ergonomie - training eng.pdf

8/19/2019 Ergonomie - Training Eng.pdf

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PAGE 1 / Manufacturing Engineering -

Ergonomic TrainingASSEMBLY & PACKAGING

JL Filisetti


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1. General Informations

2. JSI

1. General informations2. JSI explanation3. PO Adaptation4. Multi operation case

5. Exercises

3. NIOSH

1. General informations

2. NIOSH explanation3. Exercises

TRAINING CESSION


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4. REBA

1. General informations2. REBA explanation

3. Exercises

5. Part transportation


2. Part transportation explanation3. Exercises

TRAINING CESSION


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General InformationsASSEMBLY & PACKAGING

JL Filisetti


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General Informations

In our flow, we have several physical activities that can haveissues regarding operator health.

For each item, we are able to associate a methodology toanalyse the ergonomical impact of the process to the

operator.ERGONOMICAL ANALYSE OF THE 10 POINTS

Points Operations Methods

1 The operator takes the part NIOSH2 The operator carries the part to the station NF X35 109

3 The operator loads the part to the station NIOSH4 The operator takes the baby parts stored at the station NF X35 1045 The operator takes the baby parts stored closed to the station

5-1 The operator takes the part NIOSH5-2 The operator carries the part to the station NF X35 1095-3 The operator loads the part to the station NIOSH6 Effort to assemble

6-1 Control system NF X35 1066-2 Assembly JSI7 Posture of assembly REBA8 The operator removes the part from the station NIOSH9 The operator carries the part to the upstream station NF X35 10910 The operator loads the part to the station NIOSH


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The objective of this training is to explain those ergonomicalstandard methods.

File 1 – Working area File 2 – Line feeding area File 3 – Limits of effort JSI

NIOSH REBA Part transportation

General Informations


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File 1 – Working area

Extract of Norm NF X 35-104

Working area for better situation

For efforts For assembly operation For snapping / screwing For control system localisation

1000

300

300

300

500

500

200

800

GOOD ACCEPTABLE PAINFUL

WORKING AREA

300

3

0

0

200

500

500

2

0

0

Exemple: Poste 1 carrousel T7

800

200


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File 2 – Line feeding area

Extract Renault Ergonomic methods

The localisation of POE depends of its weight

The position in lower area (from ground to 600 mmheight) are acceptable

If operator can flex his knees If the cycle time is less than 15 per hour with a

weight less than 5 Kg (validation done withNIOSH methods)

Those tasks have to be also validated with REBAmethods

800 100300450600

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900


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File 3 - Limits of effort (in Kg)- Extract of Norme NF X35-106 -

Actiondirection of

the effortPosture

working area(Norme X 35-104)

1 or 2

hands 1 15 30 45 60 75 90 105 120 150 180 210 240 270

CurveNorme X 35

106

Siting with chair back 1-2 hands 18 16 14,5 13,2 12 11 10,2 9,5 8,5 7,2 6 5 3,8 2,8 BSiting without chair back 1-2 hands 8 7,2 6,5 6 5,5 5 4,5 4,2 3,8 3,2 2,8 2,2 1,8 1,4 J

1 hand 8 7,2 6,5 6 5,5 5 4,5 4,2 3,8 3,2 2,8 2,2 1,8 1,4 J2 hands 16 14,4 13 12 11 10 9 8,4 7,6 6,4 5,6 4,4 3,6 2,8

Siting - with feet support 1-2 hands 15 13,2 12 11 10 9,2 8,6 8 7,2 6,2 5 4 3,2 2,5 G

Siting - without feetsupport

1-2 hands 6 5,5 5 4,2 4 3,5 3,2 3 2,6 2,2 1,8 1,5 1,2 1 L

1 hand 6 5,5 5 4,2 4 3,5 3,2 3 2,6 2,2 1,8 1,5 1,2 1 L2 hands 12 11 10 8,4 8 7 6,4 6 5,2 4,4 3,6 3 2,4 2

