Job Site Analysis Report
Weight Checking/Barcoding Station
FTS California – Hayward, CA
Prepared by:
Dr. Allen S. Miller
Date of Analysis:
February 12, 2004
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COMPANY |
FTS California-Hayward, CA |
JOB TITLE |
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CONTACT PERSON |
Mr. Peter Ingenhutt |
D.O.T. EQUIVALENT |
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POSITION |
HR/Safety Manager |
D.O.T. NUMBER |
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OTHER CONTACT |
DEPARTMENT |
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POSITION |
BREAKS |
60 Min. | |
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ADDRESS |
18231 Murphy Parkway |
SHIFT DURATION |
8.0 Hrs. |
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CITY, STATE |
Hayward, CA |
REAL WORK TIME |
8 Hrs. |
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ZIP |
95330 |
DAYS WORKED |
Monday to Friday |
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TELEPHONE |
(209) 858-0400 ext 130 |
HOURS PER WEEK |
40 Hrs. |
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FACSIMILE |
(209) 858-9293 |
SHIFT |
1 |
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PHYSICAL DEMAND LEVEL (UPPER BODY) |
Medium | ||
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|
Peter.Ingenhutt@Fueltotalsystems.com |
PHYSICAL DEMAND LEVEL (LOWER BODY) |
Sedentary – Light |
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DATE |
2/10/04 |
UNION PLANT? |
No |
JOB DESCRIPTION
FUNCTIONAL JOB DESCRIPTION:
Weight Bar-coding Station
KEY JOB TASKS:
Employee must inspect and weigh freshly manufactured tank and place barcode on it. The employee must additionally place parts and work machinery in a safe manner.
DATA:
Information, knowledge and conceptions related to data, people or things obtained by observation and mental creation.
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Synthesizing |
Yes Yes Yes Yes Yes Yes Yes |
INFREQUENT TASKS: None
WORK PACE:
Self-paced to accomplish and finish 60 parts per hour, or in accordance with the demands of the employer.
PERSONAL TRAITS:
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Ability to comprehend and follow instructions. |
Yes Yes Yes Yes Yes Yes Yes Yes |
POSTURE AND MOVEMENT
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SUSTAINED POSTURE OVERVIEW |
Max. Consec. Min. Per Hour |
Total Daily Hours |
Possible Change Optional |
Further Description |
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Sitting |
0 |
0 |
No |
N/A |
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Static Standing |
20 |
2 |
No |
Line Dependent |
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Dynamic Standing |
40 |
4 |
No |
Line Dependent |
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Walking |
10 |
2 |
No |
Line Dependent |
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Driving |
0 |
N/A |
STATIC STANDING |
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Maximum Consecutive Minutes Per Hour |
55 |
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Total Daily Hours |
8.0 |
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Possible Change Optional? |
No |
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Floor Surface |
Cement, rubber mats |
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Step Available? |
N/A |
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Further Description |
| DYNAMIC STANDING | |
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Maximum Consecutive Minutes Per Hour |
55 |
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Total Daily Hours |
8.0 |
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Possible Change Optional? |
Yes |
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Floor Surface |
Cement, rubber mats |
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Further Description |
WORK STATION
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WORKSTATION LAYOUT |
SURFACE 1 (See Below) |
SURFACE 2 (See Below) |
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Surface |
Roller Track |
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Height |
39 in. |
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Depth |
13 in. |
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Length |
36 in. |
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Surface |
Steel |
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Debris |
No |
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Floor Surface |
Cement with rubber mat |
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Comments |
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ERGONOMIC RISK FACTORS |
IDENTIFIED? |
COMMENTS |
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Awkward Posture |
Yes |
Must bend waist at 45 degrees to weight and place bar code on the tank. |
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Static Posture |
Yes |
Standing over a part for 20 seconds. |
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Repetition |
Yes |
Job task cycle is 1 part per minute |
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Forceful Exertion |
No |
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Localized Mechanical Stress |
Yes |
Hands and low back. |
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Vibration |
No |
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Extreme Cold |
No |
Strain Index (SI)
Hand: Right Side
Job Factors Level SI Score
Intensity of exertion Somewhat Hard 3.0
Duration of exertion (%) 33.0 1.5
Efforts/Minute 1.0 0.5
Hand/Wrist Posture Good 1.0
Speed of work Fair 1.0
Duration per Day (hr) 8.0 1.0
Strain Index Score: 2.2
Recommendation:
Risk Level = Low
NOTE: Preliminary testing has revealed that jobs associated with distal upper extremity disorders had SI Scores greater than 5. SI Scores less than or equal to 3 are probably safe. SI Scores greater than or equal to 7 are probably hazardous. The Strain Index does not consider stresses related to localized mechanical compression. This risk factor should be considered separately. For additional information see Moore & Garg (1995).
