Work Injury Prevention Programs

Injury prevention programs have led to a significant reduction in workplace injuries while contributing to improved productivity, reduced turnover, improved OSHA compliance, reduced worker’s compensation claims and premium rates, and higher employee satisfaction.  The costs of a worker injury can be devastating to individuals families and affect businesses on multiple fronts.  In 2009, worker’s compensation benefits paid totaled $58 billion, and indirect costs have been estimated at 1.1 to 4.5 times the direct cost.

Indirect Costs of Worker Injury

  • Wages paid to absent, injured workers
  • Time lost due to work stoppage following injury
  • Administrative time processing injury-related tasks
  • Employee training and replacement following an injury
  • Productivity loss due to new employee training
  • Replacement cost for damaged material and equipment

Source: OSHA Injury and Illness Prevention Programs

Injury Prevention Programs: Effective and Scalable

As of 2012, 34 states, and countries around the world, have instituted required or incentivized injury prevention programs.  The results of state programs are remarkable; work injury rates have been reduced by as much as 60 percent.  Participating businesses have reported additional benefits and some have even encountered more sales opportunities due to their commitment to safety.

 Despite the evidence, many businesses are slow to adopt injury prevention programs.  The perception that implementation will be costly and burdensome, particularly for small businesses, can be difficult to overcome.  The reality has been quite the opposite.  Injury prevention programs are scalable when business owners focus on basic tenets: leadership, participation, hazard identification and prevention, training, and continuing improvement.  The effect on the bottom line is also a positive, due not only to reduced workers compensation premiums and payouts, but also indirect morale, productivity, company image, and process improvements.

Mandatory Policy or Incentivized Benefit?

In a 2012 OSHA white paper, the effect of state programs was reviewed and the results are of interest to businesses considering an injury prevention program.  Incentivized programs in Colorado, Massachusetts and North Dakota resulted in noticeably higher effectiveness compared to mandatory programs in other states.  By providing a worker’s compensation premium reduction incentive,  states reduced work injury by at least 20%, compared to mandatory programs with  10-20% reductions.

In addition to the basic principals of injury prevention and company-wide safety commitment, these results may be a factor to consider for businesses seeking to maximize the effect of injury prevention programs.  Employees who believe their management team cares about safety risks are more motivated, aware, and productive, leading to advantages above and beyond cost benefit.  Anyone who has held a management position knows that while blunt force may get the job done, it often comes with costs ranging from employee resentment to undermining the system.

Incentivize to Promote Safety Culture Investment

Incentivized programs may help to avoid unintended indirect costs while still reaping the benefits.  By incentivizing safety initiatives, employees are more likely to perceive safety as a culture as opposed to a business owner’s cost saving agenda.  Further, incentives will help to communicate safety as a company value with a higher purpose than simply complying to policy. Providing incentives for safety could be based on Key Performance Indicators constructed from hazard assessment initiatives and include cost savings sharing.  Employees that are motivated by incentives will perceive safety not as a management priority but as a mutually beneficial investment.

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.