Risk Assessment and Application of Engineering Controls to Reduce the Number of Occupational Related Musculoskeletal Disorders in a Large Pharmaceutical Production Facility

The high number of discomfort and lost work time cases in one department of a large pharmaceutical production facility, created a unique opportunity for ergonomics study and intervention. The first step in the project identified the three highest risk tasks using safety incident data. Each task was analyzed for ergonomics risk factors. Interventions were developed and implemented for these tasks. Biomechanical and subjective data were collected before and after all interventions to assess the effectiveness of the interventions. Three-dimensional dynamic flexion of the lower back data were collected using a Lumbar Motion Monitor (LMM). Electrogoniometers were used to measure wrist flexion. We used a force gauge, scale, and a tape measure to assess moments, forces, and weight. Subjective data were collected by questionnaire. A quantitative comparison of the subjective and electronic data showed reduced risk factors for Work-Related Musculoskeletal Disorders (WMSDs) of the wrist and back for all three tasks. All the interventions were shown by empirical methods to reduce the risk factors for WMSDs. The interventions were permanently implemented.