Integrate Ergonomics into Shipyard Health & Safety

The shipyard environment is complex and unique.  Workers often perform awkwardly positioned tasks in unique and varying environments and have a history of forming musculoskeletal disorders (MSDs). Nonadjustable work stations, enclosed or confined spaces, and diverse repair activities can be job requirements which contribute to health and safety risk.

Ergonomics is the study of efficiency in work environments.  Shipyards that have systematically addressed ergonomics in the work environment have been effective at reducing injury and reducing MSDs.  As a result, many companies have recognized the value of integrating ergonomics into existing safety and health programs.  Companies invested in safety policy should take general steps for initiating ergonomical improvements in the work environment, and always remember that each work environment will have different needs and limitations to consider.

Shipyard Work Environments and MSD Injuries

Shipyard Work EnvironmentA shipyard is composed of three main work environments.  Shop work, with conditions similar to manufacturing and maintenance; and Yard and Vessel work, where tasks include assembly, welding, and repair. Shoulder stress, lower back strains, and symptoms including numbness, pain and swelling can indicate a work environment for which ergonomic improvements can reduce work injuries.

In addition to reduced worker’s comp and lost worker time, ergonomic risk management initiatives can improve morale, reduce absenteeism, and increase production efficiency.

General Steps for Systematic Improvement

Integrating ergonomics into a health and safety plan can follow the following process.

OSHA Shipyards Ergonomics Report
OSHA 2008 PDF Report
  • Providing Management Support
  • Involving Employees
  • Providing Training
  • Identifying Problems
  • Implementing Solutions
  • Addressing Injury Reports
  • Evaluating Progress

These general initiatives can lead to programs and activities across departments to accomplish injury prevention goals.

Equipment Solutions and Guidelines

Ergonomics solutions can be implemented site-wide and evaluated on a task basis for unique work hazards.  Consider three equipment options and related ergonomic guidelines.

  •  Standing Platforms: Provide stability and reduce shoulder and neck fatigue, particularly for overhead work.  Ideally workers should operate with hands between waist and shoulder height.  Lightweight platforms can be utilized site-wide.  
  • Racks and Shelves: For staging, moving, storing materials, tools, equipment.  Wheeled racks simplify maneuverability.  Position between knee and shoulder.
  • Tractor Trailers: Reduce trips between work areas for transport handling and time savings.  Avoid load shifting or tipping by considering stability and balance.

For details about Systematic Improvement Measures, additional Equipment Solutions and Guidelines, and a complete summary of Shipyard Ergonomics and MSDs, view the Ergonomics for the Prevention of Musculoskeletal Disorders report online at OSHA.gov.

Ergonomic Assessment at your Shipyard

OSHA recommends setting up a plan for achieving the cost, efficiency, and morale advantages associated with ergonomics process improvement.  In unique and varying shipyard environments, operational or safety teams may need assistance to develop a plan and engineer custom equipment.

Ergonomic improvements have resulted in an 80% accident rate reduction on some shipyards, and are accompanied by operational and morale benefits that can be of great value.  OSHA provides free consultation services, and workplace access specialists also assist with recommendations and equipment design.  Contact Innovative Access Solutions to get started designing custom access equipment to meet your ergonomic safety program equipment needs.

OSHA Top 10: Guarding Floor and Wall Openings and Holes

Floor openings are a broad OSHA standard covering stairwells, ladderways, hatches, skylights, pits, manholes, and other walking or working surfaces that workers can fall into.  In industrial workplaces, floor openings commonly provide multi-level access or access to storage or materials, and are often found when labor or construction is underway.  Consider the Top 10 citations for OSHA safety standard 1910.23 in 2012.

  1. Manufacturing (302 Citations in 2012)
  2. Wholesale Trade (71 Citations)
  3. Transportation, Communications, Electric, Gas, and Sanitary Services (61 Citations)
  4. Services (49 Citations)
  5. Mining (38 Citations)
  6. Retail Trade (30 Citations)
  7. Construction (12 Citations)
  8. Agriculture, Forestry, and Fishing (5 Citations)
  9. Public Administration (3 Citations)
  10. Finance, Insurance, and Real Estate (2 Citations)

Source: OSHA 2012 Statistics and Data

Safety managers and operations personnel must keep in mind OSHA guidelines including proper railings, floor opening covers, toe boards, manhole guards, and platforms.  Industries with the most frequent violations include manufacturing, transportation/energy, and mining.  The common thread among these industries?  Material storage, operational setting variations, and multi-level access.

Wall Opening Ladder for Material Access
Storage Access
Walkway Across Floor Opening
Floor Opening Walkway
Manhole Guard with Spring Latch
Manhole Guard

 

 

 

 

If your work area provides access to multiple levels for which standard equipment will not safely facilitate, custom solutions may be necessary.  Proper equipment will protect your employees, manage worker’s comp safety risk, and prevent OSHA citations.

Innovative Access Solutions, LLC

For custom access design, Innovative Access Solutions is an experienced and knowledgeable producer of OSHA safe solutions, across industries.  For more information about IAS, visit IAScustom.com or call (800) 388-6884.