Fig. 3. Custom fixtures have reduced bending at this pipe casting plant.


received from employees and whether employees provided any suggestions for improvement. Employees were asked whether management is reacting to the training and did the employee personally try anything different. Acceptable scores for the pre- and post-tests were 70%. Overall, only 57.2% of the trainees passed the pre- test, but after training, 81.6% passed the post-test (528 participants). Tis is a 24.4% improvement in the number of people passing the test. Every facility implemented either


engineering or administrative controls, or both, designed to improve ergo- nomics at their facility. Most of the improvements focused on the identi- fied risk factor of awkward postures. For example, an electric powered lift or lift and tilt table can provide flex- ibility to workers to adjust their station and ensure proper posture (Fig. 1). Tis is an especially suitable solution where the work at the station varies considerably. For example, one facility installed used/refurbished equipment at a cost of less than $3,000 each. Another solution is to implement


administrative controls. In Fig. 2, the picture on the left shows the original workstation, requiring unnecessary bending to reach parts near the bot- tom. Pallets were added to the stack to raise the working height, as shown in the picture on the right, ensuring that the parts are always between knee and shoulder height. Tis was a no-cost solution. In an environment with less variety of products, custom fixtures can be


ONLINE RESOURCE Visit www.osha.gov/dte/grant_materials/ fy08/sh-17807-08.html to download the full training materials available from OSHA.


October 2011 MODERN CASTING | 27


developed that do not need as much adjustment flexibility, but still provide the same improvement in working postures. Te custom fixtures developed and built by one metalcasting facility


cost less than $500 each (Fig. 3).


Dr. Naira Campbell-Kyureghyan is an associate professor in the Department of Industrial and Manu- facturing Engineering at the Univ. of Wisconsin- Milwaukee. Karen Cooper is a research specialist.


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