An EASEworks Manufacturing Tutorial

Basic Industrial Ergonomics

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Scope of this Tutorial

This tutorial will give Industrial and Manufacturing Engineers an understanding of the basic concepts of ergonomics, known risk factors, methods of analyzing tasks, and suggested ways of reducing risk in an industrial or warehousing environment.

Ergonomics is an inexact science and the results of some method analyses can be open to interpretation. However a little common sense goes a long way.

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Contents

What is Ergonomics Understanding Ergonomic Risk Analyzing & Recognizing Ergonomic Problems Reducing the Risk Work Station & Tool Check Lists New Product Design EASE Contact Information

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What is Ergonomics?
A study of the relation between people and their work environment. Is used to prevent injuries and illnesses associated with the design of physical work. Is used to increase employee safety and comfort and to optimize work performance and quality.

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What is Ergonomics?
The term ergonomics comes from the Greek words ergon (work) and nomos (law). Too often ergonomics is only applied because of the Law. Ergonomics should be seen as a win/win opportunity to improve productivity and quality while increasing employee safety and morale.

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What is Ergonomics?
Reactive Ergonomics is where you respond to a work place complaint or injury. Reactive Ergonomics is where you respond to a work place complaint or injury. Proactive Ergonomics is where you analyze a proposed task at design time to prevent an injury. A real world ergonomics program should include both analyses. But due to constraints of time and staffing not every task can or indeed needs to be analyzed. Good work station & tool design will prevent a lot of problems whatever the task.
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What is Ergonomics?
Examples of work requirements that can cause discomfort, fatigue, injury, and illness are:

Stretching to reach Repeated heavy lifting High pinch forces Handling objects that are sharp, very hot, or very cold. Working with hands above shoulders Long periods of work without a change in body posture.

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What is Ergonomics?
The Goal of Ergonomics
Is to make the work fit the operator, not make the operator fit the work.

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What is Ergonomics?
And why do we need it?

Effects on the Operator

Fatigue Pain Illness sprains, back ache, etc Low morale Frustration & Irritation

Effects on the Company

Poor Quality Absenteeism Higher costs Higher employee turnover & training

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What is Ergonomics?
And what is the benefit?
Higher productivity Higher Quality Reduced operator injury Increased morale Greater job satisfaction Lower medical & insurance costs Reduced lost time Lower absenteeism Less employee turnover

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What is Ergonomics?
And why do we need it?

Effects on the Operator

Fatigue Pain Illness sprains, back ache, etc Low morale Frustration & Irritation

Effects on the Company

Poor Quality Absenteeism Higher costs Higher employee turnover & training

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Understanding Ergonomic Risk

Physical Activity Fatigue Physical Exertion Fatigue & Recovery Overexertion & Cumulative Trauma Body Type

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Understanding Ergonomic Risk

It is important to note that occasional exposure to a risk factor is not usually harmful. Significant exposure to a risk factor may be harmful to sections of the population. You cant specify the physique, age, sex of the operator. Ergonomic analysis tools are going to be based on 95% of the working population being able to do the work.

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Understanding Ergonomic Risk

Physical Activity
Our 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 hours

How the Body uses Energy

Internal: Cell Growth: Digestion: Circulation: Respiration etc. External: Walking: Lifting: Standing: Exercising: etc

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Understanding Ergonomic Risk

Fatigue
If 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.

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Understanding Ergonomic Risk

Physical Exertion
Is 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.

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Understanding Ergonomic Risk

Fatigue and Recovery

The 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.

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Understanding Ergonomic Risk

Overexertion

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

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Understanding Ergonomic Risk

The 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.

