1. Ergonomics in Welding

2. What You Will Learn:
How to identify Work-Related Musculoskeletal Disorders (WMSD’s) in welding jobs
Propose solutions for hazardous exposures
Find further information about ergonomics in welding operations

3. Common Hazards Common hazards found in welding are:
Inhaling metals fumes
Eye exposure to welding arc light
Foreign objects in eyes
Burns
Noise

4. WMSD Hazards
Welding also includes musculoskeletal disorder (WMSD) hazards such as:
Awkward body postures
Lifting heavy equipment or materials
Static postures for prolonged periods
Awkward postures of the wrist

5. WA State-funded compensable claims 1994-2004 Welders, Cutters, Solderers
By Nature of Injury
Sprains account for more than 1/3 of the compensable claims among welders in the State of Washington.
Some of those could be caused by hazardous WMSD exposures.

6. WA 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 should therefore focus on those body parts among welders at your workplace.
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.

7. 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

8. WMDS hazards most common in welding
OFTEN, MORE THAN 1 RISK FACTOR IS PRESENT
Rigorous manual 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

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

10. 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

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

12. 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)

13. The Real World
Often cost, ease of maintenance, space considerations drive the design of the workplace
When hazards can’t be engineered 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

14. Ergonomic Solutions for Welding

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

16. 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

17. Team Lifting
BEFORE
AFTER
Team lifting helps reduce heavy, awkward lifting of equipment and materials.
Hazard: Manual wire welding is a primary element in ship construction and repair.  The use of standard straight welding "whips" forces the worker to flex the wrist towards the little finger side.  Carpal Tunnel Syndrome may also be associated with the use of straight welding whips.
Solution: A bent-tip wire-welding handle (see photo) allows the worker to maintain a more natural or neutral wrist posture than straight "whips."  In this manner, the tool, not the wrist is bent.
From: SIMA San Diego Ergonomics Program

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

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

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

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

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

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

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

25. Work-related musculoskeletal disorders
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.
Most think of workplace injuries as those that are immediate and have a visible, physical effect (e.g. broken bone, cut) and the causes are tangible, concrete (e.g. slip, hit by object)
But injuries can develop over time and not be a result of a single incident. The effects are less visible (tingling, numbness, swelling) which can become more disruptive (pain, loss of function, loss of range of motion).

26. Work-related musculoskeletal disorders
They are not acute injuries such as:
Broken bones
Cuts
Slips
Falls
Trips
Motor vehicle accidents
Being struck by or caught with objects
Most think of workplace injuries as those that are immediate and have a visible, physical effect (e.g. broken bone, cut) and the causes are tangible, concrete (e.g. slip, hit by object)
But injuries can develop over time and not be a result of a single incident. The effects are less visible (tingling, numbness, swelling) which can become more disruptive (pain, loss of function, loss of range of motion).

27. Common disorders among welders
Back injuries
Shoulder pain/loss of range of motion
Tendinitis/Bursitis
Reduced muscle strength
Carpal tunnel syndrome
White finger
Knee joint diseases

28. The Ergonomics Cycle
The ergonomics cycle shows an organized way to start your ergonomics effort.

29. 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.

30. 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 & CAL OSHA Services.
On WMSD hazardous exposures visit the DOSH webpage at:
Example Template of an accident prevention program :
Ideas to reduce hazardous exposures can be found at the Ergonomics Ideas Bank
You may also write us at:

31. Thank you

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