excavator operator pda - amazon s3operator+pda.pdf · ship’s hold/ accessing the heede crane 5....

Physical Demands Analysis – Excavator (Dock and Ship) Operator

Last Revised: December 21, 2008

ErgoRisk © 2008 of 14

Job: Excavator (Dock and Ship) Operator Description: Operates the Excavator and Heede Crane

Equipment Assessed: Kinder Morgan (Excavator and Heede Crane)

ESSENTIAL DUTIES

1. Operating the Excavator (Dock, Ship, Receiving) A) Sitting B) Handling Controls C) Operating Foot Pedals

2. Operating the Heede Crane

A) Sitting B) Handling Controls

3. Climbing On/Off the Excavator

4. Gaining Access to and Exiting the Ship’s Hold/ Accessing the Heede Crane

5. Pre-Operation Inspection

Non Essential Duties:

� Keep inside of the equipment clean

� Ensure windows are clean

Shift Schedule:

The Excavator operators work 8hr shifts. The normal shift schedule is 8:00AM – 4:30PM with 10min breaks at 10AM and 2:30PM and a 30 minute break for lunch. Afternoon and graveyard shifts may be worked by the excavator operator.

Staffing:

The Excavator Operators are dispatched by themselves when working with sulpher or zinc. At Kinder Morgan, two operators are dispatched for receiving. One operator operates the ‘Receiving Excavator’ and the other operates the ‘Heede Crane’.

In addition to the tasks at Kinder Morgan, a single Excavator Operator may also be dispatched to Neptune Terminals for shipping of Potash or other tasks (e.g. blending).

Other excavator jobs may occur along the foreshore (e.g. clean-up). In the majority of cases, one Excavator Operator is dispatched.




NOTE: At the dispatch hall, the Excavator work is split into Dockwork (pink ticket) and Shipwork (yellow ticket).

DESCRIPTION OF ESSENTIAL DUTIES

1. OPERATING THE EXCAVATOR (DOCK AND SHIP)

Frequency

� Operates the Excavator for up to 7.5 hrs out of an 8-hour shift.

Equipment

� ‘Komatsu’ Excavator

Task Description

� The Excavator is a piece of heavy equipment consisting of an articulated arm and a cab mounted on a rotating platform. The excavator’s platform is mounted on tracks that allow for travel over uneven or sloped terrain.

� On the dock, the Excavator Operator uses the machine to ‘manage piles’ and direct product into transfer chutes. Operators work on top of bulk piles during when product is being shipped. The Operator is responsible for ensuring that the grizzly (grated chute to the below ground conveyor system) is fed with bulk product. This usually consists of using the articulated arm and attachment to pull product toward the grizzly or using the arm to ‘knock down’ the slopes of the bulk pile in order to allow the product to feed the grizzly (by gravity).

� On the ship, the Operator uses the controls of the machine to either ‘Trim the hatch’ (pushing product into the corners of the hold) or ‘Discharging’ (pulling/pushing product into a pile to be picked up by an overhead crane (e.g. Red Dog Crane)).

� The Receiving Excavator at Kinder Morgan is slightly different in that the Operator is responsible for offloading rail cars of copper or slag. In this case, the excavator is always positioned on a flat surface and the operator uses the arm and scoop to empty the product from the rail cars.

A SITTING Equipment Excavator Seat

Duration up to 7 hours Frequency sustained Force n/a

Task Overview

� Frequent and sustained neck and back flexion when hunching forwards to look down through the excavator floor windows to see

the work. � Frequent rotation of the neck to the left or right when looking

around work area.

� Frequent neck extension when looking up at excavator arm. � The operator is seated for the duration of the operating task.

� Natural seated posture is typically a rounded upper back and forward head posture.

� Whole-body vibration when excavator is in operation. � Significant jolts and bumps when the excavator is travelling or performing forceful movements.

� Excavator seat is adjustable




B HANDLING CONTROLS Equipment Joysticks, button controls

Duration up to 7.5 hours Frequency Constant when operating Force Minimal

Task Overview

� Each Excavator has a joystick control on each side of the operator.

These are the primary controls for the articulating arm and the

bucket.

� As well, there are gear controls on the left and track controls hat

can be operated with the feet or the hands. � Secondary controls in the cab include lights, heat etc.

� The primary grip for all of the joystick controls is a power grip.

� Wrist postures and angles vary depending on the movements. � Force required is minimal.

� The arms may be supported by the arm rests. � Complex small wrist movements in all directions may be required to

manipulate the different controls.

