Jay Kapellusch, Ph.D.

Assistant Professor

[Image] Jay Kapellusch

Enderis Hall, Room 973
Phone: (414) 229-5292
Fax: (414) 229-2619
kap@uwm.edu

Department

Occupational Science & Technology

Education

  • Ph.D., Industrial Engineering, University of Wisconsin – Milwaukee, 2010
  • M.S., Industrial Engineering, University of Wisconsin – Milwaukee, 2006
  • B.S., Industrial Engineering, University of Wisconsin – Milwaukee, 2001


Speaker Topics

  • Occupational Biomechanics
  • Occupational Physical Exposure Assessments and Modeling
  • Human Centered Design for Manufacturing Systems

Interests & Expertise

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Dr. Kapellusch’s primary research interests are in development of quantitative ergonomics job design algorithms that can be proactively used to design highly productive, safe jobs in manufacturing and service industries. He is working to integrate these algorithms with modern Industrial Engineering philosophies such as Lean Manufacturing and Six Sigma as well as traditional Industrial Engineering tools and techniques such as methods engineering and statistical quality control to provide industry with a comprehensive job design system.

On a parallel track, Dr. Kapellusch is interested in studying the physical capabilities of older and disabled populations with the primary objective of developing simple yet effective devices and/ or equipment that would enable these individuals to be more functional and productive members of society. He also works with members of the Center for Ergonomics to build upon my ergonomics systems work with industry to create comprehensive job risk management software, training packages, and to extend state of art consulting services/resources to industry on a “fee for service” basis.


Recent Publications

Refereed Journals

Kapellusch, J. M., & Dijkers, M. P. (2012). Toward improved evidence stan­dards and methods for rehabilitation: recommendations and challenges. Archives of Physical Medicine and Rehabilitation, 93 (8 Suppl 2), S185-99.

Garg, A., Kapellusch, J., Hegmann, K., Wertsch, J., Merryweather, A., Deckow-Schaefer, G., Malloy, E. J., & the WISTAH Hand Study Research Team. (2012). The Strain Index (SI) and Threshold Limit Value (TLV) for Hand Activity Level (HAL): risk of carpal tunnel syndrome (CTS) in a prospective cohort. Ergonomics, 55(4), 396-414.

Garg, A., & Kapellusch, J. (2012). Long-Term Efficacy of an Ergonomics Program That Includes Patient-Handling Devices on Reducing Musculoskeletal Injuries to Nursing Personnel. Human Factors, 54(4), 608-625.

Garg, A., Hegmann, K. T., Wertsch, J. J., Kapellusch, J., Thiese, M. S., Bloswick, D., Merryweather, A., Sesek, R., Deckow-Schaefer, G., Foster, J., Wood, E., Kendall, R., Sheng, X., & Holubkov, R. (2012). The WISTAH hand study: A prospective cohort study of distal upper extremity musculoskeletal disorders. BMC Musculoskeletal Disorders, 13(1).

Garg, A., & Kapellusch, J. M. (2009). Applications of Biomechanics for Prevention of Work-Related Musculoskeletal Disorders. Ergonomics, 52(1), 36-59.

Garg, A., Moore, J. S., Kapellusch, J. M., & Hegmann, K. T. (2007). Posture of Evidence: Separating Fact from Fiction in Workplace Ergonomics. Industrial Engineer, 39(6), 30-33.


Published Book Chapters

Garg, A., Campbell-Kyureghyan, N., Kapellusch, J. M., & Yalla, S. V. (2009). Low Back: Musculoskeletal Disorders, Job Evaluation, and Design Principles. AIHA Applications Manual, Chapter 26.

Garg, A., Campbell-Kyureghyan, N., Seo, N., Yalla, S. V., & Kapellusch, J. M. (2009). Distal Upper Extremities: Musculoskeletal Disorders, Job Evaluation and Design Principles. American Industrial Hygiene Association Applications Manual, Chapter 27.

Publications in Conference Proceedings

Kapellusch, Jay M., Kapellusch, Joel M., Garg, A., “Ergonomics ROI: Offsetting Intervention Costs with Increased Productivity” Proceedings of the 2009 National Ergonomic Conference and Exposition (NECE), Las Vegas, NV, November 2009.

