Business case for ergonomics interventions

Dr. Georgi Popov, QEPDr. Georgi Popov, QEP

Leigh Ann Blunt, Ed.D., ASP

John Zey, Ed.D., CIH

Anthony Hirner, CSPAnthony Hirner, CSPSource: Dr. Popov’s Projects

Practical Projects

Silicone Wire Problem Statement

• Silicone wire production involves variety of hazardous chemicals, toxic materials, and hazardous waste.

• Requires repetitive movements • CTD’s, Lower back injuries, CTS

• HR reported difficulties hiring new employees • High turnover rate• High cost of training and re-training

Silicone wire

Wire Production Process and MaterialsStep 1

• The first step is to feed the raw silicone into the extruder. Talc powder is applied to the raw silicone to improve the process.

Step 2• The next step is

to apply fiberglass tread on the basic silicone wire. Fiberglass tread is applied utilizing special treading machine.

Silicone wire extrusion process

Ovens

PIE

Steps 3 - 5• Third step is to apply another

layer of silicone and heat it to 4800F in order to cure it.

• The same silicone extruder like in step one is utilized.

• Fourth step is to apply another layer of thicker reinforcement layer of fiberglass.

• The same fiberglass-treading machine is utilized during this step.

• Fifth step is to apply final layer of silicone and print ink.

Spark plug boots

• The final step is to assemble the ignition wire and install spark plug boots.

• The company utilizes spark plug boots made of silicone.

Crimping silicone wires

• Manual Process

Next step• Once the insulation is stripped, it will

expose the actual wire that conducts spark to the spark plugs

Folding• The workers are folding the wire over back

onto the insulated part of the plug wire

Crimping• Employees put the end of the wire with

the terminal on it into crimping tool.

Fitting Spark Plug Boots

• Manual operation

• Apply milk like lubricant

• Test the wire

Project Cycle Efficiency Analysis

VAT - Work that customer would recognize as necessary to create the product or the service they are about to purchase.TLT - How long the process takes from start to end.

FYI: Source: Wire Lean 2007 tab

Ergonomics

• Repetitive motion is common for spark plug boots installation operations.

• Unfortunately, the nature of the work requires a lot of repetitive movements. MSD’s are common.

Countermeasures - Admin

• The administrative control option• One possible option is to reassign the boots

installation workers from the morning shift 7AM – 11AM to the packaging department.

• The workers from the packaging department will be cross-trained to install spark plug wire boots in the afternoon.

• Cost - $ 1250 training

Semi-Automatic Crimping Machine

• Initial investment – $17,500 per workstation

• Engineering cost – $ 4700 per terminal

• Utilities – $ 500 per year

• Maintenance – $ 500 per year

• Training – $ 2500 – 10 workers

• Improved productivity

• Employee morale

Full Automatic Terminal Crimping Machine

• Initial investment – $ 57,500 per workstation

• Engineering cost – $ 5100 per terminal

• Utilities – $ 500 per year

• Maintenance – $ 650 per year

• Training – $ 2700 – 10 workers

• Improved productivity

• Employee morale

Financial Analysis

FYI: Source: MS Excel Ergo Financial ROI

Financial Analysis

FYI: Source: MS Excel Ergo Financial: Financial tab

Financial Analysis

FYI: MS Excel Ergo Financial Compare proposals

Results

• The management selected Semi-Automatic Crimping Machine (SACM) option

• 3 SACM Total $ 70,100

• Admin option was implemented for a short time – insufficient results

• Reduced personnel from 90 to 47 (20% reduction due to current economic “difficulties”; 15% personnel reduction due to improved productivity; 12% other).

• Production down only 11% from 2008

Project Cycle Efficiency Analysis – Post Intervention

FYI: Source: Wire Lean PCM Lean tab

EHS INTERVENTION IS NOT AN EXPENSE --

IT IS AN INVESTMENT