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ERGONOMÍA OCUPACIONAL INVESTIGACIONES Y APLICACIONES

VOL. 7

Ergonomía Ocupacional. Investigaciones y aplicaciones:. Vol 7

EVALUACIÓN METHODS COMPARATIVE ANALYSIS OF ERGONOMIC EVALUATION METHODS FOR WORKERS STRAIN POSTURE. INTEGRAL METHOD PROPOSAL. Bettina Patricia López Torres, Elvia González, Cecilia Colunga, Eduardo Oliva-López

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FATIGUE PROPOSAL FOR A PROCEDURE TO CALCULATE RECOVERY TIME FOR THE SHOULDER IN HIGHLY REPETITIVE WORK Francisco Octavio López Millán, Enrique Javier De la Vega Bustillos, Gerardo Meza Partida, Karla Patricia Lucero Duarte

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DETERMINATION OF PHYSICAL FATIGUE ON MUNICIPAL WORKERS Claudia Selene Castro Estrada, Grace Erandy Báez Hernández, Gabriela Idalia Bacasegua Yucupicio and Alberto Ramírez Leyva

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INDUSTRIAL ERGONOMICS ERGONOMIC ANALYSIS IN THE MACHINING PROCESS OF A COMPANY Adriana Ramírez Mexia; Ernesto Ramírez Cárdenas; María Luisa García Muela; Rogelio Ruiz Martínez; Elizabeth Moreno Rodríguez

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MULTIVARIATE MODEL ON THE IMPACT OF INDUSTRIAL ORGANIZATIONS RESULTS Alejandra Ordóñez Herrera, Jorge Carlos Chapur Auais, Juan Carlos Costa Frias and José Luis Escalante Macias Valadez

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METHODOLOGICAL PROPOSAL FOR THE IMPLEMENTATION OF A PROGRAMME OF ERGONOMIC HAZARDS MANAGEMENT IN A CAR PARTS MANUFACTURING PLANT IN HERMOSILLO, SONORA. Anahi Luque-Acuña, Jaime Alfonso León-Duarte, Arnulfo Aurelio Naranjo-Flores

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OCCUPATIONAL HEALTH EDUCATIONAL SOFTWARE APPLIED TO THE ERGONOMICS FOR THE EVALUATION OF JOBS, ERGONOV Víctor Arturo Pacheco Cruz, Renaú Argüelles García, Francisco Gabriel Pecina Cruz, Ma. Cristina Guerrero Rodríguez

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EVALUATION OF SAFETY AND HEALTH WORK STANDARDS IN A FLOUR MILL Krisbel Berenice López Bajo, Amina Marín Martínez, René Daniel Fornés Rivera, Miguel Ángel Romero Ochoa

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Ergonomía Ocupacional. Investigaciones y Soluciones. Vol 7� 2014

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METHODOLOGICAL PROPOSAL FOR THE IMPLEMENTATION OF A PROGRAMME OF ERGONOMIC HAZARDS MANAGEMENT IN A CAR

PARTS MANUFACTURING PLANT IN HERMOSILLO, SONORA.

Anahi Luque-Acuña1, Jaime Alfonso León-Duarte1, Arnulfo Aurelio Naranjo-Flores2

1Department of Industrial Engineering

University of Sonora Rosales and Luis Encinas Blvd S / N

Hermosillo, Sonora 83000 [email protected], [email protected],

[email protected]

