Ergonomics: Body

Posture
Summary on Research Papers
5 Research Papers based on ergonomics implementation
in body posture are chosen and studied

Preksha Pandey

BFT/14/119
 1. Design and analysis on sitting posture in quality checking
workstation of a manufacturing company

Summary:
Introduction-
The study focuses on sitting posture in quality checking workstation of a manufacturing
company. The repetitive sitting and standing posture in a workplace could lead to ergonomic
issue. The study aims to simulate the relation of sitting posture while performing workloads
and apply RULA* analysis as ergonomics tool assessment.
The role of ergonomics is to find the best fit between a worker and his job environment.
Therefore, unnatural work posture, unsafe working places, long working hours etc. are the
reason for the implementation of ergonomics.
Table 1 shows the researches that were done in this area.
Table: 1

Methodology-
A survey was conducted to 3 respondents where they were asked certain questions about
their working environment and were required to give opinions as well. This primary data was
collected to understand the techniques to know the basic problem and implement
respective improvement techniques.
Secondary data was collected by books and internet to find related articles.
Further QFD* was used to redesign the workstation. To create or design a product that
helped in improving the sitting posture, CATIA* was used to build a model and through
analysis RULA can be utilized for this ergonomics aspect.

Results and Discussion-

Based on the House of Quality, the major portion of the percentage of the problem came
from the ergonomics workstation(32%) followed by level of fatigue(25%). This indicates that
the ergonomic workstation could improve the level of fatigue as both are inter-related.
After collected data, QFD and AHP* methods are conducted to select the best and optimum
workstation design.

Old Design New Design

Packed workstation Free workspace workstation
Non flexible movement Flexible movement
Height distance from the sitting place to the Height distance from the sitting place to the
equipment is too high, 90 degrees up to the location of equipment is less, 45 degrees up
hand. to the easy for handling
Non ergonomic workstation Ergonomic workstation based on RULA
analysis
Comparative study of old and new proposed workstation design
 2. Ergonomic analysis of an assembly workstation to
identify time consuming and fatigue causing factors using
application of motion study

Summary:
Introduction-
This study is conducted on a metal part assembly workstation which has high cycle time.
Objective of this study includes performance evaluation of workers during assembly
process. In primary phase study regarding workstation layout, process design and product
specification has been carried out. Further motion study is done for ergonomic study by
capturing motion film of assembly process using high definition video recorder. Results of
motion study revealed various fatigue causing and time consuming factors related to
worker and workstation layout.

Methodology-
Ergonomic study is carried out using application of motion study by video recorder. Handy
cam is used to record whole process in .MPEGV video format which is easy to use and
transfer from device to computer.

The process consists of repetitive tasks which seem to be because of poor ergonomics.
The assembly process includes picking and loading of parts from bins to workstation,
handling welding gun for spotting, unloading and part transfer to next station.
s it is concluded that workplace layout is improper and needs to modify it. During
assembly process various motions like rotation, more walk, bending, lifting etc. have been
observed and these tasks highly repetitive if shift working hours are considered.
Operators are not able to maintain standard body postures and movement because of
poor workplace layout. Hence lead to fatigue like shoulder stress, back pain, neck pain etc.
which reduces working efficiency.

Results and Discussion-

Motion study reveals reasons of these illnesses. Analysis of these factors is done by
motion film and root causes of these things are found out. Table below shows ergonomic
analysis of workstation obtained from motion study.
Conclusion-
Following conclusions are made from this study:
1. Natural motions of workers are constrained by poor workstation design and layout.
2. Workers are seen to be unaware of ergonomic principles
3. Frequent body postures like bending ,twisting, eye movements, lifting have been observed
for 8hrs, hence health issues are observed
4. Tool design and part design have significant effect on worker efficiency as tool is seen to be
heavy to handle, geometry of tool are not supportive towards smooth operation.
5. Workers are seen to be having discomfort while handling parts as sharp edges and large
size of metal parts may lead to fear of injury.
Following recommendation are suggested in order to overcome above problems:
1. Workers must be trained to aware and follow standard work procedure including standard
body postures, motion sequences.
2. Modify the workstation layout and design so as to suitable for good body postures and
good tool-work piece contact.
3. Use of low cost mechanical automation assistance can reduce complex tasks and hence
reduces fatigue.
4. Some work must be assigned for foot usage like foot pedal so to avoid muscular stress and
cramp to muscles.
 3. Evaluation of work Posture by RULA and REBA
Summary:
Introduction-

This ergonomic study sheds light on posture analysis of the workers in small scale industry. The
study was conducted on 15 workers engaged in small scale industry situated at MIDC Wardha
(Maharashtra, India). Video tape on different activities of the workers was prepared and then
images were cropped from it for the analysis. Evaluation of posture was carried out using RULA
and REBA*. Assessment is carried out using worksheet. The RULA method determined that the
majority of the workers were under high risk levels and required immediate change. The REBA
method determined that some of the workers were under lower levels and majority at high risk
levels. Hence it was concluded that; there is a lack of ergonomics awareness and understanding
in small scale industries.

