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Ergonomics Meets Human Factors: Building Safer, Smarter Workplaces with Dr. Era Poddar

Ergonomics Meets Human Factors: Building Safer, Smarter Workplaces with Dr. Era Poddar

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In this week’s episode of The Safety Guru, we’re joined by Dr. Era Poddar, who shares her extensive expertise in ergonomics and human factors to explore what these principles are, why they matter, and how organizations can proactively integrate them into workplace design to transform safety outcomes, boost productivity, and build safer, smarter workplaces. She discusses the wide-ranging benefits of integrating these principles, including better decision-making, reduced cognitive load for employees, fewer errors, a lower risk of serious injuries and fatalities, and measurable returns on investment (ROI) through improvements in quality, productivity, and overall safety performance. This insightful discussion also highlights how leaders can champion ergonomic improvements, leverage emerging technologies that are reshaping workplace design, and foster a culture of continuous learning and improvement. Tune in to discover how ergonomics and human factors work together to build safer, healthier, and more productive organizations. Don’t miss this episode!

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Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe yet productive operations. For those companies, safety is an investment, not a cost for the C-suite. It’s a real topic of daily focus. This is The Safety Guru with your host, Eric Michrowski, a globally recognized ops and safety guru, public speaker, and author. Are you ready to leave a safety legacy? Your legacy success story begins now.

Hi and welcome to The Safety Guru. Today, I’m very excited to have with me Dr. Era Poddar. She has a PhD in industrial ergonomics, an MBA from UBC, does a lot of consulting work in the ergonomic space, and is also an adjunct professor at the University of British Columbia. Era, so happy to have you with me today on the show.

Thank you, Eric, for the introduction. And I would like to just— mini-MBA.

Mini MBA?

Yeah, it’s not the full MBA at length, but I will reflect on that a little bit. Okay. Why I mentioned that. Yeah, thank you. I’m really glad to be talking to you today.

Absolutely. So, tell me a little bit about how you got started in ergonomics and the passion you’ve gotten for safety and ergo.

Right, it’s a very interesting question, and I, I have been asked about this for so many times. I remember talking to in one of the platforms in my previous employer, some people were talking about different epiphany happened to them, and that’s what they came. To be very honest, I never had such, such incidents, or I would say positive incidents, but what I had in the— I first, to, to be very honest, I learned about the subject when I went to the university to do my master’s program. And so, it’s a human physiology master’s from University of Calcutta. They had a specialization in ergonomics and human factors. So that’s where first I came across the subject. No one knew about this. I was pretty intrigued about the subject because it has direct implications on human life. Like, of course, industry to design and everything. So eventually, I got to love the subject, and I became passionate about it.

And it’s taking you all around the world. And so that gives you fairly unique perspectives as well in terms of how you’ve applied ergonomics in that space. Maybe let’s start with what is ergonomics and why is it so important?

Right. I should go back to a little bit because I had to also touch base on things which, which intrigued me to be part of this subject. One was like, I started my career in a design project, a mining scenario, and I thought that would be pretty interesting for the audience. So, this project ran for 1.5 years, and then we, we redeveloped or redesigned, uh, certain equipment’s, over 10 of them. And during that time, I realized this subject has a different application and we need to pursue more. That’s where I started doing PhD and all that, all the things. Uh, but as you know, life happens, things change, and I, I started my career in a university setting teaching after completing, uh, my PhD. So, while teaching, there are different design applications from physical product design to interaction design and all that. Stuff. So then, as usual, things change, uh, and I followed my husband to Middle East, and that’s where, uh, it’s a different, uh, scenario of ergonomics kind of came into my understanding because it’s a business side of it. That’s when I started my business because there was less scope of applying in the education domain.

Sure.

And before that, I lived a little, uh, time teaching in Nepal, one of the universities, medical school. So, all these things and, uh, kind of intrigued me to apply different domains of this area as well as leaving my comfort zone, I guess. So, in Dubai, we kind of, uh, what we did was, as I said, there’s less education apply— like application or courses. However, there was a scope, uh, to represent companies who had multiple offices across Middle East to help them in their ergonomics initiatives. So, you could call it a beginning of a mini-MBA for me, hands-on practice, and which I wouldn’t have done otherwise if I wouldn’t be leaving my secured career path. And that’s where it’s a different approach which, which is taken from there. And then onwards, I lived in the US and practiced, and then it came back to Canada at one point. So, through all this journey, which why I, I wanted to mention that I— it gathered to me, one is I understood the local practices, standards, and all that.

Sure.

It also did an interesting thing to me. I became more and more open and like it grew empathy to me more. And that is one of the key factors we practitioners in ergonomics do. And it’s really one of the key important factors to be successful in this field. Right. And coming back to your question, what is human factors and ergonomics? Is essentially reducing the mismatch between product or system and the user. So, in one word, however, there are several, um, definitions you could find. That is, it’s a science of work design, science of workplace design, and so on and so forth. But we always emphasize on one important aspect aspects of ergonomics and human factors, two different words. Yeah, coined together, they actually mean the same according to International Ergonomic Association. Uh, the overall— I mean, uh, the definition is, is like human factors or ergonomics is concerned with the understanding of interactions among humans and other elements of a and this profession applies theory, principle, data, and methods to design and optimize human well-being and overall system performance. So, we always focus into the system level, uh, changes so that it affects in an effective way for long term.

So yeah, in one word, it helps, uh, I think, reduce any mismatch between any system and product. And improve productivity.

And so why is it so important for businesses to look at that combination of ergonomics and human factors? And what’s the ROI that comes from it? 

It is a very interesting question. And we still, I mean, it’s proven, understood that it’s a business-friendly concept.

Sure.

Why? As I said, it reduces mismatch in very different ways. From building design to the product design, even for software design. So, there is a coin word called usability. That’s actually how you reduce the mismatch between human and the software or any interface design. So, over the years, it has been shown to be kind of helpful for the business. And why it is helpful? It reduces error, less time, and sometimes the processes are improved in, like we call them, ineffective time. How you reduce them? All this together, as well as a different reachability and use— usability, or ease of usage of any, any such product. Or given— I will just give you some examples.

Yeah, that would be good.

Yeah. Like for, uh, suppose a company who has a production line who produces certain products. Now if the workstations are higher compared to who are operating and there are a lot of reaches, like you move your hands pretty quickly and there’s long reaches. Now if we do it once or twice, that’s fine, right? And if you do it throughout 8-hour shift, sometime industry have 12-hour shift. To. Sure. So, these are the different aspects. One is size-wise, one, one is process-wise. And suppose you have kept certain products or so stored certain products in a different section. Now the employee has to go bring them. So, there are different touch points and different level of postures which is happening, which could have avoided with a better design.

Sure.

When the industry is built or when the workstation— yes, when the workstation was designed. So that’s where if we incorporate these issues, like how this whole process works, where, where people has to interact, and who will be the person who will be interacting. It is a range of people, not every— like, for even given, uh, different genders, there are sizes. And suppose, giving example, 95% percentile stature, people may not be having 95th percentile hand length or arm length, right?

Right.

So, all these challenges kind of available, or it is there within any workstation workplace setup. So, the more we kind of accommodate these requirements since the beginning, you definitely kind of benefit. And end of the day, product quality also improved. So, this whole span of activities, if we consider it effectively, we will save on time, we will reduce injuries, and the injuries will be less fatal, as well as there will be less error. As a result, you will get a product which is quality-wise better and more product. So, it’s an overall win-win for both employees and the employers in a way. I hope I understood.

No, no, absolutely. Yeah. So, and it’s something, as you talked about, it can mean how I design a plant for how the workers are going to work in. But I could also retroactively drive some improvements. So, there is less movement that’s unnecessary, less lifting, bending, stretching, overreach occurring throughout the day.

Also, less decision-making.

Sure.

Because more and more workplaces becoming automated.

Yeah.

And people are even in regular manufacturing settings; we see employees has to interact with machines where they have to put input and given that the cycle number and what is the output number and all that. So, these— all these interactions are happening at like simultaneously.

Sure.

So, there are cognitive demand as well as physical demand. I, I just gave you a very simple industrial scenario. So, there are complex scenarios like pilots interacting with machines, or we are driving a car. There are so many distractions these days, from external to internal to phone and displays and stuff. So yeah, it makes more sense to incorporate through the design at the beginning. However, it could be applied in every stage.

Sure. Yeah, to drive improvements, to improve the work practices, but also the cognitive load that you mentioned before in terms of the decision-making. I like your example of the car as well. So very, very beneficial. As you said, there’s a The ROI is really because it’s helping, one, the workers, but it’s also helping productivity directly. If you have less distractions, you have less complexity in your decision-making and less movement to complete the task. Is that fair?

It is fair. And I should also add where it is, most of the time, the ergonomics or human factors concepts are applied towards later phase, like when you have an injury, right? And this is not that proactive, more reactive approach. Unfortunately, in— especially not even only in Canada, I have seen in the US or even in the Middle East, that’s where we are called as a practitioner. So, when everything is all set, you have a process set, you have a design set, and there are also different teams working together, not including one of, like, human factors or ergonomics professionals within. So, what it does is there’s always a gap remaining. So, end of the day, which we see, there is an incident, and most popular incident which relates to ergonomics, human factors, that’s musculoskeletal injuries.

Yep. 

And that’s where people think that’s what ergonomics is, which is not at all, uh, right directions. But that’s where most of the time we are called in. So as there also huge number of dollars are lost every year, if we see the recent statistics even through WorkSafe BC locally. It’s over $2 billion of cost. 

Sure.

And over the year, like recent years. So that is something has to be definitely seen as one of the ROI where we could control this cost.

And ideally done proactively, right? So, as you mentioned in the plant design, or even at a later stage to drive improvement.

Yeah, true. Unfortunately, that is not always done that way. 

Yeah, unfortunately not. Yes. Yeah, unfortunately, sometimes you need an event to realize it wasn’t designed the right way. So, one of the things I know when we first connected that you touched on, which I thought was very interesting, is around changing workplaces. And there’s a lot of changes in the current workplace. How does that impact the space of ergonomics and human factors.

This episode of the Safety Guru Podcast is brought to you by Propulo Consulting, the leading safety and safety culture advisory firm. Whether you are looking to assess your safety culture, develop strategies to level up your safety performance, introduce human performance capabilities, re-energize your BBS program, enhance supervisory safety capabilities, or introduce unique safety leadership training and talent solutions, Propulo has you covered. Visit us at propolo.com.

Few things we have to understand. Since World War II, when the subject evolved, many organizing factors, there’s very less understanding across other disciplines about the breadth an application of the subject. So, when, uh, the workplace changes considerations came into play, especially in Canada with the Inclusive Act and all that thing, uh, the concept remained pretty old. Like, it’s not that new, right? Uh, so the changing workplace has been— we see, just giving you an example, if we visit, even you come to any public place or any workplace, you will see different variations of populations coming from different cultures, background. So how does it affect the workplaces? Uh, one is size, like your anthropometric measurements. You have a different language spoken throughout like when growing up. So, you are learning a different language, you are getting instructions through different languages. As the same— at the same time, we have different, uh, equipment’s incorporated into the workplace, more like recent AI. And over the years, we have seen a lot of more automation happen. So, employees are interacting with various different as I mentioned earlier as well, the physical, like manual material handling to giving input to the machine to do a proper setup speed.

Sure. And the production. At the same time, you are getting information through your handle devices.

Yep.

And you are also interacting with some of those displays. And there’s a workplace changes happen through the age. We have older work curse, who has limited ability to interact with digital devices, right? So, these are a complex scenario where you have different, different genders, you have different background, you have different language, culturally different thinking. We don’t have enough time to talk about that stereotype things, but it is there. We think differently, we perform, understand differently. So, these vast and different sizes, as I mentioned, we incorporate this whole group of population within a particular workplace. Right. So, definitely there will be repercussion on that. Yeah. Unless it is really designed well or it is accommodating all this requirement. And at the same time, you have differently abled people who have limitation like moving or different level of cognitive abilities. So, there are so many different challenges within that place. So, when we say the accessible or universal design concept, so we, we talk about all of these people is welcome in that workplace or any space, and they can easily interact with all these different things. And how we make those things user-friendly for them. So that’s when we talk about different level of accessibility or universal design.

Which really means a lot more flexibility in terms of how you would interface with equipment, the technology, potentially very different sitting position, if in that scenario, you’re talking about, where there’s flexibility of adjusting depending on what’s right for that particular individual.

Yeah, I can provide you another simple example. Suppose you are accessing, uh, like an ATM machine, right? Right. So now, for people like you and me, I will go walk, park the car, go walk and access. It’s not a big deal. We know these are bigger buttons and everything. Now consider this person who cannot move, who is on the wheelchair.

Yeah.

Now there are different level of accessibility they need. So, he has to access the building first. There has to be certain ramp where they can access. And then there has to be certain reach so that they can see it, still see it, and interact with the machine, right? Not only physical buttons, but there are also digital buttons. 

Sure.

So, then there are all these requirements. So, you have a person who will operate this machine standing, there’s a person who may come on the wheelchair, there’s a person who may come in differently, other way of different, and there is person who cannot see. And also, the language-wise, so people may read English well, some may not, some may come from suppose Mandarin They speak Mandarin, reads Mandarin or Japanese.

Sure.

So, consider a world where all these people live together and interact with the machine. So that’s where the usable or universal design or accessibility come.

And bringing that to workplaces as well, because the same example, it’s how do I design a work environment, whatever that work environment might be, to have that flexibility in terms of interaction.

That’s right.

Excellent. And I know one of the themes we also touched on is around now that we’re hearing more and more about exoskeletons. How does that play into these human factors and ergonomics space?

That is another interesting area of time. Anytime we talk to colleagues, they come up with this question. So, I was recently listening to one of the webinars done by— I don’t remember the organization, but the person who was presenting, Dr. Christopher Reed from Boeing, he was reflecting on many such research and applied within the Boeing scenario. I will refer some of her— some of his topics. So, exoskeleton is, of course, related to ergonomics. It’s not like insects and others. So, it’s an external structure which helps us to support while working. 

