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Ergonomics Developing An Effective Process
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Objectives Understand the elements that can be used to develop an effective ergonomics process Discuss methods for getting commitment from people at all levels in the organization Outline strategies for developing an ergonomics team and written plan. Increase awareness of key considerations and resources for all process elements.
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Process versus Program
Natural Benefit driven Interdependent Dynamic Participatory On-going Program Contrived Mandate driven Independent Static Controlled Implied ending
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What characteristics help to make a process effective?
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What characteristics help to make a process effective?
Commitment Involvement Responsibility Communication Accountability Monitoring Integration On-going Improvement
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Lets Play ERGOMANIA
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Choose The Best Answer To The Following Questions
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What Is Ergonomics ? ERGOMANIA
A) Selecting the right person for the job so injuries are less likely to occur. B) Fitting jobs and job demands to the capabilities/limitations of the population. C) A communist plot to make the American people weaker. D) Using common sense to make jobs easier. ERGOMANIA
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What Is Ergonomics ? ERGOMANIA
A) Selecting the right person for the job so injuries are less likely to occur. B) Fitting jobs and job demands to the capabilities/limitations of the population. C) A communist plot to make the American people weaker. D) Using common sense to make jobs easier. ERGOMANIA
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A Major Goal Of Ergonomics Is
A) Reduce the frequency of injuries/illnesses and costs associated. B) Design jobs so the average person can do them safely and efficiently. C) Automate all jobs that require lifting and repetitive motion. D) Confuse and frustrate people with complicated formulas and charts. ERGOMANIA
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A Major Goal Of Ergonomics Is
A) Reduce the frequency of injuries/illnesses and costs associated. B) Design jobs so the average person can do them safely and efficiently. C) Automate all jobs that require lifting and repetitive motion. D) Confuse and frustrate people with complicated formulas and charts. ERGOMANIA
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Potential benefits of an ergonomics process include:
A) Improves employee safety and health, productivity, and quality B) Fosters an environment of teamwork and continuous improvement C) Makes employees think that management cares about them D) All of the above ERGOMANIA
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Potential benefits of an ergonomics process include:
A) Improves employee safety and health, productivity, and quality B) Fosters an environment of teamwork and continuous improvement C) Makes employees think that management cares about them D) All of the above ERGOMANIA
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The principles of Ergonomics are derived from…
A) The political agenda of bleeding heart liberals B) Various sciences including anthropometry and biomechanics C) Regulation-happy government agencies that have nothing better to do D) All of the above ERGOMANIA
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The principles of Ergonomics are derived from…
A) The political agenda of bleeding heart liberals B) Various sciences including anthropometry and biomechanics C) Regulation-happy government agencies that have nothing better to do D) All of the above ERGOMANIA
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On Average, Back Injuries Account For Approximately
A) 10% of all lost-time injuries. B) 25% of all lost-time injuries. C) 50% of all lost-time injuries. D) 75% of the workers’ compensation cases under investigation by the fraud department. ERGOMANIA
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On Average, Back Injuries Account For Approximately
A) 10% of all lost-time injuries. B) 25% of all lost-time injuries. C) 50% of all lost-time injuries. D) 75% of the workers’ compensation cases under investigation by the fraud department. ERGOMANIA
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CTD stands for: ERGOMANIA A) Carpal Tunnel Disease
B) Cumulative Trauma Disorder C) Completely and Totally Disabled D) Call The Doctor ERGOMANIA
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CTD stands for: ERGOMANIA A) Carpal Tunnel Disease
B) Cumulative Trauma Disorder C) Completely and Totally Disabled D) Call The Doctor ERGOMANIA
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On average, upper extremity CTDs account for:
A) less than 10% of all lost-time injuries B) between 10% and 20% of all lost-time injuries C) between 20% and 30% of all lost-time injuries D) 75% of the workers’ compensation cases under investigation by the fraud department ERGOMANIA
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On average, upper extremity CTDs account for:
A) less than 10% of all lost-time injuries B) between 10% and 20% of all lost-time injuries C) between 20% and 30% of all lost-time injuries D) 75% of the workers’ compensation cases under investigation by the fraud department ERGOMANIA