2Department of Industrial Engineering Technological Institute of Sonora

Kino Blvd and Villa Itson Obregon City, Sonora 85201

Resumen: El objetivo es diseñar una propuesta metodológica para la implementación de un programa de gestión de riesgos ergonómicos para su identificación, evaluación y control, producidos por posturas no adecuadas y movimientos repetitivos. Se hace referencia a conceptos de ergonomía, métodos de evaluación ergonómica, programas de gestión de riesgos ergonómicos, entre otros. La propuesta metodológica a ser abordada en el estudio, trata de lo siguiente: una vez identificado el problema a ser estudiado, se comienza por hacer una revisión bibliográfica de conceptos, modelos, casos de estudio, entre otros aspectos, relacionados con el estudio. Posteriormente, realizar visitas a la organización en donde se comience a reconocer el riesgo presente en las estaciones de trabajo, establecer conversaciones y entrevistas con los operadores y administradores del área bajo estudio. Después, realizar un análisis e identificación de los riesgos, mediante la aplicación de métodos de evaluación ergonómica, mismos que serán definidos según las características del puesto de trabajo. Seguidamente, se persigue el desarrollo del estudio ergonómico propiamente dicho. Se trata de la aplicación de herramientas diseñadas para cada caso en particular. Se recogen datos específicos que después de su procesamiento se derivan en la elaboración de un informe del estudio ergonómico integral. Por último, se realiza la implementación de las acciones de mejora. Algunas herramientas utilizadas en el estudio fueron el método de evaluación ergonómica Susan Rodgers y la Encuesta de Sintomatología Osteomuscular. Los resultados obtenidos son: conocimiento del área bajo estudio, como procesos que se llevan a cabo en cada una de las estaciones, principales tareas que desempeñan los trabajadores. Así también, mediante la aplicación de la encuesta mencionada anteriormente, se obtuvo la identificación de las principales posturas que adopta el trabajador durante la jornada laboral; si transporta o no cargas mayores a 12.5 kilogramos; identificación de la principal mano que utiliza para el desarrollo de sus actividades. Además con la aplicación del método Susan


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Rodgers se obtuvo el nivel de riesgo al que están expuestos los trabajadores en cada una de las estaciones bajo estudio. Por último se muestran las conclusiones obtenidas en dicha investigación. Palabras clave: Ergonomia, Administración de riesgos ergonómicos, Susan Rodgers Abstract: The objective is to describe a methodological proposal for the implementation of an ergonomic management program for risk identification, evaluation and control created by inadequate postures and repetitive movements. References are made to concepts of ergonomics, methods of ergonomic evaluation, programs of management of ergonomic hazards, among others. The methodological proposal to be addressed in the study is about the following: once the problem studied is identified, the study is begun by doing a bibliographical revision of concepts, models, study cases, among other concepts related with the study. Previously, realizing visits to the organization in which a risk is starting to be recognized in the work stations, establish conversations and interviews with the workers and administrators from the area under study. After, making an analysis and identification of the hazards, through the application of methods of ergonomic evaluations, same will be defined according to the characteristics of the job position. Fallowed, the development of the ergonomic study is pursued. It is about the application of designed tools for each particular case. Specific data is collected that after its process is derived in the elaboration of one uniform of the integral ergonomic study. Last, the implementation of bettering actions is realized. Some tools that were used in the study were the method of ergonomic evaluation of Susan Rodgers and the Musculoskeletal Symptomatology Survey. The results obtained were: knowledge of the area studied, such as processes carried out in each one of the stations, top tasks that the workers perform. Also, through the application of the survey mentioned previously, the identification was obtained of the top postures adopted by the workers during a workday; if the worker transports or not loads heavier than 12.5 kilograms; identification of the main hand used in the development of their activities. In addition of the application of the method of Susan Rodgers, the level of hazard that the workers are exposed to in each one of the stations studied was gotten. Lastly, the conclusions obtained in such investigation were shown. Key Words: Ergonomics, Management of ergonomic hazards, Susan Rodgers Relevance to Ergonomics: The result of this investigation helps to provide a series of steps that can be taken to practice, and at the same time, can be adapted with any organization in which management and control of hazards is seeked for the area of work the workers find themselves in. Also, some tools that can facilitate the obtaining of results for certain phases that can be presented in a study were released.

1. INTRODUCTION

The study describes and develops a methodological proposal for the implementation of an ergonomic risk management programme, starting from the identification and


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evaluation of ergonomic hazards, especially those caused by inadequate postures and repetitive movements. It should be noted, that it is still in progress, and it is being held in a car parts manufacturing company in Hermosillo, Sonora. 1.1 The Ergonomics According to Hollnagel (2014) which cites Dul et al., (2012) ergonomics is a scientific discipline that treats the comprehension of the interactions between human beings and the elements that form part of a system, like the principal theories, data and methods for the welfare and performance of the workers.

