Ergonomics in Welding What You Will Learn How

Ergonomics in Welding

What You Will Learn: § How to identify causes of sprains and strains in welding jobs § Propose solutions for hazardous exposures § Find further information about ergonomics in welding operations

If you have any of the following hazards in your workplace we recommend that you include them in your Accident Prevention Program (APP).

Common hazards found in welding are: § Inhaling metal fumes § Eye exposure to welding arc light § Foreign objects in eyes § Burns § Noise

Sprains and Strains Welding also includes hazards that can cause sprains and strains such as: § Awkward body postures § Lifting heavy equipment or materials § Static postures for prolonged periods § Awkward postures of the wrist

Washington State-funded compensable* claims 1994 -2004 Welders, Cutters, Solderers By Nature of Injury Sprains are about 1/3 of the compensable* claims among welders in the State of Washington. *Compensable claims are those the involve time loss or disability payments

Washington State-funded compensable claims 1994 -2004 Welders, 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 at your workplace should therefore focus on those body parts among welders. 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.

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

Common causes of sprains and strains in welding Often, more than one of these is present § Detailed hand 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

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

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

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

The goal of a healthy work environment To simplify the welding tasks 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)

The Real World § Often cost, ease of maintenance, space considerations drive the design of the workplace § When hazards can’t be designed out, using best practices is a good alternative § Examples of good design: providing opportunities for work station adjustments, providing different types of tools, using good planning to eliminate unnecessary work

Ergonomic Solutions for Welding

Heavy Lifting Use: • • • Manipulators Lighter weight welding equipment Lighter weight cables with low stiffness Cable supporting balancers Overhead hoists Lifting and turning tables

Awkward Postures • • • Position work between waist and shoulder when possible Provide lifting tables Use motorized positioning devices Use welding guns with swivels and designed for use in both hands Try work stools

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

Tables BEFORE This picture shows the worker with considerable bending over at the waist AFTER Because the work is on a table, the worker doesn’t have to bend over as far From: Shipyard Ergonomics, 2003

Pre-Assembly Pre-assembly and material handling equipment helps reduce unnecessary lifting or any other kind of manual material handling

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

Ergonomic improvements Use wheeled tables for welding work and to transport stock and jobs. This reduces lifting and carrying of heavy materials.

Ergonomic improvements Welding leads on pulleys help reduce heavy and awkward lifting, and minimize static postures.

Ergonomic improvements Robotic automation is a feasible solution to reduce highly repetitive motions with the arms and hands. May also reduce the exposure to fumes.

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

Sprains and Strains They are cumulative (occur over time and not a result of a single incident): § Occur when the physical demands of work cause wear and tear on the body. § Involve soft tissues such as muscles, tendons, ligaments, joints, nerves, blood vessels.

Common sprains and strains among welders § § § § Back injuries Shoulder pain/loss of range of motion Tendinitis/Bursitis Reduced muscle strength Carpal tunnel syndrome White finger Knee joint diseases

The Ergonomics Cycle The ergonomics cycle shows an organized way to start your ergonomics effort. Management Support Employee Involvement Evaluate progress Problem Identification Solution Implementation Training Address Injuries

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.

More resources § 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 § Learn more about preventing sprains and strains. § Helpful tools for your Accident Prevention Program (APP) § You can also e-mail us at: Ergonomics@Lni. wa. gov

Help from L&I at no cost to you We offer free, confidential consultations to help you prevent sprains and strains in your workplace. To learn more: § Click here to email us – Ergonomics@Lni. wa. gov § Call – (360) 902 -5450 § Click here to visit our website – http: //www. lni. wa. gov/Safety/Consultation/