International Journal of Industrial Ergonomics 53 (2016) 299e305

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International Journal of Industrial Ergonomics

journal homepage: www.elsevier.com/locate/ergon

Anthropometry approach in workplace redesign in Indonesian

Sundanese roof tile industries
Iftikar Zahedi Sutalaksana, Ari Widyanti*
Department of Industrial Engineering, Bandung Institute of Technology, Indonesia

a r t i c l e i n f o a b s t r a c t

Article history: In the design of machine, tools, and working environment, a proper database of anthropometry is
Received 21 June 2015 needed. The objective of this study is to redesign workplace in Indonesian Sundanese roof tile industries
Received in revised form based on anthropometry approach and to develop corresponding anthropometric database for Indone-
28 February 2016
sian Sundanese worker. Six hundred and sixty Sundanese workers were measuredd411 male and 249
Accepted 5 March 2016
female. A set of 17 static anthropometric measures (8 and 9 dimensions in standing and sitting positions
Available online 24 March 2016
respectively) was measured for each participant. Redesign of workplace of roof tile industries in
Indonesia is then discussed.
Keywords:
Anthropometry
© 2016 Elsevier B.V. All rights reserved.
Indonesian
Workers
Redesign
Workplace

1. Introduction
As a fast growing developing country, industries in Indonesia
have been growth in numerous number. However, the increase of
the number of industries has been coupled with increasing number
of incident and accident in those industries. Various accident and
incident has been reported for years. For example, a study con-
ducted by Sutalaksana et al. (2010) found high injury and accident
in coal mining due to size mismatch between the dimensions of
heavy equipment imported from abroad and local Indonesian
workers anthropometry. Another study reported the existence
cumulative trauma disorder among workers tools in oil and gas
company due to man and equipment lack of fitness (Yassierly et al.,
2013).
Furthermore, high accident rate in workplace could not only be
found in medium and large industries, but also in small industries.
For example, back pain has been frequently reported due to
awkward postures during work (e.g., bending) because of tools
position is lower than hand position of worker (Sutalaksana et al.,
2002). With regards of small industries in Indonesia, attention
has been given by Indonesian government since small industries in
* Corresponding author. Department of Industrial Engineering, Bandung Institute
of Technology, Ganesa 10, Bandung 40135, Indonesia.
E-mail address: widyanti@mail.ti.itb.ac.id (A. Widyanti).
Indonesia account for over 99% of all firms in Indonesia and
employing more than 99 million people. The small industries also
account for 57% of Indonesian Gross Domestic Product (USAID,
2013).
Various studies related to incident and accident in Indonesian
industries have pointed out the main causes of those accidents. One
of the causes is the absence of proper anthropometry data of
Indonesian workers which in turn develops dimensional mismatch
in man-equipment system in operation. This eventually affect well-
being, health, comfort, and safety of the workers (Sutalaksana et al.,
2010; Yassierly et al., 2013).
One small industry in Indonesia that faces serious problem with
dimensional mismatch in man-equipment system is roof tile in-
dustries. In these industries, the mismatch can be found
throughout all the stages of the roof tile process. Three of the stages
are described here and are the subjects of dimensional redesign
based on anthropometry data the to be develop in this research.
The first is on the activities in the beginning of the process. After
being dwelled from dump truck, raw clay is fed to a press machine
to produce compacted clay bars. In the existing condition, see Fig. 1,
the workers must work in awkward position, i.e., squatting, which
expose the workers to high risk in low back pain.
Secondly, concerning the trimming process. Here, the already
pressed and folded clay which already have the roof tile form, have
to be trimmed for some surface imperfections. Female workers
usually perform this particular task. They sit in the long bench with

http://dx.doi.org/10.1016/j.ergon.2016.03.002
0169-8141/© 2016 Elsevier B.V. All rights reserved.
300 I.Z. Sutalaksana, A. Widyanti / International Journal of Industrial Ergonomics 53 (2016) 299e305

Fig. 1. Awkward position of worker during fed of raw clay into the press machine.

