Preventing Back Pain Through Ergonomics

By Todd Overpeck, Marketing Specialist
06/30/18

Back injuries are the most frequent injuries suffered by EnPro colleagues, and probably the most difficult injuries to prevent because there are so many cause factors that build up over time until OUCH! – the pain hits.

More and more we’re focusing on preventing those slow-building back-injury causes by applying positive ergonomics principles both in our workplace and our individual lives.

Ergonomics is a big Greek word for “labor law.” In other words, there are laws we must follow to labor safely. The goal of ergonomics is to optimize work conditions, processes and arrangement of objects at the workplace. Then, the quality of the output in regards to time and employee health will be optimal.

Ergonomics is not a stand-alone branch of science, rather it is a combination of physical and mental sciences:

• anthropometry: body sizes, shapes; populations and variations
• biomechanics: muscles, levers, forces, strength
• environmental physics: noise, light, heat, cold, radiation
• vibration body systems: hearing, vision, sensations
• applied psychology: skill, learning, errors, differences
• social psychology: groups, communication, learning, behaviors

Correctly executed and organized labor does not make people sick or hurt. All too often, in all kinds of workplaces, not only manufacturing, discomfort in the neck, back, wrist and eyes are common among employees. However, not all of this pain is caused by physical issues. All pain symptoms felt in the body can be psychosomatic. This means pain can be caused by the mind in stressful situations or because of other psychosocial events.

For more information about this concept, read The Great Pain Deception: Faulty Medical Advice Is Making Us Worse by Steven Ray Ozanich. Find it on Amazon here. 

Stress on the mind and body combines to cause pain. Let’s look at how the nature of some jobs contributes to mental and physical issues causing pain:

• Repetition - Rate and number of repetitions: performance of the same motion or motion patterns every few seconds for more than two hours at a time
• Awkward Positions - Postures and limb positions: fixed or awkward work postures such as overhead work, twisted or bent back, bent wrist, stretching, stooping, or squatting, for more than a total of two hours
• Vibrations – Duration of vibrations: Use of vibrating or impact tools or equipment, such as a jackhammer, for more than a total of two hours
• Loads (lifted) - Lifting, lowering, or carrying of anything weighing more than 35 pounds more than once during the work shift
• Loads (static) - Holding a fixed or awkward position with arms or neck for more than ten seconds.
• Force - Continually pulling or pushing objects
• Environmental Factors – Extreme cold or hot temperatures, darkness, noise
• Sitting Posture - Ensure the neck and spine do not carry more weight than necessary

The more these precipitating factors combine, the more likely employees could injure their backs. EnPro Industries has a guideline or “law” for colleagues to not lift more than 35 pounds individually. It’s much better to use lift equipment or get help from another colleague.

Employees also should understand proper individual lifting techniques.

1. Get close to the object. Use gloves if they will improve your gift. Look for a label that indicates the weight of the object.
2. Squat with the legs. Bend slightly at the waist. Use both hands.
3. Keep the weight close to your body. Push up with the legs. Use forearms and thighs to rest the load if necessary.
4. Keep the load tucked in close. Pivot with your feet. Keep your back as straight as possible.
5. When placing a load on the floor, squat with the legs. Keep the back straight. Release the load carefully.

There are many other repetitious activities that have detailed steps to keep employees safe. Applied ergonomics principles along with behavior-based safety procedures can help. But it takes time and effort, and the willingness on the part of executive leadership to invest in equipment and workplace environment changes to protect workers. That said, the benefits from ergonomics-based injury prevention outweigh the costs.

Ergonomics reduces costs. This represents an opportunity for significant cost savings. Indirect costs can be up to 20 times the direct cost of an injury.

Ergonomics improves productivity. By designing a job to allow for good posture, less exertion, fewer motions and better heights and reaches, the workstation becomes more efficient. Creating and fostering the safety and health culture lead to better human performance.

Ergonomics improves quality. Poor ergonomics leads to frustrated and fatigued workers that don’t do their best work. When the job task is too physically taxing on the worker, they may not perform their job like they were trained.

Ergonomics engages employees. Employees notice when the company is putting forth its best effort to ensure their health and safety. If an employee does not experience fatigue and discomfort during their workday, it can reduce turnover, decrease absenteeism, improve morale and increase employee involvement.

Ergonomics creates better safety culture. Ergonomics shows your company’s commitment to safety and health as a core value. The cumulative effect of the previous four benefits of ergonomics is a stronger safety culture for your company. Healthy, productive employees are your most valuable asset.

If the company is committed to ergonomics principles, individual employees can take responsibility for their own health by preventing root causes they can control. For more information about the mind-body link to preventing back pain, read Healing Back Pain: The Mind-Body Connection by John E. Sarno. Find it on Amazon link here.

Let’s look at some individual root causes and countermeasures for preventing them.

1. Sedentary / Lazy Lifestyle – Move more. Take walks with a step counter. Join a gym. Play a sport. Do yoga stretching.
2. Stress – Read a relaxation book. Take time off regularly. Identify your “energy vampires” that drain you.
3. Aging – Eat anti-aging food and proper diet. Learn about “blue zones.” Move your body every day.
4. Genes – Lose weight through diet and exercise. Identify and control inherited impulses. Take care of join health.
5. Pregnancy – Back pain can persist after pregnancy. Ease into an exercise program.
6. Repetitive Motion – Consider hobbies and sports that are repetitive. Strengthen tendons and ligaments. Increase blood flow to joints.
7. Taking it Too Easy – Too much relaxation is counterproductive. Movement in moderation is key. Aerobic movement should be 70% heart capacity.
8. Your Doctor – A diagnosis is a “status quo” not a final destination. Treat the causes, not only the symptoms. Consult chiropractors and physical therapists as well.
9. Vibrations – Freight truck drivers and even RV owners can be affected by vehicle vibrations in the range of 4-6 Hertz. Take a break every hour of driving.
10. Previous Back Problems – Your back can change and adjust to prior injuries. This can cause new back injuries.

Using ergonomics principles individually and collectively in the workplace can keep employees healthier, but it also takes motivation. A Safety Action Team specifically assigned to ergonomics and back health is a great way to keep ergonomics principles on top of mind. Form an Ergonomics Safety Action Team with volunteers who are willing to be trained by a physiotherapist. They can create simple exercise plans for everyone, and then conduct safety walks to check for ergonomics issues in the work environment that can be addressed.

Applying ergonomics principles in our workplace and our individual lives can help prevent significant back injuries, as well as make our lives generally healthier and happier.