The section on ergonomic solutions for shipyards describes changes to equipment, work practices, and procedures that can address ergonomics-related risk factors, help control costs, and reduce employee turnover. These changes may also increase employee productivity and efficiency because they eliminate unnecessary movements and reduce heavy manual work. OSHA recommends that employers use engineering controls, where feasible, as the preferred method of dealing with ergonomic issues in shipyards. The first set of solutions is applicable to all or most areas of the shipyard.
The recommended shipyard ergonomic solutions presented on the following pages have already been implemented in some shipyards. These solutions are not intended to cover all ergonomic challenges in shipyards, nor does OSHA expect that all of these solutions are applicable to each and every shipyard. OSHA recognizes that implementing engineering solutions may present certain challenges in the shipyard environment, which includes work that is performed outdoors and in cramped spaces. However, shipyard personnel are encouraged to use the examples in this document as a starting point for developing innovative solutions tailored to the specific ergonomic challenges in their individual shipyard. The solutions have been categorized according to the locations and jobs in which they are most frequently performed: - Site-wide,
- Material/equipment handling,
- Tools,
- Metal work
- Shipside, and
- Personal Protective Equipment (PPE).
SITE-WIDE | Task Lighting |  Reduces awkward postures |
Description: Positioning lights directly over a work area and/or equipment.
Advantage: - Reduces awkward neck and back position required to get close to the work to view it.
Point to Remember: - Lights on adjustable arms allow accurate positioning and can help avoid shadows and glare.
|
| Point-of-Use Tool Boards and Rigging Racks | 
Reduce awkward postures and fatigue |
Description: Devices that position work between the knees and shoulders and within easy reach.
Advantages: - Provide easy access to tools and material.
- Reduce wasted time to untangle parts.
- Reduce forceful exertions to pull tangled tools apart.
Points to Remember: - Arrange tools so that the most frequently used tools are within easy reach.
- Device can be used any time the work, tools, or equipment is farther than an arm's reach, lower than the knees, or above the shoulders.
|
| Standing Platforms | BEFORE
AFTER
Reduce physical exertions and awkward postures |
Description: Small platforms or benches that can be easily transported to the work area.
Advantages: - Platform use provides more stability for the body posture and may decrease the risk of injury when doing overhead work.
- Lightweight platforms can be folded up and carried onto a vessel.
Points to Remember: - Platform use may reduce the amount of overhead work that may cause shoulder and neck fatigue.
- When possible, employees should work with hands between waist and shoulder height.
|
MATERIAL/EQUIPMENT HANDLING | Carts, Hand Trucks, Pallet Jacks | 
Reduce lifting, pushing, and pulling forces |
Description: Wheeled devices designed to transport and carry materials.
Advantages: - Reduce lifting, pushing, and pulling forces.
- Allow heavy or awkward materials, tools, or equipment to be moved without carrying.
- Save time.
- Hand trucks and carts are available in many shapes and sizes and can be customized for special applications.
Points to Remember: - Motorized pallet jacks are preferred for frequent or distant movement of materials.
- Wheels should be appropriate to the floor conditions to minimize push/pull forces. Larger diameter wheels may improve cart maneuvering.
- Swivel wheels on the rear and fixed wheels on the front make pushing easier for longer distances.
- Swivel wheels on both the front and rear make maneuvering in small, cramped areas easier.
- Wheels should be well maintained.
- Handles should be located at the rear of the cart and at waist level.
- Load height on the cart should not obstruct vision.
- Loads should be balanced and load weight kept under the manufacturer's recommended weight limits.
- Pushing is preferred to pulling.
|
| Drum Movers/Tilters | BEFORE
AFTER
Reduce lifting, pushing, and pulling forces |
Description: Overhead handling system that easily lifts and tilts a heavy drum.
Advantages: - Eliminate manual lifting and tilting of heavy drums.
- Reduce potential for accidental contact with chemicals.
- Reduce forces on back from rolling the drum on its edge (chimming).
Points to Remember: - Different handling systems and drum grippers are available for many situations.
- Ensure the system/device is rated for the drum weight.
|
| Overhead Cranes | 
Reduce lifting, pushing, and pulling forces |
Description: Overhead devices used to lift and transport heavy items.
Advantages: - Eliminate manual lifting and carrying of heavy objects.
- Eliminate pushing heavy carts of material and equipment (i.e., sheet metal, pipes, and large tools) across rough floors.
- Various adaptors are available to attach items such as drums, boxes, bags, and hooks.