leg folded for almost 8 h a day as can be seen in Fig. 2. Reason for
folding their leg is because the bench is too high for them so that
their leg would hang when they sit normally on the bench. Also
because the trash from this process is to be dumped below the
bench. In this position, the workers are exposed to high low back
discomfort and injuries.
Finally the drying process. All of the roof tiles which are still wet
must be dried by passing them through a burning process as can be
Fig. 3. Height of burning process area.
seen in Fig. 3. In this process, all tiles are placed in shelf. The po-
sition of the shelf are from floor height to a particular height based
on preference of the owner of the roof tile industries. In this
existing condition, tall workers must bend their body during their
access to this roof burning area. This bending position posed them
to low back pain problems.
From the three unergonomic drawn from the roof tiles industry,
it can be seen that redesigning the workplace to fit the workers may
need proper anthropometry data to provide safer and more
comfortable working condition. This implies the availability of
anthropometry database is particularly very important.
Anthropometry, defined as the science of measurement and the
art of application that establishes the physical geometry, mass
properties, and strength capabilities of the human body (Pheasant,
1998), plays an important role in the design of domestic and in-
dustrial environment. With regards to domestic, daily goods and
environment, anthropometry is crucial for example in the design of
school furniture (Al-Ansari and Mokdad, 2009) and design of cloth
(Zakaria, 2010). In addition, Boyles et al. (2003) underlined the role
of anthropometry in the design of scissors for hairdressing for
safety reason. An absent of anthropometry consideration would in
most cases result in uncomfort design for the targeted users and
worse, unsafe and unhealthy conditions.
In industry, anthropometry is needed in the design of machines,
tools, and work environment in order to improve well-being,
health, comfort, and safety (Pheasant, 1998). The importance of
matching anthropometry data to the worker in the design of tools
and workplace has been recognized for years. For instance, with
Fig. 2. Working position of women workers in correcting surface imperfections of roof
regards to design of workplace, Reis et al. (2012) described the role
tile.
 I.Z. Sutalaksana, A. Widyanti / International Journal of Industrial Ergonomics 53 (2016) 299e305
of anthropometry on meat packing plant in particular for the pre-
vention of shoulder joint injury. In addition, Wang et al. (1999)
reported a design of anthropometric work environment for
Taiwanese workers to promote safety and health in the workplace.
In the context of design of machine and tools, Gadheri et al. (2014)
explained how design of combine harvester seat should consider
anthropometry data to increase safety. Hsiao et al. (2005) and
Victor et al. (2002) also stressed the importance of considering
anthropometry data in the agricultural machinery design.
Furthermore, Chang et al. (2003) showed that incorporating
anthropometry in the design of a utility cover removal operation
brought the effect of increase safety to the worker.
A valid and reliable anthropometric database is therefore crucial
in the design of machine, tools, and work environment. To ensure
validity and reliability of anthropometry data, the variability of
anthropometry data must be carefully considered since, as a matter
of fact, anthropometry data vary as it is influenced by various fac-
tors. Among the influencing factors are ethnicity (for example see
Widyanti et al., 2015; Yap et al., 2001; Ball et al., 2010; Yokota, 2005;
Jahanshahi et al., 2008; Lin et al., 2004), gender and age (for
example see Hu et al., 2007; Jurgens et al. 1990; Huang and You,
1994; Iseri and Arslan, 2009; Jarosz, 1999; Pennatur and Dowling,
2003; Wang et al., 2002; Kothiyal and Tettey, 2000) and occupa-
tion (Hsiao et al., 2002). This underlined the importance of
anthropometry data that is specific for particular population.
Whereas in many countries efforts have been made to establish
an anthropometric data base for different population groups, in
Indonesia, anthropometry database is very limited due to many
restrictions (e.g., cost and resource restrictions). Limited studies
have been conducted in Indonesian anthropometric data, for
example studies which reported Indonesian student anthropo-
metric data (Widyanti et al., 2015; Chuan et al., 2010); anthropo-
metric study of farm workers (Wibowo et al., 2012; Syuaib, 2015);
and anthropometry for Indonesian elderly population (Setiati et al.,
2010).
The purpose of this study is to redesign workplaces at Indone-
sian roof tile industries based on anthropometry approach. Since
there is a need of anthropometry data for specific population due to
various factors that influence anthropometry data as described
above, anthropometric data of Indonesian workers is therefore