"good" 1-2 hands 5 4,5 4 3,5 3,2 2,8 2,5 2,2 2 1,8 1,5 1,2 1 0,8 N

"acceptable" 1-2 hands 2,5 2,25 2 1,75 1,6 1,4 1,25 1,1 1 0,9 0,75 0,6 0,5 0,41 hand 7 6,2 5,8 5,2 4,8 4,2 4 3,5 3,2 2,8 2,2 1,8 1,5 1,2 K2 hands 14 12,4 11,6 10,4 9,6 8,4 8 7 6,4 5,6 4,4 3,6 3 2,41 hand 3,5 3,1 2,9 2,6 2,4 2,1 2 1,75 1,6 1,4 1,1 0,9 0,75 0,62 hands 7 6,2 5,8 5,2 4,8 4,2 4 3,5 3,2 2,8 2,2 1,8 1,5 1,2

"good" 1-2 hands 3,2 3 2,4 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,7 0,6 0,6 Q"acceptable" 1-2 hands 1,6 1,5 1,2 1,1 1 0,9 0,8 0,7 0,6 0,5 0,4 0,35 0,3 0,3

1 hand 3,2 3 2,4 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,7 0,6 0,6 M2 hands 6,4 6 4,8 4,4 4 3,6 3,2 2,8 2,4 2 1,6 1,4 1,2 1,21 hand 1,6 1,5 1,2 1,1 1 0,9 0,8 0,7 0,6 0,5 0,4 0,35 0,3 0,32 hands 3,2 3 2,4 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,7 0,6 0,6

"good" 1 hand 5 4,5 4 3,5 3,2 2,8 2,5 2,2 2 1,8 1,5 1,2 1 0,8 O"acceptable" 1 hand 2,5 2,25 2 1,75 1,6 1,4 1,25 1,1 1 0,9 0,75 0,6 0,5 0,4

"good" 1 hand 4 3,5 3 2,7 2,5 2,2 2 1,8 1,5 1,2 1 0,9 0,8 0,8 P"acceptable" 1 hand 2 1,75 1,5 1,35 1,25 1,1 1 0,9 0,75 0,6 0,5 0,45 0,4 0,4

GRIP tight 1 hand 18 16 14,5 13,2 12 11 10,2 9,5 8,5 7,2 6 5 3,8 2,8 C

Siting with chair back 24 21 19 17,5 16 14,6 13,6 12,4 11,2 9,5 8 6,5 5 3,8 ASiting without chair back 18 16 14,5 13,2 12 11 10,2 9,5 8,5 7,2 6 5 3,8 2,8 F

Stand Up 18 16 14,5 13,2 12 11 10,2 9,5 8,5 7,2 6 5 3,8 2,8 F

ADDUCTION

ABDUCTIONStand Up or siting

PUSH withone foot on a

pedal

Hourly frequency

Stand Up

PUSH withone hand

LIFT with onehand

Siting

Stand Up"good"

"acceptable"

PULL withone hand

Up

PULL downwith one

hand

Siting

Stand Up"good"

"acceptable"


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JSIASSEMBLY & PACKAGING

JL Filisetti


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General informations

JSI – Job Stress Index

Specific evaluation of hand and wrist

Take in consideration several physiological conditions toallow people to realise specific tasks


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Evaluation of possible impact on injuries :- If index < 3, the process is probably safe- If index > 7, the process is probably hazardous


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Methods can be used in conception :

- To chose a technical solution on product- To chose a technical solution for equipment

Methods can be used in production to improve parts orequipments in case of concern.


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2. JSI explanation


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JSI explanation

Criteria

Multiplication of coefficient to determine a score regarding the6 items of efforts :

- Intensity of exertion,- Duration of exertion,

- Effort per minute,- Hand / wrist posture,- Speed of work,- Duration of task per day,


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JSI explanation

Criteria

The analyse of each criteria give a level and its associatedcoefficient.

The multiplication of coefficient determine the JSI.


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JSI explanation

Intensity of exertion (IE)

An estimate of the strength required to perform the task onetime

A : Percentage of maximal effort


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JSI explanation

Duration of exertion (DE)

Calculation of percentage between the duration of realisedexertion during an observation period on the total observation

period

Efforts per minute (EM)

Efforts per minute are measured by counting the number ofexertions that occur during an observation period.


