fondazione ergo, il metodo mtm (methods-time measurement) - … · 2018. 9. 18. · takeaway from...

Symposium FCA

The Ergo-UAS system

and a new design approach:

overview and validation

Florence

29 August, 2018

Our Objective

Takeaway from this presentation

§ Safety level is set in the product-process design phase

§ Many competencies in I.E. and Ergonomics are shared, despite the

fact that they may have conflicting goals (Productivity vs Safety)

§ Need of a new job profile: the ERGO

MOTION-TIME ANALYST

§ EAWS (Ergonomic Assembly Work

Sheet) is the right tool

2

What will be discussed Page

1. Fondazione Ergo – a Passion for the Factory 4

2. Tools for work design 7

3. How to Create a Factory without «Fatigue» 14

4.

Validation through a longitudinal epidemiological study

of the EAWS system for the assessment and prevention

of biomechanical overload

23

5. Contact information 33

Index

Fondazione Ergo: a

Passion for the Factory1

A neutral meeting place where companies, trade unions, and universities work together towards a morecompetitive Italian system of production of goods and services

ü A center for excellence, training,

certification, research and

development in the field of labor andapplied ergonomics

ü A supplier of operational audit services

that assesses key areas ofcompetitiveness in a factory(Organization, Productivity,

Ergonomics, Industrial Relations andDigitization)

ü A technical and managerial guide tosupport the transformation of workorganization and industrial relations

ü A partner in research funding

ü A neutral, competent, and certifying

body for all work analyses andassessments of biomechanical loads.

ü A technical consultant for definingadditional contracts that refer tolabor productivity

ü An observatory of operational data

on key parameters of work

organization (breaks, work rates,incentive systems, occupationaldiseases, organizational models,

production systems)

ü A training and certification school fordelegates in the area of managementand work organization

ü A source of international research,

development projects, and specific

training programs in the field oflabor and applied ergonomics

ü A specific channel regarding work

design and ergonomics withcompanies that are part of thefoundation

ü An international benchmark on allmatters regarding work design,recognized by technical, political

and academic institutions

ü A partner in research funding

ü A source of international data oflevels of productivity from the

ground up

Fondazione Ergo

What is it and what does it offer?

Industry Trade Union Institution

Fondazione Ergo

5 areas of activity

6

Centro Studi carries out

an independent

investigation, analysis

and research on

economic, industrial,

organizational,

ergonomic and technical

topics.

BellaFactory is an audit

and certification system

based on the “Best in

Class Productivity

Rating” system, which

is designed to identify

and measure

opportunities for

system improvement.

Fondazione Ergo

supports companies

and trade unions with

technical and labor law

services in auditing and

contracting

Fondazione Ergo offers

specific technical skills,

which aim to align the

objectives of employee

productivity and health,

in addition to reaching

“Best in Class

Productivity” levels.

Fondazione Ergo is the

only Italian distributor of

TiCon, the best all-

around application

software for the

management of

Engineered Labor

Standards (ELS).

Tools for work design2

Work and Ergonomics

What is Methods-Time Measurement (MTM)

8

MTM is an engineering-based method for manual

work design that assigns a fair and sustainable

time allowance for each work task, which is then

used as a benchmark that is internationally

recognized.

MTM is a set of techniques designed to work in

harmony in a determined production system,

from mass production to one-of-a-kind

production

Identify elementary

movements

Determine the

influencing factors

Design work tasks

Calculate basic times

Ex. fasten a screw manually

Get the screw and place it in the threaded position and perform 3 screwing movements

Distance <50 cm

Code TMU

AF 2 65

ZA1 5

ZB1 10 X 2

TOT 90

Performance of basic time

100 MTM

Method Time

Work and Ergonomics

MTM is a family of systems

9

At the core of what the Fondazione does in regards to the MTM (Methods-Time Measurement) method, is use

its predetermined task time system to analyze the methods used to perform any manual operation or task, and

as a product of that analysis, set the time in which a worker should complete that task. The time required to

complete a task is directly dependent upon the method chosen for that task.

Work and Ergonomics

What is EAWS (Ergonomic Assessment Work-Sheet)

10

Definizione:

EAWS

EAWS is a comprehensive first-class ergonomic risk assessment tool of

biomechanical overloading. It considers every potential biomechanical risk an

operator may be exposed to in a particular work process.

EAWS uses a 3-level scoring system, as shown below, to evaluate the ergonomic risk, in accordance to the

Machinery Directive 2006/42 / EC (EN 614).

