Introduction to Industrial Ergonomics

Introduction to Industrial ErgonomicsLusi Susanti, Hilma Raimona Zadry

MarkingExam60%Test5% + 5%Case Study15%Labs15%ReferencesB. Mustafa Pulat. (1992). Fundamentals of Industrial Ergonomics. Waveland Press, Inc.K.H.E. Kroemer et al. (2001). Ergonomics-How to design for ease and efficiency. Prentice Hall.R.S. Bridger (1995). Introduction to Ergonomics. McGraw Hill. Mark S. Sanders & Ernest J. McCormick (1992). Human Factor in Engineering and Design. McGraw Hill.Benjamin Niebel & Andris Freivalds (2004). Methods, Standards and Design. McGraw Hill.Gerard J. Tortora & Sandra Reynolds Grabowski (2001). Introduction to human Body. Wiley.K.H.E.Kroemer (1997). Engineering Physiology. International Thomson Publishing-Van Nostrand Reinhold.Konz & Johnson (2004). Work Design: Occupational Ergonomics. Holcomb Hathaway, Publishers, Inc.

ContentsWhat is ErgonomicsUnderstanding Ergonomics RiskAnalyzing and Recognizing Ergonomics ProblemsHow to reduce the riskWork Design

Course Objectives:At the end of the class, students are able to:Understand the basic concepts of ergonomics in industryInterpret ergonomics practice in industryIdentify the ergonomics risk factors in industrial environmentGive suggestion to reduce the risk in an industrial environmentDesign the work task/workplace to improve industrial productivity.5What is Ergonomics?Various authors define ergonomics as: The study of mans relationship with his/her workplace.Fitting the task to the person rather than forcing him/her to adapt to the work environment.Designing the workplace to prevent occupational injury and illness.Discovering the capabilities and limitations of the human body.The art and science that addresses workers job performance and well-being in relation to their job tasks, tools, equipment and environment.The study of the relationship between people and machines or between employees and their environment. The study of the interaction between the worker and the process at the workplace.

What is Ergonomics? Ergonomics is the application of scientific principles, methods and data to the development of products and systems that interact with human.

What other definitions have you heard?

History of ErgonomicsThe term ergonomics comes from the Greek words ergon (work) and nomos (law).Early history-1900 Frank and Lillian Gilbreth began their work in motion study and shop management. Their work can be considered as one of the forerunners to what was later to be called Human Factors. They studied about skilled performance and fatigue, the design of work stations and the equipments for the handicapped. Ergonomics and Human FactorsHuman factors is the term used in the USAErgonomics is more prevalent in Europe and the rest of the worldFor all practical purposes the terms are synonymous.

The Goal of ErgonomicsTo generate tolerable working condition that do not pose dangers to life or health.To create acceptable conditions which people can voluntarily agree.To generate optimal conditions that are well adopted to human characteristics, capability, desires that physical, mental and social well-being is achieved.

.. is to make the work fit the operator, not make the operator fit the work.

Why Ergonomics is Important?

Stretching to reachRepeated heavy liftingHigh pinch forcesHandling objects that are sharp, very hot, or very cold.Working with hands above shouldersLong periods of work without a change in body posture.

Examples of work requirements that can cause discomfort, fatigue, injury, and illness are:

Therefore Ergonomics is Importantbecause Ergonomics can (benefit of ergonomics): Improve quality and productivity. Reduce absenteeism. Maintain a healthier work force. Reduce injury and illness rates. Reduce workers compensation costs. Increase morale or self-confidence Increase job satisfaction Reduce medical & insurance costs Reduce lost time Reduce employee turnover

The Importance of Ergonomics.In Engineering and ManufacturingDesign Improve/InnovativeHigh technology researchIn IndustrySafety and healthRisk factor and MSD

Aspect of Ergonomics Study, research and experimentation to determine human traits and characteristics for engineering design.Application and engineering designing tools, machines, shelter, environment, work tasks, and job procedures to fit and accommodate to human.Focus of ErgonomicsErgonomics focus on human being and their interaction with products, equipment, facilities, procedures and environment used in work and everyday living.The emphasis is on human beings and how the design of things influence people.