The basic objectives that ergonomics pursue are: bettering the personal interrelation of worker and machine, control of the job positioning surrounding or of the place of the behavioral interaction, generate interest for the activity endeavoring the signal of the system being significant and assumable by the person. (Mondelo, 2000)

It is for this, that the importance of Ergonomics is made noticed in a job layout, having the human being like the most important factor to take in consideration, now that the welfare, health and comfort of the worker will depend on its efficiency in the job. To deliver a real ergonomic design in a work area is a complex task; however, great benefits to workers and employers can be gathered by this effort. Thus, the ability to know some of the benefits of applying ergonomics increases the importance, now that it can be established that its application may allow better results at designing or redesigning a work station.

On another part Hollnagel (2014) signals that the real challenge of ergonomics is for the design of interphases, interaction and job surroundings, to have to go further than the concept that is obtained of traditional ergonomics and search to understand the form in which this will change the future and at the same time modify ourselves to continue existing in the environment that we have modified.

1.2 Musculoskeletal Disorders (MSDs)

Musculoskeletal disorders (MSDs) represent one of the most serious consequences of an inadequate work routine design. The symptoms are described as pain in one or more regions of the body. Also, these disorders can be caused by repetitive workloads (Roman-Liu, 2013). Furthermore, from the anatomical point of view, according to Frievalds (2004) it can be classified in six basic types which are: tendons, muscles, nerves, vascular, pockets and bone/cartilage. 1.3 Methods of Ergonomic Evaluation

Now, for ergonomic evaluation methods, the analysis of work positions can be an effective tool to assess activities at work. An important factor to implement corrective actions is the risk of muscle skeletal injuries that are associated with aggravated postures caused by efforts and repetitive movements (Hignett & McAtamney, 2000). Some ergonomic evaluation methods are: RULA method (rapid upper limb assessment) that allows rapid assessments of postures in neck, trunk and upper


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extremities. Characteristic of this method is that it indicates the level of intervention required to reduce ergonomic hazards (McAtamney & Corlett, 1993). OWAS (Ovako Work Analysis System) method, considered a relevant method for the identification and evaluation of positions characterized by providing data in short time periods (Karhu, Kansi, & Kuorinka, 1977). 1.4 Programme of Management of Ergonomic Hazards

Actually, it has been paid a major attention to the systems of integrated security, which has obligated the companies to manage in a systematic form the sources of risk (Gnoni & Bragatto, 2013). The ergonomic evaluations are increasing the work done like in the standardization of processes, for example when the practice guide is used in the work NIOSH (Törnström, Amprazis, Christmansson, & Eklund, 2008).

Ergonomic participation programs in the workplace are frequently used for ergonomic strategies that allow the reduction of muscular skeletal disorders in the workplace (Rivilis, y otros, 2008). An incident-free "culture" demands employees and employers participation for the Elimination of injuries, workplace assessment, as well as an efficient communication of the administrative organization (Morag, 2007).

Also Mondelo (2000) signals that an ergonomic intervention doesn’t limit itself to identify the factors of hazard and the inconveniences, but to propose positive solutions, and the economic viability that frames any project.

2. OBJECTIVE

To describe a methodological proposal for the implementation of an ergonomic management program for risk identification, evaluation and control created by inadequate postures and repetitive movements.

3. METHODOLOGY A methodological structure is shown that was elaborated by the Health and Safety Management System (HSMS), shown by Ontario Safety Association for Community and Healthcare (OSACH), (2010). The focus of the investigation is mixed, since is a combination of the quantitative and qualitative focus. Also, the type of investigation is descriptive, since it is to specify the characteristics and profiles of the people, groups or processes to be studied (Hernández, 2010).