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Carpal Tunnel Syndrome is:
A) An irritation of one of the nerves that passes through the wrist B) An injury to the tendons of the wrist C) A cumulative condition that develops mainly in women who type a lot D) A “work-related injury” that just happened to surface when video games and remote controls were invented ERGOMANIA
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Carpal Tunnel Syndrome is:
A) An irritation of one of the nerves that passes through the wrist B) An injury to the tendons of the wrist C) A cumulative condition that develops mainly in women who type a lot D) A “work-related injury” that just happened to surface when video games and remote controls were invented ERGOMANIA
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The OSHA ergo standard would have made companies:
A) Analyze and improve all jobs B) Analyze and improve jobs where MSDs have occurred C) Waste a lot of money on expensive consulting and training services D) Outsource jobs or move operations to another country ERGOMANIA
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The OSHA ergo standard would have made companies:
A) Analyze and improve all jobs B) Analyze and improve jobs where MSDs have occurred C) Waste a lot of money on expensive consulting and training services D) Outsource jobs or move operations to another country ERGOMANIA
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The Three Major Occupational Risk Factors For CTDs Are:
A) Repetition, Force, and Posture B) Work ethic, Experience, and Attitude C) Gender, Age, and Medical History D) Labor Unions, Lawyers, and Poor Labor/Management Relations ERGOMANIA
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The Three Major Occupational Risk Factors For CTDs Are:
A) Repetition, Force, and Posture B) Work ethic, Experience, and Attitude C) Gender, Age, and Medical History D) Labor Unions, Lawyers, and Poor Labor/Management Relations ERGOMANIA
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Proactive Methods To Identify Risk For CTDs Include:
A) Reviewing OSHA 200 logs, medical records, and workers’ comp data. B) Calculating absentee/turnover rates. C) Observing employees, analyzing jobs, and using symptoms surveys. D) Conducting pre-employment physicals, drug screening, and background checks. ERGOMANIA
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Proactive Methods To Assess Risk For CTDs Include
A) Reviewing OSHA 200 logs, medical records, and workers’ comp data. B) Calculating absentee/turnover rates. C) Observing employees, analyzing jobs, and using symptoms surveys. D) Conducting pre-employment physicals, drug screening, and background checks. ERGOMANIA
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A good example of an ergonomic modification is:
A) Hiring people who are young, strong, and don’t complain B) Providing equipment that helps to reduce the need for manual lifting C) Providing back support belts for jobs that require lifting D) Removing twinkies and pork rinds from the vending machines ERGOMANIA
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A good example of an ergonomic modification is:
A) Hiring people who are young, strong, and don’t complain B) Providing equipment that helps to reduce the need for manual lifting C) Providing back support belts for jobs that require lifting D) Removing twinkies and pork rinds from the vending machines ERGOMANIA
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The Ohio Bureau of Workers’ Compensation is most like:
A) An insurance company B) The Occupational Safety and Health Administration (OSHA) C) Welfare D) All other government agencies that just keep wasting my tax dollars ERGOMANIA
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The Ohio Bureau of Workers’ Compensation is most like:
A) An insurance company B) The Occupational Safety and Health Administration (OSHA) C) Welfare D) All other government agencies that just keep wasting my tax dollars ERGOMANIA
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The best way to sell ergonomics to top management is by:
A) Convincing them that government regulations are inevitable B) Sending them information and hope that they realize it is just the right thing to do C) Threatening them with unionization or writing “protections” into the contract D) Providing cost/benefit studies that show how it will improve the bottom line ERGOMANIA
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The best way to sell ergonomics to top management is by:
A) Convincing them that government regulations are inevitable B) Sending them information and hope that they realize it is just the right thing to do C) Threatening them with unionization or writing “protections” into the contract D) Providing cost/benefit studies that show how it will improve the bottom line ERGOMANIA
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Ergonomics Process Flow Chart
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Ergonomics Process Flow Chart
Identifies the various steps and typical order in which they should be developed Each box in the flow chart represents an element that should be considered Depending on your organization, you may not have to implement every step or address them in this exact order
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How do you currently respond to potential ergonomic hazard?
