Zavitz on Ergo
3,500% Return on Investment for Applied Ergonomics Training Class
EORM’s roving Ergo Consultant, Ben Zavitz discusses training, fine food, and ROI
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Have you ever struggled with trying to justify the cost of a training program? We all know training is an important element of professional development and essential to the long term success of any organization. When times are good, money is flowing, and almost any initiative is implemented. However, when challenging times arise (and they always do) how can we cost justify our training initiatives? One way to do this is to demonstrate the impact and value of the training program in terms that executive management wants to hear, Return-On-Investment (ROI).
Recently, I conducted a two-day applied ergonomics training class at a client’s manufacturing site. The goal of the class was to demonstrate how well-designed ergonomic assessment tools and techniques can be successfully integrated into a Lean Manufacturing and Six Sigma system and validate the value of ergonomics. The results of one team’s case study alone were enough to demonstrate a solid ROI for the whole training class.
Training Content
A comprehensive training course is like sitting down to a gourmet dinner without the calories. Both set expectations for excellence and satisfy specific needs. And, you have a variety of interesting or unique dishes (or curricula)—all served in specific order. Like most training classes we started with some background theory to whet our students’ appetite for what’s coming—this is essentially the aperitif.
Chapter one, the Appetizer or Starter, focuses on successful, risk-driven ergonomics program development and deployment options, pitfalls, and strategies. A critical part of this discussion focuses on why most ergonomics programs fail and ways to minimize failure and maximize success.
Chapter two, the Salad, is an overview of anatomy, musculoskeletal disorders, and ergonomic risk factor research. This critical information enables you to effectively use risk assessment tools and develop effective solutions.
Chapter three, the Main Course – Turf and Surf. The Turf or meat of the training is on how ergonomics can be integrated into Lean Manufacturing and Six Sigma initiatives. A five step approach for defining, measuring, and controlling ergonomics risks is presented along with proven tools and methods to assist with defining risks and eliminating the non-value-added waste of motions related to poor human performance.
Chapter four, the Main Course – the Surf part of the training, looks at tools and methods to measure speed, time, and cost associated with ergonomic improvements and solutions. The ability to measure the impact of ergonomic solutions on human performance independent of injury data is indispensable and the key to linking how ergonomics can impact Lean and Six Sigma metrics.
Chapter five, the Dessert, is the application of newly acquired skills to a client specific production area. All the tools and methods learned in the class are used to define and measure the problem, analyze solutions and calculate the impact of the solutions on risk, efficiency, cycle time, quality, and other client-specific Lean/Six Sigma metrics.
Getting Results and Demonstrating Value
The final chapter in the training or the after dinner Brandy is where the teams present the results of their individual case studies to other trainees, instructors, and company management for review, critique, and feedback. Each team is asked to discuss the following in their presentation:
- Define the issues and concerns with the current operation and the approach and facts they used to define the problem (i.e., past injuries, ergonomic risks, design flaws, efficiency, and quality issues, etc).
- Measure and quantify the problem identified in step 1 and the tools and methods they used to collect the data.
- List both the short and long term potential solutions to mitigate the concerns and issues.
- Determine the impact of each potential solution on risk reduction, cycle time, efficiency, and quality using the tools and methods from the class.
- Specify the low-cost, high impact solutions (based on results of step 4).
- Present the recommended implementation plan and accompanying impact and cost justification data to the group for feedback.
In a recent training, the results of one team’s case study yielded a 3,500% ROI for the costs of the training program. By focusing on low-cost simple solutions that have a significant impact on ergonomic risk and efficiency, one team was able to redesign the layout of the workstations and cells and implement some low cost tools. The impact of their implementation plan is as follows:
- 50% reduction in ergonomic risk (the risks scores went from a high risk to a low risk)
- New design that allows all work to be performed in primary and secondary work zones compared to the old design all work was performed in the secondary, tertiary and rare work zones
- 38% reduction in floor space
- 9.4% reduction in cycle time per shift
- 9.4% increase in production throughput per shift
- Labor cost savings of $14,000 per year (per workstation)
- Cost of solutions = $500
Take Home Message
By developing company-specific problem solving case studies during the training, we were able to easily justify the cost of the two-day applied ergonomics training class. In order to successfully integrate ergonomics into a Lean Manufacturing or Six Sigma system, you need to define and accurately measure current ergonomic risks and the total impact to predict the outcome of improvements on risk, speed, and cost. This is why it is essential to have reliable tools and methods that help gather and present facts and data. The data that the above team was able to generate happens quite frequently during training classes. If your ergonomic training classes don’t achieve this type of return, you may want to reconsider your approach. Ergonomics should not be seen as something optional but rather as a tool that can generate real savings and impact the bottom line costs of any company.
If you are interested in learning more about EORM’s high impact training courses and how achieve similar results with your company please contact me. And, until next quarter—bon appétit!
Ergonomically Yours,
Ben Zavitz, CPE
zavitzb@eorm.com
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