Points to Remember: - Ensure the system/device is rated for the load weight.
- Movement pattern should be considered prior to installation of the crane.
- Proper design of control buttons may reduce awkward hand position.
|
| Jib Cranes | BEFORE
AFTER
Reduce lifting, pushing, and pulling forces |
Description: Wall, floor, or pillar mounted I-beam with a rolling trolley/hoist used to lift and position equipment and material.
Advantages: - Eliminate manual lifting, carrying, and positioning of heavy equipment and material.
- Eliminate the need to push heavy carts across rough floors.
- May save time.
- Hose handling systems attached to the jib crane keep welding hoses untangled and eliminate dragging hoses across the floor.
- Cranes are capable of rotating 180-360 degrees for maximum versatility.
- A variety of grippers can be attached to the crane for handling different objects.
Points to Remember: - Jib cranes can be mounted to a wall, floor, or pillar.
- Most jib cranes have a reach capability of up to 20 feet.
- Movement pattern should be considered prior to installation of the crane.
- Proper design of control buttons may reduce awkward hand position.
- Ensure the system/device is rated for the load weight.
|
| Hoists/Balancers | BEFORE
AFTER
Reduce lifting, pushing, and pulling forces |
Description: Portable devices used to lift and position heavy objects or tools.
Advantages: - Reduce the force needed to lift and position heavy objects or tools over the work area.
- Reduce fatigue from frequent lifting.
- Easy to set up at locations where a crane is not installed.
Points to Remember: - A variety of attachments are available to lift different objects.
- Ensure the hoist is rated for the load weight.
- Many makes and models of hoists and balancers are commercially available (e.g., spring-loaded, pneumatic, electric, or computer-controlled).
|
| Conveyors | BEFORE
AFTER
Reduce lifting, pushing, and pulling forces |
Description: Tabletops or work surfaces with manual or powered roller systems.
Advantages: - Eliminate carrying large sheets of metal or heavy objects between work stations.
- Reduce shoulder and back fatigue caused by frequently carrying objects between work stations.
- Conveyors can be designed to move material around corners.
- Conveyors can be flexible to extend into trucks or pushed together to minimize blocking forklift traffic aisles.
Points to Remember: - Powered conveyors minimize pushing and pulling forces.
- Manual conveyors require regular maintenance to minimize pushing and pulling forces.
- Objects on a manual conveyor are easier to push or slide when at or slightly below waist height.
- Ensure that employees are aware of pinch hazards.
|
| Roller Ball Surfaces | 
Reduce pushing and pulling forces |
Description: Tabletops or work surfaces with roller balls.
Advantages: - Reduce friction force when moving, loading, or positioning large sheets of metal, wood, or pipe into a machine.
- Roller tops can be located on top of existing work surfaces and tables.
- Some rollers are capable of rotating 360 degrees allowing for objects to be rotated and turned easily.
- Powered rollers minimize pushing and pulling forces.
- Pushing or sliding objects eliminates lifting and carrying that can be more strenuous for the arms and back.
Points to Remember: - Objects are easier to push or slide when they are at waist height.
- Roller ball surfaces require regular maintenance to minimize pushing and pulling forces.
- Ensure that employees are aware of pinch hazards.
|
| Moveable Containers | BEFORE
AFTER
Reduce manual material handling |
Description: Large containers for storing and transporting materials, tools, and equipment to where they are being used.
Advantages: - Reduce material handling and improve efficiency.
- Large quantities of material (i.e., cables, welding units, hoses, rigging equipment) can be transported at one time using a forklift or crane.
- Storage containers may be customized for special applications.
Points to Remember: - Store items between knee and shoulder height whenever possible.
- Avoid using containers with high sides that require reaching.
|
| Pulley System | 
Reduces lifting, pushing, and pulling forces |
Description: Pulleys attached to tools or equipment that assist in manual handling and positioning.
Advantages: - Reduces force needed to lift, position, or operate tools or equipment.
- Pulleys can be attached to various tools, such as a powered saw, to reduce the force required to operate the saw.
Points to Remember: - One or more pulleys can be used to reduce the forces needed to handle tools and equipment.
- Ensure the system/device is rated for the load weight.
|
| Automatic Hose Roller | 
Reduces pushing and pulling forces, and repetitive motions |
Description: A machine that coils long hoses.
Advantages: - Reduces the time and effort needed to manually roll up long hoses.
- Increases efficiency.
