created additional

adverse affects on the posture of drivers seated in incorrectly adjusted seats.

Solution

Wiener Linien decided to introduce ergonomic improvements to the driver’s To decide what measures

position when constructing new low-floor trams. To decide what measures were required they

were required they questioned drivers and set up a working group that included questioned drivers and set

representatives of drivers, occupational physicians and safety experts, and also up a working group that

used expert support from the Ergonomics Department of Vienna Technical included representatives of

drivers, occupational

University’s Institute of Industrial Engineering, Ergonomics and Business

physicians and safety

Economics.

experts

The new trams incorporated the following design features for the drivers:

�? new seat with controls for the most frequent operations incorporated in the

armrests;

�? height-adjustable pedals;

�? rapid and simple individual seat adjustment;

�? special breathable seat cover material for greater comfort;

�? air-conditioned cab.

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Specific features of the new seating position included:

�? centrally oriented seating position for the driver and possibility of performing

the most frequent operations (opening and closing of doors) and the longest-

lasting or continuous operations (setting of reference values for driving and

braking commands) without twisting of the torso, and therefore without

constricted posture, by transferring these functions to the armrests;

�? adjustment facilities to adapt the seating position (height of seat and level of

foot support) and the appropriate adjustment controls (reference value setter

and door function buttons) to the physical size of the current driver;

�? contour of the backrest adjustable by the driver.

Results

To date, 41 vehicles incorporating this new driving position and the other safety

and health features have been built leading to the following results:

�? improved driver posture and reduced strain on the musculoskeletal and

motor system;

�? reduced perspiration as a result of breathable seat cover and air conditioning

of the cab;

�? significantly improved driver acceptance of the driving position and

enhanced job satisfaction.

In the medium-term further improvements are expected including:

�? reduction of occupational illnesses;

�? less time off due to illness;

�? fewer early retirements on health grounds.

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2.12 IMPROVING SEATING AND

ERGONOMICS IN FACTORY QUALITY

CONTROL WORK

COSAT, Consultores de Higiene, Segurança e

Saúde no Trabalho, S.A.

Avenida Elias Garcia, no 147 3

Dto, 1050-099 Lisbon

Portugal

Contact: Mr Luis Santos Martins

Tel: +351 21 793 11 15

Fax: +351 21 793 11 06

email: Info@cosat.pt

Ta s k

Quality control checks during the manufacture of plastic articles.

Problem

Checking for defaults in the manufacture of plastic articles is a repetitive task.

The operator’s tasks in the quality control section basically consist of:

�? picking up parts from an incoming runner to inspect them by touch and

vision;

�? putting the part back on an outgoing runner;

�? if it has a defect, placing it on the runner on the operator’s left;

�? if it does not have a defect, re-routing the part on an upper runner;

�? noting the results on a special form.

The problems were mainly:

�? health complaints by workers, particularly musculoskeletal disorders;

�? operators had to stand to do the job;

�? excessive reaching to distances to the runners, which were outside the

comfort reach and visual zones of operators;

�? for example, a bench was restricting operator access to one of the runners,

causing back pains;

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�? high rate of undetected defective parts, jeopardising customer relations and

leading to the return of complete loads in supply contracts where the

deadline had only just been met.

Solution

An ergonomic intervention was carried out under the occupational safety,

health and hygiene services. It involved a team consisting of the factory medical

inspector, an ergonomist and an occupational psychologist.

After an initial identification of health and safety risks in the workplace and

dysfunctions in the production system, a detailed analysis of the task, and the

analysis of the work activity and dysfunctions in the production system was

carried out. The postural demands on the operator in the real working situation

were recorded and analysed and those tasks involving greatest risk of

musculoskeletal changes identified.

Methods used included free and systematic observation, video recording of the

work activity, surveying and interviewing workers and the preparation and

completion of analysis tables geared towards the situations under study.

Video recordings were analysed to quantify the frequency, duration and

sequence of postures in the real work situation to give a dynamic postural

profile of operators as they carried out their work. This was done using the

PASEA computer programme (Posture Analysis System for Ergonomic

Applications) and with the support of the Ergonomics Laboratory in the School

of Human Motoricity, UTL (Lisbon Technical University).

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Based on the results of these analyses proposals to minimise the identified

health risks were made. This was done with the aid CAD techniques (computer

assisted design) and graphic modelling (3D Studio Max) to simulate the real

working situation. It included three stages:

�? modelling the actual situation;

�? preparing potential proposals, with brainstorming and value analysis;

�? preparing suggested action with simulations of the work activity.

