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Ergonomics in Welding

Ergonomics in Welding. An overview of WMSDs* hazardous exposures and solutions. *Work-related musculoskeletal disorders. What will You learn. Identify WMSDs hazardous exposures in welding jobs Propose solutions for hazardous exposures

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Ergonomics in Welding

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  1. Ergonomics in Welding An overview of WMSDs* hazardous exposures and solutions *Work-related musculoskeletal disorders

  2. What will You learn • Identify WMSDs hazardous exposures in welding jobs • Propose solutions for hazardous exposures • Find further information about ergonomics in welding operations

  3. Welding operations are necessary in many industries such as construction, manufacturing, maintenance, etc. Welding has several hazardous conditions for women and men in these jobs. Hazards

  4. Common hazards found in welding are: inhaling metals fumes, eye exposure to welding arc light (UV, visible), foreign objects in eyes, burns, noise, cuts, bruises, etc. Hazards

  5. Welding also includes musculoskeletal disorders (WMSD) hazards such as: awkward body postures, lifting heavy equipment or materials, static postures for prolonged periods, awkward postures of the wrist, etc. WMSD Hazards

  6. WA State-funded compensable claims 1994-2004Welders, Cutters, Solderers By Nature of Injury Sprains account for more than 1/3 of the compensable claims among welders in the State of Washington. Some of those could be caused by hazardous WMSD exposures.

  7. WA State-funded compensable claims 1994-2004Welders, Cutters, Solderers By Body Part The back, neck and shoulder together with the arm and hand regions make up more than one half of the injuries among welders in Washington State. Preventive efforts should therefore focus on those body parts among welders at your workplace. Welding is a strenuous occupation involving work in awkward postures and handling heavy equipment, usually with a high degree of sustained stress to arm and shoulders.

  8. Consequences of a poor working environment • Absences due to injury or illness and the transfer of welders to other tasks • Overtime for replacement workers. Welders are skilled employees • High employee turnover • Increased training and supervisory time • Reduced productivity and quality

  9. WMDS hazards most common in welding OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT • Rigorous manual precision requirements • High degree of uniformity • Awkward and static postures • Difficult work position • Heavy lifting, difficult material handling • Heavy objects, heavy welding equipment • Repetition • High work intensity

  10. Hazard Elements Duration (how long?) Frequency (how often?) Intensity (how hard?)

  11. Common postures adopted in welding Working in front Working at ground level Working above the shoulders Working at ground level, precision work Working at ground level, confined space Working above shoulders, confined space ‡From: Torner et al, 1991

  12. Awkward postures in welding Severe torso flexion Torso twisting Kneeling, squatting Bent wrists Neck flexion/extension Shoulder flexion/abduction (separation)

  13. The goal of a healthy work environment To simplify the welding performance for the welder and reduce the physical load during the work • Automate physically demanding or repetitive jobs • Expand the work content of welders (provide flexibility between jobs) • Multi-skilled workers who are able to perform different tasks within a group)

  14. The Real World • Often cost, ease of maintenance, space considerations drive the design process • When hazards can’t be engineered out, using best practices is the alternative • Examples of good design: providing opportunities for adjustments, providing different sizes, using good planning to eliminate unnecessary work

  15. Possible Ergonomic Improvements Heavy Lifting • Manipulators • Lighter welding equipment, easier to handle • Using lighter cables with low stiffness • Use cable supporting devices (balancers) • Utilize overhead hoists • Utilize lifting and turning tables

  16. Ergonomic improvements Awkward Postures • Position work between waist and shoulder, when possible • Lifting tables • Motorized positioning devices • Use welding guns with swivels and designed for use in both hands • Work stool

  17. Ergonomic improvements Team lifting helps reduce heavy, awkward lifting of equipment and materials. AFTER BEFORE From: SIMA San Diego Ergonomics Program

  18. Ergonomic improvements To reduce working with the back bent at ground level, any work table will help to adopt a safer posture AFTER BEFORE From: Shipyard Ergonomics, 2003

  19. Ergonomic improvements Pre-assembly and material handling equipment helps reduce unnecessary lifting or any other kind of manual material handling

  20. Ergonomic improvements This rotational clamp for pipe helps reduce awkward postures for the neck, shoulders and arms.

  21. Ergonomic improvements Tables for welding and transport reduce manual lifting, carrying of heavy materials. The tables also have wheels.

  22. Ergonomic improvements Welding leads on pulleys help reduce heavy and awkward lifting, static postures for long periods.

  23. Ergonomic improvements Robotic automation, are also feasible solutions to highly repetitive motions with the arms and hands. May also reduce the exposure to fumes.

  24. Possible Consequences Not implementing some or all these ergonomics guidelines may result in the following…

  25. Work-related musculoskeletal disorders They are cumulative (occur over time and not a result of a single incident): • Often occur when the physical demands of work cause wear and tear • Involve soft tissues such as muscles, tendons, ligaments, joints, nerves, blood vessels

  26. Work-related musculoskeletal disorders They are not acute injuries such as: • Broken bones • Cuts • Slips • Falls • Trips • Motor vehicle accidents • Being struck by or caught with objects

  27. Common disorders among welders • Back injuries • Shoulder pain/loss of range of motion • Tendinitis/Bursitis • Reduced muscle strength • Carpal tunnel syndrome • White finger • Knee joint diseases

  28. The ergonomics cycle provides with an organized way to start your ergonomics effort. The Ergonomics Cycle

  29. Credits The technical contents of this slideshow are based upon the presentation developed by Ninica Howard, MS, CPE, research ergonomist with the SHARP program at the Washington state Dept. of Labor and Industries.

  30. More resources • Shipyard Ergonomics for purchase at Shipbuilders Council of America at www.Shipbuilders.org • NIOSH’s Ergonomic Interventions in the Building, Repair, and Dismantling of Ships • SHARP Program • Easy Ergonomics. A practical approach for improving the workplace OR OSHA & CAL OSHA Services. www.cbs.state.or.us/osha/pdf/pubs/3347.pdf • On WMSD hazardous exposures visit the WISHA webpage at:www.lni.wa.gov/Safety/Topics/Ergonomics • Example Template of an accident prevention program : • www.lni.wa.gov/Safety/Basics/Programs/Accident • Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas Bank • You may also write us at: • ergonomics@LNI.WA.GOV

  31. Thank you

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