Kapellusch, J. M., Garg, A., “Application of Biomechanics in a Small Manufacturing Facility: A Case Study” Proceedings of the 2009 Triennial International Ergonomics Association (IEA), Conference, Beijing, China, August 2009.

Kapellusch, J. M., Garg, A., Moore, J. S., “The Strain Index: Recent Updates” Proceedings of the 2009 Triennial International Ergonomics Association (IEA), Conference, Beijing, China, August 2009.

Garg, A., Kapellusch, J. M., “Consortium Pooled Data Job Physical Exposure Assessment” Proceedings of the 2009 Triennial International Ergonomics Association (IEA), Conference, Beijing, China, August 2009.

Kapellusch, J. M., Siebers, S., Garg, A., 2008, “How to Reduce Workers’ Compensation Costs by 80%.” Proceedings of the 2008 National Ergonomic Conference and Exposition (NECE), Las Vegas, NV, December 2008.

Kapellusch, J. M., Siebers, S., Garg, A., Ulrich, T., 2008, “Ergonomic Intervention Case Study at a Commercial Lighting Manufacturing Facility.” Proceedings of the 2008 IIE Conference, Vancouver, B.C., Canada, May 2008.

Garg, A. , Moore, J. S., & Kapellusch, J., 2007, “The Strain Index to Analyze Jobs for Risk of Distal Upper Extremity Disorders: Model Validation”. Proceedings of the International Conference on Industrial Engineering and Engineering Management (IEEM 2007), Singapore. December 2-5, 2007.


Recent Funded Grants

Preventing Work Injuries and Chronic Illnesses in Truckers (4/1/2007 – 3/31/2010)
Centers for Disease Control, NIOSH

PRINCIPAL INVESTIGATOR: Dr. Arun Garg (Subcontract from University of Utah)
GOAL: Perform cross-sectional study of 1,000 truck (≤ 10,000 lbs.) drivers in two states to identify risk factors leading to elevated prevalence rates of cardiovascular disease, diabetes mellitus, obesity, hypertension, dyslipidemia, and sleep disorders, as well as increased tobacco use, and prescription and over the counter medication use relative to industrial workers and the general population. Compare Commercial Driver Medical Examination (CDME) with questionnaire, blood test and urinalysis results to develop an improved CDME. Develop and pilot test a truck driver health promotion program.
The primary objective of this study is to address factors that shorten drivers’ careers, shorten CDL certifications and contribute to increased incident of motor vehicle crashes and other injuries.
ROLE on PROJECT: Collect and analyze data for the Wisconsin sub-contract. Assist with development of improved CDME and “health promotion program.” Conduct pilot test of health promotion program in Wisconsin.
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Upper Extremity Musculoskeletal Disorders: Identifying Risk (10/1/2002 – 9/30/2009)
Centers for Disease Control, NIOSH

PRINCIPAL INVESTIGATOR: Dr. Arun Garg
GOAL: Identify and quantify risk factors for Carpal Tunnel Syndrome (CTS) and other distal upper extremity (DUE) musculoskeletal disorders (MSDs) such as lateral and medial epicondylitis, de Quervain’s disease, flexor and extensor tendonitis, and trigger finger/thumb. Study involves approximately 1,150 total workers in Wisconsin and Utah.
Comprehensive job data and health data are collected by two teams in each state. Data will be analyzed using multivariate Cox Regression (survival analysis) with time dependent covariates to determine hazard ratios that will be used to quantify job physical exposure, individual and psychosocial risk factors leading to DUE MSDs.
ROLE on PROJECT: Collect and analyze job physical exposure field data for workers enrolled in the project. Manage Wisconsin’s Job Assessment & Data Collection Field Team, consisting of 4 field members and 6 student workers. Coordinate with the University of Utah’s data collection teams. Create and manage a relational database with 1,240 fields across 8 tables to store job data for more than 1,150 workers performing more than 4,350 jobs over a period of 7 years. Analyze jobs using the 1995 Strain Index, Composite Strain Index, and TLV for Hand Activity Level. Work with Biostatistician at the University of Utah to conduct comprehensive, sophisticated statistical analyses of individual, psychosocial and job physical exposure risk factors and health outcomes data.
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Low Back Pain: Quantifying Risk (10/1/2003 – 9/30/2006)
Centers for Disease Control, NIOSH