measured in this study. In addition, we also compare the anthro-
pometry data of Indonesian workers with Indonesian students data
to learn the influence of occupation in anthropometry data.
2. Method
2.1. Subjects
Six hundred and sixty nine Indonesian Sundanese workers
(mean age ¼ 27.5 year, SD ¼ 12.3 year, 249 female) residing in West
Java, were participating voluntarily in this study. No other ethnic
was involved to avoid complication from anthropometric differ-
ences among different ethnics in Indonesia (Widyanti et al., 2015).
The workers were recruited from small groups of industries in West
Java (in Purwakarta Perfecture, Sukabumi Perfecture, and Sume-
dang Perfecture), as a part of a project, a cooperation between
Indonesian Ministry of Health and the Laboratory for Work System
Design and Ergonomics of Bandung Institute of Technology,
Indonesia. Participants were chosen based on convenience sam-
pling method. The sample reflected the Indonesian Sundanese
worker composition by age and gender in West Java, based on data
from the office of Ministry of Health in West Java. Permit has also
been obtained from the owners of the home industries.
301
2.2. Procedure and equipment
The survey was conducted by a team from Institute Technology
Bandung involving 3 faculty members as senior researchers and ten
research assistants aged 20e22 years. A three days session of
theoretical and technical knowledge of anthropometry measure-
ment was given as refresher to the assistants in order for them to
have the proper skill in anthropometry measurement in addition to
their several years of experience in our laboratory. This training
session is also intended to minimize inter-observer error (Kouchi
et al., 1996; Mislihah, 2004). In a pilot study in a laboratory
setting, we instructed observers to measure anthropometry of 2
participants based on similar procedure as well as similar tools and
equipment. If ANOVA shows no significant differences among ob-
servers' result, then it showed that inter-observer error has been
minimized. To ensure reliable measurements and recording,
random inspection was conducted by three senior researchers. The
inspections was included calibration of the measurement tools and
inspection of data recording to enable measurement accuracy until
1 point decimal. The whole survey was completed in 3 months.
Seventeen anthropometry dimensions of Indonesian workers
were measured with eight dimensions measured in standing po-
sition and nine dimensions measured in sitting position. During
measurement in standing position, participants were instructed to
stand barefooted on a flat surface with their body erect while heels,
buttocks and shoulders touched the wall. During measurement in
sitting positions, participants were instructed to sit in the anthro-
pometry chair with their torso vertically erected and their back
touched the backrest of the chair.
The measurement was conducted using traditional anthropo-
metric tools and equipment as they are quite simple, portable,
inexpensive, reliable, and accurate (Al-Ansari and Mokdad, 2009;
Ghoddousi et al., 2007; Widyanti et al., 2015). Simple tools are
needed in this study since there should be a knowledge transfer
from ITB to personnel of the Office of Indonesian Ministry of Health
in West Java. Portability of tools are crucial since anthropometric
measurement in this study was conducted in different cities and in
various scattered place depending on the location of the industries.
In addition, price was also a consideration since three-dimensional
scanner is expensive and not commonly used in a field study.
A portable weighing scale was used to measure body weight.
Martin type anthropometer, a widely used anthropometric device
for measuring heights, breadths and depths between points on the
body and standard reference surfaces in a standing posture
(Kroemer and Grandjean, 2005) were used. Anthropometry chair
used in the data collection was a taylor made chair that can be
adjusted for sitting height and arm rest height measurements using
metric scale. Both Martin type anthropometer and anthropometric
chair used in this study can be seen in Fig. 4.
All the equipment used were calibrated against standards. In the
beginning of data collection session, the subjects were informed of
the purpose of the study, equipment, measurement procedure, and
possible application of the data to be collected. Due to cultural and
religious reasons, male subjects were measured by male research
assistants and female subjects were measured by female research
assistants.
2.3. Body dimensions
The eight anthropometry dimensions measured in standing
position are stature, elbow height, waist height, hip height, knee
height, lower arm length, forward grip reach, and vertical arm
reach. Whereas the 9 anthropometry dimensions measured in
sitting position are sitting eye height, sitting shoulder height,
sitting elbow height, backrest height, shoulder breadth biacromial,
302 I.Z. Sutalaksana, A. Widyanti / International Journal of Industrial Ergonomics 53 (2016) 299e305

