Solutions for the Prevention of Musculoskeletal Injuries in Foundries

Many proactive initiatives undertaken by the foundry industry, including establishing ergonomic processes, incorporating ergonomic principles into new projects, and conducting facility walkthroughs to identify injury risks have resulted in a reduction in worker injuries and illnesses. Employees working in foundries are often exposed to ergonomics-related injury risks, such as lifting heavy items, bending, reaching overhead, pushing and pulling heavy loads, working in awkward body postures, and performing the same or similar tasks repetitively. The physically demanding tasks performed during foundry operations may be responsible for the musculoskeletal disorders (MSDs) developed by workers in this industry. Foundry workers have higher MSD injury rates than workers in general industry and construction. Although many ergonomics-related risk factors exist in foundries, this industry has found ways to make the work less stressful through ergonomic solutions. The successful efforts of some foundries to address this important issue provide a sufficient basis for replicating these actions to better protect foundry workers. This publication provides recommendations for foundries to help increase employer and worker awareness of ergonomics-related risk factors, alleviate muscle fatigue, increase productivity, and reduce the number and severity of work-related MSDs. The general information in this publication is intended to provide foundry employers and workers with effective and practical solutions. It also aims to be a useful reference source when determining the need for ergonomic assistance for specific jobs, such as melting, mold preparation, casting, shakeout and core knockout, and cleaning and cut off. The recommendations and information presented here are intended to be a flexible framework to be adapted to the needs and resources of each individual foundry. The solutions recommended in this publication may also be beneficial in other industries, such as those that handle heavy materials, use tools for multiple processes, and work on parts of widely varying sizes and shapes. OSHA realizes that some foundries, particularly small ones, may need assistance with certain ergonomic solutions. This may include developing and implementing an ergonomic process or tailoring a recommended solution to a specific situation. Therefore, employers are encouraged to take advantage of OSHA’s free consultation services to address these needs. This publication presents ergonomic solutions that are already implemented within some foundries. OSHA recommends that foundries consider these solutions in the context of a broader, systematic process that includes the elements described in this publication. Such a process will make it more likely that any solutions implemented will be both cost-effective and successful in reducing injuries. This document includes an introduction, a process for protecting workers, solutions that employers can use to help reduce MSDs in foundries, and additional sources of information on ergonomic applications in foundries.