EXAMPLES OF SUCCESSFUL ERGONOMICS PROGRAMS

GOODYEARIn 1986, Goodyear established an ergonomics element in their safety program including:Awareness trainingEstablished ergonomics committeeEstablished an audit programFixed identified problems

Geras, DT et al,. (1989). Advances in Industrial Ergonomics and Safety, I. London: Taylor & Francis. 19

Geras, DT et al,. (1989). Advances in Industrial Ergonomics and Safety, I. London: Taylor & Francis. - 1987 - 1986 mid-yearPROGRAM IMPLEMENTED GOODYEARs Accident Rates before & after Ergonomics Program20Wisconsin Aluminum FoundryFoundry has approx. 390 employeesImplemented safety & ergonomics inspectionsFixed identified problems

RESULTS:WC costs reduced by 76.6% over 2 yearsPositive reports from employees

Foundry Ergonomics Partnership Helps Employers Improve Safety and Efficiency. (n.d.). Retrieved December 7, 2008, from Occupational Health and Safety Administration Web Site: http://www.osha.gov/dcsp/success_stories/partnerships/region5/261_fep_success.html.21Sample of ImprovementInstalled lift and tilt tables for baskets of parts and conveyorsReduced liftingReduced bending and reaching Increased productivityFoundry Ergonomics Partnership Helps Employers Improve Safety and Efficiency. (n.d.). Retrieved December 7, 2008, from Occupational Health and Safety Administration Web Site: http://www.osha.gov/dcsp/success_stories/partnerships/region5/261_fep_success.html.

Parts onlift basket22How to start Ergonomics Program?STEP 1: Understand Ergonomics risk/problemsSTEP 2: Review injury historySTEP 3: Evaluate workplaceSTEP 4: Implement improvementsSTEP 5: Engage employeesSTEP 6: Re-evaluate, measure improvements

23Understanding Ergonomics RiskPhysical activityFatiguePhysical exertionFatigue & recoveryOverexertion & Cumulative TraumaBody Type

Understanding Ergonomic RiskOur bodies use energy from the food we eat to meet two kinds of physical demands.Internal demands are the processes which maintain life and growth within our bodies.External demands are the physical activities which we perform during our waking hoursInternal: Cell Growth: Digestion: Circulation: Respiration etc.

External: Walking: Lifting: Standing: Exercising: etcHow the Body uses EnergyPhysical ActivityUnderstanding Ergonomic RiskIf activities exceed our personal limits of stamina or strength (and this varies from person to person), then two kinds of fatigue may result

Localized fatigue - effects the particular part of the body that is working, for example the arms.

Whole body fatigue - occurs when several body parts are over exerted.

FatigueIs either dynamic or static.Dynamic exertion is where there is visible movement of the body.Static exertion is where the body or part of the body is held in place.Static exertion is often more tiring because the muscles have no chance to recover.Understanding Ergonomic RiskPhysical ExertionThe amount of force you use in an exertion and the length of the exertion both effect how soon and how much fatigue will set in.

Localized fatigue is best relieved by changing activities to rest working muscle groups or by resting the working limb.

Whole body fatigue is best reduced by reducing the level of body activity or by resting the body.

Understanding Ergonomic RiskFatigue and Recovery

If an operator works in an activity that exceeds their strength or stamina, then overexertion injuries and cumulative trauma injuries are possible.

Overexertion can cause immediate injuries to muscles, tendons and ligaments. Such as sprains, strains and tears.

Cumulative Trauma Injuries are of the wear and tear type and include damage to hands, wrists, shoulders, elbow and some back disorders

Understanding Ergonomic RiskOverexertion

StaminaStrengthHeightWeightThe working population varies in age, sex, health and size.In most western countries you cant specify the age, sex, fitness or size of the operator.ProportionsVisionHearingUnderstanding Ergonomic Risk

Body TypeFrequent Hand UseArms ExtendedBending & TwistingStatic Body PostureUsing ForceVibrationContact StressTemperatureNoiseFatigue

Understanding Ergonomic RiskRisk FactorsHow to start Ergonomics Program?STEP 1: Understand Ergonomics risk/problemsSTEP 2: Review injury historySTEP 3: Evaluate workplaceSTEP 4: Implement improvementsSTEP 5: Engage employeesSTEP 6: Re-evaluate, measure improvements

32Injury InvestigationTime employee began workdayTime of eventWhat was the employee doing just before the incident occurred?What happened?What was the injury or illness?What object or substance directly harmed the employee?

33SuggestionsFIRST:Create a spreadsheet Use spreadsheet to track/organize informationShare information with managers & employees

THEN:Injury Data AnalysisCreate charts and graphs to look for trendsModify standard operating proceduresImprove employee training programs

34How to start Ergonomics Program?STEP 1: Understand Ergonomics risk/problemsSTEP 2: Review injury historySTEP 3: Evaluate workplaceSTEP 4: Implement improvementsSTEP 5: Engage employeesSTEP 6: Re-evaluate, measure improvements

35How do you fix something?HammerNailsLevelTape measureScrew driverScrewsTapeAnd more

36Evaluate Work EnvironmentToolsQualitativeSemi-QuantitativeQuantitative

ChecklistsNIOSH Lifting EquationRULA37How to start Ergonomics Program?STEP 1: Understanding Ergonomics risk/problemsSTEP 2: Review injury historySTEP 3: Evaluate workplaceSTEP 4: Implement improvementsSTEP 5: Engage employeesSTEP 6: Re-evaluate, measure improvements