Sure.

So, we call them industrial exoskeleton. And there are different types. Some are automated. I mean, they are more advanced these days. But essentially, it is built to support while working.

Right, sure.

So, few, a few different types. I’m very broadly, I’m touching this. One is made for postural assist system, like when someone is working within an environment or very concise space where you cannot do any engineering changes, where you cannot implement those changes. So that person has to work in a certain position, suppose electrician, in that space. You cannot bring in any other equipment. So continuous working within that space and having those shoulder and arm muscles in the, like, over above shoulder level. So that’s when this type of exoskeleton helps. Like, it’s a postural support where hands and shoulders and— sure, other, other part is supported. There is other type of where you have full body support, like especially doing manual material handling where any other engineering changes or equipment could be provided in such certain scenario. It seems that quite a few other companies, including Boeing, is using them while making the airplanes, not— I mean, after it is done, so before that part. So since employees are using them, I had also interacted with few local clients Sometimes, uh, some of the workers like it, some don’t.

Of course.

So, some of them— I, I was amazed to hear this— the— my contact person who was saying that 2 or 3 of them didn’t like it, so they never would wear them.

Sure.

So, there are 1 or 2, it happened that they wouldn’t open it. Without that, they cannot perform. So, there are different varied level of acceptance. Sure, there’s definitely different types of acceptance level as well as, uh, I mean, the type of work people does. Depending on that, this is effective. So, it’s always the first thing we as a professional suggest. If there is option, engineering changes is better options. In any day. However, there is no, I mean, opening to incorporate such changes, then explore this. Still, there’s a lot to— yeah, there is a lot of research has to go in. It’s still developing.

Yeah, absolutely. I think for me, the first example I saw of this was, I’m going to say it’s almost a decade ago, and it was in Japan with baggage handlers, and it was around how do we reduce the lifting and switching that’s happening when they’re moving bags, which sounded very interesting if you think about the repetitive motions and the— you don’t even know how heavy a particular bag is going to be, which adds a lot more risk as well to that equation.

Yeah, you’re right. And also, I remember mentioning I think 6, 7 years back, uh, still the COVID at the beginning of COVID or before that, there were, uh, we ordered some furniture’s and people came to deliver. Some of the company who was contracted to do that, so the employees, their employees were using those exoskeletons to move those furniture’s. Yeah, so I have seen, it’s interesting, few companies adopted them pretty well. And then sometimes, as I said, it’s, yeah, not always accepted.

And as you talk about change, I think one of the things that makes good sense to transition to is what’s the role of a leader in driving that change, right? So, they can— we talked about your role coming in and assessing, but how can a leader support change?

It’s a Very important and interesting topic, and that’s one of my other passion area these days— how to incorporate human factors ergonomic concept within the strategy, right? So, we all know this concept is old enough. However, it’s less accepted amongst the senior leadership.

Sure.

One main reason is the language we speak. So, language has to be such so it is acceptable to the senior leadership. And senior leadership, one and important part which I realized over the years is, of course, they have to be trained in certain aspects. So, we as a professional has to be able to speak that language which caters to that group. At the same time, leadership has to be a little bit open towards these new concepts coming in, right, which is beyond the conventional, okay, they have— there are standards, engineering standards, and we— sure, we have it, then it is all done. It is not always the case because at the end of the day, users are human, right, right. And or whoever is using it, they are the one who is manipulating with the system.

Right. 

So, the leadership’s main, I think, the initiative would be understanding, like keeping a little open mind, one. Second is putting a human factor economics concept as a strategy goal, which is actually part of their business decisions. Then if you have a budget, allocated already, then it’s much easier to implement at the design stage than at the level when an injury already happened.

It really touches the whole space of safety by design, even in terms of if you, if you do things right at the front end, and you’re putting in the time and the effort, you’ll be much better off later.

Exactly. And also, we always say this, you have as a company, every company has their standard operating procedure or SOPs. So, it is always smart to align the programs, including safety, ergonomics, and other programs, to that, right? It’s, it’s much— it makes a lot more sense. And if you remember, I touched upon briefly on a certain point that we have various departments within a company. Unfortunately, some of them, they don’t always interact, or there’s less, less scope, or whatever may be the reason, that interaction is very important. And leadership can bring in that interaction so that same things are simultaneously done but not applied effectively. I have seen that in my practice. That quality team had come up with an idea which is not fully applicable because of the other challenges, However, there was another department have developed a newer idea and applying them within the team which others didn’t know. So again, the communication, communication, and allowing this communication to happen free flowing among different departments without a bias. So that is another leadership role I, I think would be very helpful in such initiatives.

Sure, absolutely. And so, if somebody wants to get in touch with you, what’s the best way to do so? And maybe share a little bit about the type of work that you do to help organizations in this space. 

Right. So best way to reach me through LinkedIn. Also, we have our website, www.argoera.com. You can and definitely click to that website and see our services.

Yep. 

We do offer different types of services. We do offer the program support where the corporations can— an ergonomist like us or others can work together to come up with a plan or aligning their SOPs, which is more long-term. And I think we focus more into that. However, as I— excuse me— as I said, there are a lot more focus into risk assessment or management. So that’s where a lot of business come through that area. So, we do, of course, cover that risk assessment. It could be your industrial risk assessment to corporate. At the same time, we also do worker compensation. Kind of support. I mean, you do need that kind of risk assessment as well, and all, uh, different types of workshops, being it the executive workshops to strategy level workshops, and also participatory ergonomics.

Makes sense. Excellent. So, Era, thank you so much for joining me today. Appreciate your time.

Thank you so much.

Thank you for listening to The Safety Guru on C-suite Radio. Leave a legacy. Distinguish yourself from the past. Grow your success. Capture the hearts and minds of your teams. Elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafetycoach.com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting.

ABOUT THE GUEST

Dr. Era Poddar is a Canadian Certified Professional Ergonomist (CCPE) and safety specialist, with broad international experience across North America, the Middle East, and Asia. Her expertise covers industry, academia, corporate, and government sectors. She holds a Ph.D. in Industrial Ergonomics, a NEBOSH International General Certificate in Occupational Health and Safety (practical applications), and a mini-executive MBA from the Sauder School of Business, UBC.

With more than twenty years in consulting, coaching, training, and research related to ergonomics, human factors, workplace accommodation, and safety, Dr. Poddar helps organizations meet goals in health and safety, ergonomics, and MSI control. She currently sits on the Board of Directors for the Canadian College for the Certification of Professional Ergonomists (CCCPE) and actively contributes to the International Ergonomics Association (IEA) Health and Safety Technical Committee, where she leads a group advising on ISO 45001: Guidelines for Ergonomic Processes. Additionally, she is part of the Canadian Mirror Committee (CMC) to the ISO Ergonomics TC 159.

Era is the founder director of Ergoera Services Inc. (https://ergoera.com), which provides customized ergonomics and occupational health and safety services and training. She also serves as an Adjunct Professor at the University of British Columbia, guiding master’s students and professionals in industrial ergonomics, injury prevention, design ergonomics, human-centered design, and user research.

Known as an innovative entrepreneur, leader, and public speaker, Era balances her roles as consultant, educator, researcher, and mentor. She has successfully managed multicultural teams globally, including in North America, Asia, the Middle East, and India. Her work involves leading excellence initiatives, promoting accessibility and universal design, developing safety and ergonomics strategies, and implementing quality improvement programs. Throughout her career, Era has spearheaded ergonomics programs, risk assessments, participatory projects, gap analyses, and process improvements in sectors like manufacturing, mining, food processing, government, corporate environments, and healthcare. Her evidence-based, user-centered approach supports healthier, safer, more functional, and productive workplaces, reflecting her commitment to “Design for All.”

For more information: https://ergoera.com/

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Safety in Motion: The Energized Approach for Real Impact with Michael Melnik

Safety in Motion: The Energized Approach for Real Impact with Michael Melnik

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How do you energize your safety programs to be effective, engaging, and inspire action with lasting real impact? Join us for a dynamic conversation with Michael Melnik, owner and president of The Energized Approach®, as he shares how safety programs can be reimagined to be more sustainable, fun, and meaningful. With decades of experience helping organizations “energize” their workplaces, Michael introduces the 10 energy sources—the core drivers behind truly successful and sustainable programs. Michael emphasizes the importance of safety programs that resonate with workers, engage teams at every level, and drive lasting success through leadership commitment and communication. He also shares how to revitalize existing safety programs to build a strong safety culture. Don’t miss this episode as we dive into the energized approach for real impact, putting safety in motion across your organization.

READ THE EPISODE

Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe, yet productive operations. For those companies, safety is an investment, not a cost for the C-suite. It’s a real topic of daily focus. This is the Safety Guru with your host, Eric Michrowski, a globally recognized ops and safety guru, public speaker and author. Are you ready to leave a safety legacy? Your legacy’s success story begins now.

Hi, and welcome to the Safety Guru. Today, I’m very excited to have with me Michael Melnik. He’s the owner and President of The Energized Approach that he’s been owning and running since 1991. Michael, welcome to the show. Very excited to have you with me.

Well, thank you, Eric. Happy to be here.

Let’s get started with a little bit of how you got into safety.

I got into safety through the back door. I’m an occupational therapist and an exercise physiologist. My career actually began working in a clinic as an occupational therapist. I was working with people that had strokes and spinal cord injuries and different kinds of disabilities. But the clinic that I was in opened up what was then called a Work Hardening program, and it was a program for rehabilitating injured workers. These workers were coming in with back issues and shoulder issues, and we would try to replicate their work environments before we sent them back to work so that we could train them in ways to prevent re-injury. Sure. Well, we started visiting the work sites in order to better duplicate or replicate what they were doing We were walking around and looking around and going, Oh, my. No wonder you’re sending zero people. No wonder they’re getting hurt. Look at this environment. I stepped into that environment and out of the clinic, and I was just so much happier there. There It was just louder and dirtier and just a lot more adversity, for me anyway, that was attractive to me versus the clinic. Then they said, well, look, you’re teaching all of our people in your clinic how to do things differently.

When you’re sending them back to the clinic, they’re lifting better than everybody else. They’re doing all these stretches. Why don’t you teach our people before they get hurt? As a naive young therapist, I said, Sure, I’ll come do that. Lo and behold, I realized very quickly that none of the healthy people were interested in what we had to say. That’s where I had to affect my humor and making it very practical and just more geared towards an audience that on any daily basis isn’t waking up and going, I sure hope somebody comes in today and teaches us how to lift. Been doing it for 40 years. That was really the beginning of my safety career.

I think one of your observations when you started was that people were cycling through programs, going from one program to the next and hoping for something that was going to be a miracle cure.

Again, when I began, I was pretty naive because I was truly considered to be the lifting guy. They would call me up and say, Michael, our people are hurting their backs. Would you come teach them how to lift? And I was like, Oh, absolutely. And I would come in and I would do a fun high energy class, and they’d say, oh, thank you. That was great. And then I’d get a call a week later, and the company would go, well, nobody’s lifting the way you showed. I’m like, I’m not a hypnotist, and I’m not a magician. I just showed them something else has to happen because these are long-standing behaviors. They’re not going to change because I do a half-hour class. So that’s really when it was saying to them, look, rather than me coming back and just teaching it again and having it not work again, how about we look at why it didn’t work and why it didn’t stick? And lo and behold, what we found was that means it actually involved involves supervisors and leadership and ownership to create an environment that takes the information that I was presenting and actually turns it into action.

I would say to them, they’d say, would you come in and teach our people how to lift? I’d say, I will under one condition. That means that everybody comes to this party because everybody’s got a role to play in these changes.

Tell me a little bit more about what was your secret sauce? What was the part that moved it from a training classroom environment to something where people would actually start repeating and doing?

Yeah. That’s a great question because it was really a fun journey for me. This is the point typically in the story, if I’m ever able to relay this story to people, if they’re ever curious enough to want to know, is that I’m a selfish consultant and I’m a selfish presenter. What that means is I don’t want to do it if nobody wants to play. I don’t want to do it if nobody wants to be there. I was looking at it and saying, okay, well, wait a second. Management really only wants to know how much it wants to cost, and they don’t really want to be engaged. The supervisors are telling me they’ve got other stuff that they need to focus on, and this isn’t that important. The employees are going, hey, if management and supervisors are not interested, I’m not interested. I’m just going to do whatever gets me my paycheck. I started going in and talking to my clients, and they’d bring me in to say, hey, can you help us with our safety program? I’d say, well, what have you tried? And they’re going, well, we tried this one, and we tried this and this one.

And I said, well, I don’t want to be the next program. It doesn’t work. Let’s see what we can do. So, the thing that I did, and this is really where everything changed for me, is I said, I pulled out a flip chart, and I said to this group of managers, I said, do me a favor. The thing that you are most well-known for, and it might have been a company that did, let’s say on time delivery. Sure. That was really their claim to Fame. I said, I don’t want to talk about safety. Let’s talk about what you do on a daily basis for on time delivery. What are the things that support that? They started listing their commitment systems and their communication and their consistency and their accountability. They had all of these systems. I said, okay, now, let’s talk about your back injury prevention. I pulled out another flip chart, and I said, tell me all the things you’re doing for that. All it had on it was a poster and a video. I said, okay, let’s just review these two flip charts, and you tell me which program is going to be more effective, and which one isn’t?

I did that with several of my clients, and there was this amazing consistency between what their successful programs had across the board and what their unsuccessful, mostly around safety, programs were lacking. I said, I’m not here to teach you how to do anything significantly differently. I’m only asking you to take what it is that you have demonstrated works. It It made your on-time delivery work. It makes your quality assurance work. It makes all the important programs really work well. If you’ll take some of those and bring them over into the safety world, I think that you’ll find that you have more success. Lo and behold, we came up with a system, and I actually did this in conjunction with my clients 20 years ago. We came up with what’s called an energy assessment. What we would do first is we would do an energy assessment on their successful program. Programs, and we would score them and sit there and go, what are we doing on commitment? Oh, my gosh, we’ve got this policy and this procedure and this reinforcement and this. I’m like, okay, let’s call that a five. What are you doing for communication?