Methodology-

This research study is conducted at small scale industry situated at MIDC Wardha
(Maharashtra). The video recording of the postures of the workers showing movements of
them during working was recorded. After footage the video, it was cropped to get snapshots for
the analysis of posture of the worker. Snapshots of 15 workers performing their work were
obtained. The snapshots were analyzed to fill the scores in RULA and REBA; score sheets
(appendix). The first step was overall body posture assessment using REBA method. The works
with the involvement of high risk were scored higher and those with less risk involvement were
scored 0.

Result and Discussion-

The assessment using RULA worksheet is presented in appendix. Table below presents the
different categories of the risk levels as obtained after analyzing the posture.

These results reveal that all categories of the risk levels exist in jobs postures. The table showed
that posture of 40 % workers who used in performing the activities is at high risk levels. A
further investigation with an immediate change was recommended to these workers. The table
also shows that none of the worker is at negligible risk level.

Using the REBA analysis method, it was observed that the major parts of the workers were
working in unacceptable posture at high risk levels.

Around 53% of the workers were working at high risk levels and their neck, trunk and wrist
were under high physical strain and needed a necessary action soon. Around 33 % of the
workers in the jobs were at medium risk levels and needed a necessary change. Some of the
workers in the turning jobs were bending their trunk to unacceptable limit and most of them
had upper arm under high strain. The workers were suggested to keep their trunk straight while
working.

Conclusion-

It can be concluded that; significant proportion of the workers are working in uncomfortable
and painful postures as found by analysis. This is due to lack of ergonomics knowledge and
awareness in small scale industry. Thus the workers are under moderate to high risk of
musculoskeletal disorders as determined from REBA and RULA risk level. This study
recommends the immediate implementation of ergonomics interventions with proper
knowledge among workers and health education on common postural change, implementation
and monitoring of laws among industries are recommended to take down morbidity due to
musculoskeletal disorders.
 4. Ergonomic Evaluation of Body Posture of Workers in Small
Scale Forging Industries

Summary:
Introduction-
The present study is conducted on 26 workers engaged in four different small scale forging
industries in south of West Bengal. The tool REBA is used for analyzing body posture of
number of workers working in this sector. The different work activities of the workers are
taken with the help of snapshots for postural analysis. The results of REBA shows that
immediate change of body posture of workers are required to avoid different chronic pain in
the muscles. This paper suggests that the proper awareness and appropriate ergonomics
trainings are required.

Methodology-
The present research work has been done in small scale forging unit in south 24 parganas in
West Bengal. The snapshots of worker working in different body postures in forging unit are
taken to analysis and it shows the different movements of the workers during their different
work activities inside shop floor. The snapshots are analyzed and REBA score is obtained
from that. High risk jobs are numbered higher and less risk are numbered lower as per
working method. Instant corrective actions and essential changes are recommended as well
as recommended for higher activities numbered to avoid any musculoskeletal disorders,
body fatigue and risk.

Conclusion-
It has been observed by the REBA assessment results that most of the workers engaged in
different operations in forging units are high risk level zone and needs an urgent change in
body posture for reducing their WRMSD*, stress and body fatigue. The final REBA score is 9
which is under the action level 3. This result shows the importance of considering workers
health and occupational condition to prevent WRMSDs and related risks. Proper sitting
arrangement and proper arrangement of machinery may reduce the risk level of workers. All
workers should aware about the correct posture while working in different section in forging
industry.
 5. Assessment and Implementation of Ergonomics in an
Industry

Summary:
Introduction-
During the initially conduction of the study of ergonomics at the Industry, the critical areas
having the maximum critical ergonomic areas which means having a unfavorable working
postures which leads to human fatigue which needs immediate attention, are suggested
them to reduce the human fatigueless and improve productivity.

Methodology-

1. Assembly workstation at Company a need to be redesign to eliminate awkward postures

and anthropometric mismatches to lower MSDs* problem and improve productivity
among assembly workers.
2. Cycle time and existing method of different work stations and suggesting improved
method for the same so as to reduce the cycle time and to improve productivity.
3. The workstation to improve the productivity by reducing the back pain, shoulder injury,
fatigue etc. High performance and productivity require the right sitting posture.

Suggestions-

1. Robotic assembly: Robotic assembly increases productivity but it costs the higher with
space , installation and power consumption.
2. Semi automation: By suggesting semi automatic machine with supplying sockets at both
ends of the machine, workers will easily fix them to the tube at both its end while
placing on the fixture for assembly, by reducing MSDs(Musculoskeletal Disorders) and
improve the productivity by considering three parameters like quality, cost and delivery.

Conclusion-

This study aimed to test the efficacy of an individual workplace intervention of workplace
evaluation among workers by evaluating musculoskeletal disorders (MSDs), body posture,
upper extremity kinematics, muscle activity and psychosocial factors were tested. The
proposed ergonomics interventions effectively reduced MSDs and improved body posture
with increasing productivity. Ergonomic study carried out at workstations of the MMTD
assembly station, the changes made were based on the interview with the operators,
evaluation and observations. After the study, best possible suggestion was Semi Automatic
machine has proven to be remarkable with the drastic changes in its working postures and
also in production.
 Glossary-

RULA- Rapid Uper Limb Assessment

QFD- Quality Function Deployment

CATIA- Computer Aided Three-dimensional Interactive Application

AHP- Analytic Hierarchy Process

REBA- Rapid Entire Body Assessment

WRMSD- Work Related Musko-skeletal Disorder

MSD- Musko-skeletal Disorder

Thnak-You