Stamina Strength Height Weight

Proportions Vision Hearing

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Understanding Ergonomic Risk

Risk Factors
Frequent Hand Use Arms Extended Bending & Twisting Static Body Posture Using Force Vibration Contact Stress Temperature Noise Fatigue

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Understanding Ergonomic Risk

Things to consider
Risk Activities may occur at work, and may occur at home. Consider the body posture, force requirement and hand grip when bowling or hanging washing on a line. When walking a factory, you can often tell the physically demanding tasks by the operators performing them. Big, buff, men! But consider who will get the blame (and cost) for operator injury if Big Bill hurt his back at home, and now has to do his physically demanding tasks? The work has to fit the operator, not the operator the work!

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Understanding Ergonomic Risk

Things to consider
Tasks often have multiple Risk Factors To analyze the task, multiple assessments have to be done to cover Force, Repetition, Posture, Fatigue The task time is important. If risk is found, any proposed solutions must take into account manufacturing cycle time requirements, and of course COST. COST

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Analyzing Tasks
Recognizing Problems Ergonomic Analysis Methods
We need to know how much force is involved for each body posture, how often is it repeated, for how long is it held, how often is the total task repeated and for how long the task is worked. Posture Force Repetition

Fatigue & Recovery Employee Survey

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Analyzing Tasks
Recognizing Problems

Analyzing a video of the task is the best way to make ergonomic analyses of a task

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Analyzing Tasks

Recognizing Problems

Posture - Constant Use of Hands and Fingers

Since you obviously cant assemble anything without the use of hands and fingers we have to be concerned with the position of the hands, the type of grip forces involved, vibration, pressure, temperature and the number of repetitions.

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Analyzing Tasks

Recognizing Problems

Posture - Constant Use of Hands and Fingers

Exceeding these angles may cause problems when used in conjunction with high repetition and/or force. Pronation thumb down, turning the wrist over 45 degrees Supination thumb out, palm up. Turning the hand palm up over 20 degrees Ulnar Deviation twisting hand outwards over 15 degrees

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Analyzing Tasks

Recognizing Problems

Posture - Constant Use of Hands and Fingers

Radial Deviation twisting the hand inwards over 10 degrees Flexation bending hand forward over 45 degrees Extension raising hand backward over 40 degrees

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Analyzing Tasks

Recognizing Problems

Posture - Constant Use of Hands and Fingers

Tool design is crucial. Tools need to be designed to: Keep the hand in a neutral posture. Minimize forces required to operate. Minimize vibration Have padded handles

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Analyzing Tasks
A wrap or power grip is best.

Recognizing Problems

Posture - Constant Use of Hands and Fingers

Pinch forces over 7lbs can cause injury. Hook and contact grasps expose the operator to the potential of contact stress with sharp, or hard objects. Using the hand(or any body part) to strike objects obviously isnt recommended, but you do see it, as an operator slaps something into place.

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Analyzing Tasks

Recognizing Problems

Posture - Constant Use of Hands and Fingers

Twisting or Bending of the Wrists effects the median nerve passing through the carpal tunnel which can lead to carpal tunnel syndrome. Repetitive Hand & Wrist Motions effects the tendons passing through the carpal tunnel which can lead to tendinitis/tenosynovitis. Vibration effects the blood vessels in the fingers which can lead to Raynauds Phenomenon. Pinch grips can lead to contact stress and overexertion of the hands.

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Analyzing Tasks
Arms and Shoulders

Recognizing Problems

Arms Extended Working with the arms above the shoulder can lead to the compression and entrapment of nerve in the shoulder. It also causes fatigue to the muscles of the shoulder and arm.

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Analyzing Tasks
Arms and Shoulders

Recognizing Problems

ARM AND SHOULDER Working with the elbows abducted at an angle of 25 degrees or more can lead to the compression and entrapment of nerves in the shoulder. It is also causes fatigue to the muscles of the shoulder and arm.

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Analyzing Tasks
Arms and Shoulders

Recognizing Problems

Horizontal reach over 25 inches (62.5cm) is greater than the reach of 5% of the female population without bending. A vertical reach of over 70 inches(175cm) is above the reach of 5% of the female population The longer the reach, the greater effect of any weight involved. The more off center the reach, the greater effect of any weight involved. HOME
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Analyzing Tasks
Arms and Shoulders

Recognizing Problems

The best position for assembly work is with the arms to the front, elbows close to the body, at a vertical height between the operators chest and thigh. Moving the arm across the midline of the body should be avoided.

