Ergo Cup 2005 Winners

Team Driven Workplace Solution

Honda Manufacturing of Alabama, LLC
Aluminum Die Cast Preheat Burner Ergonomic/Safety Improvement

The Aluminum Die Cast department improved the low pressure engine head preheat burner process. The previous process required that two associates carry 59 pound preheat burners and set them with an awkward reach. Removing the burners was dangerous as they are hot, posing a burn hazard and a back injury concern. The team’s goal was to create an ergonomically safe burner cart. The cart eliminates handling of burners by associates. Set up and take down time was reduced by 88%. Production has increased by 2500 additional engine heads annually. Morale improved by reducing workload and eliminating hazards.

Engineering/Ergonomist-Driven Workplace Solution

General Electric Company
Lifting Tool for MAVIG Monitor Suspensions

The Monitor Suspension Lifting Tool was designed to eliminate several risks associated with installation and deinstallation of LCD monitor suspensions, which are an integral component of GE Healthcare vascular x-ray systems. The project included designing a new tool including packaging, and redesigning the monitor suspension package. The main benefits of our project are: (1) Safe and easy installation of suspensions (2) Eliminated ergonomics related risk factors including back flexion, finger pinching, shoulder flexion/abduction (3) Eliminated special staffing requirements (multi-person lifts) (4) Cost savings on installation.

Training and Education

Safe Work Skills Program: How SAS Targets Lifting-Related Concerns

A review of SAS' injury reports revealed that 1/3 of our workers comp costs were from back injuries, many from our "labor-intensive" employees: 450 employees who frequently lift and bend. To lower direct and indirect costs, we developed the Safe Work Skills Program. Annual attendance is required and includes an educational class on safe lifting, a healthy back class where these skills are practiced safely in the actual work areas, and an ergo-safety site survey with subsequent meetings between employees and management to surface concerns. Sixty classes are taught annually. Over 75 ergo-safety concerns have now been identified and resolved as a result of the team efforts between employees, supervisors, and the Risk Management staff.