Points to Remember: - Machines can be manufactured to meet specific needs.
- Ensure the device is rated for the load weight.
|
| Hose, Cord, and Cable Management Systems | 
Reduce pulling forces |
Description: Reels that coil hoses and cords and store them out of the way.
Advantages: - Overhead reels reduce the need to drag, bend, and reach for air hoses.
- Retractable reels store pneumatic and electrical hose/cords easily and conveniently.
- Spring retractable devices reduce the need to manually wind the reel.
- Reels can be portable, mounted overhead, or attached to a wall or workstation.
- Manual and powered rewind hose reels are widely available.
- Overhead reels prevent trip hazards by keeping hoses/cords off of the ground/floor.
Points to Remember: - Minimize tangles and pinch points in the travel path to reduce the pulling forces.
- Provide enough leader on the hose to minimize pulling.
|
| Turning and Rotating Devices | BEFORE
AFTER
Reduce forceful exertions |
Description: Turntables and rotating tabletops that allow objects to be easily turned, rotated, and positioned.
Advantages: - Reduce the forces needed to position, turn, or rotate parts, tools, and equipment on a work-bench.
- Some turntables are capable of rotating completely.
- A pneumatic foot-operated rotating tabletop allows table to be easily rotated and objects to be placed within easy reach.
Points to Remember: - Turntables come in a variety of sizes, shapes, and configurations.
- Turntables and rollers can be manual or powered.
- Turntables and roller tops can be located on top of existing work surfaces.
- Turning and rotating devices require regular maintenance to minimize the forces needed to position, turn, or rotate objects on a work bench.
|
| Racks and Shelves | 
Reduce manual material handling |
Description: Devices to stage, move, or store materials, tools, or equipment.
Advantages: - Position materials, tools, and equipment within easy reach.
- Allow objects to be lifted or moved without bending, twisting, or excessive reaching.
- Wheeled rack carts allow for easy movement and maneuverability.
- Moving racks by crane reduces manual carrying of hoses and leads.
- Storing items on racks allows them to be easily lifted from mid-thigh level (instead of the floor).
- The racks also improve organization.
Points to Remember: - Store items between knee and shoulder height whenever possible.
- Racks and shelves can be customized to meet individual needs.
|
| Material Positioners | BEFORE
AFTER
Reduce awkward body postures |
Description: Devices that position and support material at an appropriate level.
Advantages: - Allow for easy positioning of large sheets of wood, steel, or aluminum.
- A sawhorse with a roller ball top and hinged sides allows employees to easily position and hold heavy sheets of plywood in a horizontal position and slide them through a saw.
- Work surfaces that are easily raised or lowered allow employees to work in neutral posture.
- Hinged work surfaces reduce bending and reaching.
Points to Remember: - Surfaces must be able to support the weight of the objects or materials.
- Powered devices are easier to operate.
- Material positioners and height-adjustable devices require regular maintenance to ensure their easy use.
|
| Moving Welding Units | BEFORE
AFTER
Reduce lifting forces |
Description: A welding unit with an attached fixture/handle.
Advantages: - Allows welding unit to be moved without lifting.
- Allows two-person efforts when relocating welding equipment.
- Reduce muscle fatigue and the risk of back injury.
Points to Remember: - Design of the fixture should allow the weight to be balanced.
- The fixture attached to the welding unit should have easy to grip handles.
|
| Large Hose Reel | 
Reduces lifting and pulling forces |
Description: Device that provides a mechanical advantage in coiling long hoses.
Advantages: - Reduces forces needed to roll large hoses.
- Can be transported with a forklift or crane.
- Hose reels can be customized for special applications.
Points to Remember: - Keep the reels well maintained and easy to turn.
- Saltwater and moisture may make reels more difficult to turn.
- Ensure system/device is rated for load weight.
|
| Synthetic Line | BEFORE
AFTER
Reduces lifting and pulling forces |
Description: Lightweight synthetic lines.
Advantages: - Up to 75% lighter than steel lines.
- Some synthetic lines can be handled by one person.
Points to Remember: - Ensure system/device is rated for the load weight.
- Store synthetic lines properly to reduce their deterioration caused by exposure to environmental conditions.
|
| Tractor and Trailer | BEFORE
AFTER
Reduce manual material handling |
Description: Devices used to move multiple units to and from the ship.
Advantages: - Loading materials and equipment onto a trailer before transporting them to the dock requires fewer trips, saves time, and reduces handling.
- Trailers come in a variety of sizes, types, and load capacities.
