Ergonomics on the Menu

Ever been injured on the job? Back always hurting?  Wrist sore from tray handling?  Worker's Comp costs soaring? Ergonomics may be the tool to help.

Bend, twist, reach, grasp…..ouch! Repeated hundreds of time during the course of food preparation, food service and clean-up, restaurant employees are at risk for work-related musculoskeletal disorders.

Musculoskeletal disorders (MSD's) are illnesses and injuries that affect one or more parts of the musculoskeletal system – bones, joints, cartilage, spinal discs, ligaments, tendons, muscles, blood vessels and nerves. Examples of MSDs include: sprains, strains, tears, nerve entrapment syndromes (carpal tunnel syndrome) or tendon inflammation (tendonitis). These disorders affect all parts of the body including backs and upper and lower extremities.

What is a work-related musculoskeletal disorder (WMSD)? 

What is "ergonomics"? 

From its Greek roots – erg (work) and nomos (rules or law), modern ergonomics has evolved into a "systems" science which uses methodologies and standards from many disciplines, including engineering, psychology, anthropology, medicine, and design.

Think of the workplace as a system of interacting elements: worker, tools/equipment, the environment and organization structure. Ergonomics considers all elements and their interactions to identify injury risk factors.

What are the goals of ergonomics? 

• Workers' capabilities

• Work tasks – job task analysis, effort , metabolic demands, repetitive motions, rest/work cycles, pace

• Tools/equipment used – weights, dimensions,

• Work environment – lighting, noise levels, temperature and humidity, flooring, furniture obstacles, pathways.

• Organizational factors – management philosophy, staffing patterns, and training.

Are ergonomic interventions expensive? 

Those who oppose OSHA’s proposed standard claim so. However, many companies disagree when they weigh the costs of ergonomic changes against their Workers Compensation costs. Injuries incur medical costs, days lost; they may also require additional training time and cost for temporary employees. Many ergonomic changes are cost free.  For example: using a telephone book (instead of an expensive monitor stand) to raise the height of a computer screen, or rearranging workstations to prevent repetitive reaching for knives.

1. Take a proactive approach. Develop an ergonomics program as part of your existing safety program. Create "ergo teams" of employees and managers to identify risk factors and injury prevention strategies for each job.

2. Training. Include ergonomics training in initial orientation of new staff as well as in your recurrent safety training. The National Institute of Occupational Safety and Health (NIOSH) recommends training employees to recognize risk factors for musculoskeletal disorders and the methods for controlling them.

3. Use the ergonomics systems approach to examine each element of the workplace system and its interactions. What would you do if several employees had developed signs of tendonitis or carpal tunnel syndrome from carrying heavy food trays?

Example of how the process can work: 

Restaurant servers tried to use correct body mechanics when carrying heavy food trays on fingertips or on the hand (with wrist bent). However, after numerous trips, the tendons and muscles of their shoulders, arms and hands were screaming!

The ergonomics team met and brainstormed ideas to meet organizational standards for productivity, be cost effective and prevent injuries.

Some ideas generated included: Tools/equipment: Use of serving carts for larger tables. The restaurant owners and employees initially balked at using existing serving carts for all tables because of the obstacles they create in pathways. Procedure: Servers were to use a team approach so that everyone at the table was served at the same time – better customer service! Handles were added to some trays for a test period so that trays could be carried using correct postures. Environment: The layout of furniture was changed slightly to improve traffic flow and accessibility for both staff and customers.  

A 5 minute training video of the ergo do’s and don’ts, starring employees was made for use in new employee orientations and recurrent training.

1. Work/rest cycles. Encourage staff to take breaks per company policy! Give the body a chance to regroup and rest muscles which may be overloaded during performance of work tasks. Appropriate work/break cycles are a primary injury prevention technique. Teach employees to pause occasionally, take a few deep breaths, rest muscles which have been moving repetitively or carrying heavy loads. Cross-train and build in task rotation to avoid overloading the same muscle groups throughout the shift. Simple changes go a long way in preventing cumulative trauma disorders.

2. Exercise programs. Before developing stretching or exercise programs, consult with trained health care professionals. Employers may not be aware of employees who have pre-existing medical conditions or musculoskeletal disorders. Exercise programs may exacerbate pre-existing conditions. Certain exercises, if performed incorrectly, may cause injuries.

3. Adjust staffing patterns. Are you expecting your staff to exceed limits of their strength and endurance during peak meal service times? Do your staffing patterns reflect the predictable fluctuations in volume?

4. Perform job task analysis for all jobs. Job task analysis identifies the physical demands, such as those required for lifting, carrying food trays, repetitive cutting in food preparation. Other criteria include the psychological, cognitive demands (working with customers) and workplace exposures (hot, humid kitchens). Identify work tasks that involve forceful exertions, awkward postures, repetitive motions, prolonged postures and exertions.

5. Hiring. Perform pre-employment skills testing based on your job task analysis to help determine if applicants who have been offered the job are able to perform the duties with or without a reasonable accommodation. Contact the EEOC for regulations.

7. Job descriptions. Include ergonomics in performance standards. For example, employees should be able to demonstrate correct body mechanics while serving food to customers. During annual performance appraisals, review the job description, job task analysis and ergonomics performance expectations.

9. Design workstations so that employees can work easily and comfortably without excessive reaching and bending. Ensure lighting is appropriate for work tasks and flooring is not slippery. Use anti-fatigue mats at stations where employees must stand for prolonged periods.

Effective ergonomics programs have the following elements

• Management commitment to providing a healthy safe work environment by providing necessary resources.

• Employee participation. What’s the best resource for injury prevention? Employees themselves! They know the job from the inside out!

• Workplace hazard identification and control of exposures which can cause musculoskeletal disorders.

• Worksite evaluations

• Training and education

• Medical management.

If you need help to kick start your ergonomics program, find an ergonomics consultant who has experience in the food industry. To locate ergonomics professionals, contact your Workers Compensation insurance carrier and local hospital rehabilitation or occupational health departments. Registered occupational therapists, physical therapists and other occupational health professionals can often direct you to qualified consultants.

Legislation. California has it’s own ergonomics standard (Title 8, Section 5110 Ergonomics) and program guidelines. 

Fed OSHA is in the process of final hearings for their ergonomics standard.

Resources:

Ergo Web Inc.

For classes in ergonomics contact local universities, Chamber of Commerce, OSHA or NIOSH.

Rannell Dahl, MS, OTR, Ergonomics Consultant at Environmental Ergonomics, can be contacted at ergonut@aol.com