� Both joystick controls move side to side and forward and back. � There are significant dexterity requirements to make fine

adjustments to the excavator arm.




C OPERATING FOOT PEDAL Equipment Travel Control Pedal

Duration up to 7.5 hours Frequency Intermittent when operating Force Minimal

Task Overview

� There are two foot pedals on the floor of the crane cab. The left pedal

controls the left excavator track and the right pedal controls the right

excavator track. Using only one track rotates the base of the machine.

� Operating the foot pedals requires ankle flexion and extension. � These foot controls can also be operated by hand levers connected to

the foot pedals.

FUNCTIONAL DEMANDS with MSI POTENTIAL

�� Operating the Excavator

Neck

� Static neck flexion slightly rounded upper back and forward head posture when looking up or down at the work can stress the structures in the

neck and upper back. � Neck rotation in the horizontal plane to watch the load being moved

laterally or twisting to control panel puts rotational stress on the structures in the neck.

Shoulder

� Dynamic awkward postures of the shoulder including forward flexion when handling the joystick or feet control handles.

� Intermittent holding of the elbow away from the side of the body when

pushing outward on the joystick controls.

Elbow/Wrist/Hand

� Complex small wrist movements are required in all directions to operate the joystick controls.

� Repetitive pinch grip is required for some knobs and switches. � Non-neutral wrist and forearm postures are required to access controls

that are behind the seated operator at the rear of the consoles.

� Repetitive thumb and finger movements are required to push buttons and manipulate joystick for small movements.

� Sustained wrist postures are required for some operations and static positions increased fatigue to muscles and structures in the forearm,

elbow and wrist. � Static small finger extension is required to stabilize the hand for fine tuning movements with the

joystick.

� Static thumb extension on joystick can stress the structures around the base of the thumb.




File photos

File photos

STRATEGIES TO MINIMIZE MSI

�� Operating the Excavator Neck � Stretch the neck muscles often to allow tissue recovery

resulting from awkward postures. Try tucking the chin to

place the neck in proper alignment with the spinal column and then rotate the head to one side or the other. Hold

the stretch for 20 seconds. � When waiting for the pile to flow into grizzly, return neck to

a neutral position and look straight ahead until required to look down again.

Back

� As much as possible, avoid sitting for extended periods of time to minimize static use of back muscles. Stand and

stretch whenever possible.

� Take the opportunity to stretch or walk during scheduled breaks to restore blood flow to the spinal tissues.

� Minimize awkward sitting posture by taking the time to adjust seat and foot pedals for best fit before starting

work. � Reverse forward leaning postures by arching the back,

squeezing the shoulder blades together and sticking the

chest out (see picture at right).

Shoulders

� Take hands off the joystick whenever not operating the controls. Let shoulders relax and hands rest in lap until required to reach back for joystick again.

� Sit as far back in the seat as possible to reduce the distance needed to reach behind to access the

controls � Use elbow rests to reduce static unsupported postures of the shoulders when operating the joysticks.

Elbow/Wrist � Maintain neutral wrist posture when operating joystick

and controls. Where possible use a power grip on the joystick to reduce stresses to the small structures in the

hand.

� Let go of the joystick whenever possible to reduce static grip stresses to the elbow, hand and forearm.

� Perform wrist and forearm stretches with elbow straight to stretch muscles and increase blood flow after periods of particularly repetitive or prolonged static

wrist and hand postures.




2. OPERATING THE HEEDE CRANE

Frequency

� Operates the Heede Crane for up to 7.5 hrs out of an 8-hour shift. The Excavator Operator at the Receiving Station may switch with the Heede Crane Operator but is not required to.

Equipment

� Heede Crane

Task Description

� The Heede Crane is a crane that rolls on rails over top of the railway tracks adjacent to the receiving station at Kinder Morgan.

� The purpose of the crane is to remove and replace lids on the railcars

before and after they are emptied. � The crane operator positions the crane directly over the car and uses

crane controls to raise and lower the head that connects to and picks up the rail car lids.

� This crane is operated in manual mode only. � The controls on this crane are basic (cab trolleys and gantries, the

head raises/lowers and clamps on/off rail car lids). � Each lid takes 2-10 minutes to remove/replace (typically closer to 2

but some are difficult). In a shift, they will typically remove and replace up to 29 rail car lids.

� In order to access the Heede Crane cab, the operator must climb a flight of stairs and then climb up a ladder to the level of the crane.