Points to Remember: - Ensure device is rated for the load weight.
- Ensure items are secure and balanced on the trailer to avoid shifting or tipping.
|
| Stack Blower on Wheels | BEFORE
AFTER
Reduces lifting, pushing, and pulling forces |
Description: A custom modification that adds wheels and a handle to a conventional stack blower.
Advantage: - By attaching a handle and wheels to each unit, stack blowers can be easily maneuvered.
Points to Remember: - Appropriate wheels should be selected based on the floor or ground surface and conditions.
- Using larger diameter wheels is often an easy way to reduce pushing and pulling forces.
- Handles should be located at about waist height for pushing and pulling.
- Ensure that the top of the stack blower does not obstruct vision.
- Pushing is preferred to pulling.
|
TOOLS | Tool Extension Handles | BEFORE
AFTER
Reduce awkward body postures |
Description: Long extension handles for hand tools.
Advantages: - Enable the operator to work standing instead of using the tools in awkward postures (e.g., kneeling or crouching).
- May reduce vibration being transmitted to the hands and arms.
- Can be attached to many types of handheld tools such as needle guns, buffing wheels, and grinders.
- The handle and tool can be attached to wheels or channel sliding plates to reduce the weight and force needed to operate the tool.
Points to Remember: - Altering the tool may pose hazards and may void the manufacturer's warranty.
- Tools should not be altered in a way that violates the National Electrical Code and must not be altered in a way that violates OSHA standards.
|
| Power Tools | 
Reduce hand and arm fatigue |
Description: Tools constructed with durable, light-weight materials.
Advantages: - Reduce hand and arm fatigue caused by holding a tool for several hours.
- Reduce force required to hold heavier tools.
Points to Remember: - If lighter tools are not available, tool balancers may be used to reduce the weight held and the forces associated with using heavy tools.
- Select lighter tools with less vibration.
|
| Low Vibration Tools | 
Reduce hand and arm vibration |
Description: Tools specifically designed to reduce vibration.
Advantage: - Reduce the vibration being transmitted to the hands.
Points to Remember: - Tool maintenance should be performed on a regular basis.
- Oiling and cleaning tools daily increases the life of the tool and reduces vibration.
- Out-of-balance or off-center grinding wheels, pads, and spindles are major contributors to vibration.
- Some tools use auto-balancing technology to compensate for off-center pads/wheels.
- Tools should be gripped as lightly as possible while still maintaining control of the tool.
- Cold hands are more vulnerable to the effects of vibration.
- Select gloves that minimize the loss of tactile sensitivity.
- Many low vibration tools are commercially available, such as grinders, sanders, and impact wrenches.
|
| Tool Balancers | 
Reduce muscle fatigue |
Description: Portable devices used to support and position tools.
Advantages: - Reduce hand and shoulder muscle fatigue caused by holding a tool for prolonged time.
- May reduce exposure to tool vibration.
Points to Remember: - Balancers require adjustment and maintenance.
- Ensure system/device is rated for weight.
- Spring-loaded, pneumatic, electric, or computer controlled models are widely available.
- Various adaptors are available to attach to different tool configurations.
|
METAL WORK | Robotic Welders | 
Reduce awkward postures and repetitive motions |
Description: Robotic technology applied to welding machines.
Advantages: - Reduce the fatigue associated with prolonged welding or welding performed in an awkward or constrained position.
- Reduce the amount of manual welding required and may improve efficiency.
- Can be operated by one person with minimal effort.
Point to Remember: - Not applicable for all welding applications.
|
| Electromagnetic and Air Presses | BEFORE
AFTER
Reduce forceful exertions |
Description: Portable electromagnetic and air presses that hold parts in place during welding operations.
Advantages: - Reduce awkward postures and forceful exertion associated with manually clamping parts prior to welding operations.
- Can significantly reduce the time needed to complete a job.
Point to Remember: - Used when welding long seams on butted metal plates.
|
| Support Bar | 
Reduces static exertions and awkward postures |
Description: A metal bar placed vertically under a long piece of steel for support as it passes through a machine.
Advantages: - Reduces static and awkward postures.
- Reduces static exertions while loading the steel into the machine.
- Useful on long pieces of steel that would require manual support.
Point to Remember: - Be sure the bar is stable and can support the load.
|
SHIPSIDE | Dry Dock Centering Device | 
Reduces pulling forces |
Description: Mechanized reel system that pulls ships into position in dry dock.