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JSI explanation

Hand / wrist posture (HWP)

Hand / wrist posture is an estimate of the position of the handof wrist relative to neutral position.


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JSI explanation

Speed of Work (SW)

Estimation of how fast the worker is working – comparisonregarding MTM-1.

Duration of task per day (DD)

Duration of the task

NOTA : Our process flow grid are done in MTM-2, but the loading ratio is similar


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JSI explanation

Coefficients regarding criteria


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3. PO Adaptation


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PO Adaptation

The objectives of this adaptation are :

To stick to the specificity of our know how

To use the same methodology

To have a very simple tool


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PO Adaptation

Explanation of « Ergo Index » file

Page

Name dept Date : Visa :

Intensity of exertion Number of operation per cycle rate of output

1 1 60 Number of parts / hour

1 Low: below 25 N2 Normal 25 to 40 N Hand/wrist posture

3 Constant work 40 to 65 N 1

4 important effort 65 to 100 N 1 Very good Extention 0 to 10° Flexion 0 to 5° l ateral deviation 0 to 10°

5 Maximum Limit : over 100 N 2 Good Extention 11 to 25° Flexion 6 to 15° later al deviation 11 to 15°

3 average Extention 26 to 40° Flexion 16 to 30° la teral deviation 16 to 20°

4 Bad Extention 41 to 55° Flexion 31 to 50° lateral deviation 21 to 25°Assembly operation 5 very bad Extention sup à 55° Flexion sup à 50° l ateral deviation over 25°

1 Time (dmh)1 manual punching move 18 speed of work duration per day

2 speed nuts 6 1 1

3 screw 15 1 very low speed below 80% 1 below 1 hour

4 Rivet 16,7 2 low speed 81 to 90% 2 Between 1 to 2 hours

5 Staple 11,2 3 Normal speed 91 to 100% 3 Between 2 to 4 hours

6 Snapping : one pressure 7,3 4 speed difficult to maintain 101 to 115% 4 Between 4 to 8 hours

7 Snapping : two pressures 14,5 5 speed impossible to maintain over 115% 5 Over 8 hours

8 Snapping : three pressures 20,6

9 Snapping : five pressures 32,810 Snapping : eight pressures 53

Manual o eration risks

JOB STRESS INDEX , no adaptation necessary - jobs probably safe

IP

Vehicule customer Product Project N°:

PLASTIC OMNIUM AUTO EXTERIOR

Ergo Index - Job Strain Index

IE

DE

FE

HWP

SW

DD


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PO Adaptation


The validation criteria are :

- JSI < 4 :no adaptation necessary – jobs probably safe

- 4 ≤ JSI < 6an adaptation could be necessary

- 6 ≤ JSI < 8the station should be modified

- JSI ≥ 8The station is non conform – jobs probably hazardous


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PO Adaptation


If modification are necessary, we can play with all criteria. Wecan modify :

- The product (IE)- The way to assemble (DE, HWP)- The equipment (DE, SW)- The process (SW, EM)

- The organisation of the shop floor (DD) This can give some constraints to product. For example, if we

have 10 snapping per minute, we can determine the maximalexertion effort to be safe.


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4. Multi operation case


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Multi operation case

In our process, operator can have several kind of operations todo (snapping, screwing,…).

In this case, we have to use this formula :

JSI op =

3

(JSI)3

n

n is the number of operations


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Multi operation case

Example

Un operator have to realise a snapping operation and ascrewing one

The JSI of snapping is 4, screwing one is 2

JSI global =

3

(2)3

2

(4)3+= 3,3


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5. Exercises


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Exercises

Exercise n°1

An operator snaps a set of rub strip on a bumper after thepaint line (60 p/h). The assembly effort is 75 N. To snap thepart, the operator press the part 2 times with his wrist in good

position. The working load is normal and the duration of workis 8 hours

- Calculate the JSI- Regarding the results, what are possible actions to

improve the process


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Exercises

Exercise n°1

Page




1 Low: below 25 N

2 Normal 25 to 40 N Hand/wrist posture


4 important effort 65 to 100 N 1 Very good Extention 0 to 10° Flexion 0 to 5° lateral deviation 0 to 10°