Rapid Upper Limb Assessment (RULA)
Rapid Upper Limb Assessment (RULA)
Analyst: Allen S. Miller
Job Name: Pressure Test
Workstation ID:
Hand: Right Side
Body Parts Posture RULA Score
Wrist Neutral 1
Wrist In mid-range of wrist twisting range 1
Upper Arms 46 to 90 3
Lower Arms 0 to 90 1
Neck 0 – 10 1
Trunk 0 – 20 2
Legs Legs/feet well-supported 1
Body Parts Posture Score Muscle Score Force Score Total
Arm+Wrist 2 0 0 2
Neck+Leg+Trunk 1 0 0 1
RULA Grand Score: 2
Recommendation: The Posture is acceptable if it is not maintained or repeated for long periods.
Detailed Summary:
Job Task Requirements
As the tanks come from the robot Station the Tank # 635 for the Toyota Tacoma weighing 9.12 kg (20.06 lbs.) or tank # 930 for the Toyota Corolla weighing 7.56 kg (16.63 lbs.) come down the roller tracks to the weight station (see Diagram 1) the employee must remove two plastic tabs from the sides of the tank that the robot cannon remove. Additionally, the employee must inspect the “O” ring and weight the tank (see diagram 2). Once the tank is weighed a bar code is printed and the employee must place the tag in its rightful place on the tank.
Diagram 1 Diagram 2
Additionally, the employee must write the weight with a white chalk pen on the tank. This procedure may not be continued in regular production. This procedure requires the employee to stand and work within a neutral posture at a workstation height of 39 inched and reach of 13 inches. Once the tank is weighed it is rolled to a cooling station and then to the thickness station.
Conclusion:
In this case there are no recommendations to adjust body mechanics to work within the confines of this station. It would be advisable to have the robot remove the excess tabs from the tank. The employee will have to remove two (2) tabs per tank with an average force of less than one (1) pound of force. That equals 2 tabs per tank, 480 tanks per cycle that is 960 times a shift an employee must remove this material. There is no recommended remedy, as utilizing the robot would raise the production time to unacceptable levels.
Additionally, due to employee being required to stand and walk around, one recommendation is anti-fatigue mats or possibly a more cost-effective alternative Personal Anti-fatigue Mat™ Insoles (http://www.mega-comfort.com/ergonomic_personal_anti-fatigue_mat_insole.htm). These insoles act as if the employee walked on anti fatigue mats anywhere they walked. The retail cost of the insoles is $19.95 and reduces muscle fatigue and as well as prolongs performance.
One of the positive aspects of the job task is the employee is not required to lift the tank or utilize severe adverse body mechanics to complete the job task. They are also able to walk and move around in a defined area. This dynamic posture is advantageous, as it requires the employee to move all muscle groups, which inherently reduces fatigue, stress and injury. Because of factors that we cannot change i.e. robot mechanics, that are set and financial prohibitive to change, job rotation is crucial, and would delay the effects of ergonomic stress to one area. This would also allow other muscles to work reducing over fatigue and injury.
Post-Offer Employment testing Requirements:
We will concentrate on lumbar, hand, wrist strength and stability. These two areas are crucial in reducing costly injury and claims.
Please understand that when we evaluated these positions, the systems were still being worked out and procedures were still in flux. We will modify these recommendations as production starts and procedures are solidified. If there are any questions concerning the above information, please feel free to contact me.
Sincerely,
________________________________
Dr. Allen Miller
ASM/sd
Dr. Allen S. Miller's Reports 