A SITTING Equipment Excavator Seat

Duration up to 7.5 hours Frequency Constant Force N/A

Task Overview

� Frequent and sustained neck and back flexion when hunching forwards to look down through the

excavator floor windows to see the work. � There are two small red tabs that are mounted on the crane to provide the operator with a guide as

to where to position the crane. In order to view these tabs, the operator must bend forward and to the side.

� Frequent rotation of the neck to the left or right when looking around work area.

� Whole-body vibration when Heede Crane is in operation. � The Heede Crane seat has some suspension and is adjustable.




B HANDLING CONTROLS Equipment Joysticks, button controls

Duration 4-5 hrs Frequency Constant when operating Force Minimal

Task Overview

� The Heede Crane has a small control box with a few primary controls.

� The left joystick controls trollying and gantrying (N/S and E/W respectively) and

the right joystick controls the crane movement (up/down). Another joystick controls the clamping/release mechanism used for picking up the rail car lids.

� Secondary controls in the cab include lights, heat etc. � The primary grip for all of the joystick controls is a pinch grip or a modified

power grip (in between the thumb and index finger).

� Wrist postures and angles vary depending on the movements.

� Force required is minimal. � There are no arm rests.

� All joystick controls move side to side and forward and back. � There are significant dexterity requirements to make fine adjustments crane

controls.

FUNCTIONAL DEMANDS with MSI POTENTIAL

�� Operating the Heede Crane

Neck � Static neck flexion slightly rounded upper back and forward head posture when

looking up or down at the work can stress the structures in the neck and upper back.

� Neck rotation combined with significant flexion of the back when looking from side

to side to line up the rail car lids with the crane head. This posture increases leverage on the muscles of the neck and upper back which must hold the weight of

the head in a static posture until the crane head is positioned correctly.

Back

� Significant back flexion and side bending when trying to line up the crane head and the

rail car lid. � Back side flexion and forward flexion can were both demonstrated at up to 45 degrees.

Shoulder � Dynamic awkward postures of the shoulder including forward reaching and handling

controls with the elbows away from the side of the body. This postures increase the

stress on the muscles that support the arm in the mid and upper back.

Elbow/Wrist/Hand

� Repetitive pinch grip or modified power grip (thumb/index finger) is used for the joysticks.




File photos

File photos


�� Operating the Heede Crane Neck � Stretch the neck muscles often to allow tissue recovery

resulting from awkward postures. Try tucking the chin to

place the neck in proper alignment with the spinal column and then rotate the head to one side or the other. Hold

the stretch for 20 seconds. � When travelling or gantrying, return the back and neck to a

neutral position and look straight ahead until required to

focus on the position of the crane head again.

Back � As much as possible, avoid sitting for extended periods of

time to minimize static use of back muscles. Stand and stretch whenever possible.

� Take the opportunity to stretch or walk during scheduled

breaks to restore blood flow to the spinal tissues. � Minimize awkward sitting posture by taking the time to

adjust the seat for best fit before starting work. � Reverse forward leaning postures by arching the back,

squeezing the shoulder blades together and sticking the chest out (see picture at right).

Shoulders

� Take hands off the joystick whenever not operating the controls. Let shoulders relax and hands rest in lap until required to reach back for joystick again.

Elbow/Wrist � Maintain neutral wrist posture when operating joystick

and controls. Where possible use a power grip on the

joystick to reduce stresses to the small structures in the hand.

� Let go of the joystick whenever possible to reduce static grip stresses to the elbow, hand and forearm.

� Perform wrist and forearm stretches with elbow straight to stretch muscles and increase blood flow after periods of particularly repetitive or prolonged static

wrist and hand postures.




3. CLIMBING ON AND OFF THE EXCAVATOR

Frequency

� Two or three times per shift depending on how the operators have structured their breaks.

Equipment � None

Task Description

� When on the ground, the Operators climb onto the machine using a combination of foot and handholds including the track (top picture).

� When accessing an excavator inside a vessel, the operator may be required to climb onto the side of the machine, maintain balance and walk along the side of the machine in order to access the cab.

ASCENDING & DESCENDING THE EXCAVATOR Equipment None

Duration 1-2 minutes Frequency 2-3 times/shift Force Body Weight

FUNCTIONAL DEMANDS WITH MSI POTENTIAL

�� Climbing On and Off the Excavator

Neck

� Significant neck flexion or rotation may occur as the operator looks down to ensure his footing when

climbing on/off the machine.

Shoulder

� Overhead reaching is required when climbing up the side of the machine. This can stress structures in the shoulders and arms.

� When accessing the machine inside a vessel, the operator may use long reaches in order to maintain three points of contact (see third picture in this section).

