September 6, 2024 by Heather
Ergonomics In The Workshop
Introduction
Workshop ergonomics might not seem very important for the part-time bladesmith, but you will still gain interesting tips from this blog post. Ergonomics will evolve with the new tools and equipment you acquire (bladesmiths always need more stuff). Kevin and I have changed the layout of our workshop countless times, and when it comes to moving giant anvils, surface grinders, hydraulic presses, and power hammers, you want to be sure of their positions as you set up your shop. It isn’t easy to move these heavy, semi-permanent machines! Get it right the first time and work around them.
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Ergonomics is all about making sure the workspace fits the worker, not the other way around. When the workshop is set up to support the body’s natural movements and posture, it can do wonders for efficiency, creativity, and well-being.
Time-saving techniques are a massive part of workshop ergonomics. When tools and materials are easily accessible, less time is wasted searching or reaching for things. Think about how much quicker tasks can get done when everything is at arm’s length and well-organized. Toolboxes on wheels, wall-mounted pegboards, and labelled storage bins can transform the workflow.
Safety shouldn’t be sacrificed for speed. We can prevent injuries and discomfort by designing workstations that minimize repetitive movements and reduce awkward postures. This balance between efficiency and safety is crucial. A well-thought-out workshop layout can help avoid accidents and promote a healthier work environment. When working alone, you can safely move around the shop with hot steel or sharp knives in your hands, but start by practising the safe way of doing this, by holding them upright in front of you. We have heard of horrible accidents of bladesmiths rushing around a corner in the workshop with a knife or hot piece of steel, only to find a student or fellow worker in the way!
Remember to walk around your workshop with hot or sharp blades held upright and in front of you so as not to cause an accident
Let’s talk about some ergonomic tools and equipment. Sit-stand stools, anti-fatigue mats, rubber mats under workbenches and buffers to prevent knives that might fall from being damaged and adjustable workbenches are just a few examples. Adjustable anvil stands are necessary if you teach bladesmithing as students come in all heights. These items can make a big difference in comfort and productivity. Investing in ergonomic tools might seem pricy upfront, but the long-term benefits of increased efficiency and reduced injury risks make it worthwhile. You strive to enjoy your time in the shop, not dread it!
Designing a Safe and Comfortable Workshop Layout
Creating an ergonomic workshop starts with a thoughtful layout. Every detail counts, from the placement of your tools to the height of your workbench. A well-designed workspace makes your tasks easier and keeps you comfortable throughout the day. When Kevin and I moved into a large shop and combined our workshops, it wasn’t easy to get used to walking from different workstations we had to do! It was lovely to have the space, but impossible to have all the tools right at hand. We overcame this problem by buying extra Allen keys and wrenches that stay with each machine to save all the walking.
First, key elements come into play when laying out your workshop. Think about workflow—how do you move from one task to the next? Arrange tools and materials in a logical sequence that matches your work process. This not only saves time but also cuts down on unnecessary movement, reducing strain.
Then, consider the optimal placement of tools and equipment. Keep frequently used items within easy reach to avoid constant bending or overstretching. Wall-mounted storage systems can help keep tools off the bench and within arm’s length. It’s not just about convenience; it’s also about reducing the risk of injury. We try to instil these methods into our students so that they will use them in their shops. We also insist that tools are packed away, lids are put on liquids and that workstations are neat and tidy. This is not as easy as it sounds!
Adjustable workstations are a game-changer. Not everyone is the same height or has the same reach. Being able to adjust your workbench height means you can maintain good posture whether you’re sitting or standing. This adaptability can drastically improve comfort and reduce strain.
Safety features must be part of your design. Incorporate things like good lighting to reduce eye strain and ensure visibility. Have you ever wondered why you often see workers wearing peak caps in movies, even though they are inside? Peak caps prevent the lights from above from affecting your eyes and keep your hair out of the way of machinery. They keep the dust from building up in your hair and being transferred to your pillow! Non-slip flooring can prevent falls, while proper ventilation keeps the air fresh and free of harmful fumes. Safety gear like gloves and goggles should be easily accessible – no point in having them if they’re hard to get to in a pinch.
We have a very well-stocked first aid box in the workshop and outside the shop, and we ensure all our students know where it is situated.
Best Practices for Ergonomic Work Habits
Adopting the proper work habits in the workshop can make a world of difference. It’s not just about having the right tools and layout; how you work matters, too. Proper lifting and handling techniques are fundamental. Always lift with your legs, not your back, and avoid twisting your body when carrying heavy items. Kevin was straightening a large billet of damascus and was in a rush. He dislocated his shoulder and tore a chest muscle in the process. Don’t rush! Using pallet jacks or dollies to move heavy loads can help reduce strain and prevent injuries.
Ergonomic accessories are your best friends when it comes to reducing strain. Wrist supports, anti-fatigue mats, and ergonomic chairs can alleviate pressure on your joints and muscles. Minor adjustments, like using a footrest, can significantly improve your overall comfort and posture. These tools are about making your body’s job easier. We want to see healthy bladesmiths that can work into their 80’s.
Creating a daily routine that prioritizes safety and comfort is vital. Regular breaks to stretch and move around can prevent stiffness and fatigue. Try to switch tasks throughout the day to avoid repetitive strain injuries. Even a minute or two of stretching every hour can make a big difference in how you feel by the end of the day. It is easy to become so focused on what you are doing that you forget to drink anything! Dehydration is a big problem when forging; make sure you have not only water but a drink that replaces your electrolytes handy at all times. We force our students to have a coffee break a few times daily, sitting outside under our beautiful Chestnut tree. They return to the shop refreshed, and the dogs love the attention outside!
Take frequent breaks from the workshop or you may end up like Kevin answering his banana instead of his cell phone!
Training students on ergonomic best practices ensures everyone’s on the same page. It’s not enough to have ergonomic tools and setups if people don’t know how to use them correctly. Don’t assume that everyone was brought up to work neatly. Most students need a bit of nagging (which I am very good at) to ensure that it becomes a habit.
Evaluating and Improving Workplace Ergonomics
Evaluating and improving workplace ergonomics is an ongoing process that keeps the workshop running smoothly and safely.
Start by conducting ergonomic assessments. Examine how workstations are used and identify potential issues or areas for improvement. Simple observation and student feedback can reveal a lot about what’s working and what’s not.
Identifying and addressing common issues is crucial. Are there tasks that always cause discomfort or take longer than they should? Investigate these pain points. Maybe it’s a poorly placed tool or an awkward workstation setup. Tackle these issues head-on to create a more efficient and comfortable environment.
Remember, an ergonomic workshop is a journey, not a destination. Constantly evaluate, adapt, and improve to create a workspace that supports everyone’s well-being and productivity.
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