5 Maximum Limit : over 100 N 2 Good Extention 11 to 25° Flexion 6 to 15° late ral deviation 11 to 15°

3 average Extention 26 to 40° Flexion 16 to 30° l ateral deviation 16 to 20°

4 Bad Extention 41 to 55° Flexion 31 to 50° later al deviation 21 to 25°

Assembly operation 5 very bad Extention sup à 55° Flexion sup à 50° lateral deviation over 25°


2 speed nuts 6 3 4





7 Snapping : two pressures 14,5 5 speed impossible to maintain over 115% 5 Over 8 hours8 Snapping : three pressures 20,6

9 Snapping : five pressures 32,8

10 Snapping : eight pressures 53

Manual operation risks

JOB STRESS INDEX 4,5 an adaptation could be necessary

IP





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Exercices

Exercice n°1

Page




1 Low: below 25 N





3 average Extention 26 to 40° Flexion 16 to 30° l ateral deviation 16 to 20°

4 Bad Extention 41 to 55° Flexion 31 to 50° later al deviation 21 to 25°



2 speed nuts 6 3 4





7 Snapping : two pressures 14,5 5 speed impossible to maintain over 115% 5 Over 8 hours8 Snapping : three pressures 20,6





IP





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Exercices

Exercise n°1

Work on product : effort to 60 N=> JSI = 3 (conform)

Work on equipment (snap aids => 1 pressure)=> JSI = 2,3 (conform)

Work on shop floor organisation (4 hours of work)=> JSI = 3,4 (conform)


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Exercises

Exercise n°2

The operator assembles on a bumper :- A central grid (100%) by snapping (effort : 75 N – 3

pressures – position of wrist « average »)

- Fog lamps (45%) by screwing (2 screws per fog lamp –position of wrist « good » – effort « normal »)- A spoiler (100 %) with staples (10 staples per bumper –

position of wrist « good » – effort « normal ») Cycle time : 50 p/h Working load « normal » on an eight hours shift

- Calculate the average JSI- Regarding the results, what are possible actions toimprove the process


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Exercises

Exercise n°2

Assembly of grid

Page




1 Low: below 25 N





3 average Extention 26 to 40° Flexion 16 to 30° l ateral deviation 16 to 20°4 Bad Extention 41 to 55° Flexion 31 to 50° later al deviation 21 to 25°



2 speed nuts 6 3 4









Manual o eration risks

JOB STRESS INDEX 3,4 no adaptation necessary - jobs probably safe

MONTAGE GRILLE

IP




E i


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Exercises

Exercise n°2

Assembly of fog lamps

Page



2 4 22,5 Number of parts / hour

1 Low: below 25 N








2 speed nuts 6 3 4










JOB STRESS INDEX 0,8 no adaptation necessary - jobs probably safe

MONTAGE AB

IP




E i


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Exercises

Exercise n°2

Assembly of spoiler

Page




1 Low: below 25 N2 Normal 25 to 40 N Hand/wrist posture







2 speed nuts 6 3 4











MONTAGE DEFLECTEUR

IP




E i


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Exercises

Exercise n°2

JSI global =

3

(3,4)3

3

(0,8) 3+= 3,52

+ (4,5)3

conform


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NIOSHASSEMBLY & PACKAGING

JL Filisetti


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NIOSH

The NIOSH calculation (National Institute for Occupational Safetyand Health) is use to determine the Recommended Weight Limit

(RWL) during part manipulation with 2 hands withoutmovement.

Regarding NIOSH, 99% of men and 75% of women are able tocarry parts with a weight lower than CMA with low risk of back

injuries.



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NIOSH

The RWL is calculated with with an equation that integrate severalitem :

- LC : Load Constant- HM : Horizontal Multiplier- VM : Vertical Multiplier- DM : Distance Multiplier

- AM : Asymmetric Multiplier- FM : Frequency Multiplier- CM : Coupling Multiplier



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NIOSH

With RWL and the weight of part, we can determine the LI (LiftingIndex).