Oh, my God. We’ve got it in several different languages for our multilingual people, and we’ve got all this. I’m like, Let’s call that a five. And we created a benchmark with their most successful programs. Then we said, now let’s go look at safety. What are you doing in the way of commitment? And they’re like, Well, that’s more of a two. Okay, programs in a two are not going to work. We got to get it up there to a higher level. What would be the things you could do on a daily basis that would demonstrate some level of commitment? And over time, we’ll then go out and rescore this and see if you’re making progress. And so, things like recognition and inclusion and flexibility and creativity, these things are things that most of my clients already… These weren’t like new terms. Sure. If I would ask about the terms, they’d go, let me show you what we’re doing for our on-time delivery. We’re super creative. I’m like, Well, you’re super creative in that. You’re showing the same video in your back injury prevention that you showed in 1984. I said, That’s not very creative. And so, we’re going to give that a one.

All right. And can we bump that up a notch? So, the energized approach, the way we talked about it, was sitting there going, and my clients got this right away, that if I go out and I say to supervisors, we’re bringing on a new program, what typically is their response?

I love it. I wanted…

Here we go again. It’ll go away soon. It’ll whatever. And what they’re describing is the energy that it’s going to take for them to try to get engaged in this. And I’m like, if your programs are coming out of the gate, sucking energy out of people, you’ve already lost the game. I don’t care how good the program is. The energy is not there. So, my career, the last really 20 years, has been working with organizations to say, Let’s create fertile ground for your programs. I’m not the guy that’s going to help you pick the best program. I’m the guy that’s going to help you package it and deliver it and support it and reinforce it and create an environment where you are destined for success no matter what. And if there are holes in the program or it’s not doing as well as it should, you’re going to have a process, the energized approach, that’s going to help you identify where are the weak links and why is this not performing?

I love this contrast of a program that you do really well, like when you talked about on-time performance, because every organization is really good at certain things. Then contrasting that with the safety program in general and just seeing what’s different in terms of how we bring this to life. I think it’s a very simple concept, but it’s very powerful.

Yeah. In all honesty, truthfully, it was totally out of selfishness of going, how do I reduce resistance? How do I reduce pushback? I’m not coming in to fight with you. I want employees engaged. I want them having fun in a trading session. I want employees in all due respect to all the other programs companies do. There’s typically only one program that is for the employees, specifically. True. And that’s safety. And yet it’s the least popular. From the employees. I’m like, Oh, my gosh. I have employees tell me all the time. They’ll say, Michael, you are one of the funniest safety speakers I’ve ever had. And I said, you got to understand, that’s not a compliment. It’s not a compliment because the R is so low for people going, safety is fun and enjoyable, and I appreciate it. It feels personal and engaging. I rarely hear people say that about whatever their existing program is. And quality control Soul does not have to be fun or engaging. It’s your job, do it, we’ll give you a paycheck. On time delivery, do it or you don’t work here. Safety is an invitation. We can’t make a person be safe.

We have to engage them and invite them and get them energized around it. We do that all the time with our kids. We do it with our family members. We want to make sure you’re not driving home if you’re not feeling safe or you had too much drink or whatever it’s going to be. We don’t sit on the and go, God, I really should tell them to be careful that I’m so comfortable right now. We don’t do that. If I’m an employee and I don’t see the company putting forth the energy to keep me safe, what message is that? That’s saying, you do not have the value for me to put out the energy to do that. In many instances, what I’ll tell my clients is, I’m not saying you have to care about this person. I’m saying, you need to learn to act like you do.

Ideally, you can actually like the person and care about them for a real reason.

I just love it if you actually like them. But I’m going to at least show you by the way you can do this stuff to have a person watching what you’re doing in the name of safety and actually say thank you and appreciate it instead of here we go again. It creates such a different environment than the typical program that’s coming in.

Awesome. When we spoke before, you mentioned 10 energy sources as part of your energy. Yes. Can you tell me a little bit about what those 10 energy sources are? What are you trying to get to people to reflect against those programs? How you found work?

Well, and again, these really were energy sources. They weren’t called energy sources before I grabbed them and did this, but they were core ingredients of my client’s successful programs. The first one was commitment. The first question I ask every client in an opening interview is, I’m just curious, has your company ever started and then stopped a program in the past? Sure. They’re going, Oh, my God. We do it weekly. I’m like, okay, so I want you to imagine now being an employee watching this ping-pong of starting and stopping and starting and stopping. If I’ve been there for 20 years and you say, hey, we’re introducing a new program, how much am I willing to invest in it? If I think it’s not going to be here in three months, I’m going to look silly. I’m going to actually wait until you’ve demonstrated the commitment, and then I’m going to get on board. And then we talk about what would make it look like you’re committed. Communication, the same thing. I’m like, if you’re walking through your facility and you see somebody doing something inappropriate and safe, number one, do you say anything? If you don’t, that’s also communication.

Absolutely. You are telling them it doesn’t matter to me. But the other thing is, how many of your employees are working safely? How often are you communicating with them about that? Because those are the people you have got to keep motivated. They’re sitting there going, I think the only way to get communicated with here is to do something wrong or to go slow or to break something. It changes the role of a supervisor. I’ll tell you a quick story. We gave us supervisors that accompanied these little business cards. On one side, it said, Thanks for making this a safer place to work. On the flip side, it was like 25 cents off of something in the cafeteria. Every supervisor started the day with a dozen of those in their pocket, and they were told, Go finds 12 people that are keeping this place safe. Thank them. So, part of their job became finding good things to talk about. A supervisor told me once, he said, Michael, I handed a card to a guy that was wearing his safety glasses because we just started a new safety glass policy. I handed it to him, and I just walked away.

One of the other employees saw me hand it to him. He goes up to the employee that got the card and said, hey, what happened? The employee said, oh, I just got this little coupon thing because I’m wearing my safety glasses. The other employee said, well, I’m wearing my safety glasses, too. The guy said, well, you’re just going to have to work harder to get caught. It’s creating a want to get caught environment instead of trying not to get caught, be an unsafe environment.

That’s a fair point. Most safety programs are all based on catching you do something wrong, and it’s all in the negative, but you also need to focus on the positive. What are the things people are doing right? Yeah. Absolutely.

Absolutely.  

This episode of the Safety Guru podcast is brought to you by Propulo Consulting, the leading safety and safety culture advisory firm. Whether you are looking to assess your safety culture, develop strategies to level up your safety performance, introduce human performance capabilities, re-energize Organize your BBS program, enhance supervisory safety capabilities, or introduce unique safety leadership training and talent solutions, Propulo has you covered. Visit us at propulo.com.

Consistency is one, meaning if you’re going to say that safety is number one, then define for me what that looks like and then go do it. Otherwise, take the poster down, because you’ve got safety is number on a poster, and safety is not even on the scale in your environment. You’re forcing people to not look at the poster, or at least not believe it. Accountability. Do you have clear accountabilities for who’s responsible for what? Inclusion. If I’m going to go do training for employees, the first thing I’ll do is I’ll try to wander through the facility and talk to employees and say, hey, here’s what I’m going to be talking about. Have you heard programs like this in the past? Anything that really resonated for you?

Anything that you’d like for me to cover? Then when I launch the presentation, the first thing I say to employees is, hey, thanks so much for helping me put this presentation together. Now we co-own it instead of, I’m the expert, I shall now share my wisdom with you. Or I’ll say, you know what? I’m going to be here for an hour. It’s too long of a time to sit for an hour. How frequently would you all like to stand? Then I it based on what they’ve recommended. Otherwise, it’s me unilaterally deciding when you should stand. Then that’s more ownership than I want. It’s not my program, it’s theirs. Flexibility. If something’s not working, don’t keep doing it. They’ll sit there and go, oh, yeah, we’ve been doing it the same way. How’s it working? Not very well. I’m like, well, you don’t say that about productivity and quality. Our productivity is terrible, our quality is terrible, and we’re not doing anything about it. You do something about it almost every day, and yet you’re doing safety the same way you’ve done it for 30 years, they notice that. Sure. You are flexible with the important things and not as flexible.

The last one the last energy source of the 10 is actually fun. And what I tell my clients is, they go, well, you don’t want safety to be silly or over the top. I said, that’s not what I said. What I said is fun. Fun is an energy. That fun. The fun is the culmination of commitment and communication and consistency and accountability and flexibility. My clients, unfortunately, before I get there, have tried to just go directly to fun. They’ve skipped communication and consistency and accountability and said, well, let’s just have a safety banquet. People are like, but you don’t take safety seriously here. Why am I supposed to be celebrating it? Versus when all those other nine energy sources present, fun happens. It’s not like you’ve gone after it, it’s the culmination. All I tell my clients is, how about periodically, maybe on a monthly basis, at least, maybe quarterly, if you can’t do that, go do an energy assessment, look at your programs and just be asking, how are we doing on commitment? How are we doing on consistency? How are we doing on accountability? It just adds a layer to the conversation. I leave them with this.

I Look, when you’re putting together your programs, yes, you need your policies and procedures, you need your PowerPoints, you need your posters, you need your handouts. Just make one of the line items, do we have the energy we need to make this successful. In many instances, it will stop you in your tracks, and it will save you the pain and agony of pushing uphill against resistance that has nothing It’s not to do with the program itself. It’s that you haven’t created the environment that’s conducive to its success.

You’ve talked about the revolving door of safety programs. If somebody’s got a program that wasn’t launch with that energy, that enthusiasm, which I think there’s a lot of people who have programs like that. Is it easier to bring the energy to the existing program or is it better to start new and bring the energy to the launch?

That is a wonderful question. I’ve had both opportunities to do both. It really depends on leadership because I have worked with some leaders who have been willing to pull together a core group of employees and actually go, I’m sorry. I’m sorry. We are seeing how ineffective this has been, but we think this thing has legs. But we now know that we need to bring you in. We need to be getting feedback. We need to be flexible with the approach, and we’d really like to give this another shot. In many instances, the employees are just flabbergasted that they’ve even been invited to this party. They’ve never heard the management apologize in any way about, we were doing this wrong. We were doing this in effectively, but we don’t want to throw the baby out with the bathwater. I don’t encourage that necessarily. But I do say you got to be willing to unwind in other words, it’s like you can’t just start tomorrow, and now the energy around it’s going to be all positive. You have to unwind some of the negative energy, and it’s going to take a little while to do that. From that standpoint, it is often easier to be starting from scratch and sitting there and going, hey, you know what?

We’ve got a new, let’s say, employee assistance program that we’re introducing or whatever it’s going to be. Let’s get the employees engaged in this. Let’s really take a look. Let’s ask the right questions. Let’s be flexible. Let’s include the right people. Let’s talk about, ahead of time, how we want to demonstrate commitment. Let’s not wait till somebody goes, oh, I don’t think they’re doing it anymore. Let’s already know what we’re going to do. It just allows you to come out of the gate without any of that resistance, as much resistance. The other beauty of it is, when I tell employees or employers that that’s the energized approach, the groups that I do the training with and I do the meetings with, that I do the meetings They’re the only ones that really call it the energized approach. To everybody else, it just looks better. It just looks like, oh, they’re just doing this better. This is more fun. This is more engaging. The communication around it is better. But they’re not associating that with a program. The energized approach is an approach. It’s the packaging. It’s not the program.

It reminds me of many moons ago, General Electric used to have something they called the change acceleration process, and they I thought it was a beautiful equation. It basically was Q times A equals E. This was particularly in the quality movement days. They would say quality of the change times the acceptance of the change equals the effectiveness of that change. Obviously, if you have a lousy quality of program, then nothing’s going to work if you have zero on that or one. But you actually don’t need the best program, 10 out of 10, let’s say, if you don’t have acceptance. You’re really focusing on; how do I get that acceptance? In some ways, you’re better off having a good program, but excellent acceptance of that program.

Absolutely. I, very early on in my career, I had grown up in school with everybody saying, Here’s the right way to lift. Sure. I started taking this into companies and finding out that the majority of people, knee problems, back problems, limited flexibility, impaired balance, whatever it might be, can’t lift right. But I’m not trying to create bodybuilders, and I’m not trying to create Olympic weightlifters. And so, I shifted completely to, can you lift better? Can you actually minimize or reduce the demands? Here’s a few principles. And what I found was 100% of my audience could lift better, and none of them were pushing back because all of them were having success. Versus Well, I can get 5% to lift right. Sure. 95% are going, I can’t bend my knees like that. I can’t do whatever. I think that, once again, it’s the idea of going… It’s really about empathy. And sitting there and going, if we’re doing safety, who’s it for? I’m going to pretend like I’m sitting in the class that we’re getting ready to deliver to them. Is this going to feel good? Is it going to feel personal? Is it going to feel like it’s for me?

Or is it going to feel like this is something that’s actually being done because the company needs to cross this off the list for the insurance company or for OSHA or for whatever it might be? As soon as you step out of your own skin and step into the audience and go, as we build this program, I’m an employee. What would feel respectful to me? What would feel like good communication? 100% of the time, they know the answer. They haven’t been doing it, but they know the answer. But it’s more work. It is more work. Again, I leave it with my clients, and I tell them, look, you can keep shopping for programs, and because you have the budget for it, that’s going to feel like an easier thing for you to do than what I’m going to ask of you. Because what I’m going to ask you of is going to be change and communication and hearing feedback, whatever. I’ll be honest with you; it is harder to do. The payoff is much bigger, but it’s harder. Yeah.

Tell me a little bit about the way you implement to make this work. Obviously, you talked about the energy assessment, getting a baseline, getting a sense in terms of what core skills, capabilities the organization already has to make things go really well. Tell me a little bit about other parts of the secret sauce.