Knee

� Supporting body weight against the force of gravity when ascending and descending stairs or ladder can put stress on the structures around the knee.

� Impact force descending the last step of the ladder can put stress on the structures around the knee, particularly if jumping down from bottom step.

� Significant knee flexion when climbing onto the machine.





�� Climbing On and Off the Excavator Neck

� Avoid sustained neck flexion when ascending or descending the stairs and ladders. Check footing

then return to looking in front when climbing up/down.

Shoulder

� Avoid extreme overhead reaching when climbing ladders. Keep arm in close to the side of the body to increase stability through the shoulder joint.

Knee

� Use hand rail or ladder rungs to help with balance and to assist in pulling up body weight when ascending or to slow rate of descent when coming down the stairs or ladder.

� Avoid jumping down from bottom step to reduce stress to the knee. � Always use three point contact when ascending or descending the excavator.

4. GAINING ACCESS TO AND EXITING THE SHIP’S HOLD/ GETTING ON AND OFF THE HEEDE CRANE

Frequency

� Ship’s Hold: Two or six times per shift depending on need. Frequency may vary depending on the needs of the crane operator. Sometimes the crane operator will put an excavator into a ship hold to ‘break up’ the crust/top of the pile and then lift the excavator to the next. This may be repeated during the day.

� Heede Crane: Four or more times per shift depending on need. Frequency may very depending on utilization.

Equipment � None

Task Description

� If an excavator is needed inside a vessel, the crane (e.g. Red Dog Crane) will be used to lift an excavator from the dock to the inside of the ship’s hold.

� The operator drives the excavator to the ship and then exits the excavator, accessing the hold through the ship. This requires travel by foot up the gangway, through the interior passageways of the vessel, through a hatch and then down a series of ladders/stairs to access the ship’s hold.

� Once inside the ship’s hold, the operator must walk over the loose bulk product (e.g. zinc) and then ascend the excavator. Once the hold is empty, the operator is required to reverse this course, climbing series of stairs and ladders to exit the ship and to return to the dock to retrieve the excavator.

� To access the Heede Crane cab, the operator must walk across uneven surfaces (railway tracks), climb a flight of stairs and a ladder (~12’) in order to get to the level of the cab.




GAINING ACCESS TO/ EXITING THE SHIP’S HOLD Equipment None

Duration 5-10 minutes Frequency 2-6 times/shift Force Body weight


�� Accessing Ship’s Hold/Heede Crane

Neck

� Significant neck flexion, extension or rotation may occur as the operator looks

down to ensure his footing when climbing up/down ladders. � Reaching above shoulder height and holding on is required when climbing

ladders. The operator may also need to move through hatchways which constrain movement and can increase awkward shoulder postures. This can

stress the structures of the shoulders and arms.

� The shoulder and forearm muscles must be able to sustain the weight of

the worker especially if a foot slips or if clothing (e.g. hi vis vest or

backpack) snags on a part of the stair, ladder or hatchway.

Hip

� Supporting and propelling body weight against gravity when ascending or descending stairs or ladder can put stress on the structures around the hip

and knee.

� Significant hip flexion is required when climbing up or down ladders and stair ladders.

Knee � Supporting and propelling body weight against gravity when ascending or descending stairs or ladder

can put stress on the structures around the knee. � Possibility for high impact force when descending stairs or ladders.

� Impact force when descending the last step of the ladder can put stress on the structures around the

knee, especially if jumping down from the bottom step.

Ankle

� Supporting and propelling body weight against gravity when ascending or descending stairs or ladder can put stress on the structures around the knee.

� Jumping down from the last step may place stress on tissues in and surrounding the ankle joint.


�� Accessing Ship’s Hold/Heede Crane Neck

� Avoid sustained neck flexion when ascending or descending the stairs and ladders. Check footing then return to looking in front when climbing up/down.

Shoulder � Avoid extreme overhead reaching when climbing ladders. Keep arm in close to the side of the body

to increase stability through the shoulder joint.

� Ensure all equipment (backpack, radios, hi-vis vests) are firmly secured before climbing in order to reduce unexpected forces and eliminate the likelihood that you will get caught up on a ladder.




Knee

� Use hand rail or ladder rungs to help with balance and to assist in pulling up body weight when ascending or to slow rate of descent when coming down the stairs or ladder.

� Always use three points of contact when ascending or descending the ladders or stairs.

5. PERFORMING THE PRE-OPERATION INSPECTION

Frequency

� Each time the operator accesses the Excavator. May be 1-3 times a day depending on the operators have structured their breaks.

