Industrial Safety and Hygiene News October 2023
Addressing Ergonomic Hazards: A Collaborative Approach for Safer Warehouses and Retail Industries https://www.ishn.com/articles/113858-addressing-ergonomic-hazards-a-collaborative-approach-for-safer-warehouses-and-retail-industries
The growth of warehousing and distribution over the past decade has been monumental, and the Occupational Safety and Health Administration (OSHA) has recognized the urgent need to address and prevent workplace hazards in this sector. With over 1.9 million people employed, the issue of ergonomic hazards in warehousing and retail has taken center stage. These risks, related to physical strain and poor design, extend beyond immediate accidents to affect long-term well-being and efficiency. (1)
In this article, we'll explore the intricacies of ergonomic hazards, from physical ailments like muscle strains and carpal tunnel syndrome to the broader implications they have in the workplace. We'll also explore OSHA's national emphasis program and uncover practical, impactful solutions that can be implemented across various work environments.
OSHA's National Emphasis Program
Warehousing and retail sectors present multifaceted challenges that demand keen understanding, targeted attention, and proactive investment. Recognizing the complexities of these challenges, the Department of Labor announced a national emphasis program aimed at reducing and preventing workplace hazards in warehouses and distribution centers.
The program targets several key areas, including but not limited to, powered industrial vehicle operations, material handling and storage, walking and working surfaces, and heat and ergonomic hazards. By focusing on these aspects, the program aims to mitigate risks and cultivate a safer work culture across the warehousing and retail industries.
However, addressing ergonomic hazards isn’t always easy and presents a multifaceted challenge for employers. These hazards aren't merely a result of one incorrect action but often stem from a combination of poor design, lack of training, and inadequate awareness. Solutions require collaboration between employers, employees, regulators, and experts in the field.
Ergonomic Hazards: A Complex Challenge
Ergonomic hazards have become a critical concern in the fast-growing warehousing and retail sectors. They are not just a threat to worker well-being but also a challenge to overall business efficiency. The complexity of these challenges arises from their deep embedding within routine tasks and the far-reaching consequences they can have. Here are some of the most common risks:
Muscle Strains
For a warehouse worker who must repeatedly lift heavy packages, muscle strains might become a chronic issue. Simple actions like bending or twisting improperly can compound over time, leading to severe injuries. In a distribution center, a worker lifting 50-pound boxes might not feel immediate discomfort, but the repetitive strain without proper lifting techniques or supportive equipment can lead to long-term back or shoulder problems.
Carpal Tunnel Syndrome
Employees that perform repetitive tasks, like cashiers or data entry personnel, as well as people working in the food, steel, wood, furniture, electronic, and automotive industries, are at greater risk of carpal tunnel syndrome. Prolonged, repetitive hand movements without adequate support and posture can lead to this painful condition. A cashier using a poorly designed scanner repeatedly might develop wrist pain, a precursor to carpal tunnel syndrome. (2)
Tendinitis and Lower Back Injuries
Tendinitis and lower back injuries are common, particularly where workers engage in repetitive motions or maintain uncomfortable positions for extended periods. Workers who perform the same arm movement all day might develop tendinitis. Similarly, employees who stand or sit in an incorrect posture for long hours might suffer from lower back discomfort or injuries.
Accessible and Impactful Solutions
Addressing ergonomic hazards doesn't need to be a daunting task. The following are accessible and impactful strategies tailored for diverse work environments:
1. Workstation Adjustments
Workstations play a vital role in employee comfort and health. By making smart, strategic changes, employers can reduce long-term health risks.
- Office Space: Adjustable standing desks allow employees to switch between sitting and standing. This flexibility can alleviate back pain and increase overall comfort.
- Retail Environment: Padded mats and adjustable heights at cashier's counters minimize standing fatigue and encourage proper posture. By considering the physical demands of the role, businesses can improve job satisfaction.
2. Proper Lifting Equipment and Training
Proper lifting techniques and equipment prevent strain-related injuries, promoting a safer workplace.
- Warehouse Investment: Automated lifting equipment ensures workers don't exceed safe lifting limits. This technology investment can pay dividends in reduced injury rates and higher productivity.
- Training Sessions: Regular hands-on training on proper manual handling techniques helps workers of all experience levels lift and carry items safely and understand their safe capacity, preventing unnecessary injuries.
3. Ergonomic Tool Design
Ergonomic tools, designed with the user in mind, decrease fatigue and injury.
- Manufacturing: Grips on hand tools that fit the user's hand reduce wrist strain, enabling workers to operate more efficiently.
- Retail: Carts with easy-to-maneuver wheels reduce physical effort, making the process of transporting goods more efficient and less physically taxing.
4. Stretching Programs
Athletes stretch before activity so should your Industrial Athletes. Simple stretching exercises prepare the body for physical labor, fostering a culture of physical well-being.