To enable operators to work seated one of the major problems of the existing

layout, the excessive distance for reaching for parts on the lower runner, the

upper runner and the rejected parts side runner had to be solved. The runners

were brought closer to the operator so that they were positioned in the comfort

reach and visual zones of the operators (an analysis of the operators�? comfort

zones was made). The variables of reach and free space were taken into

account in redesigning the workstation.

Frequency of tasks and therefore movements such as reaching was also an

On-the-job training was

important consideration in deciding where to position elements in the

provided to facilitate

redesigned workstation, particularly the runners. In principle the elements of

adaptation to the new

the workstation used most frequently needed to be closest to the operator. One

working situation and to

of the restrictions affecting the operator in reaching towards the runner was the

overcome resistance to

bench sited between the operator and the runner. This was replaced with a

change on the part of

smaller one.

operators

The design of a system based on ergonomics alone does not eliminate harmful

risks to the health of operators associated with postural problems. Problems

may arise in the implementation stage if it is not monitored and if operators are

not trained. On-the-job training was therefore provided to facilitate adaptation

to the new working situation and to overcome resistance to change on the part

of operators.

Results

A survey was carried out with operators to validate the action:

�? output increased by over 30%;

�? errors fell from 17% to 2%.

The operators referred to the following aspects of the new work situation:

�? greater comfort;

�? the chairs are comfortable, leading to a reduction in postural discomfort of

the lower limbs at the end of the working day;

�? reduction in tiredness;

�? due to the technical changes carried out to increase output rates, the rate of

the runner carrying parts to be inspected increased and the work rate

increased as a result.

�? improved motivation because management showed concern not only with

increasing production but also with the safety, comfort and health of the

operators.

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2.13 ERGONOMICS PROGRAMME FOR SMES

Uusimaa Regional Institute of Occupational

Health

Arinatie 3, FIN-00370 Helsinki

Finland

Contact: Ms Ulla Könni, Tuija Rönnholm

Tel: +358 9 47471 - +358 9 506 1087

email Ulla.Konni@occuphealth.fi, Tuija.Ronnholm@occuphealth.fi

Ta s k

Developing an ergonomic small workplace programme with 24 SMEs to assist

them in the prevention of musculoskeletal disorders

Problem

Twenty-four small businesses had previously taken part in a Small Workplace

Programme on maintaining and promoting working ability, organised by the

Finnish Institute of Occupational Health. A follow-up survey indicated that three

out of four employees in the companies had suffered from musculoskeletal

symptoms during the past 12 months. The MSD problem was further confirmed

by examinations of some employees sent by their companies to a physician at

the Finnish Institute of Occupational Health. In addition, the management and

staff in the companies and the occupational health services felt that there was

a need for improved ergonomics in their workplaces.

The small companies with MSD problems came from a wide variety of sectors:

Companies Companies companies total

with �? 50

Industry with less with 10-49 number of

than 10 Employees employees employees

Metal 1 5 5 823

Electronics 1 3 92

Printing 1 1 173

Hotel/restaurant 3 75

Commerce 1 3 94

In total 3 15 6 1,257

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European Agency for Safety and Health at Work

Solution

A multidisciplinary consultant group from the Uusimaa Regional Institute of

Occupational Health developed ergonomics programmes in co-operation with

the staff of the 24 companies. The process used to develop the programme

with the small workplaces is given in the box.

Process to develop an ergonomics programme to prevent MSD at small

workplaces

Annual information

Interviews and filming in

meeting

participating companies

Setting up of ‘development

groups�? (information

exchanges between groups of

workers)

Identification of issues for

proposed improvement

Review of actions

and next steps

Improvement measures

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At a launch meeting with the companies goals were set concerning the

development of ergonomics interventions in their workplaces. The precise

measures to be taken by the companies were agreed with them during the

development phase. Towards the end of the development phase an assessment

meeting was held to review progress on the initial goals, whether the agreed

measures had been implemented, for example whether the company had made

new procurements or if there was anything that required further processing and

discussion at the company level. An important element was to review what was

considered to have been a success and what could have been done differently.

Also effectiveness of co-operation with and between the Occupational Safety

and Health Services was reviewed at this stage. A final evaluation meeting was

held to discuss whether the measures taken had had any effect on ergonomics.

