Ergonomics Initiative at Cummins

What is Ergonomics? Ergonomics is the study of the relationship between people and their environment. The goal of ergonomics is to make the work fit the worker instead of making the worker fit the work.

The worker fits the work Without proper manual handling techniques With proper manual handling techniques MANUAL HANDLING

The work fits the worker ERGONOMICS

Why should we care?

Good for people A WORLDWIDE PANDEMIC ? The increase started in the mid-eighties in the US and the decrease started about 10 years after as the result of preventive measures Good for people The same phenomenon of increase in industrialised countries in Europe who just realize the amplitude of the problem (e.g. France)

Synchronizing flows & Ergonomics Ergo Improvements with Synchronizing Flows Process Eliminating… Wasteful repetition Excessive material handling Increasing efficiency through… Optimizing human motion Creating more efficient and less stressful postures on the body Good for business

EMPLOYERS' OBLIGATIONS Council Directive 89/391/EEC of 12 June 1989 on the introduction of measures to encourage improvements in the safety and health of workers at work EMPLOYERS' OBLIGATIONS General principles of prevention: (a) avoiding risks; (b) evaluating the risks which cannot be avoided: (c) combating the risks at source; (d) adapting the work to the individual, especially as regards the design of work places, the choice of work equipment and the choice of working and production methods, with a view, in particular, to alleviating monotonous work and work at a predetermined work-rate and to reducing their effect on health. (e) adapting to technical progress; (f) replacing the dangerous by the non-dangerous or the less dangerous; (g) developing a coherent overall prevention policy which covers technology, organization of work, working conditions, social relationships and the influence of factors related to the working environment; (h) giving collective protective measures priority over individual protective measures; (i) giving appropriate instructions to the workers.

EMPLOYERS' OBLIGATIONS Council Directive 89/655/EEC of 30 November 1989 concerning the minimum safety and health requirements for the use of work equipment by workers at work (second individual Directive within the meaning of Article 16 (1) of Directive 89/391/EEC) EMPLOYERS' OBLIGATIONS Equipment suitable for the work. Selection takes into account working conditions, hazards from the workplace before and after. Minimize the risks. Work equipment must comply with the provisions of any relevant Community directive which is applicable. Work equipment is kept, by means of adequate maintenance, at a level such that it continues to comply with the same provisions. Inspection of work equipment (before and during use). With work equipment involving specific risks to the safety or health of workers, the use of work equipment is restricted to those persons given the task of using it, and in the case of repairs, modifications, maintenance or servicing, the workers concerned are specifically designated to carry out such work. The working posture and position of workers while using work equipment and ergonomic principles must be taken fully into account by the employer. Workers must have adequate information and, where appropriate, written instructions on the work equipment used at work, containing : - the conditions of use of work equipment, - foreseeable abnormal situations, - the conclusions to be drawn from experience, where appropriate, in using work equipment. Workers must be trained for the use and maintenance/repair of the work equipment.

Council Directive 89/656/EEC of 30 November 1989 on the minimum health and safety requirements for the use by workers of personal protective equipment at the workplace (third individual directive within the meaning of Article 16 (1) of Directive 89/391/EEC) EMPLOYERS' OBLIGATIONS All personal protective equipment must: (a) be appropriate for the risks involved, without itself leading to any increased risk; (b) correspond to existing conditions at the workplace; (c) take account of ergonomic requirements and the worker's state of health; (d) fit the wearer correctly after any necessary adjustment. The conditions of use of personal protective equipment, in particular the period for which it is worn, shall be determined on the basis of the seriousness of the risk, the frequency of exposure to the risk, the characteristics of the workstation of each worker and the performance of the personal protective equipment. Adequate information on each item of personal protective equipment shall be provided and made available. Personal protective equipment shall be provided free of charge by the employer, who shall ensure its good working order and satisfactory hygienic condition by means of the necessary maintenance, repair and replacements. Personal protective equipment is, in principle, intended for personal use.

