Success Brief:

Management commitment to reducing ergonomics risk factors, and preventing ergonomic injuries, resulted in all facility and task operation’s injury and illness rates being 100% below their respective industry rates. Investment in equipment, ergonomic program enhancements, and training led to this accomplishment.

Problem:

Heat Treat operators were required to lift heavy parts baskets out of a large water tank (quench tank). Due to the way that the work area was configured, employees could only lift the baskets out of the tank with one hand. Employees stood on a platform above the tank to lift the baskets up and over the lip of the quench tank. Heavy loads, or oddly shaped and/or large parts, made lifting the parts awkward and more difficult. Employees previously asked management for a hoist as they were being injured and needed mechanical assistance with the heavy and awkward loads to prevent further injuries.

Solution:

The employer:

1. Conducted ergonomic task assessment.
2. Strengthened their ergonomics program by conducting regular job-specific training for safe manual material handling practices, with a practical demonstration of proper lifting techniques.
3. Implemented ergonomics awareness training for employees, which is now required as part of onboarding and provided annually to employees.
4. Installed a hoist at the quench tank for personnel to use.

Impact:

The DART facility rate went from 0.5 in 2022 to 0.0 in 2023 and the facility Severity rate went from 13.12 to 0 for the same time period. The Heat Treat operation DART and Severity rates remain at 0.0.

Source: Mary A. McCoy, PE – Safety Manager; Pedro Dumaua - Sr. Corporate Manager EHS/ESG

Submission Reference Number: 22-101033