Ergonomics

Many of the Costs of Poor Ergonomics are Less Obvious or Quantifiable

• Reduce worker injury with lighter tools
• Less torque reaction
• Proper use of tools
• Less noise and vibration
• Tool supports/workstations

For the most part, poor ergonomics will cause a decrease in productivity when a worker gets tired or uncomfortable.  The tangible costs are for insurance claims or medical costs to repair an injury.

If ergonomics reduces the operators' productivity, estimate the time savings and use the formulas discussed under productivity to find the payback time.  If your are able to find hard costs such as insurance or medical costs specifically related to fastening, then use this information below.
 

MEDICAL / INSURANCE COSTS:

(solution costs)
 

/

=

TOOL REPAIRS / BREAKAGE:

Often, balancers and workstation components keep a work surface clear and prevent tools from falling and breaking.

(solution costs)
 

/

=

A pulse tool is more ergonomic than their existing inline clutch screwdrivers.  Two operators over the last couple of years have had carpal tunnel claims and surgeries, costing about $24,000.  The customer needs to purchase 10 UX-450SD pulse tools at $1,400 each for the entire line to prevent further occurrences.

(10 X $1,400) / ($24,000 / 2 years) = 1.17 years or 1 year, 2 months payback

This means that the purchase of the pulse tools will pay for themselves in just over 14 months!
 

An electronics manufacturer has dropped several electric screwdrivers in the past year that needed replacement housings.  The production manager wants to purchase some tool supports (balancers, rails, etc.) to prevent this.  The cost of the repairs was $400.  The tool support equipment will cost about $350.

($350) / ($400) = .875 years or 10.5 months

This means that the purchase of the accessories will pay for themselves in just over 10 months!
 

• Production management and operators
• Human Resources or personnel department
• Ergonomist or safety manager
• Purchasing