Ergo Cup - Re-Educação Postural

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.



“Before” Situation: Process Map

musculoskeletal Disconfort

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Program Begining dez/07 jul/08

Period

Pain

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Pain Rate

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Employee

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Before After

16 employees with posture deviation and on pain



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



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



Improvement: DescriptionPosture Evaluation



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



Improvement: DescriptionGROUP 01 – POSTURE ADVICE



Improvement: DescriptionGROUP 02 – REEDUCATION



“After”: Process MapEmployees on therapy

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On therapy Finish Therapy

musculoskeletal Disconfort

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Program Begining dez/07 jul/08

Period

Pain

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“After”: Process Map

Pain Reduced 83,2 %

APRIL(2007)DEC(2007)

Pain Reduce 95,8 %06 Out

APRIL(2007) JULY(2008)

Improvement Percentage

0102030405060708090

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A B C D E F G H I J K L M N O P

Employee

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ovem

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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



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.



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



Improvement: Performance ObjectivesThe ergonomics related accident rate has reduced to zero since the start of this program:

2

1

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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

Healthcare

Ergo Cup - Re-Educação Postural