Ergonomics interventions

Evaluation forms were also used to obtain feed back on experiences.

were developed on the basis

of the needs and goals of Ergonomics interventions were developed on the basis of the needs and goals of

the individual companies the individual companies. A wide variety of methods were used and examples

are given in the box below:

Ergonomic measures taken by companies: Some companies used several

ergonomic intervention methods.

companies companies companies

with �? 50

Ergonomics intervention methods with < 10 with 10-49

employees employees employees

Developing workplace ergonomics together 1 8 4

Guidance on ergonomic working methods 2 9 3

Ergonomics training or briefings to employees 1

Designing the layout of the

Workplace/workstation 3 2

Teaching and using the method of mapping

workplace ergonomics 4

Using the method of developing working

Conditions and the work community

(questionnaire) 1

Consulting ergonomics experts 1 4 3

Assessing the strain on the musculoskeletal

system 1

Finding solutions in problem areas 1 1

Creating an ergonomics library 3 15 6

Training to relieve neck and shoulder

Symptoms

Workstation ergonomics campaign 3 2

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European Agency for Safety and Health at Work

Thirteen companies chose to develop ergonomics together. The employees of

companies were always involved in developing the ergonomic interventions,

using ‘participatory ergonomic methods�?. Through the project companies made

concrete improvements in working conditions and workstations. Some of these

measures were ‘small-scale�? and ‘immediate�?. Some target areas required more

substantial investments and the companies made further plans to implement

them in the longer term.

Results

The ‘developing ergonomics�? programme was successfully implemented in the

companies based on the initial goals set:

�? concrete improvements in working conditions and workstations were

successfully implemented;

�? company planning on health and safety was developed e.g. by budgeting

and planning for longer term interventions;

�? the project promoted employee participation in health and safety and

developing ergonomics solutions;

�? there was an increased awareness of ergonomics among staff and managers;

�? it encouraged co-operative working between some companies on health and

safety.

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2.14 ERGONOMICS FOR JUNIOR SCHOOLS

Lundborgs sjukgymnastik

802 55 Gävle

Sweden

Contact: Ms. Lotta Lundborg

Tel: +46 (0) 26 609898

Fax: +46 (0) 26 654898

email: lundborgs.sjukgymnastik@swipnet.se

Ta s k

Sitting still for long periods of time in junior school classrooms (pupils aged six

to nine years).

Problem

There was concern that prolonged periods of sitting still on ill suited and poorly

designed school furniture puts strain on the musculoskeletal systems of young,

growing children, and may favour the use of one side of the body. It also means

that the pupils are not made aware, by example, of the importance of suitably

designed tools and equipment (e.g. furniture) and variations in posture and

activity.

Solution

The prevention of strain-related problems in school children solution consists of

at least three parts in a coherent programme: provision of suitable furniture of

the correct size; exercise; education, training and awareness raising. To help

achieve this ergonomics programmes for junior schools have been developed

and introduced.

Physiotherapists are now promoting ergonomics knowledge and application in

Physiotherapists are now

this area through the provision of:

promoting ergonomics

knowledge and application �? detailed information to pupils, teachers, other members of staff and parents;

�? assistance in the purchasing and testing of school furniture;

�? instruction in lifting techniques etc.

�? exercise during breaks, etc.,

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European Agency for Safety and Health at Work

Results

Preventing a child from gaining serious strain injuries and providing education

and training on the issue saves society vast sums of money now and in the

future:

�? school furniture of the correct size is reducing the direct danger of uneven

strain and problems;

�? sufficient and correct exercise is increasing ability of the child’s body to cope

with strain later in life;

�? the programme increases the pupils�? understanding of ergonomics and

allows them to be in a position, in the future, to demand a good working

environment.

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2.15 INTRODUCING ADJUSTABLE

WORKSTATIONS ON A PACKING

PRODUCTION LINE

R. Twining and Company Ltd

Royal Quays

North Shields

Tyne and Wear, NE29 6AR

Contact: Ms Lesley Whittaker

Tel: 0191 296 0000

Fax: 0191 296 0982

Email: lesley.whittaker@twinings.com

Ta s k

Packing tea on a production line

Problem

The workstation was not adjustable which proved to be a real problem for the

workers, whose heights and body sizes vary considerably. It was also unsuitable

for left-handed workers. Worker heights ranged from five feet to six feet three

inches. The workstation was too low for tall operators causing them to adopt

stooped back postures. It was too high for small operators, but if they raised the

height of their chairs (if they were able to) this resulted in their legs dangling

without support.

