Today's linemen often start off in the field as strong, healthy workers. Over time, due to the repetitive nature of the job, their bodies wear out and many develop shoulder, elbow and wrist injuries.

We Energies (Milwaukee, Wisconsin) uses advances in the field of ergonomics to help people work safely. The utility evaluates common tasks and tools to determine if they can be improved upon to keep workers safe from unnecessary risk and injury.

An example of ergonomics at work is the change from manual tools to equipment that is battery-operated or hydraulic. We Energies made this shift to improve productivity and reduce on-the-job injuries and associated medical costs.

Reviewing Research

Five years ago, We Energies partnered with the Electric Power Research Institute (EPRI) and Marquette University to identify processes that could be improved through ergonomics. Researchers observed linemen performing about 30 different routine tasks in the field. Through the researchers' recommendations, the linemen identified safer and more effective ways to do their day-to-day jobs.

We Energies made major changes in its tools as a result of the EPRI study and its own experience. The company invested in hydraulic and battery-operated cutters, presses and drills. Over the last five years, We Energies purchased a hydraulic and battery-operated cutter and press for each of our line crews, troubleshooting crews, and cable, contractors and URD teams. While there was a learning curve as the linemen adjusted to the new tools, they now report they couldn't live without them. Our field crews now have the right tools to do the right job, and the number of injuries has decreased significantly.

Ergonomic Improvements at Work

In the past, two linemen in a bucket truck were needed to cut a jumper with old manual bolt cutters. One worker would hold the wire while the other would operate the wire cutter. With the new battery-operated cutter, the task has become a one-person job. Wire cutting is now safer to perform because workers have more control over the primary wire, and they're not straining their elbows, arms and shoulders in the process.

In addition to wire-cutting improvements, the EPRI study revealed that We Energies' manual press required substantial physical force to operate and caused significant shoulder injury. In light of the research, the company invested in a battery-operated hydraulic press.

The Economics of Ergonomics

Adopting new tools requires significant investment. Therefore, We Energies created a business case to demonstrate how the new tools would save money in terms of long-term benefits rather than short-term savings. The utility focused on the fact that while the new tools cost more upfront, ultimately, the company would save on medical expenses. These savings would exceed any short-term costs.

In addition to the written business case, We Energies allowed people to feel the difference for themselves and actually use the new, ergonomically approved tools. This physical demonstration garnered the additional support needed to move the project forward.

An Ergonomics Committee was Born

Once the decision was made to invest in battery-operated tools, We Energies formed an official ergonomics committee. Every month, the committee discusses ways to increase productivity in the field and lessen discomfort and fatigue on the job site. The committee is comprised of people at varying levels of the organization. Executives, managers and engineers participate, as well as linemen from the overhead and underground divisions.

Many great ideas have sprung from the ergonomics committee's roundtable discussions. In addition to adding battery-operated hydraulic tools, We Energies also has invested in lightweight mats for tasks that require kneeling or any extensive time spent on a hard, uneven or bumpy surface. (In the past, employees used plywood for this purpose.) Benefits include reduced injuries and efficiencies, including time savings of loading and unloading equipment.

Injuries Can Be Prevented

As any lineman knows, working in the utility industry can lead to repetitive-use injuries. Through ergonomic tools, field professionals can lessen the risk of injury. In addition to improved personal safety, the company as a whole benefits from a happier, healthier workforce.

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Fred Wenzel is a leading line mechanic for We Energies. He has worked in the utility industry for the last 20 years.
Fred.wenzel@we-energies.com

2008 ERGONOMICS REPORT

The Electric Power Research Institute (EPRI) published in March 2008 an ergonomics handbook for the electric power industry. EPRI focuses on ergonomics related to electrical generating stations in this latest ergonomics handbook. EPRI has been offering ergonomics information to utilities since 1999. To prepare the recent report (available at www.epri.com), EPRI reviewed power plant engineering literature, partnered with Marquette University and worked closely with a utility.

HOW TO IMPROVE THE ERGONOMICS AT YOUR UTILITY

1. Put the tools in the hands of the decision makers

   Utility executives often keep tabs on the operations of the field crews, but if they're not out in the field on a daily basis, they may not know exactly what tools their linemen are using to get the job done. To educate them about the different tools that are available on the market, set up a meeting with executives and allow them to test out different tools so they can experience the difference in comfort, usability and safety firsthand.

2. Research the market

   Many different vendors offer a variety of tools, and it's important to find the ones that best fit your field workforce. For information on specific tools and vendors, visit the online Buyer's Guide available at www.tdworld.com.

3. Keep an eye on technology

   To stay on top of the latest advancements in ergonomics, attend electric utility trade shows and read industry magazines.

4. Get involved

   If possible, try to participate in your utility's ergonomics committee, and discuss ergonomics during your daily and weekly job-site safety meetings.