The criteria are :- LI < 1 Low risk of back injury- 1 < LI < 3 Potential risk of back injury- LI > 3 Mandatory modification of equipment



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NIOSH

Methods can be used in conception :- To chose a technical solution on product

- To chose a technical solution for equipment

Methods can be used in production to improve parts or

equipments in case of concern.


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2. NIOSH explanation

NIOSH explanation


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NIOSH explanation

Criteria

The RWL is calculated with with an equation that integrate severalitem :

- LC : Load Constant- HM : Horizontal Multiplier- VM : Vertical Multiplier- DM : Distance Multiplier- AM : Asymmetric Multiplier- FM : Frequency Multiplier- CM : Coupling Multiplier

We compare the RWL and the weight of part to determine LI

RLW = LC x HM x VM x DM x AM x FM x CMRLW = LC x HM x VM x DM x AM x FM x CMRLW = LC x HM x VM x DM x AM x FM x CMRLW = LC x HM x VM x DM x AM x FM x CM

LI =LI =LI =LI = weightweightweightweight of part (kg) / RWL (kg)of part (kg) / RWL (kg)of part (kg) / RWL (kg)of part (kg) / RWL (kg)

NIOSH explanation


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NIOSH explanation

NIOSH explanation


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NIOSH explanation

LC : Load Constant = 23 Kg

HM : Horizontal Multiplier = 25/H

Limit : 25 < H < 75

VM : Vertical Multiplier = (1-0,003|V-75|)Beginning of the movement Limit : V < 75

H

MD

CG

MG

IC

IM

CD

H

V

NIOSH explanation


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NIOSH explanation

DM : Distance Multiplier = 0,82+4,5/DLimit : If D < 25, D = 25

AM : Asymmetric Multiplier = 1-0,0032*ALimit : 0 ° < A < 135 °

If A >135 ° => AM = 0

D

Initial position Final position

Mid-sagittal plan Asymettric plan

AF

F

Ha

Ha

A

He

I

I

NIOSH explanation


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NIOSH explanation

FM : Frequency MultiplierV in inches => limits = 75 cm

NIOSH explanation


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p

CM : Coupling Multiplier


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3. Exercises

Exercise


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Exercise n°1


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REBA

ASSEMBLY & PACKAGING

JL Filisetti


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REBA

The definition of REBA is :- Rapid Entire Body Assessment

With this method, we are able to evaluate posture of workeron this working station. We use the complete body for thisevaluation.

We have a score per posture from 1 to 15

Score

REBA

Niveau de

risqueAction

1 Négligeable Pas d’action nécessaire

2-3 Faible Action éventuelle4-7 Moyen Action nécessaire

8-10 Fort Action immédiate

11-15 Très fort Poste non conforme

Score over or equal to 8

Mandatory corrective action



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REBA

LIMIT

This is a picture. This method don’t take into account thefrequency to realise the operation.



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REBA

Tool in conception- In development phase

- To validate an equipment

Methods can be used in production to improve parts orequipments in case of concern.


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2. REBA explanation

REBA explanation


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p

Penché ou supportele poids du bras

Épaule surélevée

Bras en abductionou tordu

Position du bras

Position du poignet

Si poignet tordu

Flexion dupoignet

Position de l’avant bras

REBA explanation


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p

Pasd’ajustements

Position de la nuque

Nuque tordue

Nuque penchée sur le côté

Flexion de lanuque

Position du tronc

Tronc penchésur le côté

Tronc tordu

Poids total (corps

+ charge

éventuelle) porté

de manière

symétrique,

marcher ou êtreassis

Position des jambes et équilibre

Poids total (corps +charge éventuelle)porté de manièrenon symétrique,être sur un pied ouposture instable

Flexion des jambes

Genoux fléchisentre 30 et 60°

Genoux fléchis à

plus de 60°

REBA explanation


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* Cases à cocher pourcertaines opérations declippage

Une ou plusieurs parties ducorps sont statiques, parexemple cette posture esttenue plus de 1min

* Groupe de petites actions;par exemple plus de 4 foispar minute (sans compter lamarche)

Actions provoquent deschangements rapides ou

une posture instable

Masse de la chargeou force requise

*Chocs ou développementrapide de force (écart de

force important)

Fréquence – force requise - Interface

Interface Main-Objet Bonne prise en main

Prise en main acceptable mais

pas idéale ou acceptable enavec une autre partie du corps

Médiocre – Prise enmain pas acceptablebien que possible

Pas acceptable –difficile, pas sûre, pasde poignées ou la priseen main n’est pasacceptable en utilisantles autres parties ducorps

Partie du corps utilisée ?