38Implement ImprovementsJUSTIFICATION:Improving the safety of the workplaceCost-benefit analysis

BENEFITS:Delivering on commitmentsReducing injury riskReducing potential injury costs

39Tool-task designConsider the orientation of the tool and task

Facility 8Basket with parts on a lift/tilt table

Bending to get a partBETTERBAD40Workstation and fixture designed to allow productive work with both hands

An ideal workstation that permits the operator to assemble two products by going through a series of symmetrical motions made simultaneously away from and toward the center of the body

How to start Ergonomics Program?STEP 1: Understand Ergonomics risk/problemsSTEP 2: Review injury historySTEP 3: Evaluate workplaceSTEP 4: Implement improvementsSTEP 5: Engage employeesSTEP 6: Re-evaluate, measure improvements

43Engage Employees/WorkersInvolve workers in the decision process and ask for inputExample: before purchasing a new hand tool, have a trial period with a select group of workers and ask for their opinion.

Talk with workers on a regular basisExample: Ask how their production day is going, whether the equipment is working well or if they noticed anything different. These are clues to quality or safety issues.

Provide positive reinforcementReward good ideas, for example, a gift card for the local movie theater for the best ergonomics/safety idea.

44How to start Ergonomics Program?STEP 1: Understand Ergonomics risk/problemsSTEP 2: Review injury historySTEP 3: Evaluate workplaceSTEP 4: Implement improvementsSTEP 5: Engage employeesSTEP 6: Re-evaluate, measure improvements

45IMPROVEMENT PROCESS CIRCLE

46Evaluate, re-evaluate and follow upTraining feedback questionnairePost training evaluation testFollow up on the training effectiveness in the next 3-4 months

47Back SafetySafe lifting includes knowing limitations, getting help if an item is too heavy, lifting with the legs instead of the back, keeping items close and avoiding twisting when lifting and lowering.

Preventing Slips, Trips, and FallsWires and cords should never be stretched across an aisle or under carpeting. Under the desk, cords should be organized to reduce chances of catching a loose cord on your foot and tripping.

Office Ergonomics"Office Safety Evaluation" points to a new Web-based safety training tool entitled "Computer Workstation Evaluation: Location, Fit, and Use," which will be highlighted in the next issue of the IT Times.Top 3 Office Safety IssuesCopyright @ 2008 by ERGOFile Cabinet SafetyFile cabinets that are not secured to the wall can tip when heavy top drawers are opened. Fire and Electrical SafetyIt is unsafe to plug a power strip into an extension cord. Use extension cords only for temporary powerChemical SafetyAre you properly handling and storing office chemicals such as laser printer toner cartridges? Store toner cartridges in the boxes they came in, and place them back in their bags and boxes after use. Safety TrainingPeriodic office safety training is recommended to heighten employees' safety awareness. Additional Office Safety Issues:

Copyright @ 2008 by ERGOOffice ergonomics

Copyright @ 2008 by ERGOIf you sit to work at the computer, maintaining proper body posture is important. The best position while working at the computer is with the keyboard in front of you and the monitor directly in front of the keyboard.The mouse should be placed next to the keyboard. Seated posture

Copyright @ 2008 by ERGOSupported and comfortable posture Adjust the chair or stool for overall comfort and support. Learn adjustment features Adjust the chair or stool to the appropriate height of the work surfacePosition the keyboard in front of you and the monitor directly in front of the keyboardPlace the mouse next to the keyboardPosition the chair up close to the work surface This will reduce excessive reaching Relax your shoulders and keep elbows close to the bodyPlace your thighs and forearms somewhat parallel to the floor Clear obstacles from under the deskChange positions frequently to avoid stiffness and to keep blood circulating Seating basics

Copyright @ 2008 by ERGOSit back in the chair and let the back of the chair support your upper body. Add support in the low back if needed for optimal comfortSit with head above shoulders, shoulders above hips Keep your feet supported on the floor or with a footrestYour thighs should be somewhat parallel to the floor with hip angle at 90 to 130 Avoid pressing the backs of your calves against the front of the chair or stool. This can interfere with blood circulation to the lower legsAllow for optimal movement of legs under the desk by keeping the area clear of obstaclesAdjusting your computer workstation1. Backs and legsCopyright @ 2008 by ERGO

Avoid turning or twisting to view the screen. As you look at the monitor, the first line of type should be at about eye level or slightly belowMake sure the monitor is low if you are a bifocal wearer to eliminate awkward neck posture, or ask your eye care provider about using computer glasses The monitor screen should be positioned at approximately an arms length awayThe best distance is when you can view the screen clearly without leaning forward Adjusting your computer workstation2. Head and Eyes

No-No: Potential for neck strainErgo : Headset reduced risk for neck strain Copyright @ 2008 by ERGOIncrease the font size or the zoom magnification of the document if needed to see clearly Avoid extreme postures like leaning forward, bending downward, or tilting your chin to look upIf you have vision challenges, ask your eye care specialist about using computer reading glasses2. Head and Eyes (cont.)