Ignore it and hope nothing happens Stop and offer assistance, and leave it at that Stop and ask the employee or supervisor more about the job and the hazard Report the issue to the ergo/safety team or coordinator and hope they take care of it Report the issue to the ergo/safety team or coordinator and check for follow-through
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Obtain Top Management and Union Commitment
Top management and the union must collectively agree to support and commit to the ergonomics process. Top management and union leadership should have joint meeting(s) to discuss the ergonomic process and its components.
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What are the key selling points for the following groups?
Owners/shareholders Top management Department managers Engineers Maintenance Supervisors Hourly employees
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Group Activity
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Scenario II Bill Gates You are the Top Management at your company. Your Safety Director wants to initiate an ergonomics process. What kind of information do you as Top Management need to know before you can make a decision?
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Resources and Support needed from Top Management
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Executive Summary (app. A-1)
A tool that is used to inform and/or sell the ergonomics process. Outlines the intent of the ergonomic process and identifies expected outcomes of implementing a process. Appendix A-1
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Tools to help show support and commitment to the Process
Letter of commitment (Appendix A-2) Memorandum of understanding (Appendix B-1) Appendix A-2, B-1
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Top Management And Union Commitment
If top management and/or the union is not willing to commit to the ergonomics process we recommended that you POSTPONE your efforts until a firm commitment can be agreed upon by both parties.
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Bottom Line Top Management needs cost benefit information before they can support an Ergonomics Process.
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Cost And Benefits Associated With An Ergonomics Process
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Costs of Developing an Ergonomics Process
Process Costs Project Costs
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Costs of Developing an Ergonomics Process
Process Costs Team Meetings Team Training Employee Training Materials and Forms Equipment for Analysis and Documentation Medical management consultation Project Costs Analysis/Research Engineering Equipment Purchase Installation Maintenance Training Production disruption
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Materials and Tools for Ergo Process Development
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Materials and Tools for Ergo Process Development
Camcorder Digital Camera Tape Measure Push/Pull Gage Job Assessment Forms Assessment software Design Guidelines Reference Materials Bulletin Board Suggestion Forms Training Videos Handout Materials
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What Are The Benefits Of An Ergonomics Process ?
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Benefits Of An Ergonomics Process
Reduced Turnover Reduced Recruiting and Training Costs Reduced Absenteeism Increased Productivity Reduced Re-Work & Scrap Increased Wages/Benefits Reduced Injuries/Comp Cost Better Morale Team Work Costs Ergonomics Process
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The Cost Of Injuries The direct cost of an injury includes the medical and indemnity costs Indirect costs of injuries are usually 1 to 4 times as much as the direct costs
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Indirect Cost Multiplier
If Direct Injury Cost is: $ $2,999 $3,000 - $4,999 $5,000 - $9,999 $10,000 or more Multiply by… 4.5 1.6 1.2 1.1
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Example of Total Injury Cost Calculation
Assume an injury has a direct cost of $9,000 Estimated indirect cost = Direct Cost x Multiplier $9,000 x 1.2 = $10,800 Direct Cost + Indirect Cost = Total Cost of Injury $9, $10,800 = $19,800
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A Better Way to Express the Costs of Injuries
To calculate an incident’s impact on your profitability, you should use your profit margin to determine the amount of sales required to pay for the incident.
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Determining Impact of Injuries On Profitability
1) Divide your total profits by total sales to get your profit margin. Total profits = Profit Margin Total Sales 2) Divide the total cost of an injury/illness by your profit margin to determine how much sales your company must generate to pay for injury/illness. Total Cost of Injury/Illness = Sales required to pay for Profit Margin injury/illness
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Impact On Profitability Example
The total profits for a company is $1,000,000 with the total sales volume being $25,000,000. The profit margin for the company is: Total Profits = Profit Margin = $1,000,000 = .04 Total Sales $25,000,000
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Impact On Profitability Example (Continued)
What sales amount is required to pay for one $3,000 dollar carpal tunnel syndrome? Total Cost of an Injury/Illness = Sales to pay for an injury/illness Profit Margin $3,000 = $75,000 in sales required .04
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U.S. General Accounting Office Study Results
HILL & GRIFFITH Company May 6, 1998 U.S. General Accounting Office Study Results NOTES: ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Ergonomic "Awareness" Presentation 10
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Cost Reduction/ Case Studies
Navistar - $1.4 Million (1993) Truck Assembly - 4,000 employees (Ohio) Reduced to $544,000 (1996) SOCHS - $100,000 (1994) Nursing Center employees (Maine) Reduced to $70,000 (1996) Texas Instruments - $2.6 Million (1991) Defense/Electronics - 2,800 employees (Texas) Reduced to $244,000 (1996) U.S. GAO Study Results
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Cost Reduction/ Case Studies Continued...