4.1. Height of machine adjustment during feeding of clay into press

machine

Improvement can be conducted by adjusting the height of the

press machine in line with elbow height of the workers (95th
percentile). Another improvement can be applied by arranging
maximum distance between workers' position and the press ma-
chine based on forward grip reach (5th percentile). The proposed
dimension of the placement height of machine based on anthro-
pometry criteria can be seen in Fig. 5.

4.2. Height of bench for surface imperfections correction

It is clear that the problem here is again, the dimensions, in this

Fig. 4. Martin type anthropometer (a) and anthropometry chair (b) used in this study.
hip breadth, popliteal height, buttock popliteal, and buttock knee.
These dimensions were chosen as these dimensions were the
mostly used for design of tools and work stations in the kinds of the
industries. For example, adjustment of height of machine for clay
press in roof tile industry use anthropometry data of stature and
elbow height.
case of the bench which was designed without proper anthropo-
metric consideration. Therefore, the anthropometry database
developed in this study could contribute for the improvement of
the work system. The required data for the case are popliteal height
for height of the bench (5th percentile), buttock knee length for
distance between bench and table surface (95th percentile), sitting
elbow height for table height (5th percentile) respectively. The
proposed dimension of the bench based on anthropometry criteria
can be seen in Fig. 6.
4.3. Height of the ceiling of roof tile burner
Improvement can be conducted by adjusting the height of the
ceiling of the roof burning area to 95th percentile of standing
height of the male Indonesian worker as can be seen in Fig. 7.

3. Results 5. Discussion

A separate descriptive statistics of anthropometry data for
Indonesian workers according to gender can be seen in Table 1 for
standing position and Table 2 for sitting position, respectively.
A comparison has been conducted by comparing anthropo-
metric data of workers with available anthropometric data for
Indonesia Sundanese students (n ¼ 157, Widyanti et al., 2015). The
result can be seen in Table 3.
4. Application of anthropometry approach in the design of
workplace in Indonesian roof tile industries
Considering the mismatch between design of tools and equip-
ment with the anthropometry of workers which eventually affect
well-being, health, comfort, and safety of the worker in industries
in Indonesia, some efforts need to be performed. Below are ex-
amples of applying anthropometry in the redesign of three work-
places in the roof industry mentioned earlier.
Redesign of workplace of Indonesian roof tile industries has
been proposed in this study and seventeen body measurements of
Indonesian workers were summarized which consist of eight and
nine dimensions in standing and sitting position respectively. This
anthropometry data is valuable for the designing of workstations,
tools and protective equipment for Indonesian population, in
particular for roof tile industries' workers.
Related with redesign of workplace in Indonesian roof tile in-
dustry, longitudinal study is needed in order to observe the
improvement in performance and system efficiency in the work-
place of roof tile industry after the redesign. However, from the
preliminary study in the roof tile industry, the workers support the
redesign of the workplace due to uncomfort position during work
and some negative symptoms they have suffer for years related
with work. The expected improvement after redesign of workplace
in Indonesian roof tile industry is in line with a study conducted by
Anema et al. (2004), in which in their two years study they proved
that the use of anthropometry in design system has reduce human
error and hazard in workplace and improve system efficiency.

Table 1
Anthropometry data of Indonesian workers in standing position.