Council Directive 90/269/EEC of 29 May 1990 on the minimum health and safety requirements for the manual handling of loads where there is a risk particularly of back injury to workers (fourth individual Directive within the meaning of Article 16 (1) of Directive 89/391/EEC) General provision The employer shall take appropriate organizational measures, or shall use the appropriate means, in particular mechanical equipment, in order to avoid the need for the manual handling of loads by workers. Organization of workstations The employer shall organize workstations in such a way as to make such handling as safe and healthy as possible, considering: - the characteristics of loads, - the characteristics of the working environment and the requirements of the activity. Information for, and training of, workers Employers must ensure that workers and/or their representatives receive general indications and, where possible, precise information on: - the weight of a load, - the centre of gravity of the heaviest side when a package is eccentrically loaded. Employers must ensure that workers receive in addition proper training and information on how to handle loads correctly and the risks they might be open to particularly if these tasks are not performed correctly.

Directive 2002/44/EC of the European Parliament and of the Council of 25 June 2002 on the minimum health and safety requirements regarding the exposure of workers to the risks arising from physical agents (vibration) (sixteenth individual Directive within the meaning of Article 16(1) of Directive 89/391/EEC OBLIGATION OF EMPLOYERS The employer shall give particular attention, when carrying out the risk assessment, to the following: (a) the level, type and duration of exposure, including any exposure to intermittent vibration or repeated shocks; (b) the exposure limit values and the exposure action values ; (c) any effects concerning the health and safety of workers at particularly sensitive risk; (d) any indirect effects on worker safety resulting from interactions between mechanical vibration and the workplace or other work equipment; (e) information provided by the manufacturers of work equipment in accordance with the relevant Community Directives; (f) the existence of replacement equipment designed to reduce the levels of exposure to mechanical vibration; (g) the extension of exposure to whole-body vibration beyond normal working hours under the employer's responsibility; (h) specific working conditions such as low temperatures; (i) appropriate information obtained from health surveillance, including published information, as far as possible.

Good for legal compliance Why should we care? Good for legal compliance

Benefits of Ergonomics Fewer recordable injuries Decreased restricted/lost work days Lower worker’s compensation cost Improved quality Reduced absenteeism Improved employee morale More cross-functional employees (rotation)

Cummins Ergonomics Initiative Must be effective Must be simple Must be affordable

Results: Cummins Recon Memphis, TN Effective Zero Ergonomic Injuries in 2004!

Cummins TurboTechnologies Huddersfield Effective

Ergonomic Risk Factors Repeated exertions. Sustained exertions. Forceful exertions. Stressful postures. Contact stress. Temperature extremes. Vibration and noise. Simple

Results: Cummins Recon-Memphis, TN Workers Compensation Costs 1999-2002 Affordable

ERGONOMICS INITIATIVE Objectives Stop the ergonomics related problems pandemic within Cummins Inc. Anticipate and prevent the problems when the symptoms aren’t visible yet Use common approach/tools within Cummins Inc. Comply with the law

ERGONOMICS INITIATIVE Corporate support Corporate procedure Trainings in ergonomics Ergonomics introduction Ergonomics is Good for Every Body Ergonomics in Action Toolkit / methodology

ERGONOMICS INITIATIVE Toolkit / methodology Ergonomic improvement team Prioritization between departments Prioritization between workstations (employees input and informal complaints, “Symptoms survey” form, Ergonomic Evaluation form)

ERGONOMICS INITIATIVE Toolkit / methodology Ergonomics improvement program Ergonomic analysis (Ergonomics in Action methodology) Specific ergonomic analysis

RMP Injury Risk (Based on historical data from 2000-2003) #7 Accessory Drives (Based on historical data from 2000-2003) #11 Welding #10 Conn Rods #6 Disassembly #8 Lube Pumps #5 250 Salvage #4 HVWP #1 Holset Turbos #9 Maintenance #3 250 Assembly #2 Other Head Assembly #12 Materials

ERGONOMICS INITIATIVE Training 100% of the workforce to be trained in Ergonomics is good for Every Body 1% of the workforce to be trained in Ergonomics in Action Trainees get homework after the course Trainers certification program

ERGONOMICS INITIATIVE Ergonomics scorecard

Questions? Comments?

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