Well, I’ve been doing this for over 30 years now, and I can’t cold call a client a potential client and sell myself because they’re not in the place where they’re going, Boy, I really would like to do some change. I’d like to make things a little bit harder. I’d like my responsibilities to change. I’d like to have to communicate more. Almost 100% of my clients have come from me presenting somewhere, and then it resonated. I may be at a national safety conference; I might be at some other regional conference. More often than not, One, two, three, five, however many, a handful of people will come up and go, oh, my God, we need you. I’ll say, all right, well, we’re going to do a preliminary assessment. I’ll either get on a conference call with a bunch of people or whatever, and I’ll lay out the process. We call it an energized approach to maturity assessment. All it means is, do you want to play? Are you willing to make these kinds of changes? What What’s the level of communication that you have throughout your organization currently? How have you implemented things in the past? And let’s play pretend, and let’s talk about the kinds of things that I may be coming in with, because what you don’t want to do is I don’t want to come in and upset the apple cart.

I don’t want to create conflict for you. I don’t want to create anxiety for you. I want people to be hungry for this stuff. So, let’s just see what the appetite is. That being said, I’ve never done any two clients at exactly the same pace because their maturity level for doing it or the population that they have, they’re not all the same across the board. So it might be that I’m working with one client on one energy source a quarter. And all we’re going to do is go, can we spend the next quarter having our employees go, wow, they are really committed to safety. Boom. Knock that energy source out. Let’s go to the next one. Now we’re going to look at consistency. What you say becomes what you do. What are the different ways that you can make that happen for the next quarter? So it might be that it’s a yearlong process. There are others where over the period of a quarter or maybe even over a month, we knock them all out because they really only were lacking in three.

Sure.

Let’s really hammer those home. But it does require leadership commitment.

Of course.

I spell out for them, what does that look like? It’s not going to be extraordinary, but you cannot… If you start this and then pull the plug on it, it is going to bite you. You really got to decide, we are going to stay in this We’re going to get the feedback. We’re going to make the changes that we need. But what I let them know, too, is you can make those as small as you want. Because if you typically walk by somebody in the hallway and you never say anything to them, in fact, even look away for five years, and then one day you walk by them and you just give a nod, you’ve just increased by 100% the level of communication with minimal effort. We talk about What are the minimal things that you know you can continue to do that will reinforce these things? I’m not asking for anything extraordinary to begin with, but what you’re going to find is when the responses from employees and supervisors are really positive, that’s going to energize you to want to do more of that because you’re going to like that result.

For sure.

So, it becomes a loop. It becomes a loop.

Excellent. Michael, thank you so much for coming on sharing your story. If somebody wants to have more details, learn more about the Energize approach, how can they do that?

Well, there’s multiple ways to reach me. My website is just energizedapproach.com. What’s also on there, and I love to talk to people about this stuff. Anybody that’s listening to this, it probably could tell that I like to talk this stuff, and it never notice. It really excites me.

Never noticed.

They can certainly give me a call at 612-940-3242. Happy to take people’s calls, or it’s just [email protected]. is my email.

Perfect. Sounds good. Thank you so much for coming on the show. I appreciate you sharing a story, and I very much agree your approach to how much energy is it and how you contrast it to the things that people are able to do well inside an organization, and how do you bring that into the safety arena?

Eric, I appreciate the opportunity to talk to your listeners, and hopefully I’ll hear from some, and we can continue the conversation.

Excellent. Thank you so much. Take care.

You, too.

Thank you for listening to The Safety Guru on C-suite Radio. Leave a legacy. Distinguish yourself from the past. Grow your success. Capture the hearts and minds of your teams. Elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafetycoach.com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting.

ABOUT THE GUEST

Michael Melnik is an occupational therapist with a master’s degree in exercise physiology. He is the owner and president of The Energized Approach, a company that helps organizations “Energize” their workplaces, their safety programs, and their people. For more than 30 years, he has presented his practical, high-energy, and humorous approach to more than 750,000 participants around the world. He is the author and talent in several award-winning injury prevention videos that are used by thousands of companies, and is the creator of the ReachOut365 Video Coaching Platform. Clients include Delta Airlines, The Home Depot, Coca Cola, Wells Fargo, PetSmart, Wal-Mart, Willis Towers Watson, Best Buy, Exxon Mobil, and many more.

For more information: www.energizedapproach.com

Email: [email protected]

Ph: 612-940-3242

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Rethinking Ergonomics for Safer Workplaces with Robert Pater

Rethinking Ergonomics for Safer Workplaces with Robert Pater

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ABOUT THE EPISODE

Discover how to keep your workplace safer, stronger, and more in control—one smart move at a time. In this engaging and informative episode of The Safety Guru, we welcome Robert Pater, founder of MoveSMART®. Robert brings a unique perspective, blending martial arts principles with cutting-edge safety and ergonomics to explore how internalizing mental and physical safety practices can elevate your safety culture. Drawing on decades of expertise, he shares practical strategies to rethink ergonomics for safer workplaces, engage senior leaders in safety initiatives, make safety changes easy to boost compliance and effectiveness, and tap into “eureka moments” that enhance learning retention while driving deeper, lasting behavioral shifts. Don’t miss this conversation packed with actionable ways to reduce injuries, improve ergonomics, and empower workers to take control of their safety.

READ THE EPISODE

Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe, yet productive operations. For those companies, safety is an investment, not a cost for the C-suite. It’s a real topic of daily focus. This is the Safety Guru with your host, Eric Michrowski, a globally recognized ops and safety guru, public speaker and author. Are you ready to leave a safety legacy? Your legacy success story begins now.

Hi. Welcome to the Safety Guru. Today, I’m very excited to have with me Robert Pater. He’s a founder Managing Director of Movesmart. He’s authored well over 370 articles in safety. Robert, really excited to have you with me today on the podcast. I think we’re going to have an exciting conversation I have.

I’m looking forward to it, Eric.

Excellent. How did you start in safety and into this quest of 370 articles plus?

Yeah. This goes back because I’m not a spring chicken any longer. A long time ago, I was coordinating the Stress Management Center of a Hospital. Let me back up a little bit. My undergraduate degree is in organizational development and Leadership Processes or processes as a Canadian. Then my master’s degree is in industrial psychology. I learned when I was studying industrial psychology about the early ergonomists, Gilbreath, Sam Taylor, and all of those people. I went, wow, this is very similar to what I was doing in my practice of internal martial arts. I was struck by that. Fast forward, so I’m coordinating the Stress Management Center of a hospital in Portland, Oregon, where I live. The occupational health nurse said, hey, Robert, you are doing anything this afternoon. No. I said, well, there’s the Oregon Governor’s Occupational Health and Safety Would you like to go? It happened to be literally walking distance from the hospital. It was like two blocks away at that point. I went there, and this is one of the times you didn’t have to register in advance. This is quite a while ago. I was very, very disappointed in what I saw because people were reading stuff.

They were like, why are you reading? Why don’t you just give it out? The papers and stuff like that. There was nothing what I call innovative there. I went, Okay. I looked at the brochure and I saw who was running it, and I contacted the person after this conference was over and I said, hey, can I do an RFP, Request for Proposal? Because I think I can do something that I might add because I was doing a lot of training at the time. The organization is quite a bit but based on my background. They said, well, do you know we do this every other year? No, I didn’t know that. I’m clueless. He said, Tell me about yourself. I told him, he said, would you like to be on the steering committee? We would love to have higher level training and safety. It was quite a while ago. So, I said, Sure. And I thought that was very impressive, except anyone he could rope in to be on the steering committee, he was happy to get in. I was like, Meat, fresh meat. So, I did this, and we’re sitting around because it’s every other year in Oregon, it still is.

We’re in a bi-annual, basically budget, so it’s a bi-annual conference. So, we’re sitting around, and I knew a lot about the martial art that I was doing then was a jiu-jitsu system, and I was a third-degree black belt in at that point. I had my own views when I was teaching this about what to do, how to prevent fall, how to keep your balance, what to do if you do fall. I said, What about something on slip trips and falls? And all of these corporate safety people were going, wow, I’d love to see something new and different on slip trips and falls. I went, and I didn’t even know it was an issue. I started researching it. Shortest version is I pilot it with an organization I was working with. I got there and I said, well, how many handouts should I bring? I said, I don’t know. Before they knew how many signups there would be. This is all different now. And they said, Bring 15. Well, I was a Boy Scout, and the motto when I was a Boy Scout was be prepared. And my motto was, you could never be prepared enough.

I brought 30 and 300 people showed up. They had to open up the rooms, the dividing rooms in this hotel. I went, wow, and I started getting hired. That’s the short version. My very first article that I ever wrote was published in the June 1985 issue of Professional Safety magazine, a motion training and Analysis for the ’80s. It shows you how long ago that was. I’ve done a reprise on that, and that got me started. I started getting hired right away, and then pretty soon, somebody sent the American Society of Safety Engineers, which is CSSE’s sister organization. Sure. Now, they changed their name a few years ago to American Society of Safety Professionals. But the person who was in charge of continuing Ed back then, contacted me. I didn’t even know who he was. He said, I hear you’re doing stuff on ergonomic-related things. Yeah. He said, we need somebody to do continuing education courses in ergonomics, three-day courses. I said, Well, I’m not a traditional ergonomist. He says, oh, I could get a lot of people to do that. I want a different approach. That’s good. So, they hired me, and I went around North America doing three-day programs on ergonomics.

I said, this is what I know about. This is what I don’t know. I was like, Shit, we’ll talk about this. But ergonomics is, and I’ve learned a lot more since then, as you might expect.

Yes. So, let’s get into what is ergonomics and why is it so critical?

Okay. Well, ergonomics to me is basically you’re dealing with among the most common injuries that people have. Predominantly musculoskeletal injuries, strains and sprains, whatever you want to call it, call different things, a communal trauma disorders, different things, but they’re super common. Even though they’re not usually considered a CIF, serious injury fatality, to me, it’s a serious injury because of the numbers of injuries. If you look at the hit parade of every organization that have charted the most costly compensable injuries, workers’ comp or WCB or WSIB, if you’re in Ontario province, injuries in the United States, anywhere, you’ll see soft tissue injuries are at the top of the It is the leader on the hit parade over and over again, and people who try to do all things. So, one thing, cost money. Two, organizations are working thinner, which they are nowadays, it reduces productivity. Organizations are turning down work because they can’t cover it. Some organizations, they can’t hire enough people to do that. It affects not just people, which is a fallacy. People often think binarily where they think, well, you’re either injured on a claim or you’re Okay, you’re 100%, like a life switch.

But this is more like a dimmer switch where people have varying degrees of impairment. People have been working for a while, especially as they get older, and especially in Western Europe and in North America, the workforce has been statistically aging. The longer you’ve been working, the longer you live, the more likely there’ll be cumulative trauma that wears you down. There are people who work, and it’s not a question of doing this because they’re out of touch, but they basically are working impaired. They might be working 75% or 60%. That’s the top, like a battery as it ages, as it wears down its maximum capacity. There’s a lot of factors about productivity, about all of impairment, and it affects other people. Co-workers have to pick up the load. So ultimately, this is a major injury source. So, what we deal with are three types of injuries, personal injuries. Soft tissue injuries is the number one thing we deal with. Two, slip trips and falls, and three, hand injuries. And these are all movement-related injuries that are intimately related in our mind.

Excellent. So, tell me a little bit about I know when we talked, or initially, you talked about how this space has been hijacked. Tell me a little bit what you mean by that and how you look at improving the fit between people and the work that they’re doing.

Okay. To me, hijacked is, you’re right, I did use that word, and that’s a little strong. I think it’s going to be people offended by that. What is the expression, if you have a hammer, the world looks like it’s filled with nails? A lot of people, if you look at the early ergonomists, around the turn between the 19th and 20th century, there were people who were focusing on movement, as I said, Frederick Taylor, Frank and Lillian Gilberts, and all of that stuff, and many others. But ergonomics really came to play. If you look at the history, During the War II and cockpit ergonomics in the Korean War, and it became an issue of design, which is really important. To me, what many people call ergonomics, they default towards designing the workplace and the workstations and tools to fit tasks, workers and the tasks that they do. I agree with that. That’s one part, though. The thing that I take issue with is that that is not the only part of ergonomics. If you look at ergonomically certifying organizations, they acknowledge that now at this point. I define ergonomics, and the word ergonomics does not mean design.

It means literally ergo, which means energy or work, I think from the Greek, I believe, might I say it might be the Latin, I think it’s the Greek. And nomics means study of or science of. And so, it’s a study of work or energy. It’s not design. I define ergonomics as improving the fit between people and their tasks, at work or at home, whatever it may I believe there were three ways, three strategies to do that. See, if you define that as design, all you can do is design things out, buy new tools, that you have no other actions in your toolkit. Whereas This way, the first thing always should be designing out risks that you can design out. I absolutely agree with that, but that’s only the first step. The reality is, what do you do when people are working from home or they’re working on a client’s surf or they’re walking in the parking lot where you can’t cover the entire parking lot and stop it from raining and being wet? To me, the second aspect is that the first aspect is bringing work closer to people by, again, design and purchasing, basically.

The second aspect is bringing people metaphorically closer to work by helping them make adjustments the best they can. The third is the ideal, which you do both, like two hands clapping together. We believe that the highest-level ergonomics is a combination of first design and purchasing out what you can, realistically, but not stopping there. Our Bailiwick, because there’s a lot of people who are really good at design, is basically helping people make adjustments to areas that are not cost-effective. I could give you lots of examples of that. At home, you can’t design up people’s exposures at home where they may get cumulative exposures and cumulative trauma.

Or even if you think about maintenance repair workers that are going to different sites, utility workers that are digging or doing work above ground. If you’re an electrical utility, it’s not a controllable environment.

Absolutely. Great examples, Eric. We’ve worked with those people a lot. In fact, often have gotten called in, initially at organizations by the maintenance professionals because they have no control of where they have to go in their awkward positions, and they can’t say, well, let’s read it. Well, you can’t shut down the whole facility. To redesign that, it’s not cost effective and not likely or if it is, it’s not within their power. What do you do until then? I agree.

