Manufacturing Excellence Initiative

$250 Billion

Overexertion is #1

• Includes injuries related to lifting, pushing, pulling, holding, carrying or throwing
• $15.1 B in direct costs to businesses
• More than 25% of the national burden

Other Exertions/Bodily Reactions #5

• Includes injuries resulting from bending, crawling, reaching, twisting, climbing, stepping, kneeling, sitting, standing, walking
• $4.27 B in direct costs

$29,000

Ergonomic Benefits

• Reduced workers comp claims
• Increased throughput & productivity
• Streamlined operations
• Solutions for specific material handling problems

Injury Case Study

Direct Costs

• $20,000
• Emergency room, MRI, hospital stay

Indirect Costs

• Time-Related Costs = $5,288
• Non-compensable time, overtime, time lost by non-injured workers, supervisor time

Indirect Costs

• Production-Related Costs = $130,000
• Lost production, reduced output

Indirect Costs

• Equipment and/or Materials Damage-Related Costs = $2,740
• Equipment repair, equipment rental, material damage

Cost/Benefit of Ergonomic Intervention

• Hydraulic scissor lift with tilt & Install = $9,000
• Maintenance (life asset) & Training = $2,000
• Total Cost of Intervention = $11,000
• Total Cost of Injury = $158,028

Stats & Data courtesy of:

• Liberty Mutual Research Institute for Safety
• National Council on Compensation Insurance
• Milbank Quarterly
• Safety, Health & Environmental Body of Knowledge