PRINCIPAL INVESTIGATOR: Dr. Arun Garg
GOAL: Quantify risk factors leading to low back pain. Study involves approximately 800 workers in Wisconsin, Utah and Texas. Comprehensive job data and health data are collected by two teams in each state. Data will be analyzed using multivariate Cox Regression (survival analysis) with time dependent covariates to determine hazard ratios that will be used to quantify job physical exposure, individual and psychosocial risk factors leading to general low back pain, low back pain requiring medication, low back pain requiring medical attention and low back pain leading to lost workdays.
ROLE on PROJECT: Collect and analyze job related data for workers enrolled in the project. Manage Wisconsin’s Job Assessment & Data Collection Field Team, consisting of 8 field members and 2 data managers. Coordinate data collection efforts with partner facilities at Texas A&M and University of Utah. Design and develop a relational database with 1,397 fields across 5 tables to store and process job data for approximately 900 workers performing nearly 3,000 different jobs over a period of 3 years. Analyze jobs using the University of Michigan 3D Biomechanical Static Strength Prediction Model, Maximum Acceptable Weights and Forces (MAW), and Revised NIOSH Lifting Equation. Coordinate statistical analyses to study relationships between individual, psychosocial, and job physical exposure risk factors and health outcomes data.
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Home Health Care: Reducing Musculoskeletal Hazards (9/30/2000 – 9/30/2002)
Centers for Disease Control, NIOSH

PRINCIPAL INVESTIGATOR: Dr. Arun Garg (Subcontract from the University of Utah)
GOAL: Identify factors leading to injury of home health care personnel, including nurses and nursing aides. Develop protocols and/or solutions that will reduce or eliminate musculoskeletal and other identified hazards to these workers.
ROLE on PROJECT: Interview workers and patients and collect data at multiple field locations in WI, IA, and Canada. Design and conduct a laboratory study to evaluate the effectiveness, as rated by both health care providers and patients of different brands and types of patient transfer equipment such as total lifts, sit-stand lifts, ceiling hoists, walking belts and transfer boards. Assist with development of solutions to identified risks.

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Private Sector

Determining the Protective Properties of “Kong” Gloves (9/1/2009 – 4/30/2010)
ORR Corporation

PRINCIPAL INVESTIGATOR: Naira Campbell
GOAL: Test the effectiveness of Kong gloves for protecting workers’ hands from impact related injuries.
ROLE on PROJECT: Co-PI, develop testing protocol, design testing equipment, supervise graduate students assigned to project.

Improving the Safety and Ergonomics at E.ON U.S. LLC facilities (9/1/2009 – 12/31/2009)
E.ON U.S., LLC

PRINCIPAL INVESTIGATOR: Naira Campbell
GOAL: Comprehensively review injury data for company. Work with company to train employees, analyze jobs, and develop solutions to safety and ergonomics concerns.
ROLE on PROJECT: Co-PI.

Ergonomic Design and Manufacturing of Assembly Fixtures and Equipment (9/1/2008 – Present)

PRINCIPAL INVESTIGATOR: Jay Kapellusch
GOAL: Design, build and implement fixturing and tooling for high speed, flexible human based production systems.
ROLE on PROJECT: Work with industrial engineers at company to design fixturing and tooling. Supervise manufacturing of fixturing and tooling in the University of Wisconsin – Milwaukee machine shop.
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Ergonomics System for SSI Technologies (8/1/2008 – 12/31/2009)
SSI Technologies

PRINCIPAL INVESTIGATOR: Jay Kapellusch
GOAL: Develop a low cost, comprehensive ergonomics system for a company with two diverse manufacturing facilities (sinter metal and fine electronics assembly) with very different management styles and cultures. System will be uniform across both companies and be capable of reducing incident of injury and minimizing workers’ compensation costs.
ROLE on PROJECT: Design comprehensive ergonomics system for company. Work with safety manager to implement system. Manage occupational therapist collecting data and assisting with program implementation on-site.

