The Ergonomic Design of workplaces and work organisation in a small to medium size entreprise - Germany

The issue under discussion

An analysis of the company's workplace showed that:

• fettlers have to bend forwards to perform many of their tasks;
• they have to handle heavy loads (18-20 kg);
• awkward positions are taken when seizing cast parts that are far apart and sometimes below trunk level;
• the height of the workbench and grinding machines is not adapted to workers;
• climate, lighting and noise conditions are poor;
• there is no policy for breaks and job rotation.

Action taken

Complementary methods were used to assess the strains, including:

• a worker survey;
• a workers' workshop to analyse the work process, complemented by analyses based on photographs and video;
• an evaluation of risk factors such as noise and climate;
• checklists to identify psychosocial and physical - such as standing and sitting or poor posture - risk factors and health problems;
• the “controlling features” (Leitmerkmalmethode) method to identify carrying, lifting, pushing and pulling tasks;
• ergonomics measurements with the CUELA system (computer-assisted recording and long-term analysis of musculoskeletal loads).

The following measures were developed by an interdisciplinary team made up of safety representatives, members of the staff committee, workers, an occupational physician, representatives from the statutory accident insurance and social security body, and occupational and safety experts:

• use of lifting/tipping containers;
• introduction of height-adjustable workbenches and grinding machines;
• use of easier-to-handle iron-barred boxes;
• introduction of job rotation and short breaks;
• improvement of the lighting and ventilation system.

Workers were given time to familiarise themselves with their new working conditions and were offered support from the team. Further analyses and measurements were performed to ensure that the measures had improved the working conditions without introducing new strains.

Results achieved

The costs of implementing these technical measures amounted to about €16,000 which is a reasonable investment for a small to medium size enterprise (SME). Clear benefits for the company will only become apparent in the longer term. Nevertheless, bending postures at an angle of more than 20° and the manual handling of heavy loads have been almost eliminated. This model workplace could be introduced in similar SMEs, such as those involved in welding or metalworking.