Right, exactly. I have read some of your articles where you talk about the martial art of safety. You talked about your jiu-jitsu background. Tell me a little bit more about the martial art of safety, what it means to you, and how that links into Move Smart. Okay.

For me, there’s different types of martial arts, and this is just my opinion. I’m not saying I’m an expert. I’ve been doing this for quite a while. One of our directors of Move Smart training is, in my mind, a martial arts master. But I’ve done this quite a while, and I’m going to do some things. But to my view is that… Oh, by the way, I’ve written a book on martial arts and leadership that’s in five languages, neither here nor there. I probably out for it. To me, the martial arts focus that we look at is what I call, and not just me, internal martial arts. What internal martial arts deals with is direction of energy. It incorporates both mental and physical skills. It’s not, how do you beat up people? How do you get the strongest, the fastest that you can do? It’s how can I redirect forces? But redirecting forces in internal martial arts starts from within. If you can’t… One of my martial arts instructors said to me once, Hong Chou, Wing Shong kung fu, said, If you can’t control your own temper, you’ll never be able to fight effectively. If you can’t calm yourself down.

So, you have to start within. And that is another quote from that, which is great, which is great. The Philippine approach in martial arts with the guy that studied with a little bit said, I asked my master how to make this world a better place. He said, Develop yourself first. I believe that internal martial arts, as well as highest level safety is an internalization process. It starts by changing people’s minds so that they can be more in control of themselves and their own safety. It deals with mental and physical skill sets, of which I can talk about if you want, it doesn’t matter. But that our people can learn and they can apply everywhere that are portable, that are not based upon working on somebody’s providing for me, but when something unexpected happens, I still have skills I can use and apply Not that it means it’s going to fix everything, but I can do the best I can. We tell people, if you’re in a very poorly designed environment, you’re never going to… With your best skills, you’re never going to make that a great workplace, but you make it less bad. Maybe if you could put the odds 15 or 20% more in your favor of not being injured, that’s the best you can do.

That’s better than nothing. 100%. You’re not a victim. That’s basically what it is, it’s like having better control of yourself. We have a catchword phrase that we talk about is safer, stronger, more in control. So, we’re more in control of ourselves first. Does that help? Give you an idea?

Yeah, very helpful. Yeah, absolutely. I think that also gets into some of the pieces we started out with in terms of the learning and development and how you drive skill sets around this.

Absolutely. That’s one of the things that I feel very, very strongly about. Like, martial arts are not based upon… I mean, you have to start with an attitude, which is, to me, the other word for mindset. You go in there with the right attitude, but you still have to have the skills. You have to know what to do in situations. It’s not enough. It’s critical, but it’s not enough. It’s a precursor. Then you have to have the mindfulness of what’s unique about the situation, and you have to have the skills to be able to deal with that, go, oh, I haven’t even counted this before. What might I possibly do to make the situation better or at least less bad for me, less risky.

This episode of the Safety Guru podcast is brought to you by Propulo Consulting, the leading safety and safety culture advisory firm. Whether you are looking to assess your safety culture, develop strategies to level up your safety performance, introduce human performance capabilities, re-energize your BBS program, enhance supervisory safety capabilities, or introduce unique safety leadership training and talent solutions, Propulo has you covered. Visit us at propulo.com.

When we last connected, one of the things you talked about that was really important is how do you get senior leaders engaged in these programs. You had a cool story about golf and how you use that as a connection point. Tell me a little bit about it, because that’s a big part of what’s missing is I see a lot of programs where they teach something on ergonomics, and then it falls apart.

Yeah. One of the things that we believe strongly is that the best way to develop internal motivation for safety, to internalize safety, is to hook into people’s already existing motivation, as opposed to try motivating them by what you think is important to them or what you think should be important to them as a safety professional or leader.

100%.

And so, this story, and I could give you lots of examples like this, but the story about this was I remember going to a large manufacturing organization. There was a guy there, and we’d done a bunch of move smart training, and the guy came in there and he was angry with me. I was perplexed because it got really good reception, number one. Number two, what we did, and number two, injuries started going down by a lot. People were using it. They could calculate. They could see the leading indicators as well as the trailing indicators. And he said, Come here. And he closed his door, and he pointed to a diploma on the wall, and it was a PhD. He had a PhD in ergonomics. He said, I got a PhD in ergonomics. What do you get? And I said, I just have a master’s degree in industrial psychology. One part of that. I said, you know? And he said, well, how come they’ll listen to you and not to me? I tell them to bend their knees. I said, and what I wanted to tell him was that… Because I am not telling them anything.

I’m letting them discover this and letting them decipher themselves and figure that out and make their own decisions and show with methods that we’ve developed. And I said, But I said to him, it’s like we try to do this so it’s interactive and let people try to figure it out for themselves through guidance that we give. He still wasn’t very happy with me, but he persisted on wanting to be the person who was dictating writing and telling, as opposed to bringing it out from people. And there’s been, subsequently, been a lot of studies in neuroscience that when people have self-convinced, they learn faster, and the learning stays longer. There’s a great article in Scientific American by… Her last name was Solie. She got a PhD in neuroscience herself, and she quoted other studies on this and self-convincing is the way to go. We’ve been doing that for a long time. It’s the basis of martial arts. If it doesn’t work, It’s useless. It’s got to work for you. Even if it works for him and her, it doesn’t work for me. It doesn’t matter. That’s what we focus on. To me, the key with senior management and everybody is hook into their personal, again, existing motivation.

The mistake in my mind that a lot of safety and ergonomics professionals do make is they make an assumption, which ironically is anti-ergonomic, is that everyone has a one-size-fit all motivation system. Every senior manager is only interested in bottom line, how much money do I save? I’ve run into a lot of managers who are more concerned about keeping people at work. I met some who were more concerned with morale when morale was plummeting or It’s productivity, whatever. Maybe it’s not just workers’ comp claims to be reduction. It’s not to the absence of payouts. What we have learned is that if you can find what people are really interested, such as in this particular case, without going into it, finding that a senior manager who could be less interested in ergonomics or safety, frankly, or minimally just theoretically interested. But when I saw that he had a golf club, a driver, and I mentioned that, I said, would you like to see something that might work better for your drive. All of a sudden, he gave me all the time in the world because I hooked into… I was lucky. Just happened to be. Dumb luck.

That is the key. That’s one of the reasons, by the way, we believe for anybody out there, make ergonomics focus not only on work and prevention of injuries at work, but what can you do at home? Not only injury prevention, but what can I get out of it? What are the benefits to me beyond the absence or reduction of prevention of injuries that I may never believe will really happen to me. That’s one of the critical aspects. Then the other aspect, I’m bringing this down, there’s a lot, too, but make it easy for people to change. I believe that… I run an article once; I make it easy leadership. I believe that the key to a successful leadership in general is, one, make it easy for people to change. The less I ask for people to do, the better. The 15 minutes I get with senior managers is better than the 2 hours I really wish I had that I’m not going to get or they’re going to be on their computers. So, what can I do in the time they’re lot of? The less I ask of them, the more they’re likely to do it.

Secondly, make it easier for them to help me get better at what I do. Those are really the principles that we operate with, and it seems to work.

I think the part as well is the more you connected with the individual. I was actually just talking earlier today to a CEO who’s comparing two different leaders, very senior leaders, and how one of them was able to get a very strong engagement through and through in safety all the way to the grassroots, the engagement, the involvement, versus the other one is equally committed to safety, but for some reason, they’re still struggling in the middle. The main difference between the two leaders is one is just very personal, makes it their own. They’re both equally committed to safety, but this one connects with everybody, like you said, makes it personal with everybody. It’s personal to him in terms of how he shows up. The result is, lo and behold, in a two-year period, huge, huge shift in terms of people seeing my leaders is committed, seeing their supervisors are committed, and showing up for safety, and they care about their personal safety, whereas it was nothing like those two years prior. It had that impact through the entire organization, just by buying into it, showcasing it, making it real.

Great example, Eric. Seeing very similar things. To piggyback on that even further, the type of injuries that we’re dealing with, again, soft tissue injuries, slip trips, and falls, and hand injuries, are Personal and everybody, I don’t care if you’re a senior manager, everyone is prone, and their families are, too. This is the example that I always find about ergonomics. It is a leveler, a potential leveler in an organization. The type of exposures and risks people have and the injuries that people have. It does not matter if you’re sitting behind a desk all day and have shearing forces from sitting too much or you’re traveling and carrying suitcases. Everyone is prone. Great example, Eric.

What do you do to get those leaders to get personally involved? Because I think in our prior conversation, hopefully I’m not confusing conversations, but you were mentioning I’ve seen multiple programs through and through. They look the same, but some work and some don’t work. They just would go through the flavor of the moment, change it every year or so. But it’s not about the program, it’s about how leaders show up.

Yes, I think that is really important. Now, one of the things that we do differently, and this comes ultimately from my background in organizational development, industrial psych, is that we don’t believe in training, for what we do, at least. When I think that as of training, where one person, a so-called expert, imparts information to other people and expect them to go ahead and do that. The problem with that for us is the type of, again, injuries that we address are based upon people who have long-standing habit patterns. People have lift, pushed, pulled, walked.

The same way forever. Exactly. Use their mouse the same way forever.

Exactly. So, one shot exposure for a multiple exposure injury over years and years and years at a habitual are less likely to make a difference. So, one of the things that we believe is develop leadership internally in an organization. I’ve written on this, too. The only thing we do at this point is we work with organizations, and we train, we call them instructor catalysts, internal catalysts, to first do initial training, then to go ahead and often coach and reinforce this on an often very basis that’s informal. Sometimes we find the best type of reinforcement are in the break rooms or in the parking lot, and the supervisors just talking during the meeting, five-minute meeting, that’s about something else, a different toolbox meeting. Then formally, how do we keep this alive on an organizational level? That makes a huge difference that organizations are flabbergasted by. If you can get people to become committed, excited advocates, internal advocates who actually have skills that people haven’t seen and can do and do something differently, it goes a long way. That’s one thing. But often senior managers will often be extremely excited this, too, because, again, they’re individuals first.

Approaching them as individuals, just like you said, focusing on a personal level is critical and structurally embedding that in the organization. It’s not relying upon someone like me to keep coming back to them. Because we work with huge organizations. We’re small. We can’t keep coming back to United Airlines or US Steel or Hans or some of our biggest clients over a long period of time. It’s not cost-effective. We don’t have the manpower or the interest in doing that. We want to decrease dependency on us and try to create internal dependency, both not only within people, but also within the organizations. Does that answer at all? Yeah, it does.

I think the other part that makes it challenging with ergonomics is the… Like you talked about, there’s a habit that goes on for a very long period of time, but the cause-and-effect relationship between the actions I’m taking, and the result takes a very long time to actually get it. Once you get it, it’s a problem, its pain, and it’s very hard to go backwards.

Great example. Can I hook up on that a little bit? Yeah, please. Okay. What we often, I even talk about that often these injuries are the straw that broke the camel’s back. You’ll hear and see people, maybe it’s happening to people listening is that you do something that you’ve done thousands of times before. Pick up a shirt off a bed or a piece of paper on the floor and you, quote, throw your back out. Well, it’s not because of the weight of that, it’s the compounding motions of the again, straw that broke Campbell’s back. It’s cumulative trauma. There are studies on this that show a lot of soft tissue injuries are cumulative trauma based. So, think about the positive aspects. Why instead, if I found ways to make these motions in a safer manner so it didn’t build up over time? Well, the problem with that, just like you’re bringing it up, is that it’s not reinforcing to say, I’m going to do this to be safe. What we focus on, do this so you feel stronger. You can feel more balanced. You have more energy, again, emphasizing the benefits that people can really feel very, very quickly.

And so, they are self-reinforcing. When people are self-reinforced and they go, I’m very pleased. That felt good, they’re more likely, we think, to compound those motions again. And that’s what we base what we do upon.

And very linked to some of the work on habit formation and in terms of you need to get a shorter term, near term, recognition reward from doing it. And so, the injury is something in the future you don’t expect to have. But feeling stronger, feeling more energized is something near term.

More about absolutely, fully, totally agree with you. And in fact, we believe, we’ve created demonstrations where people feel immediate dramatic improvements in their balance and their strength and less force transfer to small of the back, for example. People go, Wow, it’s amazing. It’s incredible. That’s what we hear all the time. We’re used to it. But now we have to train and say, okay, how do you really use this? We in real life? I agree with you. Again, it goes back to the less you ask of people, the easier you make it for people to feel the difference, to make a change, the more likely they’ll continue to do that.

And that last piece you just mentioned gets me to Eureka Moments. We talked about that as well. If you feel instant gratification, recognition, tell me about the link to eureka moments and some of the research from Duke around the neuroscience of it.

So, we’re doing this in June. And recording this. And the, what do you call it, in May, so a month ago, Duke University came out with a study that was in Neuroscience News, which I subscribe to. I invite everyone to subscribe to that. It said, Here’s the title of it, take a Moment’s double memory by rewiring the brain. Basically, the study showed that so-called aha, where that insight, those moments of exciting insight, starts creating a massive change where people remember it and they will duplicate that. Again, according to Duke University quotes, rewire is the brain. That’s what we’ve been doing for a long time without those studies because we know it works. It’s human nature. A lot of studies come out and prove scientifically what a lot of people knew for a long period of time, experientially. That’s what we believe, and that’s where those immediate—that I talked about earlier about those immediate improvements in balance and strength and reduction of force and tension in areas that are uncomfortable come from. We’ve doing that, that really gets people’s attention from anywhere, from senior CEOs of companies down to people working offices all the way throughout.

If somebody wants to get in touch with you, so you’ve shared a fair bit about Move Smart and how you bring the martial arts to safety, how you engage your leaders to get better traction on programs, what’s the best way to get in touch with you to get more discussion, more conversation on this topic?

