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How to calculate the cost/benefits of ergonomics training
It’s not enough to say that an ergonomics training program will reduce workers’ compensation costs. You have to show the benefit, in dollars and cents:
1. Identify the cost due to the ergonomic problem.
2. Calculate the cost of training.
3. Show estimates of savings.
4. Calculate ROI.
COST OF THE PROBLEM
Companies are interested in controlling all types of costs — direct costs, lost time days and restricted-duty days due to on-the-job injuries.
Identify measurable costs associated with an ergonomic problem. Some examples of problems:
• Back strains;
• Neck strain;
• Arm strain;
• Carpel tunnel.
For example: Employees in Company A lost a total of 100 days during a 12-month period due to back strain. At an average cost of $12.15/hour, the total cost of lost work days (wages only, not medical costs) was $9,720.
COST OF THE TRAINING
The cost of the training includes your costs (in the example below, $10 per employee), plus the direct cost of taking employees out of their jobs for the time of the training. It may also include the cost of involving employees in identifying the problem and developing a training manual, as well as follow up time off the job, if required.
The process follows:
1. Identify the number of employees to be trained (those who are at risk for the injury).
Example: 90 workers who perform heavy lifting
2. Calculate the average wage of the targeted group.
Example: Wages range from $9.45 to $14.85 an hour, for an average wage of $12.15.
3. Calculate the direct cost of 90 employees to attend a 30-minute training session:
• 90 workers @ $12.15 average hourly wage = $1,093.50
• Cost of wages for 30-minute session = 1/2 x $1,093,50 = $546.75
• Training fee = $10/person x 90 = $900
• Total cost for training 90 workers: $900 + $546.75 = $1,446.75
4. Estimate the return-on-investment: A 50 percent reduction in lost time due for back strain would result in a savings of $4,860 - $1,446.75 = $3,413.25. This is an ROI of 236 percent!
5. Measure actual return-on-investment. For a given period of time from the time following training (for example, 12 months), measure the actual cost savings in lost time and calculate the actual ROI.
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