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Ergo Cup 2004 Winners

We had 20 participants, the most ever, in the competition this year. And the winners are:

Ergo Cup Categories
1. Team-driven Workplace Solutions-At least 75% of the problem solving effort (problem identification, assessment of the issues, improvement definition, implementation, and refinement) is conducted by individuals whose primary duties are production and maintenance jobs. Some technical support by in-house Health & Safety or Engineering/Ergonomist staff is allowed (as members of the team or as support to the team), but the bulk of the activities are conducted by the production and maintenance team members.

Honda of Canada Manufacturing
Alliston, Ontario, Canada
Ergo Hitch

Auto parts are delivered line-side using flatbed carts and tow-motors. Before the solution, trains of carts were connected using a basic hitch-and-pin device, requiring frequent back- bending. 18,000 connections occurred daily, causing 8 back injuries per year. A novel tongue and hitch design (*under patent review) eliminates bending. This innovation was evaluated as a top entry in Honda's North American and World-wide Technical Festivals. Results show 0 injuries since implementation, an 11% reduction in cycle time across 23 delivery processes, and a total annual savings of $737 200/yr ($2/unit).

2. Engineering/Ergonomist-driven Workplace Solutions-At least 75% of the problem solving effort (problem identification, assessment of the issues, improvement definition, implementation, and refinement) is conducted by in-house Engineers and Ergonomists. Some technical support by outside consultants is allowed, but the bulk of the activities are conducted by in-house resources.

General Electric Company
Decatur, AL
Snap In Drain Pan /Roller Wheel Press Operation

Decatur manufactures 15,16,17, & 18 ft. 3 refrigerators. This was a two-part project: (1) to redesign the drain pan used to capture moisture from the condenser and compressor, and (2) to eliminate the ergonomic issues from aligning the clips that hold the condenser/drain pan in place. With this project we redesigned the drain pan to a snap-in style and eliminated the ergonomic force problem described in this entry. The project accomplished the following for our site (1) eliminated materials (screws & clips), (2) eliminated the initial ergonomic alignment issue and the force problem from the snap-in design, and (3) eliminated labor (4 people). Securing the condenser to the drain pan had resulted in 13 OSHA Recordables (CTS, Tendinitis) and other ergonomic complaints of wrist, shoulder, neck, elbow, and back pain.

3. Training and Education-A planned process (i.e. series of activities driven by learning objectives) that results in specific knowledge or skills related to ergonomics problem solving (problem identification, assessment of the issues, improvement definition, implementation, and refinement). The education initiative should lead to significant workplace solutions that improve ergonomics.

Ford Motor Company
Dearborn, MI
Ergo Junkyard Wars

"Ergo Junkyard Wars" is a unique approach to developing a significant solution to existing manufacturing ergonomic concerns! Non-ergonomic hourly (skilled trades) and engineers volunteered to compete and find the best solutions, while being educated in ergonomics throughout this hands-on event!!

2004 Competitors

Team-Driven Workplace Solutions

Engineering/Ergonomist-Driven Workplace Solutions

Training & Education

2003 ERGO Cup Winners

"High caliber of presentations. Ergo Cup was outstanding." —Desiree Betz

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