0-25 Points Low risk recommended; no action is needed

>25-50 Points

Possible risk not recommended; redesign if possible,

otherwise take other measures to control the

risk

>50 PointsHigh risk to be avoided; action to lower the risk is

necessary

Green

Yellow

Red

Work and Ergonomics

What is the Ergonomic Assessment Work-Sheet (EAWS)

11

Page 1

(Section 0)

Heading

Overall rating

Extra points

Page 2

(Section 1)

Postures and movements

Page 3

(Section 2 e 3)

Action forces

Manual handling of loads

Page 4

(Section 4)

Upper limbs

Work and Ergonomics

Standard of Reference of EAWS

12

EN 614 Principles for ergonomic design

EN 12100 Basic terminology, methodology, and principles for ergonomic risk assessment

EN 14738

Safety of Machinery – Anthropometric requirements for the design of machine workstations

EN ISO 7250 Basic human body measurements for technological design

EN 1005-2

Safety of Machinery -

Manual handling of machinery and

component parts of machinery

ISO 11228-1

Ergonomics –

Manual handling – Lifting and

Carrying

EN 1005-3


Recommended force limits for

machinery operation

ISO 11228-2

Ergonomics –

Manual handling – Pushing and

pulling

EN 1005-4


Evaluation of working postures in

relation to machinery

ISO 11226Ergonomics –

Evaluation of working postures

EN 1005-5

Safety of Machinery-

Manual handling of low loads at

high frequencies

ISO 11228-3Ergonomics – Manual handling –

low loads at high frequencies

STA

ND

AR

D C

EN

STA

ND

AR

D IS

O

Work and Ergonomics

EAWS International Key Users Meeting

13

In January 2017, the first reunion of the EAWS

International Key Users Meeting (EIKUM) was held in

Milan, in which the primary user companies of the

EAWS system (Ergonomic Assessment Work-Sheet)

met.

In collaboration with the Deutsche MTM-Vereinigung

e. V., the Fondanzione Ergo invited all of the primary

user companies of the EAWS system in Europe that

use the system in their plants to create a team of

professionals (managers in manufacturing, process

engineering, or health and safety) and companies

interested in collaborating on the future strategic

development of EAWS.

The following companies were present: CNHi,

Truck&Bus (IVECO), Magneti Marelli, FCA, Automobili

Lamborghini, VW & Audi, Miele, Brose e Stihl.

How to Create a

Factory without

«Fatigue»3

The Ergo-UAS model

Ergo-MTM factor for calculating recovery time

§ Ergonomic factor (Fergo):

– For each workstation, determine the ergonomic factor as a function of:

• The sequence of assigned operations (line balancing)

• The overall static ergonomic workload (poor body postures held longer than 4 seconds)

• dynamic ergonomic workload (frequencies of the movements of the upper limbs)

§ Technical-Organizational factor (Ft-o)

– The Technical-Organizational Factor is the allowance for:

• any variation that is not included in the MTM system and not related to biomechanical load

• Unplanned but structural events (ex.: receive extraordinary instructions from supervisor ; unreported micro-losses)

15

Fmagg= Fergo + Ft-o

In light of the most recent regulations on biomechanical loading (Legislative Decree 81/2008 and ISO 11228.1 /

2/3 standard) it is essential to consider all the factors that influence the design and organization of a work

process (static and dynamic). The old methods used to determine recovery factors (rest) are no longer effective

(see next page)

The Ergo-UAS model

Analysis of Rest Factor

16

• Grab object

• Transport it

• Place object

• Press

• Block

• .......

Frip-1

Frip-2

Frip-3

Frip-4

Frip-5

Frip-n

Tstd-1

Tstd-2

Tstd-3

Tstd-4

Tstd-5

Tstd-n

• Assigns a variable rest factor (from 1% to 23%) for every micro-time element

• The average rest factor per workstation is almost equal for all jobs (around 6%)

• Does not consider the frequency of actions (dynamic load)

• Independent of the sequence of operations assigned to the workstation (static load)

The Ergo-UAS Model

Introducing the Ergo-MTM factor

17

PDL 1 PDL 2 PDL 3 PDL 4

PDL 1 PDL 2 PDL 3 PDL 4

Calculate Ergo-MTM factor

(EAWS)

1,0%2,5%

4,5%

7,0%

10,0%

13,5%

17,5%

22,0%

27,0%

32,5%

38,5%

45,0%

52,0% 52,0% 52,0% 52,0% 52,0% 52,0% 52,0%

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

55%

60%

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115

0 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110

Ft-o +Fergo

MTM Analysis

(calculate basic task times)

1

EAWS Analysis

(calculate fatigue)

2

ERGO-MTM3

Calculate standard times4

Recommended technical-

organizational grid (Ft-o)

Fergo according to the

EAWS score

Recovery time

The Ergo-UAS Model

Initial line balancing and calculating the ergonomic factor using the traditional method

18

Min/Shift

EA

WS

Ind

ex

Ergonomic Work Allowances and

EAWS Indexes are not correlated

The Ergo-UAS Model

Initial line balancing and calculating the ergonomic factor using the ERGO-UAS system

19

Ergonomic Work Allowances

and EAWS Indexes connected

through the EWA model

Min/Shift

EA

WS

Ind

ex

The Ergo-UAS Model

New line balancing and calculating the ergonomic factor using the ERGO-UAS system