- Construction Site: Mandatory stretching routines keep muscles flexible, preventing strains. The inclusion of these routines highlights a company's commitment to worker health.
- Distribution Centers: Guided stretching sessions led by professionals foster camaraderie among workers, building a supportive work culture.
5. Strategic Storage and Placement
Intelligent organization minimizes physical exertion, having long-term positive impacts.
- Retail Store: Storing heavier items at waist level prevents unnecessary bending and stretching, making the shopping experience more efficient for both employees and customers.
- Warehouse: Placing high-demand items closer to packing areas reduces walking distance, saving time and reducing fatigue.
6. Collaboration Health Care Professional Service Providers
Athletic Trainers, Physical and Occupational Therapists, Ergonomists and Exercise Physiologists provide personalized solutions that reflect individual needs.
- Factory Assessments: Service providers can customize workstation solutions, enhancing comfort without sacrificing productivity.
- Retail Chain Expertise: Regular consultations with ergonomic experts can lead to store layouts that reduce physical stress. This collaboration between design and health experts can create a more comfortable environment for both employees and customers.
Implementing Lasting Change
Addressing ergonomic hazards through these solutions not only ensures compliance with safety regulations but fosters a healthy work environment. These approaches signal to employees that their well-being is a priority, leading to higher morale, productivity, and retention.
What makes these solutions truly accessible and impactful is their adaptability across different sectors and the relatively low cost of implementation. By actively engaging in these practices, employers create a win-win situation, enhancing both the safety and efficiency of the workplace.
Injury prevention specialists can substantially mitigate and prevent ergonomic-related injuries in the workplace. Their methods and success stories offer insights into the effectiveness of systematic strategies. Let's explore the key services these professionals offer and how those translate into tangible results.
1. Job Demands Analysis (JDA)
JDAs evaluate the physical requirements of various job roles, allowing for targeted prevention strategies. A manufacturing company could analyze the repetitive tasks on the assembly line. By identifying specific strain points, onsite injury prevention specialists can help them redesign workstations, leading to a reduction in related injuries.
2. Ergonomics: Customized Optimization of Workspaces and Tasks
Onsite injury prevention specialists take ergonomics beyond compliance, focusing on customized solutions for each workplace. In a large assembly or production plant, they can redesign workstations and tool placement based on individual employee needs, which can reduce complaints of musculoskeletal discomfort.
3. Wellness Initiatives: Educating Employees About Healthy Practices and Injury Prevention
Through engaging workshops and educational programs, onsite injury prevention specialists foster a culture of wellness within organizations. For example, they might initiate a “Wellness Wednesday” program in a retail chain, offering weekly sessions on proper lifting techniques, stress management, and nutrition. This program can lead to improved employee satisfaction scores and decreased absenteeism rates.
Success Story: The Case of DB Schenker Logistics
DB Schenker, a global logistics company, faced escalating musculoskeletal disorder (MSD) costs at various locations. These costs affected not only finances but also employee satisfaction and overall efficiency. In response, onsite injury prevention specialists formulated a targeted strategy.
An emphasis was placed on early intervention, ergonomics and injury prevention through training, education, and proactive engagements. Ensuring that employees were well-versed in proper techniques and practices and encouraging these industrial athletes to seek care at the first sign of discomfort. This strategy was supported by continuous monitoring and feedback, fostering sustainability through ongoing assistance.
The results were significant, including financial savings through a dramatic reduction in MSD-related costs (with some sites nearly eliminating them), improved employee well-being marked by fewer reported injuries and increased job satisfaction, and enhanced efficiency that led to greater client satisfaction. https://atlas-ips.com/results/db-schenker/
A Proactive Approach with Proven Results
Addressing the multifaceted challenges of ergonomic hazards in the warehousing and retail industries demands collaboration, understanding, and innovation. As these sectors continue to expand, affecting the lives of over 1.9 million workers, the urgency to create a safe and productive environment becomes paramount.
The solutions to these ergonomic challenges require careful analysis, tailored strategies, and a proactive approach. From making smart adjustments to workstations to engaging with onsite injury prevention specialists for personalized solutions, these strategies create a win-win situation for employees and employers.
In the wake of OSHA's national emphasis program, the path forward is clear, and the tools are accessible. This is not merely about complying with regulations or preventing injuries; it's about forging a working environment where every individual can thrive. By embracing these initiatives, businesses can not only enhance safety and health but elevate productivity and overall satisfaction. Ultimately, addressing ergonomic hazards is not just a responsibility; it's an opportunity to innovate, engage, and prosper.
About the authors:
Kyle Schmoyer - Atlas IPS Contributing Writer - Safety Director with 10+ years of experience in the manufacturing, construction, oil and gas, and chemical industries.
Curt DeWeese – Atlas IPS Director - A Physical Therapist with over 30 years of experience in injury prevention and program management. Curt’s knowledge and experience is in onsite early intervention and first aid, case management, functional testing and ergonomics.
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