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Analyzing Tasks
Bending and Twisting

Recognizing Problems

The lower the reach, the greater effect of any weight involved. The more off center the reach, the greater effect of any weight involved.

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Analyzing Tasks
Bending and Twisting
The risk angles are leaning more than 5 degrees, twisting more than 15, and bending more than 60.

Recognizing Problems

In general twisting, bending and leaning of the torso should be avoided. Repetition with weight in a poor body posture may cause injury in a significant percentage of the population.

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Analyzing Tasks
Bending and Twisting
Bending & Twisting also applies to the neck. In general neck side bending or held in a twisted position is to be avoided. Bending the neck back further than 5 degrees or forward further than 20 should also be avoided Use of head protection such as a welding mask needs to be accounted for in any fatigue assessment

Recognizing Problems

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Analyzing Tasks
Posture

Recognizing Problems

The operator needs to be in a balanced posture. The effects of repetition and force will be increased detrimentally due to poor posture!

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Analyzing Tasks
Posture

Recognizing Problems

Methods that analyze body posture include:RULA Rapid Upper Limb Assessment. REBA Rapid Entire Body Assessment. NIOSH 91 Takes Body Posture into Account.

There are other methodologies. The screens shown earlier are based on RULA. Note: Note This tutorial does not explain how to use RULA.

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Analyzing Tasks
Posture
.

Recognizing Problems

The task shown here has two RULA action level 4s, meaning that an immediate change in method is suggested

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Analyzing Tasks
Force

Recognizing Problems

Lifting Pushing Pulling Carrying Pinch Force Holding in place

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Analyzing Tasks
Lifting

Recognizing Problems

This screen shows input for NIOSH91, as well as for the Alpha analysis

The most frequently used lifting analysis in the USA is the NIOSH91 guide. This has a maximum weight of 51 lbs (23kg) It mainly uses weight and body posture to determine a lifting index for the 5% female.

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Analyzing Tasks
Force

Recognizing Problems

An index of 1 or less is ideal, but may be unrealistic. What % of your workforce are 5% female Some companies are OK with a 2 or below This screen shows the results of a NIOSH91 analysis of a given lift

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Analyzing Tasks
Force
Whilst NIOSH91 focuses on the entire body, the analysis shown here gives results for strength, fatigue and recovery by back, shoulder, elbow and hand. A 4 means that 95% of the working population cant do the task without risk of injury.

Recognizing Problems

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Analyzing Tasks
Force
By using the tools available you can see areas of concern Rule of thumb as you increase the weight of a lift (50 lb max) the more neutral you must keep the body posture.

Recognizing Problems

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Analyzing Tasks
Force

Recognizing Problems

Note: The affectivity of safe lifting techniques has been questioned. Proper lifting is not a substitute for a well engineered work place. Loads that can be lifted by the legs from a squat can exceed the capacity of the lower back. Other variables that can effect the degree of difficulty in lifting loads safely are: Size (bulk) of load Floor/shoe traction Stability of load Adequacy of grip Distance to carry Space constraints Available rest between lifts Capability of the employee  skill in handling loads  past injuries

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Analyzing Tasks
Force Pushing
Pushing is better than pulling (less strain on back). Pushing can be split into whole body or arms only. Suggested standing force limits are 50lbf using 2 hands. A 2 wheel manual cart should not be loaded with >250lb or 114 kg. 3 or 4 wheel manual cart should not be loaded with >500lb or 228kg

Recognizing Problems

Pulling
Pushing can be split into whole body or arms only Suggested force limits are 24lbf using 2 hands.