American Express Financial Advisors - $484,000 (1992) Financial planning/investment - 5,300 employees (Minnesota) Reduced to $98,000 (1996) AMP Inc. - $73,000 (1993) Electronic Assembly employees (Pennsylvania) Reduced to $28,000 (1996) U.S. GAO Study Results
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Benefits: Average $ per CTD Claim
HILL & GRIFFITH Company May 6, 1998 Benefits: Average $ per CTD Claim 21946 9123 9518 6601 5322 4860 2512 2469 3014 1685 NOTES: ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ U.S. GAO Study Results Ergonomic "Awareness" Presentation 15
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To Receive a Copy of the GAO Study:
HILL & GRIFFITH Company May 6, 1998 To Receive a Copy of the GAO Study: Call US General Accounting Office or access their website Report # GAO/HEHS phone (202) NOTES: ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ U.S. GAO Study Results Ergonomic "Awareness" Presentation 17
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Form Ergonomics Team
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Team Structure Steering/Advisory Group role (p. 9)
In general, most teams are comprised of 6-10 members. Some teams have an “open seat” or sub-teams.
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Who Should Serve On The Ergonomics Team ?
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Potential Ergonomic Team Members ( see page 11)
Facility or Operations Manager Union Representative Supervisors Hourly Employees HR/Personnel Director Engineers/Facilities Planning Maintenance Personnel Plant Safety Representative Health Care Provider Purchasing Personnel
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How Do You Solicit Volunteers To Serve On The Ergonomics Team ?
OH PICK ME PICK ME
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Solicit Volunteers Criteria for soliciting and choosing ergonomic team members should be created. Desirable qualifications and characteristics might include:
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Ergonomics Team Members
Consider using an application form to solicit volunteers (sample form located in Appendix H-4). Prospective Ergonomic team members must be solicited and asked to serve on the team on a voluntary basis, they should not be mandated to serve on such a team. Appendix H-4
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ERGOMANIA Round 2
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A Management Responsibility In The Ergonomics Process Is:
A) Deny all back injury and cumulative trauma claims. B) Define responsibilities and hold people accountable for ergonomics. C) Make people afraid to report symptoms. D) Eliminate all lifting and repetition from jobs. ERGOMANIA
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A Management Responsibility In The Ergonomics Process Is:
A) Deny all back injury and cumulative trauma claims. B) Define responsibilities and hold people accountable for ergonomics. C) Make people afraid to report symptoms. D) Eliminate all lifting and repetition from jobs. ERGOMANIA
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One Supervisor Responsibility In The Ergonomics Process Is:
A) Discipline people who don’t lift properly or use good body mechanics. B) Encourage workers to promptly report aches and pains and suggestions. C) Convince associates not to worry about things like back pain and wrist pain because they usually just go away. D) Avoid mentioning words like ergonomics and carpal tunnel syndrome. ERGOMANIA
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One Supervisor Responsibility In The Ergonomics Process Is:
A) Discipline people who don’t lift properly or use good body mechanics. B) Encourage workers to promptly report aches and pains and suggestions. C) Convince associates not to worry about things like back pain and wrist pain because they usually just go away. D) Avoid mentioning words like ergonomics and carpal tunnel syndrome. ERGOMANIA
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One Employee Responsibility In The Ergonomics Process Is:
A) Promptly report concerns and suggestions to supervisors. B) Always use the squat lift technique. C) If your back starts to hurt, go to the store and get a back support belt. D) Resist any changes to the way the job has always been done. ERGOMANIA
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One Employee Responsibility In The Ergonomics Process Is:
A) Promptly report concerns and suggestions to supervisors. B) Always use the squat lift technique. C) If your back starts to hurt, go to the store and get a back support belt. D) Resist any changes to the way the job has always been done. ERGOMANIA
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Ways To Get All Employees Involved In An Ergonomics Process Are:
A) Tell a few employees and ask them to spread the word. B) Use cash rewards and incentives. C) Through frequent communication and involvement opportunities. D) Through coersion and intimidation. ERGOMANIA
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Ways To Get All Employees Involved In An Ergonomics Process Are:
A) Tell a few employees and ask them to spread the word. B) Use cash rewards and incentives. C) Through frequent communication and involvement opportunities. D) Through coersion and intimidation. ERGOMANIA
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Decisions That An Ergonomics Team Should Make During Formation:
A) When, where, and how often the team will meet. B) Who will be on the team and what are each person’s responsibilities. C) How to communicate information throughout the organization. D) All of the above ERGOMANIA
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Decisions That An Ergonomics Team Should Make During Formation:
A) When, where, and how often the team will meet. B) Who will be on the team and what are each person’s responsibilities. C) How to communicate information throughout the organization. D) All of the above ERGOMANIA
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Important Criteria For Ergonomics Team Members To Possess Are:
A) Superior knowledge and technical skills B) Avoids challenging company policies and established norms C) Good communication skills and ability to work with others D) Is the brother of the CEO ERGOMANIA
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Important Criteria For Ergonomics Team Members To Possess Are:
A) Superior knowledge and technical skills B) Avoids challenging company policies or established norms C) Good communication skills and ability to work as a team player D) Is the brother of the CEO ERGOMANIA
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Improvement Projects Should Be Prioritized Based On:
A) The number of people that will be affected by the change. B) The frequency and cost of injuries in the operations. C) The cost and ease of making the modifications. D) Any of the above. ERGOMANIA
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Improvement Projects Should Be Prioritized Based On:
A) The number of people that will be affected by the change. B) The frequency and cost of injuries in the operations. C) The cost and ease of making the modifications. D) Any of the above. ERGOMANIA
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An Effective Ergonomics Process Is Characterized By:
A) Posters and training classes that show people how to use good posture and body mechanics. B) Elimination of all manual work . C) Continuous improvements that make jobs safer and more efficient. D) A system for rotating workers to various jobs. ERGOMANIA
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An Effective Ergonomics Process Is Characterized By:
A) Posters and training classes that show people how to use good posture and body mechanics. B) Elimination of all manual work . C) Continuous improvements that make jobs safer and more efficient. D) A system for rotating workers to various jobs. ERGOMANIA
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Ways To Keep All Employees Informed Of The Team Progress:
A) Encouraging informal discussions between employees and team members. B) Posting meeting minutes and project logs on bulletin boards. C) Company newsletter D) All of the above ERGOMANIA
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Ways To Keep All Employees Informed Of The Team Progress:
A) Encouraging informal discussions between employees and team members. B) Posting meeting minutes and project logs on bulletin boards. C) Company newsletter D) All of the above ERGOMANIA
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Blueprint For Success (appendix D-1)
The Blueprint is a summary of steps that should be followed when writing an ergonomics plan The examples are intended to provoke discussion and guide the team or organization through the process The written plan should be a fluid document; meaning that as process improvements are developed, it should be updated Appendix D
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Steps 1 and 2 - Develop a Mission Statement and Goals
Keep it brief Consider short term and long term goals Be ambitious, but also realistic Be specific Define activities, not just outcomes Communicate it
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Tools and Resources for Defining Mission and Goals
Organizational values and mission OSHA ergonomics guidelines Ergonomic implications from compliance with other regulatory agencies Statistics/Case studies/Success stories from others in industry (competitors) Perception survey OCOSH Course - GEN Winning Management Commitment
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Steps 3 & 4 - Determine key members and responsibilities
Get management and labor representation Specify roles and responsibilities Define people who will serve as resources
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Resources for Determining Roles and Responsibilities
Job descriptions/day-to-day responsibilities Performance evaluation criteria related to safety and ergonomics Team charter from other successful committees or projects Formal education and Training records
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Steps 5 & 6 - Define Operating Rules, Format & Logistics
Establish regular time, place, and format Determine how and what types of info will be communicated Determine where documentation will be kept
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Tools and Resources for Developing Safety/Ergo Teams
OCOSH courses GEN Developing Safety Involvement Teams GEN Facilitating Safety Meetings University outreach programs Companies specializing in organizational development Facilitator training
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Step 7 - Develop Training