Ergonomics System for Three Watlow Corporation Facilities (1/1/2007 – 12/31/2009)
Watlow Corporation

PRINCIPAL INVESTIGATOR: Jay Kapellusch
GOAL: Develop comprehensive ergonomics and safety system to reduce workers’ compensation costs, decrease incident and severity of injury and increase employee productivity and product quality.
ROLE on PROJECT: Serve as lead consultant. Work with executive management to develop systems and protocols for ergonomics and safety systems. Build ergonomics steering committee. Guide direction of ergonomics and safety system during the start-up period (first 18 months). Train engineers on ergonomics principles and use of quantitative job assessment tools. Maintain and track all relevant system performance statistics. Manage occupational therapist performing duties at the facility.
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Evaluation of Powder Paint Operations at Harley Davidson (1/1/2008 – 12/31/2008)
Harley-Davidson, Inc.

PRINCIPAL INVESTIGATOR: Jay Kapellusch
GOAL: Evaluate the risk of the powder paint operations at two large manufacturing facilities. Provide recommendations to engineers to improve both the safety and efficiency of the operations. Help engineers and union members work together to improve the operation.
ROLE on PROJECT: Perform all risk analyses, report results in meetings with management, operators and union representatives.

Production Facility Evaluation and Design (12/9/2005– 12/8/2006)
Openfirst, LLC.

PRINCIPAL INVESTIGATOR: Arun Garg
GOAL: Evaluate new high speed mail inserting equipment to determine the operational efficiency of the man-machine interface. Design and develop modifications to the new equipment to optimize the production levels of the equipment subject to operator constraints. Optimize production system performance prediction models. Evaluate production efficiencies and perform cost-benefit analysis of in-line versus off-line finishing of printed materials. Create a tactical plan to incorporate first shipment of new equipment. Create strategic plan, including revised facility layout to take full advantage of new high speed inserting equipment as well as all proposed in-line/off-line finishing equipment. Accommodate anticipated sales growth over the next 5 years.
ROLE on PROJECT: Oversaw team of 2 investigators and 2 student workers performing all evaluations. Reviewed and revised company’s production models based on evaluations of new equipment potential as well as time-study data from existing equipment. Prepared final report and gave presentations to company executives. (Work saved company more than $2,000,000 in unnecessary equipment costs and reduced inventory costs).
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Ergonomic Evaluation of Retail Store Operations (6/1/2006 – 7/31/2006)
Farm and Fleet

PRINCIPAL INVESTIGATOR: Jay Kapellusch
GOAL: Assess musculoskeletal risk factors present in retail store operations. Provide recommendations to mitigate those risk factors.
ROLE on PROJECT: Supervised therapist collecting data on-site. Performed all quantitative analyses of data. Develop recommendations to mitigate identified MSD risks. Reported findings to company’s management team.

Integrating Office Ergonomics into the Design of Radiology Workstations in a Hospital (9/23/2005 – 12/31/2005)
United Hospital System

PRICIPAL INVESTIGATOR: Jay Kapellusch
GOAL: Design new radiology workstations in a local hospital to make best use of new radiology equipment. Use principles of office ergonomics to reduce operator strain.
ROLE on PROJECT: Managed ergonomist performing evaluations and selecting workstation equipment (desks, chairs, keyboards, etc…). Designed workstation layout of new space. Setup all workstations on site.

Analysis of Criterion Mail Sorting Equipment (5/8/2002 – 7/31/2002)
Bell & Howell Mail & Messaging Technologies

PRINCIPAL INVESTIGATOR: Arun Garg
GOAL: Perform comprehensive ergonomics analyses of energy expenditure requirements and manual materials handling risk of MSDs based on design parameters of newly developed Criterion high speed mail sorting equipment. Analyses were used to demonstrate superiority of the newly designed Criterion equipment versus its predecessor equipment.
ROLE on PROJECT: Perform risk assessments for manual materials handling, assist with energy expenditure calculations and write final report for project.