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Analyzing Tasks
Force Pinch Forces
Pinch forces of over 2lbs (1 kilo) are generally considered to have injury potential

Recognizing Problems

Carrying
Carrying loads greater than 50 lbs is to be avoided. The load should be kept close and near waist level The load should have handles
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Analyzing Tasks
Force Hold in Place
Holding a force in place is very fatiguing as the muscles dont get to rest and recover

Recognizing Problems

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Analyzing Tasks
Force Repetition
Affects by: Causing fatigue if insufficient recovery time Compounding the effects of force Compounding the effects of poor body posture

Recognizing Problems

A no significant weight assembly task where all parts are under a pound can still have risk if the repetitions are high enough. In tasks with a less than 30 second cycle time, more than 1500-2000 similar hand motions per hour can lead to injury

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Analyzing Tasks
Fatigue and Recovery

Recognizing Problems

Localized fatigue can be analyzed as we have seen with tools like the Alpha analysis. Whole body fatigue can be analyzed by using a Kilo Calorie Analysis or an industrial engineering tool such as a PF&D (Personal Fatigue & Delay) analysis

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Analyzing Tasks
Employee Survey

Recognizing Problems

Dont ignore the operator. Not only will they tell you where a task causes discomfort, but often they have thought of ways of alleviating it. HOME
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Analyzing Tasks
Employee Survey

Recognizing Problems

Compare the results of your ergonomic analyses with the survey.

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Reducing the Risk

The Basics

Design each work station follow a checklist Use ergonomically designed tools follow a checklist Have work instructions and ensure the operator follows them Do an analysis of the task

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Reducing the Risk

Constant use of hands & fingers rotate to jobs where hand use is lower. Arms extended & unsupported alter the design of the work station to bring the work closer. Dont work above shoulders, dont require elbow abduction (elbows up). Bending & Twisting reposition the objects to the front of the worker at an appropriate height Using significant force reduce the weight of the load if possible, keep the body in neutral postures, use assisted lifts, reduce pinch forces, use power grips, minimize lift distance.

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Reducing the Risk

Static body posture alternate between standing and sitting, rest one foot on a support while standing Vibration isolate body from vibration source, rotate to non vibrating job, use better designed tools Contact Stress cushion exposed body parts (eg gloves), pad hard or sharp objects, round or smooth rough edges Heat/cold limit exposure to temperature extremes, provide heating/cooling systems, provide protective clothing Noise use hearing protection, reduce exposure to high noise levels.

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Reducing the Risk

Lifting provide handles, allow large containers to tilt or have collapsible sides, raise tote bins to appropriate height Holding in place provide clamps or fixtures

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Reducing the Risk

But is management going to buy off on it?
Can you cost justify it? Have you made productivity improvements? Is the new cycle time better or worse? Is that acceptable?

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Reducing the Risk

This solution using a lifting arm while greatly reducing the risk has added 8 seconds to the cycle time Does it matter?

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Work Station & Tool Check Lists

The use of work station and tool design check lists will go a long way in alleviating ergonomic problems. If your answers are negative, fix them if possible

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Work Station & Tool Check Lists

Does the work space accommodate the smallest employee reach to the largest employee clearance? (No=Bad) Are work surfaces and chairs adjustable? (No=Bad) Does the work keep the operator immobile? (Yes=Bad) Requires handling of large bulky materials regardless of weight? (Yes=Bad) Is the floor slippery? (Yes=Bad) Is matting provided? (No=Bad)

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Work Station & Tool Check Lists

Does the work require eye focus at differing distances? (yes=bad) Is lighting adequate? (no=bad) Are noise levels less than 85 dbA for ambient and less than 140 dbA for impact? (no=bad) Is humidity in the range 20 to 85? (no=bad) Is temperature in the range of 66-79F for light work, 64-74F for medium and 60-68F for heavy? (no=bad)

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Are there peak loads of muscular effort? (yes=bad) Frequent or extreme lifting requirements? (yes=bad) Excessive pushing, pulling or carrying? (yes=bad) Is material manually moved over long distances? (yes=bad) Are there extended reaches? (yes=bad)

