Ergo engineering reduces injuries

  • Published
  • By Lanorris Askew
  • Warner Robins Air Logistics Center Public Affairs
ROBINS AIR FORCE BASE, Ga. (AFPN) --  Intervention, funding and innovative technology means workers on the F-15 Eagle fuel tank buildup crew no longer have to use their heads, according to Mary Ann Gahhos.

No, they do not have to stop thinking, but they can stop using their heads and other body parts to stuff F-15 fuel tanks with foam -- resulting in a 40-percent reduction in risk of injury and a savings of $44,000.

A year ago, it was not an easy job to stuff foam inside the tanks to reduce fuel sloshing, according to buildup crewmembers.

"When you think of foam you think soft and fluffy, but this foam is very dense and hard to maneuver," said Gahhos, ergonomics program manager and occupational health program manager for the 78th Medical Group. "The workers were using their feet, hands and head to push the foam in, and this was resulting in upper extremity musculoskeletal problems."

Pat Deike, maintenance directorate engineering technician, brought those ergonomic risk factors to the attention of the ergonomics working group here. After studying the problem, the group contracted a company to develop a proposal, conduct a baseline analysis, and develop or find an intervention strategy and tools to help reduce ergonomic risks.

Ed Irwin, senior rehabilitative engineer and ergonomist at the Mercer Engineering and Research Center, said though contracting took quite a while, the process was a success.

"We were able to reduce the push forces 60 percent, and duration of exertion by 25 to 50 percent," he said. "The overall cumulative risk reduction was 40 percent."

The dramatic reductions were because of three new intervention tools: a vacuum bag, Delrin Separators and bladder-fitting tools. The vacuum bag compresses the foam without damaging it by allowing it to expand with new pliability, and the Delrin Separators allow the foam sheets to be inserted easier.

"This new vacuum has helped to reduce the amount of effort it takes to do this job," said Ronny Golden, aircraft systems worker. "Anything that is repetitive wears on the body, so being able to make this job a little easier helps to keep us from wearing out so fast."

Stephen Givens, another aircraft systems worker, also praises the separator.

"When you're working in such a small area, it helps to save your arms, shoulders and back from a lot of stress," he said.

Ultimately the program showed positive results all the way around, officials said.

"We were able to come in and not only show improved quality of the working environment, but we were able to reduce injury and improve productivity at the same time," Irwin said. "We were able to use some innovative techniques both in the analysis and the development of the intervention. It was a really great project to work on."

According to Gahhos, in fiscal 2002 work-related injuries in the buildup crew ranged from cases of carpal-tunnel syndrome to arm strains along with an estimated $112,000 in medical costs.

Irwin said the production improvement also resulted in a savings of seven man-hours per aircraft, causing the cost of the contract to break even in less than seven months.

"It was definitely a process improvement," Gahhos said. "The ergonomics working group is active at Robins and tries to intervene when we see ergonomic problems. The (group) saw the problem, helped identify the tools to fix it and … made it a success."