Dimension Male Female

Mean SD P5 P95 Mean SD P5 P95

Stature 158.12 7.37 144.96 169.00 148.50 5.62 139.25 157.00

Elbow height 98.70 7.15 90.30 107.08 97.03 57.37 85.00 101.05
Waist height 93.07 5.28 84.00 101.32 91.18 8.88 83.60 99.40
Hip height 80.90 5.61 71.24 88.54 79.03 6.24 68.60 88.35
Knee height 43.61 4.62 38.72 49.00 40.34 4.14 34.05 47.10
Lower arm length 23.69 2.09 20.50 27.00 22.80 1.57 20.50 25.90
Forward grip reach 76.25 8.61 60.00 86.38 61.41 6.87 54.65 77.75
Vertical arm reach 199.64 15.01 182.66 214.40 185.53 11.29 172.65 196.70
 I.Z. Sutalaksana, A. Widyanti / International Journal of Industrial Ergonomics 53 (2016) 299e305 303

Table 2
Anthropometry data of Indonesian workers in sitting position.

Dimension Male Female

Mean SD P5 P95 Mean SD P5 P95

Sitting eye height 70.38 5.89 60.68 76.72 65.93 3.24 61.00 71.15
Sitting shoulder height 54.67 3.53 48.30 60.50 53.97 32.70 46.20 57.00
Sitting elbow height 24.45 9.49 17.12 51.00 22.41 3.40 17.74 28.43
Backrest height 40.36 5.93 27.00 48.44 37.22 9.20 23.00 48.75
Shoulder breadth biacromial 17.93 3.62 13.00 26.00 18.47 17.09 14.00 20.40
Hip breadth 31.37 3.14 26.00 36.00 31.88 2.87 27.00 37.10
Popliteal height 40.74 2.20 37.18 44.00 38.97 2.49 36.00 42.50
Buttock popliteal 42.56 2.77 38.00 46.50 40.99 2.46 37.75 45.75
Buttock knee 51.95 3.19 45.80 56.62 49.00 3.24 44.00 54.00

Table 3
Anthropometric differences between Indonesian workers and students.

Body dimension Male Female

Worker (411) Student (N ¼ 77) Worker(249) Student (N ¼ 80)

Mean SD Mean SD Mean SD Mean SD

stature 158.12 7.37 167.01 5.31 148.48 5.62 155.10 4.99

elbow height 98.70 7.15 102.67 4.66 97.03 57.49 95.28 4.98
waist height 93.07 5.28 98.91 4.73 91.16 8.89 94.07 6.52
knee height 43.61 4.62 47.18 3.13 40.33 4.14 42.77 2.98
lower arm length 23.69 2.09 27.98 5.47 22.80 1.58 24.48 4.11
forward grip reach 76.25 8.61 80.01 5.16 61.43 6.88 75.08 4.52
vertical grip reach 199.64 15.01 212.26 8.79 185.52 11.31 197.67 18.07
sitting eye height 70.38 5.89 74.55 6.62 65.96 3.22 69.23 4.55
sitting shoulder height 54.67 3.53 58.29 4.02 54.02 32.75 54.26 3.20
sitting elbow height 24.45 9.49 23.22 4.49 14.57 11.06 21.77 2.89
backrest height 40.36 5.93 45.77 5.67 37.21 9.21 45.18 9.04
hip breadth 31.37 3.14 34.42 4.58 31.89 2.88 35.03 4.00
shoulder breadth biacromial 17.93 3.62 21.77 5.18 18.48 17.12 19.07 4.10
popliteal height 40.74 2.20 43.80 3.18 38.97 2.50 41.10 2.98
buttock popliteal 42.56 2.77 44.27 4.11 40.98 2.45 44.31 3.36
buttock knee 51.95 3.19 53.97 4.87 48.99 3.24 52.82 3.61
*
cited from Widyanti et al. (2015).