�? Operators with larger thighs had difficulty in squashing their legs under the

fixed width of the workstation. The limited space caused pressure to be

exerted on the upper thigh;

�? two out of three of the chairs were unsuitable in that they were not

adjustable. At least one of the chairs was fitted with a ring, which was

designed to act as a footrest. Operators who rested their feet on the ring

were forced into positions, which restricted blood circulation.

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European Agency for Safety and Health at Work

�? waste bins (for damaged tea bags) were situated at a distance from operators

and in some cases placed behind them. This resulted in twisting and

stretching;

�? boxes piled high around operators interfered with human contact. Operators

reported experiencing feelings of being hemmed in;

�? left-handed workers had to spend a significant amount of time at the start

of their shift rearranging workstation furniture in order that they could carry

out their job.

Solution

The project was carried out by a team from the company with expert advice

The team met over a

provided by an ergonomist, a health and safety expert and a psychologist from

number of weeks to

the local University (Sunderland University). The workplace team comprised: brainstorm possible solutions

four shopfloor operatives (including representatives from all three shifts), the and potential solutions were

Occupational Health Nurse, the Administration & Training Manager and the taken back to the workplace

Line Manager. and tried out

Part of the solution including training a small team of shopfloor workers in

ergonomic risk factors and to enable them to participate fully in risk assessment

and solution generation.

The starting point was for the team to carry out an assessment of health and

safety risks (with a particular focus on MSD) as required by national legislation

(Management of Health & Safety at Work Regulations) on the production line

where the problems were occurring.

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Facilitated by the University experts the team met over a number of weeks to

brainstorm possible solutions to the problems they had identified. Potential

solutions were taken back to the workplace and tried out. A logbook was used

by the operators to record ideas as they occurred. All those working on the

production line were encouraged to become involved in putting forward ideas

and testing them. As a result:

�? a new fully adjustable workstation was designed according to ergonomic

principles;

�? fully adjustable chairs were ordered and all operators were educated in the

importance of adjusting their chair and workstation at the beginning of the

shift;

�? waste bins were placed close to and to the side of workers;

�? the high stacks of boxes were eliminated as a result of a change in work

practices.

Results

�? Each operator on the production line now has a fully adjustable workstation

which fits his or her needs no matter how small or large he or she is;

�? the working environment is also far more pleasant as a result of the high

stacks of boxes having been removed. This has had the effect of enabling

operators to look around the room. A number of them have said that this had

made them feel ’less bored�?.

s50

European Agency for Safety and Health at Work

2.16 WORKER REHABILITATION USING

VOICE RECOGNITION COMPUTER

SOFTWARE: ‘TALK YOURSELF INTO A

JOB�? TRAINING PROGRAMME

GMB (Trade Union, UK)

London Region,

53 Duke Street

Chelmsford, Essex,

Contact: Ms Rosalind Lawless

Tel: +44 1245 345165

Fax: +44 1245 345129

email: Dave.Powell@gmb.org.uk

Ta s k

Use of display screen equipment or other computer operated equipment by

workers with or who have had a work-related musculoskeletal disorder.

Problem

Continuing the employment of workers, such as experienced display screen

equipment operators, once they have developed a work-related upper limb

disorder.

The GMB is a trade union whose members work in both office and factory

workplaces. The union was concerned that workers who had developed long-

term musculoskeletal disorders, from manual operation of keyboards or the

mouse, other repetitive office work, or factory tasks e.g. on factory production

lines, were unable to continue in employment. The following may have

contributed to the development of the disorder in the first place: very repetitive

tasks, insufficient breaks, poor posture, stress, fast pace of work e.g. to meet

production targets and bonus targets, insufficient or poorly designed workplace

equipment, lack of job rotation etc, insufficient / no training on the safe use of

the equipment, VDUs and the mouse may also have exacerbated the MSD.

Once the worker had developed such a condition it was impossible for them to

51s

Turn your back on musculoskeletal disorders

continue in the same or similar work involving repetitive movements etc. Those

with the MSD can therefore find themselves unemployed and also unable to

carry out other everyday basic tasks. For the organisation it means the loss of

an experienced, trained and skilled member of staff.

Solution

To continue in the same or similar employment the way the computerised

equipment is operated by the worker needs to be changed. Voice-operated

equipment exists but workers need training in its use if they are to remain

employable. A special course ‘Talk your way into a job�? was set-up to help meet

this challenge.

