They next identified a series of key variables affecting the process outcome that included: First, the team outlined the sequence of events from workstation assignment to task performance and potential injury. Once the "Six Sigma" project team developed its charter and defined its task, it then began by defining the current process. While each of the four steps of the "Six Sigma" project are outlined below, a more detailed discussion of the "Six Sigma" methodology appears at the end of this case study. Following the steps prescribed under "Six Sigma", Dow developed a "Six Sigma" project team, which first defined the primary contributing factors to MSDs in the DDC function, and then sought to reduce the those factors by 70 percent. Because "Six Sigma" emphasizes sustainable results over short-term fixes, Dow has found it particularly useful for EH&S projects. "Six Sigma" is a disciplined, process-oriented approach to problem solving, adopted by Dow and many other companies, which emphasizes the reduction of defects in processes, products and services by applying a four-step improvement methodology. While the rate of ergonomics-related injuries among the DDC workers was low (only three were reported in 1999), the Company chose to make proactive improvements before ergonomic injuries increased in number or severity.ĭow's EH&S function decided to address ergonomic injuries at DDC using the "Six Sigma" problem solving methodology. Because DDC's approximately 1,250 workers (including employees and contractors) work primarily at desktop workstations, where they spend the majority of their time working at computer keyboards, they were increasingly susceptible to ergonomics injuries. Dow Design and Construction ("DDC") is responsible for managing the design and construction of Dow's facilities worldwide. In 2000, the company identified an opportunity to improve its injury rate within the Dow Design and Construction business unit. These goals call for a reduction in the Company's reportable injury and illness rate by 90 percent to 0.24. In 1994, Dow adopted a set of voluntary 10-year EH&S goals to dramatically improve the Company's performance by 2005. Dow is a science and technology company that develops, manufactures and provides various chemical, plastic and agricultural products and services for customers in over 180 countries. The Dow Chemical Company's Innovative Use of "Six Sigma" 3Īvoiding ergonomics-related injuries is an important component of The Dow Chemical Company's ("Dow" or "the Company") overall emphasis on safety and health. This project, which utilized a problem-solving methodology called "Six Sigma," offered an innovative way to address Tricia's concerns for the development and implementation of a sustainable program to reduce MSDs throughout her business. She also knows that any reductions achieved under the new program must be sustained over the long term, and she is concerned that over time employees and managers will "backslide" on their commitment to the program and return to their ergonomically risky behaviors.įortunately for Tricia, she could refer to a similar project successfully undertaken by the Design and Construction function of The Dow Chemical Company, which is discussed in the case study below. Because of constraints on both her budget and time, Tricia would like to design one basic program that is flexible enough to implement company-wide. Tricia also suspects, but is not sure, that many of the root causes of MSDs are the same across the different operations and divisions in her business. Only by knowing the root causes can she implement with confidence controls that would achieve positive results. Although she has some theories, Tricia does not know for sure what factors are causing or contributing to the employees' MSD complaints. Before she can understand what changes to make in either the workstations or the work practices in those divisions, she must identify the root causes of MSDs among the operators. Yet, as illustrated below, in many companies there are inherent difficulties and concerns associated with addressing this increased ergonomics risk.įor example, Tricia, the Environmental, Health and Safety (EH&S) Leader for the Specialty Chemicals Business of The Dow Chemical Company, wants to reduce MSDs among computer workstation users throughout her business' various divisions and operations. 2 As computer workstation users spend more and more time at desktops, the risk of MSDs occurring has increased. 1 The resulting worker injury claims and loss of productivity are estimated to cost $13 to $20 million per year for U.S. In 2002, ergonomics-related injuries accounted for a third of all workplace injuries involving missed work time, with an average absence of nine days per injury. Ergonomics-related injuries, including musculoskeletal disorders (MSDs) caused by repetitive strains, continue to be a serious problem for employers.
0 Comments
Leave a Reply. |
AuthorWrite something about yourself. No need to be fancy, just an overview. ArchivesCategories |