With regards to the influence of gender in anthropometry data,
results of this present study are in line with other anthropometric
study in this case, there are differences between male and female
data (see Chuan et al., 2010; Widyanti et al., 2015 for example). As
expected, Indonesian male workers are in general bigger and taller
than Indonesian female workers. With regards to the occupational
differences in Indonesian anthropometry data, a comparison with
Indonesian student anthropometry data (Widyanti et al., 2015)
shows that for 16 of 17 dimensions (94% of all dimensions), male
students have larger dimensions than male workers. In the case of
female workers, similar picture has been found also in 16 of 17
dimensions. In this study, we compare Indonesian workers and
Indonesian students' anthropometry data, with comparable age
and ethnicity. Differences between Indonesian workers and stu-
dents' anthropometric data found here are primarily related with
occupational differences. Whereas student mostly involve in study
activities, worker must perform heavy work such as lifting and
lowering heavy materials and face exposures in dangerous envi-
ronment and awkward position such as squatting, all are hazards
with high risk of low back pain. Since the worker usually start to
work in the beginning of their maturity, it is likely that the skeletal
development have been suppressed during their activities. Even-
tually, it makes the anthropometry dimension shorter than it could
be. This is in line with a study conducted by Hsiao et al. (2002)
which explained that one role of occupation in anthropometry
data is related with job effect. For instance, mining children which
have long periods of exclusion from ultra-violet radiation have
suppressed skeletal development, thus shorter than they could be.
Differences between Indonesian workers and students' anthro-
pometric data due to different occupation can be explained from
different socio economics status as well. The student participants
have, in general, relatively high socio economics status, as in
Indonesia, less than 10% of Indonesian citizens could pursue their
study to university level due to financial reasons. Average income of
the parents of university students are higher than Rp. 5.000.000,-
(US $ 450) per month (BPS, 2014). In contrast, workers participants
in this have in general, monthly income less than Rp. 1.000.000,-
(US $ 100). Higher socioeconomic status implies higher income and
is associated with better education, better nutrition, better child
care, and better medical and social services (see Iseri and Arslan,
2009; Widyanti et al., 2015 for a review).
This present study has limitation in term of limited number of
subjects and unbalanced number between male and female
participant, since convenience sampling was conducted in col-
lecting the data. Regarding the limited number of subjects, the
statistical power of sample size is very high, since calculation of
sample size using a ¼ 0.05 and confidence level 95% results in
required sample size is less than number of data which has been
collected for all anthropometry dimensions measured. Another
limitation is that participants of this study are limited to Sundanese
ethnic living in West Java province. Based on Widyanti et al. (2015)
who found that there are ethnic differences in Indonesian anthro-
pometry data, anthropometry of Indonesian workers from ethnics
other than Sundanese should be measured as well. Furthermore,
concerning the fact that the participants in this present study are
restricted to small home industries with low socio economic status,
304 I.Z. Sutalaksana, A. Widyanti / International Journal of Industrial Ergonomics 53 (2016) 299e305
Fig. 5. The proposed dimension of the position of press machine based on anthro-
pometry criteria.
other study measuring anthropometry of Indonesian workers from
medium, in particular big industries should be considered to be
conducted as well. There is a possibility that workers from medium
and big industries with better salaries and better socio economic
status would have a different set of anthropometry data.
In this study, we only compare anthropometric data of home
industries with student data. Further study of anthropometry data
from different occupation is needed to strengthen a conclusion that
occupation influence anthropometric data. This conclusion is
important in particular for the development of Indonesian
anthropometric database. If occupation does play an important role
Fig. 6. The proposed dimension and design of the bench based on anthropometry criteria.
Fig. 7. The proposed dimension of the height of burning process area.
in Indonesian anthropometric database, this factor should be
considered as well as a variable. An anthropometry database that is
specific for specific population in Indonesia is certainly needed.
In conclusion, this present study gives examples that redesign of
workplaces in Indonesian small industries to provide safer and
more comfort workplace is possible simply through matching the
worker anthropometry and the equipments' dimensions. Besides
from presenting anthropometry data of Indonesian workers, this
study give valuable insight of the influence of and gives valuable
insight of the influence of occupation on anthropometry database.
However for a good anthropometry data of Indonesian much more
is needed. Therefore, further research should be performed to
compile Indonesian anthropometry database for specific popula-
tion as well as application of anthropometry approach in design
and redesign of workplace and equipment.
 I.Z. Sutalaksana, A. Widyanti / International Journal of Industrial Ergonomics 53 (2016) 299e305
Acknowledgement
The authors would like to thank the West Java Office of the
Ministry of Health of Republic of Indonesia for their support during
the data collection of this study.
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