Probably easy as two ways, there are movesmart.com is our website, or look at me in my LinkedIn profile. I have a lot of… If you connect with me, I put all my articles on there as they are published, and I’m constantly writing. I’m in graduate school perpetually, always writing. That’ll be another way or contact me in any way. But I’m hoping that this is of value to people. The principles are not something that are germane only to us. We have worked this and refined this over almost four decades, three plus decades, but I believe they can be used by anybody, anywhere, to make significant and lasting changes.

Excellent. Well, thank you so much, Robert, for joining me today. I appreciate the conversation. We’ve covered a lot of ground.

Thank you very much, Eric, for having me.

Thank you for listening to The Safety Guru on C-suite Radio. Leave a legacy. Distinguish yourself from the past. Grow your success. Capture the hearts and minds of your teams. Elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafetycoach.com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting.

ABOUT THE GUEST

Robert Pater is the Founder and Managing Director of the MoveSMART® system for significantly reducing soft-tissue injuries and slips/trips/falls while simultaneously elevating Safety culture and leadership. He has published over 370 articles (in Professional Safety, Occupational Health & Safety, and many others). He’s also the author of “Leading From Within”, in 5 languages.

Globally, their client list has included:   Airgas, Alcoa, American Airlines, BHP Billiton, BMW, BorgWarner, BP, Cummins, Cushman & Wakefield, DuPont, Frito-Lay, Hawaiian Airlines, Honda, Honda Canada, Kimberly-Clark, Kinross Gold, Kloeckner, Marathon Oil, Michelin, Nissan, Nutrien, ONE Gas, Pfizer, Prysmian, Solventum, United Airlines, U.S. Steel, and many others.

Robert has an MA in Industrial Psychology and an undergraduate degree in Organizational Development. 

For more information:  www.movesmart.com

LinkedIn profile: https://www.linkedin.com/in/robertpater/

Email:  [email protected]

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Why Self-Care Is a Safety Issue: The Business Case for Expanding Training with Liz Kirk PhD

Why Self Care Is a Safety Issue The Business Case for Expanding Training

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Do you or your team members engage in a computer-intensive role in the workplace? If so, we’re confident that you’ll greatly benefit from the expertise of Dr. Liz Kirk, founder of Beyond Ergo and one of Australia’s leading researchers and trainers in ergonomic and self-care competencies. In the newest episode of The Safety Guru, Liz expresses why self-care is a safety issue by sharing the negative effects taking place as a result of our increasingly sedentary and screen-intensive work style, including a higher risk of musculoskeletal injuries and disorders. Tune in as Liz shares her research into personal protective behaviors, such as postural mindfulness and developing habits of releasing muscle tension, to decrease musculoskeletal aches and pains at work.

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Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe yet productive operations. For those companies, safety is an investment, not a cost, for the C-suite. It’s a real topic of daily focus. This is The Safety Guru with your host, Eric Michrowski, a globally recognized ops and safety guru, public speaker, and author. Are you ready to leave a safety legacy? Your legacy’s success story begins now.

Hi, and welcome to The Safety Guru. Today I’m very excited to have with me, Dr. Liz Kirk. She’s from Beyond Ergo. She won Dean’s Award for her research at the University of Queensland in reducing muscular computer-intensive pain. Beyond Ergo goes beyond ergonomics for a broad range of personal protective behaviors, particularly for computer-intensive roles. So, Liz, very excited to have you with me today. And you’re joining us from Western Australia. Beautiful spot. So, tell me a little bit about your background.

Thanks, Eric. And thanks for letting me join you today and for everybody to hear a little more about this new range of injury risks associated with computer-intensive work. So, my background originally has always been in training of some kind. Before I went back into corporate health, I was doing adventure-based experiential training programs for team building and leadership. And in those great days when we used to send everybody out into the wilderness and sell them and do problem-solving, things like that, which was much fun. But the Beyond Go programs that I deliver now were born out of my own experience of needing to get back into corporate health. And to do that, I joined a large corporation, actually in a contact center. And it was the first time I had to use computers for a really long period of time. And what I thought was going to be a very easy 9 to 5 sit-down job, turned out to be the most stressful job of my life. Very quickly, I developed back pain, shoulder pain, headaches, and sore eyes. And by the end of the day, all I wanted to do was go home, pour a large Scotch, sit in the cupboard, and talk to nobody.

So very quickly, I realized that I was the least likely person to be injured because I knew about this stuff. I knew about healthy exercise, injury prevention, the basics of workplace health and safety, and office ergonomics. And I had the disposable time and income to care for myself. But I still experienced that growing pain, the stress, and the accumulating medical bills, and I still ended up injured. So it was after that experience that I understood that it really doesn’t matter how much you know if you can’t convert that knowledge into practical work skills. And that’s what sent me back to do my PhD in these programs that now form the founding. The founding foundation of the Beyond Ergo programs. So, the things that I’d like to share with your listeners is that the largely unrecognized issue of pain and injury amongst knowledge workers, and how the stunning success of technology has created this great surge in health and injury risks. Why we need to now have a broader focus when we’re planning training, and why that training must go beyond an economic checklist to build the self-care competencies that people need when they’re involved in computer intensive work.

What’s changed in the business context where the dynamics need a much broader view?

Well, as I say, the stunning success of technology means that knowledge workers can now work from almost anywhere. And people still have this perception that computer work is easy. I mean, how could you get injured in an office? But sitting at computers all day is surprisingly mentally and physically demanding. Computers have also become integrated with every part of our lives, leisure, and in work. And that has removed those natural breaks from screens. And it’s reduced the recovery time from those poor postures and the small repetitive movements that contribute to overuse injuries. This, combined with our increasingly sedentary lives, means that, in general, we have a decline in physical conditioning, and that leads us to an increased risk of pain and injury and increased recovery times when we do get injured. In fact, Dr. David Marshall, who was the medical director at the Sports Medicine Children’s Healthcare Atlanta, said that their technology injuries have now surpassed sporting injuries in their clinic. And we know from the research that Gen-Z is now entering the workforce already injured, and primary school children are now showing signs of prehistoric postures, all because of their now current high screen use.

So, it’s a growing and concerning problem, and you can see it filter down through the generations. And I knew from my PhD research that over 86 % of knowledge workers report aches and pains, and over 11 % suffer from chronic pain. And just in Australia, and we’re not very big, just in Australia, chronic pain costs our economy $55 billion a year. And of that, $7 billion was simply lost in productivity. That’s before you’d add any other business expense to cover any other injury or illness in the workplace. So, for Australia, we only have 30 million people. That was a loss of $540 in lost productivity for every person in the Australian workforce. And sadly, that’s not all the bad news because when COVID forced everybody home into flexing work, those reports of doctor visits and allied health services increased significantly. And together with the other social isolation and depression, and loss of productivity that we’re now seeing filtering through in the research when COVID forced everybody home into flexy work. And I think one of the pieces is you’ve got people moving from the work environment, desktop to home using a laptop, probably not the most economical or economically sound work environment, which aggravated the circumstances. Is that a fair statement?

Absolutely, Eric. That’s absolutely right. So clearly, the whole world of work for computer-intensive work has changed drastically over the last 20 years. And now we have to question whether an economic checklist is adequate for staff trying to manage an increasingly complex array of work choices like hot desking, working remotely, sit-stand workstations, multiple screens, and mobile devices. And we’re now getting research on the new health risks associated with this increasingly sedentary behavior, including the increased risk of heart attack, type 2 diabetes, various cancers, and depression. And for businesses that where flexi work has created a situation where managers must still ensure safe work conditions, but they now actually have less control over the work environment and less oversight about how staff likes to work or how they choose to work. So, the jump into laptops was so essential during COVID. Still, it’s added that extra layer of risk of injury because we’ve all heard stories about people sitting on their beds to work, using ironing boards as tables, or getting leg pain because hard deck chairs were never meant to be designed for eight hours of sitting each day. We also know that we need to expand the economic recommendations that we’re sending home for flexi work because they do need to cover laptops.

And as an example, the economic recommendations state that laptops should not be used flat on the work surface for more than two hours a day. But I don’t think I’ve talked to anybody here in Australia, and I don’t know what it’s like there for you, but managers have not realized that. And they haven’t sent the equipment home or given the training to make sure that staff that are on flexi work can set up their workstation properly. And of course, using laptops flat on the work surface forces people into that turtle posture that now looks so natural because we see everybody doing it. But your head is now jutting forward to look more closely at the screen. Your neck is in compression, which leads to fatigue and headaches, poor concentration, increased muscle tension, and can even lead to injury of your vertebrae over time. That slouched posture, sorry, slouched posture, say that twice, actually compresses your abdomen and slows your circulation. And of course, the small keyboard increases your input errors. So ,it’s a really big issue often people are wondering whether that’s really how that’s affecting our flexi workers. And I like to give them an example of a lady that I worked with some years ago.

Her name was Jean, and she worked for a help line, a 1 in 300 help line for seven years, without any injury or health concerns to do with her computer work. But when she had the opportunity to go home to work, she just thought that was going to be great. So, Jean took that economic checklist and purchased the right office chair, a document stand, plugged in her mouse, and sat down to work. But after just six months from working from home, Jean was experiencing significant pain and mounting medical bills. Weekly physio and acupuncture appointments had replaced her yoga classes and her beach walks because her neck, shoulders, and back pain was so extreme. So, in just six months, Jen’s shoulder needed cortisone injections, and surgery was already planned. So that was just in six months of working from home because she hadn’t been given all the support and training that she needed to cope with this new range of skills and information she needed because the checklist couldn’t cover all the issues she faced. It couldn’t demonstrate how to adjust her furniture. It couldn’t check if the equipment was positioned correctly. And there was no one to check Jen’s work posture while she worked.

And that was, I have found, a major concern and a major cause of people building pain and ending up in injury. So, whenever I take a workstation assessment, I always quietly stand behind the person and take some photos while they work, so they can see their work posture. And when I showed Jean her posture, she was absolutely done found it, because she had no idea. She had been constantly leaning on her elbow to work. And we find that a lot. People are unaware. It feels so natural the way they’re sitting. They don’t realize how poor their posture really is. So, after I made the economic adjustments and we built Jean a very positive work behavior program, she could return to her yoga and start her early morning walks. But the real tragedy was that the damage to Jean’s shoulder was considerable, and she still needed surgery. And that’s certainly one of my frustrations, is that I’m not called in until people are already in extreme pain. By then, the damage is often already done, and it couldn’t be reversed. So, it’s one of the reasons we need to broaden this scope of training for knowledge workers, from the reactive wait until somebody’s in pain, to the more preventative style of building these self-care competencies.

Sure. And so we touched before on the importance of having a broader focus on going beyond just ergonomics. Tell me a little bit about those additional components being yond just the economic and desktop set up.

Yeah, sure. And what I’d like to do, too, when I do that, after I do that is show the business costs that are associated with not giving people the new self-care skills that they need. Because, of course, companies allocate significant time and money to their employee assistance programs and the return-to-work programs, all to cover these work-related injuries. But logically, it’s better to promote injury prevention. And, of course, being safety, the first step in any safety prevention program is to follow the hierarchy of controls. And in relation to computer-intensive work, that still means defining and implementing the tiers of elimination, substitution, engineering, administration, controls, and, of course, PPE. But PPE for knowledge workers is different. My research shows that this final tier for injury prevention should be PPBs. These are personal protective behaviors. So, these are the competencies that allow individuals to consistently identify and take early action to eliminate or at least manage the triggers that are personally causing them pain and then prevent that pain and stop it from progressing to an injury. So, these skills will enable staff to take greater personal control over their health and safety in computer-intensive work environments, no matter where they work.

So, the most efficient way to do that, of course, is by building training that extends to build these personal protective behaviors. So, it’s a more holistic range of knowledge that goes beyond the economic checklist to build transferable, actionable self-care health and safety skills. So, in the Beyond Ergo programs, we describe these holistic ranges of skills as the three pillars of personal protective behaviors. And the first, of course, is getting the ergonomics right. But it’s not just about going through a checklist. We also demonstrate how to refine those generic recommendations to match stature. And the example I love to give is that one of the most common mistakes I see is people having their screen set either too high or too low. And the economic recommendations say that the center of your screen should be 17 and a half degrees below eye level, but nobody actually knows what that means, and they don’t know how to judge it, so they don’t even bother to try. And I’d love people to try this as they’re listening to your podcast to check screen height. If you place your arm parallel to the work surface and point to your screen, you should be pointing to the center of your screen because your fingertips are now about 17 and a half degrees below eye level.

So, it’s so easy. And you’re not pointing to the center of your screen, you know you have to adjust your screen height. So, by using this action, you’re actually refining those generic economic recommendations to match your stature. And it doesn’t matter if you’re 6’8 or 4’0, it automatically works no matter where you are. And actions are also easy to remember. You don’t need any special equipment. And of course, you always have your body with you. So, it doesn’t matter where you are, you can adjust your workstation set up to match your structure properly and the tools that you’re using. So that’s the first pit here. The second pillar of personal protective behaviors is building a wider range of positive work behaviors. And that, of course, goes beyond eating a healthy snack and taking the stairs. And these include the obvious, like supporting mini and micro breaks, doing the stretches, and knowing how muscular carotid disorders start. But the biggest benefit I found in the work that I did is by coaching postural mindfulness. And we touched on that with Jean. She didn’t know she was sitting in an awkward posture. So, learning to feel when you’re working in poor postures, and developing habits of consistently releasing muscle tension and resetting posture back to relaxed and neutral is really important.