In the UK some Government projects have been set up to assist and provide

The course also covers public funding for initiatives to re-skill workers for future employment. The union

workplace health and safety worked with a regional programme (Essex TEC Skills 2000 Challenge Project) to

information, coping

obtain the funding and set-up the special training course. The custom built

strategies for MSD sufferers

course was designed and developed to provide tuition to MSD sufferers on the

and advice on how other

use of voice recognition software, predominantly for word-processing activities,

workplace aids can help

as an alternative to standard typing and mouse use; thereby enabling

minimise the effects of MSDs

employment re-integration / retention. Eligible people from the local area, with

upper limb MSD, can take advantage of this free course that is held one-day per

week for six weeks, with tuition being provided on a one to one basis.

It was recognised that rehabilitation support should go beyond just training in

the use of equipment. The course also covers workplace health and safety

information, coping strategies for MSD sufferers and advice on how other

workplace aids can help minimise the effects of MSDs. Assistance is also

provided on career re-direction, when necessary. The newly acquired and

effective communication technology skill (voice recognition) can provide the

client with new and further employment opportunities.

s52

European Agency for Safety and Health at Work

Similar training programmes can also be provided for workers in employment

or their employers to enable their retention at work, by the provision of voice

recognition training and advice. A charge has to be made for this service.

As a general support and promotion of worker rehabilitation the union has also

been involved in providing advice and information to a variety of organisations.

This includes: demonstrations and advice on voice recognition software and its

benefits; how to obtain Government financial assistance for employing MSD

sufferers; how to retain people with MSDs in the workplace is also disseminated

to a variety of organisations.

Results

�? Workers have been retained in employment by switching to the use of voice

recognition software to carry out their work, who would otherwise have

become unemployed;

�? unemployed individuals with MSDs have returned to the workplace, utilising

their new voice recognition skills and MSD coping strategies, where

appropriate;

�? to date, approximately 1/3 of the clients who have completed the course,

since its start in September 1999, are in, or about to enter, paid employment.

This would probably not have been possible if they had not attended the ‘Talk

Yourself into a Job�? course.

53s

European Agency for Safety and Health at Work

PRATICE

MSDs

PREVENTING

ANNEXES

55s

Turn your back on musculoskeletal disorders

3.1 SOURCES OF FURTHER INFORMATION

More information about preventing musculoskeletal disorders is available

from the Agency website http://osha.eu.int where the full text of all Agency

publications can be downloaded free of charge.

Further examples of solutions to MSD risks can be found at

http://europe.osha.eu.int/good_practice/.

The Agency website also provides links to EU legislation,

http://europe.osha.eu.int/legislation/, and to Member State sites where

national legislation and guidelines may be found.

AGENCY REPORTS

The European Agency has recently published a �? Work-related Low Back Disorders Agency facts

range of reports, fact sheets and campaign Work-related low back disorders, covering

Fact sheets provide concise information on a

material relevant to the MSD debate. All of both low back pain and low back injuries,

range of OSH issues and are usually available in

these are available on line at the Agency’s web are a significant and increasing problem in

all 11 official Community languages.

site http://agency.osha.eu.int/ publications/ Europe. This report examines the prevalence,

�? Facts 3 �? Work-related Musculoskeletal

and in a limited number of printed copies from origins, work-related risk factors and

disorders in Europe

the EC’s Publications Office EUR-OP in effective prevention strategies for low back

�? Facts 4 �? Preventing Work-related

Luxembourg (http://eur-op.eu.int), or from its disorders, A5 (available in English). Cat TE-

Musculoskeletal Disorders

sales agents (http://eur-op.eu.int/general/en/s- 32-00-273-EN-C

�? Facts 5 �? Work-related Neck and Upper

ad.htm).

Limb Musculoskeletal Disorders: summary of

Agency report

�? The State of Occupational Health in the

Information reports �? Facts 6 �? Repetitive Strain Injuries in the

European Union �? a pilot study

Member States of the European Union �?

