Peggy Ross
RN, MS, COHN-S/CM, FAAOHN, CSP, CPE Senior Corporate Manager, Environment Health and Safety Baxter International Inc.
VIEWPOINTS E Lean Ergonomics Helps Drive Safety, Productivity
rgonomics focuses on the fi t between job tasks and worker characteristics and capabilities. Ergonomics is an engineer- ing discipline with issues often rooted in equipment design. Lean ergonomics incorporates ergonomic concepts and also builds on lean concepts by eliminating wasted movement (of product or the body) to improve produc- tivity and reduce risk of injury. For example, if a worker bends forward to reach for frequently used items, force is placed on the lower back and time is wasted. Moving items closer promotes improved posture, saves time and improves effi ciency. This is a win/win situation—for the worker and production. If a product is carried many times, transporting it does not provide value (defi ned as something the customer is willing to pay for) and im- pedes product fl ow. Eliminating this wasted movement improves productivity while reducing risk of injury. Baxter International Inc. has an ergonomic inte-
gration strategy that includes engineering—preven- tion through design and lean ergonomics. The company’s multidisciplinary approach to ergonomics actively engages engineers and sup- ports a fully integrated approach. Many of Baxter’s engineers are trained on ergonomic design concepts, lean ergonomics, anthropometrics and biomechanics to support design decisions that fi t the worker and support productivity.
Lean ergonomic concepts are deployed through- out Baxter to support risk reduction and productivity improvement. Engineers often identify lean ergonomic improvement opportunities. For example, at one of Baxter’s manufacturing plants, operators had to remove vacuum pipes to look for product. This task was performed during machine gage changes and line clearances. Removing a vacuum pipe takes time and presents moderate ergonomic risk for the wrist, elbow and shoulder when using tools. The local engineer de- signed a clear section to allow for inspection without
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removal. This improved effi ciency by eliminating the time to remove the vacuum pipe for inspection and also eliminated risk of injury by 100%. In another example, a safety hood had to be
removed twice during machine gages changes and line clearances to allow for inspection. The hood was heavy and diffi cult to remove, maneuver and place aside. It was later picked up and held in place while screws were replaced. This presented a high risk of elbow, shoulder or back injury because the hood weighed 10 kg and was an awkward size. To improve effi ciency and reduce risk, an engineer in the facility designed a clear Lexan enclosure. The top swings up on hinges while the sides slide on a rail frame. The de- sign eliminated ergonomic risk of injury and improved productivity as the hood is quickly maneuvered for visual inspection. Examples like these are captured and shared at Baxter as ergonomic best practices that may be duplicated at other manufacturing sites. Engineers play a key role in Baxter’s ergonomic
integration strategy deployment. Lean ergonomic improvement ideas can originate from individual engineers, kaizen teams, safety professionals, er- gonomic teams, ergonomists, occupational health experts and our operational excellence partners. Ideally though, ergonomic concepts should be part of how manufacturing equipment and processes are designed, and not something retrofi tted. We can but imagine the benefi t of having these types of ideas consistently imbedded in designs—before equipment reaches production. To facilitate this, we encourage engineering programs to include ergonomic concepts in their curriculum.
Baxter International Inc. provides a broad portfolio
of healthcare technologies that save and sustain lives, including home, acute and in-center dialysis; sterile IV solutions; infusion systems and devices; parenteral nutrition; biosurgery products and anesthetics; and pharmacy automation, software and services.
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