This behavior has proven to provide the greatest benefits and decrease aches and pains, and of course, those injuries that go along with it. Because if you can’t feel when you’re working an awkward posture, and you don’t recognize that there’s an eight star, then you can’t go ahead and fix it. Because if you can’t feel it, you can’t fix it. So that’s the second pillar is these broad ranges of positive work behaviors. And the third pillar is building the targeted physical conditioning we need to speed recovery and help prevent common aches and pains, especially of the neck, shoulders, and upper back. So, recommending aerobic classes and massage and yoga and going to the gym is, of course, great. But there are very specific dynamic stretches and strengthening exercises that knowledge workers need to habitually do if they’re going to avoid pain and injury. And as an example, the research shows four recommendations for recovering from and preventing neck, upper back, and shoulder pain. And these are, and of course, the first one is ergonomics, getting your ergonomics right. So, you’re setting everything up so you’re not sitting in awkward postures. The second is your stretches.

So designed to release that muscle tension and recover through periods of work. The third is aerobic exercises. And trials of aerobic exercises found it significantly reduced migraine frequency, pain intensity, and duration. But while the most dominant approach we talk about is getting the ergonomics right, the fourth strategy was targeting the strengthening of muscles of the neck and shoulder girdle. And that always worked consistently. So, in the podcast Download, there’s a link to an article that explains those and the four exercises that strengthen the neck and shoulder girdles. That’s probably a lot more valuable than me trying to describe them.

This episode of the Safety Guru podcast is brought to you by Propulo Consulting, the leading safety and safety culture advisory firm. Whether you are looking to assess your safety culture, develop strategies to level up your safety performance, introduce human performance capabilities, re-energize your BBS program, enhance supervisory safety capabilities, or introduce unique safety leadership training and talent solutions, Propulo has you covered. Visit us at propulo.com.

And there’s really good visuals to help with those exercises in the show notes.

Yes, absolutely. The article has those as well. And of course, the big question I’m always asked when in relation to doing these extending training and whether it’s really of benefits to extend training is whether there’s a business case for increasing that investment in training, and why that’s important. Because it’s easy to see how individually and accumulatively, the risk for computer intensive work is obviously a concern. But the examples I have that show the cost benefits are really important. Actually, the calculator I use actually comes from OSHA. So, the American Occupational Safety and Health Administration have designed the Safety Pays calculator. And this calculator is designed to calculate the potential damage to a business’s profitability from various work-related injuries. So, to explain why it’s important to extend training and to this wider range of personal protective behaviors, I input into the calculator three common overuse injuries. And the figures will demonstrate the direct and in direct cost of those injuries to a company. So, I chose three. The first one is carpal tunnel syndrome. And the cost of that injury to the company was over $64,000 just for one case of carpal tunnel syndrome.

One case of an inflammation injury, so we’re thinking tendonitis or repetitive strain injury, was nearly $82,000. And one case of a strain, like upper back pain or shoulder pain, was calculated at $70,000. So, most managers I talk to find those figures very surprising. But the safety pay calculator actually goes beyond that because in that calculator, you can enter the percentage profit that you would make on each sale. And if there were any cause for concern, they need to try the calculator because the figures that come out of the amount of sales you have to make to cover the cost of those injuries are absolutely eye-watering. But my concern, of course, is more about thinking about the injured employee because while the cost of the business is high, the immediate financial burden for the injured person is much higher because they cover over 70 % of the associated costs of that injury. And a significant muscle, little disorder can reduce their earning capacity for the next 4 to 5 years. So that’s not only the pain and disability that affects their work and their private life, with stress and injury and pain, but also their earning capacity and their quality of life because it decreases their income now, but also how much they can save for retirement and their financial security in the future.

I love the example you shared earlier around the angle for the monitor because I think whenever you see the diagrams like you said, the 17 and a half degrees is really hard to conceptualize. Here’s a very easy tool for somebody to quickly particularly assess their workstation. I’m wondering if you could also share maybe some tips on the laptop side of the equation because you talked about how people have moved to laptops, and I know a lot of people have set up at home where their laptop connects to monitors and have external keyboards and mice, which then makes it look more like a desktop. But then you’ve also got the person who travels who can’t travel with a monitor as well.

That’s exactly right, Eric. And the whole reason we love laptops is that they’re so portable. So, by having a broader range of skills and doing the physical conditioning means that when you can’t set up your laptop on your little laptop stand or with an external keyboard and all the things that you need if you need to work with it flat, you also know that you’re going to start getting some discomfort, that it is awkward. So, then you have your strength-enhancing exercises, you have your dynamic stretches that release that tension. There is a great exercise that I love to do. And the research showed that this one exercise can reduce upper back and neck pain by 50 % when it’s done regularly. And it’s even more important now that we use laptops so much. It’s called the Roll Reset Relax. And what it does is that, as you know, when you work on any computers, but particularly laptops in this hunch turtle position, we build up a lot of tension in the neck and shoulders. And the only way to release that tension is by doing big movements and consciously relaxing. So, the Roll Reset Relax is designed to do that.

You do big shoulder rotations; you do big rotations forward and then big rotations backward. And then, you take a deep breath and consciously relax your arms into your lap and reset your posture back to a neutral position. So, you get the feel of your body being squared up to your monitor and your laptop keyboard. And you release that tension because those fine motor units switch on, and they can’t switch off again until you do those big movements. So often, when we’re working, they can be switched on for eight hours a day, but we don’t consciously relax them, which is a great cause of pain and discomfort. So, roll, reset, and relax. You do big shoulder rotations, take a deep breath and consciously relax, and reset your posture, leaning back in your chair, squaring yourself up to your monitor and your keyboard, and relaxing back into relaxed and Neutral. And as I say, the research showed us that by making that a habit, doing that throughout the day, anytime that you find yourself leaning to one side, or you’ve lent forward to read from the screen, or you’ve been sitting down for a while, just repeating that can reduce that upper back pain and neck pain by 50 %.

Excellent. So again, how do I organize my workstation, and then the exercise I really liked as well your other elements around a broader range of tools that look into posture and mindfulness, things of that nature. So, tell me a little bit about how companies can help address some of these risks. Obviously, flex work is still present, and the pandemic is mostly past, but people are still working in dispersed environments in many organizations, and even if they come back to the work environment, these risks are still present.

Oh, that’s right. And in fact, I think flexi work is going to be here to stay. It’s certainly one of the conditions that people are looking for, and that will adjust over time. But of course, these managers are really looking now to health, safety, and wellness programs to meet their workplace health and safety obligations, but also to provide that commercial edge of reversing the decline in productivity that a lot of us are seeing and acquiring and retaining new talent. So, decreasing the attrition rates and improving levels of labor costs, because we’re not seeing so much absenteeism and present teens and stress. So this is best done by expanding training and the expectations of the training that knowledge workers need to include this broader range of health and safety self-care competencies. So, as I say, I’ve dubbed it the personal protective behaviors, the PPBs. Individuals need to consistently identify and manage the new complex range of health and injury issues that are associated with computer-intensive work. And for businesses, that means enabling staff to take greater personal responsibility for their health and safety, no matter where they work. And in turn, that will improve their productivity and reduce the chance of work injury claims.

So as I say, remember, Jean there, that after seven years of being a dependable and valuable staff member, in just six months from working from home, she was in so much pain that the company was covering the significant direct and indirect costs of lost productivity, medical bills, return to work programs, overtime payments, and of course, the company had a reputation hit as well because people don’t want to work where they know they’re going to get injured or they’re not getting the support that they need for these. So, in terms of the programs that are out there, obviously, people should really look for this broader range, not just doing the checklist of hiring a seated massage or giving people discounts to go to the gym or go to yoga classes. But if they would like to see more of how the Beyond Ergo programs work, then, of course, there’s links in the program to my website. But there’s also a free webinar that’s coming up on the 19th of July, which is about the practical skills team leaders and managers can use to build resilience and stress management. And it’s all about frontline leaders being able to nurture their teams, before they need the big stress management conversation, that Are You Okay conversation, which can be very intimidating for team leaders and for their teams as well.

And it can feel quite intrusive. And, of course, I’m very happy for people to connect with me on LinkedIn. And I’d love to share ideas and information. I’d love to know how I can help people.

Absolutely. So, your website is Beyondergo.mom.au. It has many resources, including, as we’ll include in the show notes, the stretching exercise we talked about earlier, as well as the OSHA calculator. And if somebody wants to reach you, is that the best way to start the conversation?

Yes. LinkedIn is probably the best way to do it. Yeah, absolutely.

Excellent. Well, Liz, thank you very much for coming and sharing your wisdom about economics and going beyond just a standard checklist economic program. I think it’s something organizations definitely need to think about as we embrace flexible work environments. But even in an office environment, the environment still requires good economic environments and the right reinforcement for success.

Yeah, thank you, Eric, and thank you for letting me share these concerns and ideas about all things new with these computer-intensive work environments.

Absolutely. Thank you for joining us.

Thanks, Eric.

Thank you for listening to the Safety Guru on C-Suite Radio. Leave a legacy, distinguish yourself from the pack, and grow your success. Capture the hearts and minds of your teams. Elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafetycoach.com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting.

ABOUT THE GUEST

Dr. Liz Kirk (PhD) won the Deans Award at the University of Queensland for her 2013 PhD research focused on defining and reducing levels of musculoskeletal pain and MSD among knowledge workers in the Australian Contact Centre industry. While the original research focused on using clients’ anthropometry to refine ergonomic recommendations to match stature, the Beyond Ergo talks and workshops now go beyond ergonomics to build a broad range of Personal Protective Behaviours (PPBs). These are the new WHS and wellness self-care competencies knowledge workers need to take greater personal responsibility for their health and safety in computer-intensive work environments, no matter where they work.
 
For more information: https://beyondergo.com.au/
Four ways to help minimize screen-related neck and shoulder pain: https://beyondergo.com.au/reduce-neck-pain/

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Ergonomics as a Lever to Improve Safety, Quality, Productivity, and Employee Engagement with Carrie Taylor

Ergonomics as a Lever to Improve Safety, Quality, Productivity, and Employee Engagement

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ABOUT THE EPISODE

According to OSHA, implementing an ergonomic process is effective in high-risk industries and increases productivity. Join our conversation with professional ergonomist Carrie Taylor to learn the many benefits of ergonomics in improving overall safety, quality, productivity, and employee engagement in the workplace. Tune in to learn strategies to drive impact and success in implementing proper and safe ergonomics within your organization!

READ THIS EPISODE

Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe yet productive operations. Michrowski, for those companies, safety is an investment, not a cost for the C suite. It’s a real topic of daily focus. This is The Safety guru with your host, Eric a globally recognized ops and safety guru, public speaker, and author. Are you ready to leave a safety legacy? Your legacy’s success story begins now.

Hi, and welcome to The Safety guru. Today I’m very excited to have with me Carrie Taylor. Carrie is a certified Ergonomist with 30 years of experience in the space, heads a firm called Taylor Ergonomics. Carrie, welcome to the show.

Thank you.

So, maybe why don’t we get started with a bit of background in terms of ergonomics and how it helps safety, maybe as a starting point.

Sure. Ergonomics is thought of as the art and science of fitting work to people. Most Ergonomists have studied Kinesiology, sometimes psychology. There’s another branch of ergonomics that deals with more cognitive capabilities. But the area where I practice is mostly biomechanics. So, we’re looking at physical size and strength of workers and trying to make sure that workplaces are built with those capabilities in mind.

Sure. And so, what are some of the main benefits of looking at ergonomics in a workplace? And what environments would benefit the most from an ergonomist?

So mainly, ergonomists are employed in the safety sector trying to attack the musculoskeletal disorders or strain sprain injuries that occur in the workplace. So, a good chunk of those, often about half of workplace injuries are related to that mismatch between workers and jobs and creating those musculoskeletal injuries. So, we are often brought in to help with trying to address those injuries. So, in terms of which environments benefit more, I think anyone who’s in a workplace who’s uncomfortable is probably subconsciously thinking about ergonomics and how could I make myself more comfortable. I spent most of my career working with manufacturing, healthcare, offices, distribution, areas where people are working in jobs that are either heavy or repetitive or awkward. Those kinds of hazards are the ones that we’re typically trying to tackle.

Obviously, work environments where it’s repetitive, that makes a lot of sense. What about environments where the work is different? I’m thinking, for example, utility workers that are not in a safe environment day in and day out but are dealing with lifting, they’re moving things, they’re going up holes, so there’s different hazards, or even fireman in terms of coming in and out. What are some of the applications in those environments?

Those are important jobs where economics needs to be considered. They’re much more difficult for us to assess because those things aren’t happening all the time, so they’re harder to see and they’re harder to measure. And it’s harder to wrap your head around how we can fix something that doesn’t happen all the time. But they’re very important hazards to address. Sometimes we can take a different look at them and say, okay, well, maybe it is causing people to be uncomfortable, but maybe there’s other problems that are associated with the mismatch between the worker and the workplace that we can tackle, such as maybe they’re not able to keep up with the pace of… They expect the pace of work, or maybe they’re not able to produce the quality of work that the employer expects.

You’ve recently done some work and some research around linking ergonomics to quality and productivity. Can you share a little bit more in terms of how ergonomics can impact broader organizational metrics such as quality and productivity?

I think it’s important for us as autonomous to start thinking about how else we can cost justify improvement. One of the challenges we find is that there are some cost benefit analysis tools out there that might look at if you’ve got a back injury, it’s costing the organization this many dollars. And so therefore, if you prevent that back injury, you’re going to save money over the long run. But what we recognized was that those tools don’t do a good job of estimating the other benefits that ergonomics interventions might have. So, they can’t really help you to say, okay, well, if I improve the quality of work on this job because the person is not working in this awkward sustained posture anymore, how much money will I save the organization by doing that, or if I’m able to make them a little bit faster. So, part of our research project was we wanted to be able to try and build a better tool for factoring those costs in, particularly where the injuries haven’t happened. Maybe they haven’t happened yet because it’s a new facility, or maybe they haven’t been attributed to a specific job because maybe there’s job rotation, or it’s just difficult to get those stats.

But most of the tools that are available only work if there’s injury cost that you can grab onto. And so, we wanted to build a tool through our research project that would help economics and safety professionals and whoever else is trying to implement an economic improvement to capture those other costs and try to build those into a cost justification case.