Advantage: - Reduces the extreme pulling forces previously required to manually pull a vessel into a dry dock.
Point to Remember: - Check lines frequently and replace damaged ones.
|
| Lighter-Weight Blowers | 
Reduce lifting forces |
Description: Lighter-weight blowers used to move air in small spaces.
Advantages: - Reduce the lifting forces associated with carrying blowers onto vessels.
- Have handles for easy carrying.
- The weight is more balanced for easy carrying.
Point to Remember: - Ensure the air volume is adequate.
|
| Stools and Creepers | BEFORE
AFTER
Reduce awkward postures |
Description: Portable seats that allow the employee to be seated while working.
Advantages: - Provide support in the right position for hard-to-reach areas, such as underneath ships, decks, or platforms or when working below waist level.
- Tools, equipment, and materials can be attached to the stools/chairs for convenience.
Points to Remember: - Adjustable stools and creepers are preferred.
- Locking the casters helps prevent the stools and creepers from moving unexpectedly.
- Some stools can be custom made.
|
| Gas Line Connector Rack | 
Reduces material handling |
Description: A device that allows gas lines to be connected to one central location.
Advantages: - Reduces the number of gas tanks that are handled.
- The rack can be moved by crane as a single unit.
Points to Remember: - The gas racks are assembled by the vendor.
- Use of the gas rack is more efficient when used by several employees in the same area.
|
| Davit Cranes | 
Reduce manual lifting and handling |
Description: Devices mounted to dry docks to move heavy items onto or off of vessels.
Advantage: - Reduce manual lifting and handling.
Points to Remember: - Ensure the device is rated for the load weight.
- Many types, sizes, and capacities of overhead cranes are widely available to lift and transport heavy items.
|
| Block Lifting Device | BEFORE
AFTER
Reduces manual handling |
Description: A hook-like device that allows wood blocks to be lifted by a crane or forklift.
Advantage: - Reduces the manual lifting, moving, and positioning of very heavy wood blocks.
Point to Remember: - Ensure device is well maintained.
|
PERSONAL PROTECTIVE EQUIPMENT | Anti-vibration Gloves | 
Reduce hand-arm vibration |
Description: Gloves with anti-vibration properties.
Advantage: - Reduce the vibration being transmitted to the hands and arms from vibrating tools such as grinders, needle guns, and sanders.
Points to Remember: - Optimal fit is essential to reduce unnecessary fatigue.
- Anti-vibration gloves should not dramatically increase grip diameter.
- Gloves should be chosen to minimize the loss of tactile sensitivity.
- Full finger gloves provide the maximum protection.
|
| Elbow Pads | 
Reduce contact stress |
Description: Pads to protect the elbow from contact stress.
Advantage: - Useful for working in cramped spaces and/or leaning on the elbows.
Point to Remember: - Elbow pads should fit snugly but should not compromise circulation in the arm.
|
| Shoulder Pads | 
 Reduce contact stress |
Description: Pads that protect the shoulder when carrying objects on the shoulder.
Advantage: - Reduce the contact stress to the shoulder.
Points to Remember: - Shoulder pads should be used when an item cannot be transported with a cart or other transport device.
- Carrying heavy objects on the shoulder often causes excessive pressure applied over a small area.
|
| Kneeling Supports | BEFORE
AFTER
 Reduce contact stress |
Description: Support devices that distribute weight and reduce knee strains.
Advantage: - Reduce pressure within the knee while kneeling and prevent the knee from bending too far.
Point to Remember: - When possible, work surfaces should be raised to minimize kneeling.
|
| Kneepads | BEFORE
AFTER
Reduce contact stress |
Description: Pads worn to protect the knee when kneeling on a hard surface.
Advantage: - Kneepads reduce contact stress.
Points to Remember: - When possible, work surfaces should be raised to minimize kneeling.
- Kneepads should fit snugly but should not compromise circulation to the lower leg.
- Kneeling on one or both knees can cause contact stress on the bones and soft tissues of the knees.
- Contact stress can reduce circulation and pinch nerves.
- Pad should be replaced when cushion material becomes compacted.
- Select fire-resistant pads when performing hot work.
|
Taken from http://www.osha.gov/dsg/guidance/shipyard-guidelines.html#process
1 comment:
Great post, Cranes are typically used to move and assemble heavy equipment. Crane sizes run the gamut from the enormous ones all the way to much smaller ones which tend to be used in factories and workshops. Thanks
Jib crane
Post a Comment