The methodological proposal to be addressed in the study is about the following: once the problem studied is identified, the study is begun by doing a bibliographical revision of concepts, models, study cases, among other concepts related with the study. Previously, realizing visits to the organization in which a risk is starting to be recognized in the work stations, establish conversations and interviews with the workers and administrators from the area under study. After, making an analysis and identification of the hazards, through the application of methods of ergonomic evaluations, same will be defined according to the characteristics of the job position. Fallowed, the development


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of the ergonomic study is pursued. It is about the application of designed tools for each particular case. Specific data is collected that after its process is derived in the elaboration of one uniform of the integral ergonomic study. Last, the implementation of bettering actions is realized. Next, in a delicate manner a methodological proposal is shown:

3.1 Recognition of the risk: This phase tryes to identify the risks that exist in the manufacturing plant under study, work processes, statistical information on accidents, incidents and associated costs in a certain period of time.

An instrument that can be used to identify the hazards, is the Musculoskeletal Symptomatology Survey (Osteomuscular, 2007) that covers aspects like top postures that the worker adopts during his or her day, the main hand used by the worker in the development of their activity in their area of work, the carrying of loads, among other more aspects.

3.2 Identification and assessment of risk factors: It is required for each position or task, to identify the type of ergonomic risk by the use of ergonomic assessment methods, according to the particular conditions in the associated work station. An ergonomic assessment method that can be used, Susan Rodgers is the method, which assesses muscle groups as: neck, shoulders, back, arms and elbows, hands, wrists and fingers, knees and legs and feet and ankles, and that as Uribe, De la Vega, Lopez, & Duarte (2013) citing Chengalur, Rodgers & Bernard (2004) discussed a method that seeks to recognize muscle fatigue, caused by the intensity of effort, duration of effort, and the frequency of effort per minute in each muscle group in performing an operation. 3.3 Management and Control of risks: Once risks have been identified and assessed, the following task is to make use of mechanisms for their control, and subsequent reduction or elimination. For example: implementing control strategies basic hazard management, improvement proposals for the work stations to reduce the level of hazard, implement specific hazard controls, fostering a culture of organizational security. One aspect that can be considered for the establishment of proposed improvements is to take into account the anthropometric measures of staff working in the organization, so that the design is done, appropriate to the physical dimensions of personal working in the organization. 3.4 Assessment and corrective actions: This stage focuses on tracking of ongoing assessment and corrective action on occupational hazards. One of the actions that can be performed at this stage is to make the assessment again at the workstation that was previously evaluated and which


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changes were made to improve it. So it is recommended to apply the same method that was used before the implementation of improvements again. 3.5 Strategic review and continuous improvement: This stage is to communicate and follow up on the targets set in the programme; review of risk levels periodically; and to assess the opportunities for continuous improvement. One of the actions to do, is to make use of a risk review format, it is regularly used (every 3 to 6 months) in order to monitor risks in workstations and verify whether these risks have decreased. For example, compare the number of injuries that have occurred on shoulders in the current year, with the number of injuries obtained in the previous year.

4. RESULTS

4.1 Recognition of risk First it was come to know each of the workstations that make up the study area, to have knowledge of the operations, major movements and postures that adopt a worker during the work day. To which the Survey of Symptoms Musculoskeletal applied to three shifts of the organization, only that provision of the Organization, some questions of the original format of the survey were omitted and which were discussed were concerning: Name, age, sex, season, time in office, main positions adopted by the employee during the workday, cargo transport and last main hand is used for development activities.

It should be noted that the study was developed in an area which has three main stations, named Carousel 1, carousel 2, carousel 3, in which components are manufactured car part. Each of the three carousels, are composed of different stations, which processes that contribute to the manufacture of components are carried. In Figure 1, shown the results obtained in the carousel 1, for identifying positions.

Figure 1. Identification of positions, carousel 1


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In the previous graph, it can be seen that most of the workers belonging to the carousel 1 in three shifts, over 80% of the time duration of the working day are standing in their work areas. But also, on turn 1 it can be seen that a certain percentage of the time taken other positions like squatting. In Figure 2, the results obtained for the transport of loads on the carousel 1 are shown.

Figure 2. Cargo transportation, carousel 1

For the carriage of cargo, in the figure above can be seen that most of the workers do not carry or handle higher loads at 12.5 kg and assume only an amount greater loads to transport 12.5 kg. Figure 3 shows the main hand that is used for development activities.

Figure 3. Main hand is used in the development of activities, carousel 1


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According to the previous figure, the development of the activities made by the workers in their work areas, most make use of both hands, but there are also workers that make use of the right hand.