Seul paramètre concernant la fréquence

REBA explanation


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Most of ergonomical methods integrate frequencyin task evaluation : JSI methods NIOSH methods

Example of a posture with a score of 8 Acceptable with a low frequency Non acceptable with a high frequency Validation of this task with NIOSH methods

Integration of an index regarding frequency

REBA explanation


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REBA score regarding frequency

Frequence used by Renault intheir ergonomical analysemethods

Example

Fréquence (Nombre defois par heure)

PondérationREBA

200 f/h +2

Score REBAInitial

FréquenceScore REBA

final

200 f/h 8

6

Upper carrier loading (E70)


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3. Exercises

Exercise


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Exercise n°1Calculate REBA on this operation

Exercise


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Exercise n°2Calculate REBA on this operation


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Part transportation

ASSEMBLY & PACKAGING

JL Filisetti


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Part transportation calculation

This method is based on norm NF X35 109. We cancalculate the weight than a person can carry during his

work.

The norm NF X35 109 takes in consideration the capacity ofa man between 18 and 45 years to carry 50 Kg per minuteon 10 m long with good condition.


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2. Part transportation explanation

Part transportation explanationPLASTIC OMNIUM AUTO EXTERIOR


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Population (age et sexe) Charge maxi sur 10 m (Kg/mn) Coef. Population (CP) CritèreHommes 18-45 ans 50 1Hommes 45-65 ans 40 0,8Femmes 18-45 et Hommes 15-18 ans 25 0,5Femmes 15-18 et 45-65 ans 20 0,4 1

Distance (m) Charge maxi (Kg/mn) Coef. Distance (CD) Critère20 25 0,510 50 1 14 100 22 150 31 200 4

Tache Charge maxi sur 10 m (Kg/mn) Coef. Tache (CT) CritèreCondition de référence (*) 50 1 1Soulèvement à partir du sol 25 0,5Transport en condition défavorable 25 0,5(*) t°neutre, sol plat, non glissant, sans obstacl e

Fréquence sur ref Charge maxi sur 10 m (Kg/mn) Coef. Fréquence (CF) CritèreOcasionnel : maxi 1 x 5 mn 60 1,2Répétitif : > 1 x 5 mn 50 1 1

Charge Transpostable Admissible (kg/mn) 20

Somme des masses pièce (**) 14,6Cadence horaire (en p/h) 55

Charge réelle transportée (kg/mn) 13,4

(**) Somme des ports de charge unitaire pièce et de l'ensemble

Conformité norme 67%

Process conforme à la norme NF X35-109


Port de charge - NF X35-109


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3. Exercises

Exercises


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Exercises n°1 – Check the conformity - man between 18 – 45 years n°2 - Check the conformity - woman between 45 – 65 year s

Activité

100 cm

Montage absorbeur

11Evacuation PC

assemblé

Poids 3,5 kg

Peau

PC

N° Opérations

Standardized Work Graphe

0,6 kg 0,85 kg0,75 kg 1,2 kg

Renfort decrosse (jeu)

AbsorbeurGrille

centraleSupport

technique

Prise support technique

Montage supporttechnique

Prise renforts de crosse

Montage renforts decrosse

Prise PC

Pose PC

Prise grille

Montage grille

sans pièce

avec pièce

9

Déplacements

Prise absorbeur

10

1

2

3

4

5

6

7

8

Takt Time

Kaizen

Opérateur N°

55 p/h

1

x

MachinesoudageGrille

central

Renfort decrosse D

1

8

6

23

45 7

Renfort decrosse G

AbsorbeurSupporttechnique

9

10 11

ergonomie - training eng.pdf

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