Equipment � None

Task Description

� Operators perform a visual inspection of the Excavator by walking around the equipment. Operators are looking for major mechanical issues (oil leaks, equipment damage, and damage to articulating arm or attachment).

NOTE: The joint ranges of motion required to perform the visual inspection is significantly less than the postural ranges required to ascend the Excavator. As well, the operator is free to use a variety of different body postures to perform the visual inspection so MSI risks for this task are relatively low.

PRE-OPERATION INSPECTION Equipment None

Duration 1-2 minutes Frequency 1-3 times/shift Force Minimal


�� Performing Pre-Operation Inspection

Neck � Neck flexion may occur as the operator looks down to assess the condition of the tracks.

Back

� Bending and stooping may be required to assess the condition of tracks

Shoulder

� Above shoulder reaching may be required if the operator decides to look more closely at a potential problem with the engine or with the articulating arm.





�� Performing Pre-Operation Inspection Neck

� Avoid sustained neck flexion when performing assessments. Look down briefly and then move head

back into a neutral position once area is visually inspected.

Back � Avoid twisting or bending the back when assessing low parts of the Excavator. Instead keep inward

curve in the low back and go down on 1 knee to assess low areas. Move feet rather than twisting back when turning to inspect other areas.

Shoulder � Keep arm close to the side of the body and avoid overhead reaching as much as possible.

6. ENVIRONMENTAL CONSIDERATIONS

Exposure to Elements

� The operator is inside the Excavator cab for the duration of the time he/she is operating the machine. The operator is exposed to the elements when ascending/descending the Excavator and when performing the pre-operation inspection.

Uneven Surfaces

� The Excavator is constantly moving over uneven surfaces which increases the bumps and jolts inside the cab.

Vibration

� The operator is exposed to whole body vibration throughout operation of the excavator. There are also significant bumps and jolts as the excavator changes direction, particularly if moving up and over piles of bulk material.

Other (Chemicals)

• PPE is required due to the types of products being handled. Workboots, Hi-Vis vests, respirators, dust masks, gloves, white coveralls and hardhats are frequently worn.




7. PHYSICAL DEMANDS SUMMARY TABLE

Job Demands

Max. Weight/

Avg. Weight

(Kg)

Duration

per

exposure h

=hrs

s=secs,

m=m

ins

h=hrs

Frequency

UNABLE

to p

erform

Comments

Lifting/Carry 5 R Handling a fire extinguisher in the case of an

emergency.

Push/Pull 5/3 <10s F/C Complex small movements of joystick forward and

back, and gross movement to open/close cab door

Supporting Body Weight 20m O Ascending/Descending Excavator via steps, stairs and ladders and ladders, 5-6 times/shift

Gripping / Handling <1m F/C Joysticks & other controls: repetitive small movements STRENGTH

Fine Motor Skills <10s F/C Complex small movements of joystick control to

operate articulating arm and attachment.

Sitting 7.5h F/C Constant sitting for duration of work

Driving 7.5 O Intermittent travel to get to pile and to adjust position

of excavator.

Standing <15s R Stand to adjust seat, or during visual inspection

Walking 100m O Walk from machine, up gangway to vessel, through

passageways and down ladders, stairs to access hold.

May be repeated 2-6X per shift.

Bending/ Stooping 4-6h O May occur when excavating below the level of the

machine (looking down, bending fwd.)

Sustained Crouching/ Kneeling

N

Climbing Stairs 5m O Ascend/descend ladders and stairs to access hold.

Climbing Ladders 3m O Ascend/descend ladders and stairs to access hold.

May need to descend multiple short ladders.

Crawling N

Balancing <5m R When climbing onto Excavator inside hold

Throwing N

POSTURE & MOBILITY

Overhead Reach <5s R Climbing ladders when ascending/descending

Exposure to Elements <5m O Ascending/descending excavator or during visual

inspection

Uneven Surfaces O When accessing excavator inside vessel

Proximity to moving objects N Not within the cab, outside there are front end loaders

(dock, bulk warehouses), or overhead crane (when

inside vessel)

Vibration (upper extremity) N

ENVIRONMENT

Vibration (whole body) 7.5h F/C Constant low level vibration when operating excavator

Frequency Ratings:

N: Never

R: Rare - Not daily or up to 1% of shift (<5mins/day)

O: Occasional - 1%-33% of shift (up to 2.5hrs)

F: Frequent - 34%-67% of shift (2.5-5hrs)

C: Constant ->67% of shift (>5hrs)

excavator operator pda - amazon s3operator+pda.pdf · ship’s hold/ accessing the heede crane 5....

Documents