Concordia students help firms identify workstation risks
Each year, cumulative trauma disorders caused by repetitive motion cost US businesses nearly $7.5 billion in worker’s compensation claims, according to the Bureau of Labor Statistics, and three-fifths of those injuries come from the manufacturing sector.
Bill Reedy, health, safety and environmental officer at Hayes Brake, Mequon, a manufacturer of brakes for heavy construction, agricultural and off-road vehicles, can attest to the statistic. "At our company, approximately 85% of the injuries that occur are ‘soft tissue injuries.’ These are often caused from repeated motion usually related to ergonomic problems between employees and machines."
But addressing how to effectively reduce those injuries can be a costly venture, especially for businesses like Hayes Brake, which employs around 350 workers. Ergonomic consulting services can charge up to $1,500 per day for workplace evaluations.
Because of the financial strain such services can impose, Reedy was pleased to learn about a student-training program at nearby Concordia University Wisconsin. Designed by the Occupational and Physical Therapy leadership team at the university, the Student Ergonomics Partnership (STEP) program takes Occupational Therapy and Physical Therapy students into area companies for "hands-on" ergonomics experience. While gaining hands-on experience, the students aid business owners by identifying high-risk jobs – jobs more likely related to worker’s compensation claims.
The process
According to assistant professor of occupational therapy Carrie Scheel, a certified work-capacity evaluator at Concordia, "The process for the student-consulting program is really quite simple. First, our professors meet one-on-one with area business owners to identify specific jobs which they feel could be labeled as ‘high risk’ for worker’s compensation claims. Once a job has been identified, we assign teams of occupational therapy and physical therapy students to come on-site at the place of business and conduct job analyses.
"While there, they gather information, using video and still photography of the physical aspects of the job, to document potential risk factors. They also interview employees to gain insight into how the job is performed, as well as ideas of what changes the employees feel need to be to make their jobs safer. Management is also interviewed to better understand what they feel needs to be changed in the workplace.
"Returning to campus, they review this data, with faculty assistance, and compile recommendations for making the job safer. Those recommendations are then placed into a formalized report which is given to both employees and management."
Immediate impact
According to Reedy, "The first time we had students into Hayes Brake, they helped us to identify a number of operations which weren’t as ergonomically correct as they could be. Most tasks involved repetitive reaching and lifting and turning, which were the bulk of our worker’s compensation cases.
"They also helped us to better understand the benefits of investing in adjustable worktables, redesigning work station fixtures, better positioning supplies and putting in torque arms to reduce the snap of your wrist when using a torque wrench."
Reedy continues, "All of these suggestions positively impacted our bottom line as well. Prior to their visit we had six cases of carpal tunnel, and since, we have had none."
This semester, the students are back at Hayes Brake, looking at Polaris handlebar master cylinder brake-lever lines; a Polaris brake caliber line; and a 2-660 heavy-duty brake line used for many types of off-road heavy-duty equipment.
"We realize these lines also have a lot of repetitive motion components to them and we are hoping that the students will be able to help us eliminate ergonomic risks before they occur," Reedy said.
"This is a great resource for our company and a tremendous learning opportunity for Concordia’s students," Reedy said. "We have lowered our worker’s compensation claims to below national averages because of our affiliation with the STEP program. We have employees who are glad to see the company being proactive in reducing injuries. And we are helping future OT/PT students receive valuable real world experience, as well as an insight into the brake industry and the ergonomics challenges we are facing on a daily basis."
"Plus," added Reedy, "an unexpected benefit of being affiliated with the Concordia’s Student Ergonomic Partnership program is that our employees have learned so much from the students that they now regularly evaluate themselves for the things that they may be doing incorrectly. It seems as though they are always looking at how to further reduce their chance of injury; it’s a heightened sense of awareness that everyone benefits from."
To date, the program has performed job analysis in the printing, small engines, plastics and brakes industries.
Larry Floyd, president, Plastic Molded Concepts, Eagle, said, "I would not have been able to afford this level of professional consulting. It is a great resource for small businesses."
For more information about becoming involved with the STEP program, contact Professor Carrie Scheel at 262-243-4429.
Nov. 8, 2002 Small Business Times, Milwaukee