20

Method redesign, different work organization and new line balancing to

evenly distribute the load

Min/Shift

EA

WS

Ind

ex

The Ergo-UAS System

EAWS Point distribution

21

Starting point

Situation proposed

with ERGO-UAS

The Ergo-UAS Model

ERGO-UAS is a preventive tool in ergonomics

§ Process design

− Simulation tool

− Productivity-Ergonomics

connection

− Cross-functional approach

(Design-Industrialization-

Production)

§ Comprehensive analysis tool

− Posture

− Forces

− Material handling

− Upper limbs

§ Work design

− Line balancing

− Saturation

− Breaks and extra time

− Efficiency management

§ Risk mapping

− Dynamic map

− Risk evaluation connected with

the work cycle definition

− Reduced ergonomic analysis cost

− ALWAYS UP TO DATE

22

Main users

Validation through a longitudinal epidemiological study of the EAWS system for the assessment and prevention of biomechanical overload

4

• In order for observational data to provide a sound basis for decision-making, the

assessment should be validfor the targeted purpose and the results should be

reproducible

Criterion/concurrent

validity; Predictive validity

Face validity; Intra + inter

observer repeatability

• Takala et al, 2010

• Indices or composite measures are “Primarily intended as an instrument

for priority setting in ergonomic work

• Needs to be validated

• Must never be used in a way that obscures an analysis of the effects of single exposure variables”

• Kilbom A, 1994

Validation of the EAWS system

Background

• To investigate the predictive validity of EAWS (scores and composite measures)

• How well will risk estimates generated by the method be shown to be associated with musculoskeletal disorders

(MSDs)?


Aim of the study

Longitudinal study design

• Cohort: random sample of the working population in the FCA

Melfi Plant

• Production workers involved in manual jobs

• Administrative and non manual workers (controls)

• Baseline in 2017-18 and Follow-up in 2019-2020

Exposure assessment

• EAWS (Ergonomic Assessment Work-Sheet)

The study protocol has been approved by the Bioethics Committee

of the University of Bologna


Methods

Clinical

assessment

More detailed information on symptoms

and disability

Physical examination

MSDs symptoms

in the past 12 months

STOP

No MSDs symptoms

in the past 12 months

Anthropometric data, personal

characteristics, family and personal

health history

Working history

MSDs Symptoms

(current and past)

Symptoms Survey Nordic

Questionnaire

Cli

nic

al

asse

ssm

en

t

I le

ve

l

Cli

nic

al

asse

ssm

en

t

II a

nd

III

le

ve

l

Diagnostic procedures (MRI, NCS)


Methods

• Several outcomes will be defined using different case definitions based on symptoms or symptoms and the results of physical examination and instrumental findings (MRI, EMG)

• Low back disorders: low back pain, low back pain and

evidence of neurological deficit, lumbar disc disease

• Rotator cuff syndrome

• Epicondylitis (medial or lateral)

• Carpal tunnel syndrome

• Cubital tunnel syndrome

• Hand wrist tendonitis


Methods

• To date, the cohort is composed by 1357 subjects:938 manual workers

419 clerks and non-manual workers

• All the subjects completed the I and II level assessment

(questionnaire and physical examination); the III level is currently underway

• Exposure will be assigned to each subjects according to the job title and the EAWS score (overall evaluation and

separate sections)


Project progress

• MSDs are common in the general population

• Prevalence and incidence are dependent on the case definition adopted

• Monitoring the prevalence and incidence of MSDs is necessary for the early identification of an increased risk of

MSDs with respect to different levels of biomechanical exposure


Discussion

• Data will be analyzed to estimate prevalent cases at the baseline and incident cases at follow up and to demonstrate that workers involved in manual tasks designed according to

EAWS do not present a significant increase in the risk of suffering from disorders and/or diseases affecting the musculoskeletal system


Discussion

Fondazione Ergo and the University of Bologna carry out the study thanks to the collaboration of FCA, a large automotive company, and with the scientific contribution of a panel of

experts from academic and non-academic institutions

The Core Team formed by the following specialists:

• Prof. Francesco S. Violante (UNI.BO)

• Prof. Roberta Bonfiglioli (UNI.BO)

• Prof. Maria Pia Cavatorta (POLI.TO)

• Prof. David Rempel (University of California, Berkeley)

• Prof. Pietro Apostoli (UNI Brescia)

• Ing. Ivan Lavatelli (PwC)

• Ing. Gabriele Caragnano (PwC and Fondazione ERGO)


Conclusions

Contact Information5

Fondazione Ergo

Principali Contatti

34

Gabriele Caragnano

PartnerPwC Advisory SpAOffice: +39 02 66720445Mobile: [email protected]

Gabriele Caragnano

Direttore TecnicoFondazione ERGOOffice: +39 0332 239979Mobile: [email protected]

Roberta Bonfiglioli MD

Associate Professor of OccupationalMedicineAlma Mater Studiorum - University of BolognaDepartment of Medical and Surgical [email protected]

[email protected]

fondazione ergo, il metodo mtm (methods-time measurement) - … · 2018. 9. 18. · takeaway from...

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