Production Ergonomics Observation Guide

• Employee Name

• Manager Name

• Document No.

• Location

• MU

• Date of Observation

  Date

Thumbs Up

Potential Source of Unsafe Behavior

• 1) Flipping boxes onto packer.
  2) Retrieving frame from top of cans on pallet.
  3) Handling shells.
  4) Manipulating shells at denester.
  5) Removing wrappers from can lids while at high height.
  6) Placing and removing tanks in tank wash.
  7) Handling tanks
  8) Retrieving frame from
  

Corrective Actions and Behaviors

• Adjust lift table height before retrieving boxes.

  Safe

  At Risk

  N/A

• Cut tape on bottom of box before removing box from case.

  Safe

  At Risk

  N/A

• Slide frame across pallet to minimize reach distance.

  Safe

  At Risk

  N/A

• Use handholds when handling totes.

  Safe

  At Risk

  N/A

• Move fewer shells at one time from lift table to denester.

  Safe

  At Risk

  N/A

• Work with the hands in a thumbs up position to minimize wrist deviation.

  Safe

  At Risk

  N/A

• Handle items below waist and elbow height.

  Safe

  At Risk

  N/A

• Wait until the can lids have lowered before removing the wrappers.

  Safe

  At Risk

  N/A

• Raise lift table to elbow height before cutting shrinkwrap.

  Safe

  At Risk

  N/A

Score

• At Standard

  At Standard w/ Corrective Action

  Below Standard

• Comments

Elbows In

Potential Source of Unsafe Behavior

• 1) Handling stacks of shells on denester line.
  2) Reaching to palm buttons.
  3) Reaching to tanks on pallets.
  4) Removing wrappers from can lids while at high height.
  5) Move fewer shells at one time from lift table to denester.
  6) Carrying broken down boxes to bin.
  7) Sliding shells across pallet.

Corrective Actions and Behaviors

• Move fewer shells at one time from lift table to denester.

  Safe

  At Risk

  N/A

• Adjust lift table height to slide shells directly onto denester line.

  Safe

  At Risk

  N/A

• Walk around pallets when retrieving items.

  Safe

  At Risk

  N/A

• Wait until can lid height decreases to remove wrapper.

  Safe

  At Risk

  N/A

• Use a cart to push broken down box to recycle bin.

  Safe

  At Risk

  N/A

• Ensure that pallets are repaired when needed to avoid trauma to the elbow/shoulder while in awkward position.

  Safe

  At Risk

  N/A

Score

• At Standard

  At Standard w/ Corrective Action

  Below Standard

• Comments

Spine In Line

Potential Source of Unsafe Behavior

• 1) Twisting rather than taking a step when retrieving items from pallet.
  2) Pushing shells along line at denester.
  3) Twisting to load cases from pallet onto packer.
  4) Reaching to retrieve tanks from tank wash build up area.

Corrective Actions and Behaviors

• Stand close to pallet while loading/unloading.

  Safe

  At Risk

  N/A

• Keep load in line with spine.

  Safe

  At Risk

  N/A

• Position shoulders over the toes while handling loads.

  Safe

  At Risk

  N/A

• Stand close to product when placing/retrieving.

  Safe

  At Risk

  N/A

• Take a step rather than twisting the back.

  Safe

  At Risk

  N/A

• When pushing shells down line, stack several columns of shells so as to not push as far.

  Safe

  At Risk

  N/A

Score

• At Standard

  At Standard w/ Corrective Action

  Below Standard

• Comments

Comfort Zone

Potential Source of Unsafe Behavior

• 1) Looking up to displays located above eye height.
  2) Looking at nest stacked above eye height.

Corrective Actions and Behaviors

• Stand on appropriate catwalk to work with controls and displays.

  Safe

  At Risk

  N/A

• Handle smaller stacks of nest to avoid looking above line of sight.

  Safe

  At Risk

  N/A

Score

• Select At Standard At Standard w/ Corrective Action Below Standard

  • At Standard
  • At Standard w/ Corrective Action
  • Below Standard

• Comments

Keep It Close

Potential Source of Unsafe Behavior

• 1) Reaching across pallets to retrieve tanks.
  2) Reaching across pallets at depalletizers and denesters.
  3) Loading cases onto packer.
  4) Reaching across pallet on palletizer to reach shells.

Corrective Actions and Behaviors

• Stand close to pallet while loading/unloading.

  Safe

  At Risk

  N/A

• Keep load in line with spine.

  Safe

  At Risk

  N/A

• Position shoulders over the toes while handling loads.

  Safe

  At Risk

  N/A

• Rotate between tank set up, loading, and unloading (Tasks with dissimilar risks).

  Safe

  At Risk

  N/A

• Slide cases across packer and onto belt.

  Safe

  At Risk

  N/A

• Walk to the side of pallet to reach shells, instead of reaching.

  Safe

  At Risk

  N/A

• Ensure that pallets are repaired when needed.

  Safe

  At Risk

  N/A

Score

• At Standard

  At Standard w/ Corrective Action

  Below Standard

• Comments

Keep It In Sight

Potential Source of Unsafe Behavior

• 1) Load totes from floor height to tote wash belt.
  2) Loading tanks to and from pallet at tank wash.
  3) Loading cases onto packer.
  4) Handling empty pallets.

Corrective Actions and Behaviors

• Place totes on a cart to keep height between knee and shoulder.

  Safe

  At Risk

  N/A

• Keep several totes stacked to minimize bending while retrieving them.

  Safe

  At Risk

  N/A

• Stand close to pallet while loading/unloading.

  Safe

  At Risk

  N/A

• Keep load in line with spine.

  Safe

  At Risk

  N/A

• Slide cases across packer and onto belt.

  Safe

  At Risk

  N/A

• Walk to side of pallet to reach items, rather than reaching.

  Safe

  At Risk

  N/A

• Ensure that pallets are repaired when needed to avoid trauma to the elbow and shoulder.

  Safe

  At Risk

  N/A

Score

• At Standard

  At Standard w/ Corrective Action

  Below Standard

• Comments

Results

Top Three Improvement Objectives (Be Specific)

• 1)

• 2)

• 3)

Summary

• At Standard

• At Standard w/ Correction

• Below Standard

• Employee Signature

  Sign

• Manager Signature

  Sign