What are some of the things that an organization can look like in terms of driving the quality productivity, linking it back to to economics? Because I would imagine it can get into a workstation design if you’re in manufacturing in terms of perhaps less movement, more sustainable movements, which can also demonstrate productivity gains. If I’m thinking of, for example, an automotive, it’s very easy to show that shaven a second, or not easy, but once you shave a second, there’s a significant impact on the full production line. So, all of these pieces, is there environments where they have looked at that linkage between quality, productivity, and economics?

There’s a ton of research out there that look at specific case studies and where they’ve been able to make an improvement and capture some cost. But there isn’t a paper that helps you figure out how to do that in your own organization. I can give you three examples where we try, maybe not quantitatively, but that people will be able to relate to. As a quality example, I spent years looking at a job, looking at it, meaning I walked by it and I saw it and I knew it was a problem, but there weren’t injuries there. The job involved inspecting a part. The part was a flat piece that had contours on it, and the worker was responsible for inspecting grooves that were horizontally oriented on the top of this part. So, in order to see the grooves, they had to see if there were components in them and if they were properly placed. In order to see the grooves, they either had to bend over the part on the conveyor as it moved by, or they had to lift the part up and re-orient it so that they could see inside the grooves. Because while they were standing, there was no possible way for them to actually see the components.

So, I knew that there was a lot of neck bending. I knew that they were lifting this part unnecessarily, but there wasn’t a case for it. I couldn’t say there’s a high risk of injury. They were rotating, so they weren’t there all day. And so, after years of saying, why can’t we tilt this conveyor? I just want to tilt this conveyor. And apparently that was a big deal. And the engineering manager said, I carry, we don’t need to. There’re no injuries. It’s not important. I walked into the quality manager, and I said, I think they could do a lot better job of this inspection if the part was tilted towards them. And he said, oh, you know what? We’re actually spending X number of thousands of dollars a month to have a person at our customer’s site, reinspecting those parts because they’re slipping by. I’m like, Wow. After all these years, I just wasn’t talking to the right person. I think that was an example where we could make a big impact if we had just been working with quality more closely and trying to help them understand where it’s a human capability that we’re not designing for. So that was one example. A productivity examples. I’ve been working with a client who has a lot of people doing grinding. So, they’re grinding off long tubes, and its super quality sensitive. So, there’s never going to be a quality issue because they’re going to keep working at it until it’s perfect. So, it’s inspected all the time. But the cost of that quality is that the job is very demanding. So, they’re bending over, they’re running this grinder, they’re pushing really hard. It’s awkward, it’s forceful, and they do it for long periods of time. And so, we started looking into, well, are there better abrasive materials that they could use on these grinding guns that maybe you wouldn’t have to push as hard? And so, we started looking for that, and we brought in some vendors, and they tried some new products, and we found some abrasive materials that reduced the amount of time that it took for them to grind the tubes. And it also took less effort, so they didn’t have to push as hard on the tool. So, we were able to make an economic improvement that had a big impact on the workers’ comfort, but also had a big impact on their productivity because they were able to do the job in less amount of time.

Again, there’s a productivity example, but it wouldn’t have any effect on the quality. The quality was going to be perfect either way because we were going to inspect it and keep doing it until it was right. And the third area where we’re trying to have an impact outside of musculoskeletal disorders is an employee engagement. So, what happens when an employee is working in an uncomfortable position for long periods of time, or they’re doing something that’s heavy and awkward and they’re at risk of developing an injury, they start to become disengaged. They’re not able to work as effectively. They aren’t as happy to be at work. If they’re in customer service, it probably affects their interaction with the people that they’re talking with, their customers. So, I see this right now as a huge opportunity, I guess, for people who are implementing remote work programs. So, in an office environment, we’ve done, to date, a pretty good job of building furniture that’s adjustable. So, we’re sitting in good chairs. Our lumber back is supported. The screens are all height adjustable. The keyboards are adjustable. We’ve gotten to a good point in economics in office environments. But now we send people home and they want to be home, so they’re not going to complain about the work environment.

And so, we’ve been starting to do virtual office assessments for people working in their home offices, and they’re required to send us in a video so that we can see what they’re doing before we work through an assessment with them on a video chat. And what we’ve seen is abominable. People are working at kitchen tables on wooden chairs or on a sofa with a TV table and their arms are fully outstretched. And I think if their supervisors could see them, if we had all these people in an office working in these clusters, we would be awestruck. We would say there’s no possible way that they could work productively in that environment and be engaged and work effectively. But it’s happening and it’s happening all over the place. And I think that eventually these people are going to be in so much pain that they’re not going to be able to get anything done. So, I think there’s another huge opportunity for us there is to try and think about how are we expecting people to work when they’re in a home office environment? And how can we optimize that? How can we help them to be working in an economic environment?

So, I think those are really good examples. I think the first two, really for me, sent a message that it should be ideally part of a continuous improvement process that’s part of quality management, where people are looking at it both from a safety standpoint but also how do I improve the quality of the product that I’m delivering and really looking at it holistically because it sounds like from the opportunities you have or you’ve seen, it’s not just a cost benefit analysis, it’s also how do we improve the overall workflow so that the worker is happier, safer, but also delivering to a better outcome with its quality of productivity.

Yeah, absolutely.

What can safety organizations do to get closer? Because that tends to be a challenge in many organizations. The two parts are separate, even if there’s a lot of connections. Have you seen some areas of success around this?

I think we must work more closely with engineering. If there is a continuous improvement, a Six Sigma, a Lean program that we need to reach out to those people and offer to collaborate because the problems that they are working on probably are the same types of problems that we’re working on. I think in Canada, most autonomous come in through the safety door. When I’m called for an economic consulting project, it’s usually HR or safety that’s calling me. But we also get calls from engineering. When we’re getting calls from engineering, we know that those changes are going to be implemented because it’s in the engineer’s interest to try and optimize the design of the work. I think with safety, it’s harder because they’re reliant on legislation or injuries in order to be able to justify a change. So, an employer might make a change because it’s the right thing to do. But if it’s an expensive change, it becomes more difficult to justify. Sure.

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Your last example, the one around the economics from home, I’ve seen a lot of organizations implement that at the front end of COVID when people were sent home to do some ergo checks at home because as you mentioned, a lot of people didn’t have the right office environments for it. I think you bring up a good point that people are happy being at home, so they may not necessarily report the discomfort until it’s too late and becomes a significant issue, what are some of the things that organizations can do to get ahead of this? So, you mentioned doing the ergo assessment. I’ve seen some organizations do virtual ergo assessments, not necessarily even with an Ergonomics, but just to show me your workstation, not in a negative way, but just to say, okay, let’s understand what you have and say what you need to invest in your work design to be more productive. Tell me a little bit about some of the things you’ve seen in that area.

I think it’s important to provide employees with training so that they’re able to set up their workstation, but also the resources that they need. So, a lot of employers allowed people to take stuff home from the office at the beginning of COVID, so people brought their chairs home. They might have brought their… If they had a sit stand desk, I know some people have been allowed to take that home, but we need to make sure that people are able to work in a decent posture and get some posture changes during the day and that they feel that if they have a problem, they can reach out and get some help for it. And some organizations offered a budget, so they would say, okay, here you can have $1,000 a year for wellness. But they gave so much flexibility around how that money could be spent that people would spend it on yoga classes and things that are valuable but they’re still sitting on the sofa and working on the TV table. So, I think it needs to be a priority. I think at the beginning, we thought this was temporary, right? So, we all just did what we could to get through it but now it’s become permanent, and I think we can’t have people working at the dining room table permanently.

It’s interesting because a lot of the tools, even standing desk, have become much more affordable for home office compared to before. Because if you think about the ones in the investment and incorporating competent environments that used to be incredibly expensive, but now they’re available in a very tight budget, even in many cases, where there’s different modular elements that people can create. There’s a lot more options.

Yeah, there is. There’s a lot of products on the market that I wouldn’t recommend as well. A lot of the sit stand desks don’t go low enough for most people. It’s like anything, I guess, supply and demand. There are suppliers out there that are producing cheap quality products that when you buy it, you’re going to be disappointed. But by and large, there are some good products that have come down a lot in price as well. So, it’s become a lot more practical to set up a decent home office.

Sure. Thank you for sharing. You had some good examples in terms of connecting with different parts of the business in terms of how ergonomics has a bigger, broader impact than just on safety. One of the key elements, obviously, in terms of driving safety, but also ergonomics is a supervisor. Tell me a little bit about some of the strategies that can empower supervisors to have a great impact around ergonomics.

We found that supervisors are the middlemen between the workers that know the jobs and management who know the organization but might not have their feet on the floor as much. When we approach organizations trying to look for opportunities to improve ergonomics, we try to approach the supervisors and get some time with them. They’re busy but try to get some time with them to try and understand where the opportunities might be. So, we ask them about what jobs people are trying to post out of. So, if there’s a job that it’s an entry level job and the first opportunity people want out of it, that’s probably a job where there’s economic issues because there’s a reason why people want out of them. And we ask them, where do the mistakes happen? So, if there’s a quality issue, if a defect gets out of your department, or people are making mistakes, or if they’re missing things when they’re inspecting, where is that happening? Because again, perhaps it’s because the job isn’t designed well for them. Where do bottlenecks happen? So, if people are standing around waiting for somebody to finish something, who is it and what are they doing?

Because that might be another opportunity for us to try and fix things. And if there is a job where people are most likely to call in sick, which job is it? That day that such and such a schedule, all of a sudden, you’ve got three people absent and you’ve got to try and cover that. A lot of times, absenteeism is really a better indicator of the ergonomics issues than WSIB type of stats. Those are kinds of things that supervisors will have a better sense of, perhaps in the HR Department or the manager in the department because they are the ones who are having to try and solve those problems.

Absolutely. The other part you mentioned earlier is you did the research project trying to look at quality and economics and productivity and trying to find some of the linkages. Can you share a little bit about some of the findings and learnings from that project?

Yeah. We had a project set up that was partially funded by Sonami, and we were doing it in conjunction with college. Our original goal was to try and find partners, industry partners that would allow us to try to cost justify an ergonomics improvement that they were already working on for another reason, but try and do that based on quality, productivity, and employee engagement metrics. So, the first interesting piece that we learned was that it’s hard to get industry partners to sign up for those kinds of things. Most of our contact people are HR and safety, and so the idea to them, the idea of trying to reach out to their quality and their production people was maybe overwhelming. I don’t know. We don’t really know why we had so much trouble, but we didn’t manage to get enough industry partners to do the project the way we had originally planned to. So that was interesting. So, we pivoted and decided, okay, instead of trying to apply a cost benefit analysis tool, let’s try to build one, build a spreadsheet, and build training around how to use it. So that’s what we did. We created a course for engineers, safety, and ergo people that would help them to identify and quantify those improvements in productivity, quality, employee engagement, so that they’d be able to cost justify an ergonomics improvement.

So, we created this one-day course, and we piloted it. It went really well, so we’re going to be running it again. But it was essentially, we taught them about some of these Lean and Six Sigma tools because part of our research team had some expertise in that area. And then we helped them to apply it and helped them to try and mock up and quantify what would happen if you changed this. So, we used a board game operation, and we helped participants to see, okay, well, I can see that this is an ergonomics issue. If you’ve played the game operation, you know that it involves bending and holding tweezers, and it’s repetitive. And so, we created this situation where they had to quantify what the problems with that were and how productive a surgeon would be in that job and what quality issues, so how many times they hit the buzzer when they were trying to remove the organs. And then we were able to mock up in the workshop some improvements. So, we gave them the ability to change the working height and the reach and lighting and tools and all kinds of things and then mock up and quantify.

And so, it’s through that process of experimentation that they were able to actually put some numbers to how the how the surgeon felt about the job. So, what engagement effects would we have? And how productive was he or she? And how many times did they hit the buzzer or drop an organ when they were transferring it? And so, we were able to build a little spreadsheet that would quantify all of that and help to cost justify an ergonomics improvement using those other metrics. So, we’ve been trying to use it when we have the opportunity within our practice, and we’re looking for obviously more opportunities to use it more and fine tune it. But it’s got a lot of promise, and I think that’s the way we want to go in the future to try and help clients cost justify their ergonomics.

Improvements. sounds good. So, Carrie, thank you for sharing a lot of insights across the spectrum for economics. Important elements from a consideration in terms of safety programs, in terms of where to eliminate, where to go find some opportunities. I’d like your comments around the supervisors and all the way down to home offices and some of the opportunity’s organizations have to make sure that people are working in the right work environment. So, thank you so much for joining me today, Carrie. If somebody wants to get in touch with you. What’s the best way to do that?

Probably through our website, TaylordErgo.com.

Sounds good. Thank you so much. Have a wonderful day.

Thank you.

Thank you for listening to the Safety guru on C-Suite Radio. Leave a legacy, distinguish yourself from the pack, grow your success, capture the hearts and minds of your teams, elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafety coach. Com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting.

ABOUT THE GUEST

Carrie Taylor, M.Sc., CCPE, CPE, R.Kin., Principal Ergonomist

Carrie Taylor launched Taylor’d Ergonomics Incorporated in 1995, after working in the field for several years. Carrie holds an undergraduate degree in Human Kinetics, and a Master of Science degree, both from the University of Guelph. She has attained professional ergonomics certification in Canada (CCPE) and the United States (CPE), and she is also a Registered Kinesiologist. Carrie has experience in many industries, including automotive parts and assembly, food processing, small motors, offices, chemical processing, airlines, nuclear, health care, and many more. Carrie is based in our Cambridge office.

Taylor’d Ergonomics is a team of ergonomists, spread between London and the Greater Toronto Area. Our ergonomists enjoy developing and facilitating training, tackling challenging client projects, and supporting regular ongoing clients with ergonomics programs. Projects include physical and cognitive demands analyses, design reviews, office assessments, best practices and, of course, cost-justification projects.

For more information: www.TaylordErgo.com or email [email protected]  

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