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Could loads be reduced by using more frequent, lighter loads? Can Lifting Aids be used? Can the lifting be replaced by sliding? Are hand holds or handles available? (No=Bad) Does the job exceed the capabilities of most employees? (Yes=Bad)

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Is the operator working with the neck bent further than 1520 degrees? (Yes=Bad) Are the wrists bent or flexed? (Yes=Bad) Are there twisting motions of the wrist? (Yes=Bad) Are the arms outstretched? (Yes=Bad) Is the work required above the shoulder? (Yes=Bad) Are most reaches to the front of the operator? (No=Bad)

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Work Station & Tool Check Lists

Is the body leaning forward? (Yes=Bad) Is there excessive twisting or stretching? (Yes=Bad) What are the cycle time requirements of the task? Is this a high volume task? Is the operator sweating? Having problems keeping up? (Yes=Bad) Would you like to do this task? Every day? (No=Bad) Could you do this task? Every day? (No=Bad)

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Work Station & Tool Check Lists

Is this the right tool for the task? (no=bad) Has wrist flexing been eliminated? (no=bad) Can the tool be used in either hand? (no=bad) Are operators elbows close to the body? (no=bad) Are dual handles 120 degrees apart? (no=bad) Does it permit a full grasp? (no=bad) Is the handle long enough? (no=bad) Is it easy to hold? (no=bad)

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Work Station & Tool Check Lists

Tool Design

Is the handle oval shaped? (no=bad) Does it have plastic on it ? (no=bad) Are all the fingers used to trigger it? (no=bad) If not, is the thumb? (no=bad) Is it easy to trigger? (no=bad) Has vibration been minimized? (no=bad)

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New Product Design

New products should not be designed solely for function, but also for assembly. Part of DFA (Design for Assembly) is accounting for ergonomics. EASE, Inc has integrated software modules that reflect this belief.

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New Product Design

New products are designed in a DFA module that uses standard touch labor data as part of the process. When a beta design is ready, it can be transferred to a routing system, standards in place by operation for the addition of material handling data (where parts are in relation to the work station & operator, that may not be known at design time) and input of manufacturing engineers.

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New Product Design

The process plan is then transferred to line balancing to ensure that different production schedules can be met. Each station for a new process, should have an ergonomic review done proactively. If problems surface at this stage, the beta design can be sent back for revision. Once the design is acceptable, work instructions can be added to the routing, and we are ready for production.

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EASE Inc.

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Who is EASE Inc?

EASE Incorporated is an international corporation, founded in 1986. EASE is headquartered in Southern California with satellite offices in Europe and the United States. EASE Incorporated provides productivity improvement services through the application of the EASEworks Software, training, consulting services and implementation support.

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EASE Customers

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The Service
Our major focus is to offer sustainable productivity improvements and cost reductions for our clients. We can provide you with consulting assistance for. .

       

Equipment Evaluation Facility Layout Establishing Best Practices Competitive Benchmarking Design Engineering Process Engineering Production Engineering Implementing Ergonomic Improvements

       

Training and Training Support & Certification Improving Labor Efficiency Productivity Analysis Implementing Lean Manufacturing Manufacturing Engineering ISO 9000 Implementation Developing Work Standards Process Mapping

EASE will provide engineers with extensive experience in YOUR industry. Your engineers will have the ability to take over, with confidence where we leave off. confidence,
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Software
EASEworks Software modules cover:

 Work Standards  Product Cost Estimating  Line Balancing

 Work Instructions  Ergonomics  Design For Assembly

EASE Inc. provides full training, start up assistance and consulting services for all modules. Software customization services are also available.

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Contact Information

EASE Inc.
27405 Puerta Real, #380 Mission Viejo, CA 92691

Phone: (949) 348-7511 Fax: (949) 367-9906 E-Mail: [email protected] Web: www.easeinc.com

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