Meat + Poultry - February 2010 - 67

The beef processing floor at Tyson's Dakota City, Neb., plant was designed with
ergonomics in mind. (Photo courtesy of Tyson Foods)

(Continued from Page 66)
floor while all bone belts and vacuumpackaging equipment are located one
floor below.
"Our ergonomics program builds
a team because you get everybody involved; it really is a joint effort," Rupp
says. "Jim Hilton [29-year company
veteran who is an assistant hourly trainer (AHT), ergonomics monitor and a
UFCW Local 222 member] has been
instrumental in this program through
his work, ranging from testing knives
to helping find solutions on a number
of production floor challenges."

Committed to success
Tyson and union executives agree the
company was committed to this program from the start. The program
began under the leadership of the late
Bob Peterson, former IBP chairman
and CEO. Ron Goodrich, vice president of operations at the time, headed
the program in its early years.
"The biggest challenge was getting
everyone educated on what ergonomics was," says Bob Collins, plant HR
manager, long-time Tyson executive
and a Tyson ergonomics pioneer, on
launching the program.
"We had to hire consultants to
train trainers on what a stressor
was," adds Denny Golden, training/ergonomics manager who has
been with the company 29 years and
oversees the Dakota City ergonomics program. "I have been managing
the program since 1990."
"We also needed to teach line supervisors about non-verbal commu-

nications," he adds. "People having
a problem may be rubbing a hand or
shrugging a shoulder. That continues
to be an important every-day process
our supervisors observe."
Jim Lochner, company veteran,
ergonomics champion and recently
appointed chief operating officer of
Tyson Foods, says Tyson has spent
millions of dollars in developing ergonomically-designed equipment
and process improvements, as well
as on training over the past 20 years.
"However, the real key to the program's success has been the workers
who serve as safety and ergonomics
monitors," he adds. "The input we've
received from hourly production workers and the participation of our plant
and corporate management teams
have been invaluable."
Tyson takes much pride in this program, says Tom Dunlop, HR manager of the Dakota City complex. "We
have a joint committee at the plant
comprised of Tyson management
and our hourly workforce - called ergonomic monitors. We have monthly
and weekly meetings and work jointly
with Local 222 to make this a better
workplace for the worker."

Room for improvement
When Tyson kicked-off this program, its Dakota City complex was
an older facility in need of ergonomic
changes, Golden says. "We looked
every morning at the proper stand
height for our line people," he adds.
"The tables they worked on were positioned low on the floor. So you'd try

to get someone 6 ft. 4 inches as close
to the floor drain as you could, since
the floors sloped down to the drains.
When we got someone 5 ft. tall, we
had to work on the stand to get them
at the right height. We spent millions
of dollars since then making adjustable stands."
Today, when glancing down a line,
all workers' heads, regardless of their
height,- are at an even height.
The program begins with orientation training for new production
workers, which can be done in almost any language; continuing ergonomics training for veteran production workers; involving and training
hourly workers as 'ergonomic monitors'; worksite analysis and redesigning work stations and equipment; and
a medical management program focused on early detection and treatment
of workplace injuries and illnesses.
"Our AHTs check with trainees
every day to make sure they are not
having problems," Hilton says. "If
they have knife or steeling problems,
we work with them to correct it."
Ergonomics was a key factor when
Tyson redesigned its multi-million
dollar Dakota City beef
processing floor, which
became operational early in 2006. Many engineering projects were
designed to modify work
stations and equipment
to reduce physical stressors on the job including:
Lochner
* Knife handles were redesigned internally from hardwood
handles to a variety of cushion-grip
handles;
* Height-adjustable work stations were
installed;
* Heavier traditional saws/power tools
were replaced by lighter-weight
equipment;
* Hydraulic/mechanical assists, such
as chuck roll assists and automated
knuckle pullers, were installed to help
lift or separate product;
* Adjustable overhead chains and conveyors can now be lowered or raised

www.MeatPoultry.com * February 2010 * Meat&Poultry * 67

http://www.MeatPoultry.com

Meat + Poultry - February 2010

Table of Contents for the Digital Edition of Meat + Poultry - February 2010