Also, the results obtained in the carousel 2 were the following: as to the identification of postures all workers belonging to carousel 2 in three shifts, most of the time remain standing in their work areas. Moreover, for the transport of loads, most workers do not carry or handle higher loads than 12.5 kg and only a small number of transport workers bear greater loads than 12.5 kg, finally in the development of their activities within their work areas, most workers make use of both hands, but there are also those who use the right and left hands.

The results on the carousel 3 were: to identify positions, the majority of workers, great part of the time working hours remain standing in their work areas. Regarding transportation of loads on the carousel 2 in three shifts, workers are not carrying or handling higher loads at 12.5 kg. In the development of activities, most make use of both hands, but they use the left and right hand especially.

So also for the recognition of hazard, statistical records of the organization for the period January to November last year, about accidents and incidents that occurred in that period, in the area under study, in order to detect available were consulted major regions with the highest incidence. Figure 4 shows the data obtained.

Figure 4. Accidents and incidents by regions of the body

Figure 4 shows that the main regions of the body that had a higher incidence or accidents, was shoulders, hands and back, so that these data may indicate that workers are exposed to risk factors in their work areas.


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4.2 Identification and evaluation of risk factors: At this stage the identification and assessment of risk factors was performed using the method of ergonomic evaluation of Susan Rodgers, it was applied to each of the stations that are part of the three carousels belonging to the study area. Each of these carousels performs trades manually and some make use of any tools or equipment. However, according to visits to the area and according to the survey results shown above, we have that for the performance of each of the activities performed in workstations, they are done standing and they also make use of both hands to carry out activities.

It is noteworthy that one of the activities that were made during the assessment with the method mentioned above, was the filming of tasks to be analyzed in more detail, and with this power detecting certain body angles that are formed when different postures are adopted in task performance, as this is often complicated when viewed directly to the worker. The results obtained are shown below. Table 1 shows the results of evaluation on the carousel 1:

Table 1. Susan Rodgers Ergonomics Assessment stations Carousel 1

Carousel 1 Group of muscles Station 1 Station 2 Station 3 Station 4 Station 5

Neck 9 2 5 2 6

Shoulders 9 6 10 5 6

Back 9 6 10 6 6

Arms and elbows 9 2 5 6 1

Wrists, hands

and fingers

9 2 10 6 1

Legs and knees 9 4 7 5 6

Ankles, feet and

toes 9 4 7 2 1

Source: Data obtained from ergonomic evaluation calculations.


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According to that observed in the previous table, station 1 has a high level of hazard in all muscle groups, station 2 has a low level of hazard in neck, arms and elbows, wrists, hands and fingers, legs and knees, ankles, feet and toes and in turn, has a moderate risk on the shoulders and back. Furthermore it can be seen that station 3 is the one with a higher level of hazard, unlike other stations, since it has very high level of hazard on the shoulders, back, wrists, hands and fingers. Table 2 shows the results of evaluation on the carousel 2:

Table 2. Susan Rodgers evaluation stations Carousel 2

Carousel 2 Group of muscles Station 1 Station 2 Station 3 Station 4

Neck 8 1 6 1

Shoulders 8 1 1 1

Back 8 1 1 1

Arms and elbows 8 1 1 1

Wrists, hands

and fingers

8 1 1 1

Legs and knees 8 1 1 1

Ankles, feet and

toes 8 1 1 1


In the previous table it can be noted that most stations have a low level of hazard for each muscle group, except for station 1, which has a high level of hazard in all muscle groups. Table 3 shows the results of the evaluation are shown in the carousel 3:


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Table 3. Susan Rodgers evaluation stations Carousel 3

Carousel 3 Group of muscles Station 1 Station 2 Station 3 Station 4

Neck 2 7 2 2

Shoulders 2 10 2 2

Back 2 7 2 2

Arms and elbows 2 5 2 2

Wrists, hands

and fingers

2 7 2 2

Legs and knees 2 7 2 2

Ankles, feet and

toes 2 7 2 2


The above table shows that in most of the stations the hazard level is low. However, in Station 2 it can be seen that there is a high level of hazard on the shoulders, and a moderate level of hazard in neck, back, arms, elbows, wrists, hands and fingers, legs, knees, ankles, feet and fingers.