Determine specific training needs Consider in-depth training for team or coordinator Provide overview of process for entire staff Develop job-specific training for all
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Resources for Ergonomics Training and Materials
OCOSH Courses ERG Ergonomics for Office ERG Ergonomics Applied ERG Ergo and Safety for Healthcare Corporate and other Internal Resources Colleges and Universities Safety and Ergonomics Web Sites Ergonomics Consulting Firms Product Vendors
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Blueprint Group Activity
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Blueprint Group Activity
You are an Ergonomics Team that will address the following steps from the Blueprint for Success to create your written program. Steps 1 & 2 Steps 3,4,5, & 6 Step 7 Appendix D
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Step 8 - Collect and Analyze Relevant Data
Identify what is relevant and available Determine where it is and how to get it Avoid overanalyzing Look beyond the strains and sprains
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Collect & Analyze Trend/Historical Data
What kind of data do you have to help identify and analyze injury trends? Where do you find the data? Appendix E
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Step 9 - Develop Guidelines for Prioritizing Jobs and Issues
Define key factors Determine ranking or weighting for factors Provide data collection forms and methods Use quantitative and qualitative data Provide for flexibility Build on successes
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Tools for Outlining Prioritization Methods
Perception surveys Cost data Symptoms surveys Ergonomics assessment software
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Step 10 - Develop Procedures for Ergonomic Job Analysis
Develop standard data collection forms Determine appropriate assessment tools Use quantitative and qualitative data List of authorized/ recommended analysts
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Resources for Ergonomic Hazard Assessment Tools
NIOSH lifting guide - or Snook Guidelines for Pushing or Pulling Force - State of Washington Risk Factor Checklists - BWC Consultants OHIOBWC
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Step 11 - Establish Process for Solution Development
Develop ad hoc project team structure Specify roles and responsibilities Identify resources for information, ideas, and products Provide cost/benefit estimating tools
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Tools and Resources to Assist with Solution Development
Brainstorming Fishbone diagramming Success stories Outside consultants Vendors Industry/Trade groups EMPLOYEES!
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Step 12 - Devise Procedures to Assist with Approval Process
Develop template for presenting proposal Provide suggested cost justification method and benchmark Offer pre-presentation review process List decision makers
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Tools and Resources for getting approval for projects
In-house resources Success stories from others in industry Cost/Benefit formulas Compliance - Knowledge of other safety and health issues and requirements Success stories from other projects Grants
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Step 13 - Outline the Solution Implementation Process
Develop ad hoc project team structure Specify required steps and responsibilities Provide expected timeframes for steps Develop sign-off sheets and routing Outline means of communicating status
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Tools and Resources to assist with Implementation Process
Action plan templates Input from people involved in similar types of projects Input from employees Communication
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Step 14 - Develop Project Evaluation Techniques
Define measurables Specify timeframes for follow-up Specify person(s) responsible Provide templates for documentation Develop procedure for follow-up on issues
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Tools and Resources for Project Documentation
Comparison with Ergonomic guidelines Follow-up assessments Post-intervention surveys Bulletin boards Various electronic means Project documentation forms (appendix H)
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Step 15 - Develop Protocols for Medical Management
Define symptoms and reporting process Institute transitional work policies Develop standard forms for all aspects Develop roles and responsibilities Communicate to all
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Resources for Medical Management Assistance
Managed Care Organizations (MCOs) Transitional Work Developers Local Hospitals and Medical Centers Industrial Rehab Centers Appendix G
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Step 16 - Outline Methods for Monitoring the Overall Process
Develop objective measures Focus on activities and outcomes Relate successes with organizational values and business pursuit Implement continuous improvement
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Tools for Monitoring the Ergonomics Process
Use the Process Monitoring Checklist in Appendix H-26, to assess your company's current ergonomics process. Appendix H-26
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Any Questions ? Thank You
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