Take regular, short posture and vision breaksIf you use the phone for extended periods of time, hold the receiver rather than cradling it against your shoulderUse a headset to allow you to use your hands while talkingCopyright @ 2008 by ERGOAdjusting your computer workstationEliminate glare or reflection on the monitor screen by positioning the monitor at a 90 angle from the window. Tilting the monitor, closing blinds or using a glare screen can help to reduce glare Document holders elevate materials allowing your head and neck to remain in an upright posture Position the document holder at the same height as the monitor screen2. Head and Eyes (cont.)

Copyright @ 2008 by ERGOAdjusting your computer workstationPreferred viewing distance is 20 to 40 inches

20 to 40 inchesCopyright @ 2008 by ERGOAdjusting your computer workstation

Copyright @ 2008 by ERGOAdjusting your computer workstationKeep shoulders relaxed with arms comfortably at your sides Adjust the work surface or the height of your chair if your shoulders are elevatedAvoid repetitive and excessive reaching Sit close to the keyboard and place the mouse next to the keyboard or as close as possible Avoid working with your arms extendedKeep frequently used items within easy reach Armrests on the chair can offer support for your arms and shoulders if used properly. 3. Shoulder and Arms

No-No: Excessive reach for the mouse

No-No: Work surface too highCopyright @ 2008 by ERGOAdjusting your computer workstationWhen keying, your forearms should be somewhat parallel to the floor with wrists at the level of the elbows or below. Avoid bent wrists Avoid placing your forearms or hands against a hard or sharp surface such as the work surface or desk edge, for a sustained period of time. Soft edging and palm rests are available to protect your arms from contact stress4. Wrist and HandsCopyright @ 2008 by ERGO

Ergo: Wrists straight by tilting keyboard No-No: Wrists bent Adjusting your computer workstation

No-No: Bent Wrist and Fingers and Thumb Ergo: Straight Wrist and Relaxed Fingers No-No: Bent Wrist and Fingers and Thumb Ergo: Straight wrist, air space under wrist, relaxed fingers. Alternate use of hands to rest the dominant one4. Wrist and Hands (cont.)Copyright @ 2008 by ERGOAdjusting your computer workstation

Copyright @ 2008 by ERGOModel Computer Workstation Keyboard trays WITH wrist support.Split "Natural" keyboards to facilitate neutral wrist angleFully adjustable ergonomic chairDocument holder to minimize head/eye & neck movementsCorner desk units to position monitor directly in front of employeeFoot rest where requested.Re-organization of working materials within employee arm reach.Alternative pointing devices (e.g., scrolling mouse or trackball devices

What you can do to reduce risk potential ?Copyright @ 2008 by ERGOChange Postures FrequentlyOrganize Your WorkstationAlternate Job TasksAvoid EyestrainProtect Your Back and Hands

Be aware of your posture!!!Wear shoes with good support and cushioning if your work requires a lot of standing or walking If standing in one spot for long periods, anti-fatigue mats can help redistribute weight. Resting one foot on a small (4-6) platform while standing, then shifting to the other foot, can help to relieve low back strain If your feet dangle when you sit back in the chair or stool, adjust the foot ring or footrest so that your feet are supported If your stool lacks back support, you can tilt the seat forward or use a seat wedge to position the back and the pelvis in a more natural posture Try to avoid spending long periods looking down while reading. Use a copy holder to elevate materials

Change posture frequentlyCopyright @ 2008 by ERGO

Ergo: Rest on a platform or box Ergo: Use an anti-fatigue mat Copyright @ 2008 by ERGO Lifting and CarryingSize up the load before you lift and make sure that the item is not too heavy for you to manage alone. If it is, ask for assistancePlan the lift before you start. When team lifting, pick one person to call the signals. Avoid walking backwardCheck the route and be sure the path is clearGet a firm footing. Keep your feet shoulder-width apart and center yourself over the loadKeep your back in its natural S curve rather than rounded in a C curve when you lift

Copyright @ 2008 by ERGOAvoided:

Recommended:

Copyright @ 2008 by ERGOWorkstation and fixture designed to allow productive work with both hands

An ideal workstation that permits the operator to assemble two products by going through a series of symmetrical motions made simultaneously away from and toward the center of the body

Questions?