2008/09 GE Ergo Cup CompetitionTraining & Education Initiative
GPR – Global Posture Re-education Ergo Cup Project Primary Contact: Marcelo Vicente EHS Specialist 55 15 2101-5561 [email protected]
Energy InfrastructureWater & Process TechnologiesSorocaba Site, Brazil
2008/09 GE Ergo Cup CompetitionTraining & Education Initiative
Project Title Ergo Cup Project Leader: Marcelo Vicente – EHS SpecialistErgo Cup Project Team Member #1: Luciani Bassan – PhysiotherapistErgo Cup Project Team Member #2: Nelson Lima – Physiotherapist
3 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
Background
In 2006 and 2007, Sorocaba had 2 and 1 recordable cases ergonomics related, following. In 2006, It was lost 186 days of regular job. In 2007, this number was 91 days.In the beginning of 2007, the number of employees complaining about musculoskeletal discomfort and posture pain were 22.
4 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
“Before” Situation: Process Map
musculoskeletal Disconfort
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10
Program Begining dez/07 jul/08
Period
Pain
Lev
el
A
B
C
D
E
F
G
H
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Pain Rate
0
2
4
6
8
10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Employee
Pain
Lev
el
Before After
16 employees with posture deviation and on pain
5 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
Improvement: DescriptionPlanning and ergonomics workplace adaptation are the keys Planning and ergonomics workplace adaptation are the keys
for production improvements performance and employee work for production improvements performance and employee work capabilities adjustment to the labor activities. The implementation capabilities adjustment to the labor activities. The implementation and/or modification on machines and workplace bring benefits to and/or modification on machines and workplace bring benefits to work and reduce the harm to employees. work and reduce the harm to employees. Besides the Besides the ergonomics investments on workplaces, the GE Water – Sorocaba has ergonomics investments on workplaces, the GE Water – Sorocaba has introduced a full program of ergonomics solutions to improve the introduced a full program of ergonomics solutions to improve the workers health.workers health.
Since April 2007, we have been working with two physiotherapists on Since April 2007, we have been working with two physiotherapists on Preventive Therapy with the GPR – Global Re-educational Posture Preventive Therapy with the GPR – Global Re-educational Posture
What is GPR ?What is GPR ? It is an ergonomic program to work with It is an ergonomic program to work with the workers healththe workers health It a preventive Physiotherapist program It a preventive Physiotherapist program It has qualified professionals following the It has qualified professionals following the workersworkers
6 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
Improvement: DescriptionHow does it work ? Posture Evaluation of 100 % of employees. Split it up into 2 groups Group 1: Posture advice, that means, after a posture evaluation and extra data from medical department those employees are trained on posture information for their workplace activities and regular life.
Group 2: After posture evaluation and extra data from medical department, these employees go to physiotherapy, where will happen a global posture reeducation.
Posture Evaluation
Reeducation Posture Advice
Preventive Posture Education Program
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Training & Education Initiative
Improvement: DescriptionPosture Evaluation
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Training & Education Initiative
Improvement: DescriptionEvaluation Form
Things Evaluated• Satatic Balance• Inclination Test• Rotation Test• Especial tests
• Cervical column• Ecapular Waist• Sagittal Plan• Frontal Plan
• Bycicle Weels Test
• Sitting Test• Person Routine• Medical History
9 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
Improvement: DescriptionGROUP 01 – POSTURE ADVICE
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Training & Education Initiative
Improvement: DescriptionGROUP 02 – REEDUCATION
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Training & Education Initiative
“After”: Process MapEmployees on therapy
10
6
On therapy Finish Therapy
musculoskeletal Disconfort
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10
Program Begining dez/07 jul/08
Period
Pain
Lev
el
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
12 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
“After”: Process Map
Pain Reduced 83,2 %
APRIL(2007)DEC(2007)
Pain Reduce 95,8 %06 Out
APRIL(2007) JULY(2008)
Improvement Percentage
0102030405060708090
100
A B C D E F G H I J K L M N O P
Employee
Impr
ovem
ent
13 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
Improvement: Program NumbersMonth Posture
EvaluationStart GPR
Out of GPR Issue Following Therapy Advice Folder and
Training
April/07 21 06 - 00 06 00May/07 20 05 - 00 26 00June/07 05 - - 00 34 00July/07 14 01 - 00 38 00
August/07 07 - 02 00 39 00September/
07 00 - - 02 30 16
October/07 02 - - 02 43 09November/07 02 01 - 00 29 09December/07 01 - - 00 17 10
January/08 05 01 02 01 23 10February/08 05 02 - 00 17 04
March/08 04 - - 02 43 04April/08 04 - 02 03 34 04May/08 05 - - 08 28 07June/08 06 - - 10 39 07July/08 02 - - 06 34 08
Total 103 16 06 34 480 + 34 = 514
88
14 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
Improvement: Innovation, Simplicity & Knowledge TransferEach employee has an individual session with the physiotherapist and can have your issue followed by then.On before training it this specific approach was not possible. On the table before, the numbers of the program can be seen.Training is also personal, so that more efficient as we can see on the results achieved.
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Training & Education Initiative
Improvement: Impact $ A F E T Y P A Y S !Estimated Costs of Occupational Injuries and Illnesses andEstimated Impact on a Company's Profitability
The injury or illness selected: Strain. Average Direct Cost: $ 27,820 Average Indirect Cost: $ 30,602 Estimated Total Cost: $ 58,422 The net profit margin for this company is 3.0 %. The ADDITIONAL sales necessary - to cover Indirect Costs are: $ 1,020,066 - to cover Total Costs are $ 1,947,400
Report generated by OSHA´s Safety Pays software
The program cost is U$ 30,00.00 a year.
You can save U$ 1,917,400.00 per accident
16 /GE / 2008/09 GE Ergo Cup Competition
Training & Education Initiative
Improvement: Performance ObjectivesThe ergonomics related accident rate has reduced to zero since the start of this program:
2
1
0
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
2
EMPLOYEESS
2006 2007 2008
YEAR
EMPLOYEES AWAY FROM WORK FOR MUSCULOSKELETAL / POSTURE ISSUES
156
18
3
88
0 0 0 00
20
40
60
80
100
120
140
160
2006 2007 abr/07 2008
DAFW / RWA FOR MUSCULOSKELETAL DISCONFORT/ POSTURE ISSUES
DAFW
RWA