John J. Kovacs, a.k.a. The Workbench Guy, is V.P. & G.M. of Kessler America. He has been providing numerous industries with top quality industrial workbenches, height-adjustable ergonomic worktables, sit-stands and anti-fatigue work mats.
To help companies appreciate the potential business impact of ergonomics programs, the Washington State Department of Labor & Industries compiled reports of ergonomic investments and successes. The following brief summaries show the potential for significant economic benefits as a result of implementing ergonomic interventions.
Success Stories
A military repair service invested $35,212 in equipment, including a vacuum life, anti-vibration gloves, keyboard trays, and anti-fatigue mats. Injuries due to strains decreased 23% in one year, saving the business $87,400. The benefit-to-cost ratio? 2.5-to-1.
A gravity feed roller system set at waist height reduced lifting and twisting at a packaging plant. The company experienced a five-fold decrease in days lost due to musculoskeletal injuries, sickness, and workers’ compensation costs. A 25% increase in productivity accompanied a 100% reduction in lost workdays.
Waist-high carts for carrying goods to wrapping machines in the packaging section of a manufacturing plant reduced walking and bending. As a result, productivity jumped 400%.
Adjustable assembly tables made it easier for workers at a window treatment fabricator to reach parts and raise and lower their worktables. The incidence of compensable claims went from twenty claims to two claims over five years.
A manufacturer paid $300,000 for an automatic palletizer to replace hand palletizing. The company experienced a return on investment of 23.6% per year over 10 years.
An automotive parts manufacturer purchased 20 tilt stands for parts baskets and 100 anti-fatigue mats. An investment of $22,986 yielded an 88% reduction in musculo-skeletal disorders in seven months.
A screen manufacturer spent $40,000 on semi-automated tables, which reduced awkward postures and high forces. As a result, quality improved, production increased, operator fatigue went down, and employee morale shot up. In 18 months, the incidence rate for musculoskeletal disorders went from 69 per 200,000 work hours to 0. The lost days rate went from 2342 per 200,000 work hours to 0.
A large electronics manufacturer spent $355,000 on an ergonomics program that included workstation redesign, training, and elimination of high-risk tasks. Productivity went up 37%. The return on investment was 1,675%. The company saved $100,000 per year in reduced labor costs and $2.1 million per year overall.
A large communications equipment manufacturer purchased scissor lifts, installed sit/stand adjustable workstations, and instituted job enlargement. In two years the number of ergonomics-related lost workdays went from 298 to 0. The company saved $1.48 million in workers’ compensation costs in five years.
An electronics assembly plant installed adjustable sit/stand workstations for $57,000 and realized savings of $490,000. Lost workdays decreased 57% over 12 years.
Comprehensive Ergonomics Program
Success with ergonomics entails more than just buying the right equipment. Employees must participate in the process, giving input and suggestions. They often know what is needed to make their jobs safer and easier. Employees must also receive training in how to use any new equipment. Without employee involvement, companies may not realize the full benefit of ergonomic investments.
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