This wide-ranging pilot study provides a

�? Repetitive Strain Injuries in the Member summary of Agency report

snap shot of the current state of

States of the European Union �? Facts 7 �? Future Occupational Safety and

occupational safety and health in the

This short report is is based on the results of Health Research Needs and Priorities in the

European Union. It combines statistical

a survey questionnaire distributed in 1999. It Member States of the European Union �?

evidence on OSH with the qualitative

was carried out at the request of the Dutch summary of Agency report

knowledge and experience of all the key

Ministry for Social Affairs and Employment �? Facts 9 �? Inventory of Socio-economic

actors involved. 478 pages, A4 (available in

who wanted to know how different Information about Work-related

English). Cat TE-29-00-125-EN-C (Summary

European countries define and measure the Musculoskeletal Disorders in the Member

reports in all languages will be published in

RSI problem and the types of policies and States of the European Union (DE, EN, ES, FR)

December 2000)

actions they have in place to tackle it. 32 �? Facts 10 �? Work-related Low Back Disorders

pages, A4, (available in English). Cat. Nº AS- �? summary of Agency report

24-99-704-EN-C �? Future Occupational Safety and Health

�? Work-related Neck and Upper Limb Research Needs and Priorities in the Campaign materials

Musculoskeletal Disorders Member States of the European Union

�? European Week for Safety and Health at

In response to a request from the European Based on data collected in the Member

Work 2000

Commission, this report has drawn together States this report summarises views and

The Agency has produced an information pack

knowledge from an extensive set of sources. policies on the most important future

consisting of posters, leaflets, factsheets and

These include the contemporary scientific European research topics for Occupational

postcards to promote the European Week

literature, the views of an expert Safety and Health. Psychosocial issues

2000 and its theme of the prevention of work-

international scientific panel, current (particularly stress), ergonomics (particularly

related musculoskeletal disorders.

practice, employer and employee manual handling) and chemical risk factors

representatives and a number of official (particularly carcinogens and substitution)

authorities from Member States. 114 pages, emerge overall as the top priorities for future Additional information on other Agency

A5, (available in English). Cat. Nº AS-24-99- research. 56 pages, A5, (available in publications is available at the Agency’s web

712-EN-C English). Cat. Nº TE-27-00-952-EN-C site http://agency.osha. eu.int/publications/

s56

European Agency for Safety and Health at Work

3.2 OVERVIEW OF PRACTICAL EXAMPLES

Industry/ Main source of Main

Country Title

Workplace problem intervention

B Adapting a fork lift truck Warehouse Driving Redesign

DK Improved organisation of workstation Textile/furniture Workstation Changes to

for sewing of mattresses manufacture layout/foot pedals workstation and

equipment

DK Avoiding manual lifting using a Food Heavy lifting �? Lifting aid

“vacuum�? device to lift meat carcasses

D An intelligent lifting device for Furniture Heavy, unwieldy loads Mechanical aid

loading a high frequency press manufacture/

table tops

EL Improved seating and reduced Textile Seating, pedal Improved workstation,

lifting in garment manufacture manufacture operation, pushing equipment, transport

heavy loads methods

E Automating removal of protective Electro-domestic Repetitive, Automation

plastic from stainless steel parts goods forceful task

manufacture/

dishwashers

E Reducing manual effort in factory Manufacturing/ Heavy loads, awkward Lifting aid, redesign of

loading tasks chemical products postures/sacks, barrels workplace layout

F Removing repetitive risks from Electro-domestic Highly repetitive work Mechanisation,

assembly of small components goods changes to

manufacture workstation and

organistaion

I Technical devices to reduce Food Frequent manual Automation

manual handling and repetitive handling of

work in meat packing heavy loads

NL Mechanical aids for handling Glazing/ Heavy, dangerous, Mechanical hoists,

glass panes construction awkward loads carts

A Redesigning tram driver’s position Public transport Poor driving position Redesign of tram cab

P Improving seating and ergonomics Manufacturing/ Repetitive work, Seating, workstation

in factory quality control work plastic goods stretching and reaching redesign

FIN Ergonomics programme for SMEs Small businesses/ MSD from various External service

various sectors types of work programme with

SMEs to introduce

ergonomic changes

S Ergonomics for junior schools Schools Poor furniture design External service

programme to

introduce ergonomic

equipment, training,

information

UK Introducing adjustable workstations Food Repetitive work, Changes to seating,

on a packing production line seating and workplace layout

workplace layout

UK Worker rehabilitation using Office MSD from display Rehabilitation: Training

voice recognition computer screen equipment use in voice operated

software: “talk yourself into (mouse, keyboard) equipment and advice

a job�? training programme

57s

European Agency for Safety and Health at Work

Turn your back on musculoskeletal disorders (MSDs)

2000 �? 57 pp. �? 16,2 x 22,9 cm

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