The above results show the stations with high level of hazard, which, seek to establish improvement proposals that may decrease the level of hazard in order to reduce accidents, labor sicknesses and to increase the welfare, health and Accordingly to worker productivity.

6. CONCLUSIONS

Conclusions about the implementation of the methodology so far are preliminary. However, until now, the conclusions about the importance of implementing an ergonomic hazard management program to improve the workplace. With this study, reference information is found to carry out the implementation of the program. In addition, a flexible methodology that can be adapted to organizations, according to the conditions present in the work areas, as well as the characteristics of the jobs, since according to the above, it may use different methods addressed ergonomic evaluation. Moreover, what made the study so far , it could recognize this risk in the study area , as


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some characteristics of the jobs , as the main positions adopted by the employee during the workday were found whether or not handle heavy loads , as well as the main hand you use to develop their activities. Besides the major regions of the body where injuries occurred over a period of time was found.

Finally the level of hazard in each of the workstations in the study area, so with this, you can identify the main stations which should seek to establish proposals to decrease the level of hazard was obtained.

REFERENCES

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Gnoni, M. G., & Bragatto, P. A. (2013). Integrating major accidents hazard into occupational risk assessment: An index approach. Journal of Loss Prevention in the Process Industries, 751–758.

Hernández, S. (2010). Metodología de la investigación. México: Mc. GrawHill. Hignett, S., & McAtamney, L. (2000). Rapid Entire Body Assessment (REBA). Applied

Ergonomics, 201–205. Hollnagel, E. (2014). Human factors/ergonomics as a systems discipline? "The human

use of human beings" revisited. Applied Ergonomics, 40-44. Karhu, O., Kansi, P., & Kuorinka, I. (1977). Correcting working postures in industry: A

practical method for analysis. Applied Ergonomics, 199–201. McAtamney, L., & Corlett, E. N. (1993). RULA: a survey method for the investigation of

work-related upper limb disorders. Applied Ergonomics, 91–99. Mondelo, P. R. (2000). Ergonomía I. México: Alfaomega. Morag, I. (2007). Intel's incident-free culture: A case study. Applied Ergonomics, 201–

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http://www.osach.ca/products/ffacts_e/PH-FHSM0-E-100301-TOR-001.pdf OSTEOMUSCULAR, F. E. (2007). Rama Judicial del Poder Público Consejo Superior

de la Judicatura Sala Administrativa Dirección Ejecutiva de Administración Judicial. Recuperado el 13 de Febrero de 2013, de http://200.74.129.92/ModeloCSJ/archivos/F-AGS-19/F-AGS-Temporal12%20FORMATO%20ENCUESTA%20DE%20SINTOMATOLOGIA%20OSTEOMUSCULAR-2.doc.

Rivilis, I., Eerd, D. V., Cullen, K., Cole, D. C., Irvin, E., Tyson, J., y otros. (2008). Effectiveness of participatory ergonomic interventions on health outcomes: A systematic review. Applied Ergonomics, 342–358.

Roman-Liu, D. (2013). Comparison of concepts in easy-to-use methods for MSD risk assessment. Applied Ergonomics, 1-8.

Törnström, L., Amprazis, J., Christmansson, M., & Eklund, J. (2008). A corporate workplace model for ergonomic assessments and improvements. Applied Ergonomics, 219–228.

Uribe, D. U., De la Vega, E. B., López, F. O., & Duarte, K. L. (2013). ERGO-MODAPTS: DEVELOPMENT OF A MODEL BASED ON THE STUDY OF TIMES


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PREDETERMINED MODAPTS AND SUSAN RODGERS ERGONOMIC EVALUATION. En C. G. Espejo, E. B. De la Vega, & E. M. Chacón, ERGONOMÍA OCUPACIONAL. INVESTIGACIONES Y APLICACIONES (págs. 69-76). México: Sociedad de Ergonomistas de México A.C. (SEMAC).

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