Hasbro a star in ergonomics

Michelle Swafford

Wednesday, Dec. 10, 2003 | 11:08 a.m.

The nation's second-largest manufacturer of games and puzzles has significantly reduced accidents among employees by establishing multiple ergonomic and safety programs.

Now, Hasbro Games, a division of Hasbro Inc. in East Longmeadow, Mass., hopes to teach other companies how to improve their workplaces. Executives from Hasbro spoke Tuesday to about 1,500 attendees at the 10th annual National Ergonomics Conference and Exposition, which runs through Thursday in Las Vegas.

From 1985 to 2003, the company reduced ergonomic cases involving sprains and strains 85 percent, which has improved the company's competitiveness in the board-gaming business, said Pedro Caceres, senior vice president of operations for Hasbro Games. The company ramped up training programs and improved working conditions for its 1,500 employees, most of whom are factory workers.

"There is a direct correlation between safety and quality performance and company performance," Caceres said. "Ergonomics is a tool we need to use to be more competitive. We do it for the health of employees and (because) there is a cost associated with not doing it."

People are the key component in making ergonomics and machinery work properly, Caceres said.

Hasbro created a corporate policy on safety, health and environmental practices, which included ergonomics. Then it established a strategic plan for carrying out those practices. The company's Massachusetts building has been divided into 12 areas and each one has an ergonomics team, which meet monthly to discuss area goals and achievements.

Every two years, corporate officials audit the manufacturing plant to make sure everyone is using the company's safety, health and environmental practices correctly.

Another training opportunity for Hasbro employees is an annual ergonomics conference. In 2002, Hasbro started holding ergonomics conferences and invited Occupational Safety and Health Administration employees to speak about safety.

In addition to regular training programs, Hasbro has a bulletin board with safety information in the five languages commonly spoken in the company. The board includes proper lifting techniques signs and data on company accidents. A suggestion box is also available for employees to contribute their thoughts.

"Communication, communication, communication, is the most important thing," Caceres said. "Communication generates common action."

Many of the employees are trained in first aid and cardiopulmonary resuscitation skills. Also, Hasbro has a physician, nurses and a medical area within the factory to respond to emergencies quicker.

Hasbro has redesigned its workplaces, too. Materials are no longer on the floor. They are now stored at a level where employees can lift them between their knees and shoulders. Anything that is deemed an ergonomic concern is given a red tag so it can be addressed. As machinery is replaced, the company's safety and ergonomic policies are kept in mind, Caceres said.

Caceres said companies should obtain external certifications to validate their safety and ergonomics programs whenever possible. For example, Hasbro participates in a few best-industry practice programs such as ISO 9001-2000 and OSHA's Voluntary Protection Programs. Companies must meet various criteria set by the program sponsor and onsite evaluations to participate. As a result of Hasbro's involvement with such programs, it has won various awards.

In addition to Caceres' tips on how to improve company workplaces, more than 100 exhibitors showcased the latest version of computer workstations, hand tools, chairs and other gadgets designed to reduce workplace injuries.

Phillip Snyder, president of Wyandot Seating in Bucyrus, Ohio, was demonstrating piVot chairs. The chairs contain polyurethane tubing that moves with the body and has 11 adjustments. When people shift their weight or reach for something, the base of the chair slides with the body to keep the back aligned, Snyder said.

"It allows you to exercise whether you like it or not," he said.

The suggested retail price for piVot chairs is $1,000, but they are available for as low as $550, Snyder said.

Deta!ls, a Steelcase company in Grand Rapids, Mich., was showcasing Height-AdjusTable desks. The work surfaces can be raised or lowered by pushing a button, which electronically adjusts the desks to heights between 24 and 52 inches. Suspended trays can be attached to the desk for telephones, flat screen computer monitors and pen holders. The suggested retail price is about $1,200, but they are available from dealers for between $600 and $800, said James Kemp, director of sales for the eastern United States.

DynaFlex Intl., based in Anaheim, Calif., demonstrated Gyro Exercisers, which strengthen hand, wrist and arm muscles and improve coordination to prevent carpal tunnel and other injuries. Prices range from $24.95 to $39.95 depending on the features and are available in sporting goods stores.

They are designed for computer users, but can be used by anyone who uses their hands a lot, company President Tom Smith said.