1-Introduction To RFMSI

Human Factors/Ergonomics
in Industrial Systems
Hilma Raimona Zadry, Lusi Susanti, Nilda Tri Putri
Semester I, T.A 2015/2016
References
1.
K.H.E. Kroemer et al. (2001). Ergonomics-How to design for ease and

efficiency. Prentice Hall.
2.
R.S. Bridger (1995). Introduction to Ergonomics. McGraw Hill.
3.
Mark S. Sanders & Ernest J. McCormick (1992). Human Factor in

Engineering and Design. McGraw Hill.
4.
Benjamin Niebel & Andris Freivalds (2004). Methods, Standards and

Design. McGraw Hill.
5.
Gerard J. Tortora & Sandra Reynolds Grabowski (2001). Introduction to

human Body. Wiley.
6.
K.H.E.Kroemer (1997). Engineering Physiology. International Thomson

Publishing-Van Nostrand Reinhold.
7.
Konz & Johnson (2004). Work Design: Occupational Ergonomics.

Holcomb Hathaway, Publishers, Inc.
Contents
1.
2.
3.
4.
5.
What is Ergonomics
Understanding Ergonomics Risk
Analyzing and Recognizing Ergonomics
Problems
How to reduce the risk
Work Design
Course Objectives:
At the end of the class, students are able to:
1.
2.
3.
4.
5.
Understand the basic concepts of ergonomics in

industry
Interpret ergonomics practice in industry
Identify the ergonomics risk factors in industrial
environment
Give suggestion to reduce the risk in an industrial
environment
Design the work task/workplace to improve industrial
productivity.
What 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?
What other definitions have you heard?

Ergonomics is the application of scientific
principles, methods and data to the
development of products and systems that
interact with human.
History of Ergonomics
The 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 Factors
Human factors is the term used in

the USA
Ergonomics is more prevalent in

Europe and the rest of the world
For all practical purposes the

terms are synonymous.
The Goal of Ergonomics

1.
2.
3.
To 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?
Examples of work requirements that can cause discomfort,

fatigue, injury, and illness are:
o
o
o
o
o
o
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.
Effects on
the Operator
Effects on
the
Company
Fatigue, pain, illness

Low morale
Frustration
Irritation
Accidents
MSDs
Poor Quality
Absenteeism
Higher turnover
Higher training
Higher cost
Therefore Ergonomics is Important

because 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 Manufacturing
Design Improve/Innovative
High technology research
In Industry
Safety and health
Risk 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 Ergonomics
Ergonomics 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
GOODYEAR
In 1986, Goodyear established an ergonomics

element in their safety program including:
Awareness training
Established ergonomics committee
Established an audit program
Fixed identified problems
Geras, DT et al,. (1989). Advances in Industrial Ergonomics and Safety, I. London:
GOODYEARs Accident Rates

before & after Ergonomics Program
PROGRAM IMPLEMENTED
- 1987
- 1986 mid-year
Geras, DT et al,. (1989). Advances in Industrial Ergonomics and Safety, I. London:
Wisconsin Aluminum Foundry
Foundry has approx. 390 employees

Implemented safety & ergonomics inspections
Fixed identified problems
RESULTS:
WC costs reduced by 76.6% over 2 years
Positive 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.
Sample of Improvement
Installed lift and tilt tables

for baskets of parts and
conveyors
Reduced lifting
Reduced bending and

reaching
Increased productivity
Parts on
lift basket
Foundry Ergonomics Partnership Helps Employers Improve Safety and Efficiency.

(n.d.).
Retrieved December 7, 2008, from Occupational Health and Safety
How to start Ergonomics Program?
STEP 1: Understand Ergonomics risk/problems
STEP 2: Review injury history
STEP 3: Evaluate workplace
STEP 4: Implement improvements
STEP 5: Engage employees
STEP 6: Re-evaluate, measure improvements
Understanding
Understanding Ergonomics
Ergonomics Risk
Risk
Physical activity
Fatigue
Physical exertion
Fatigue & recovery
Overexertion & Cumulative
Trauma
Body Type
Understanding
Understanding Ergonomic
Ergonomic Risk
Risk
Physical
Physical Activity
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
How the
the Body
Body uses
uses Energy
Energy
Internal: Cell Growth: Digestion:

Circulation: Respiration etc.
External: Walking: Lifting:

Standing: Exercising: etc
Understanding
Ergonomic Risk
Risk
Fatigue
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.
Understanding
Ergonomic Risk
Risk
Physical
Physical Exertion
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.
Understanding
Ergonomic Risk
Risk
Fatigue
Fatigue and
and Recovery
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.
Understanding
Ergonomic Risk
Risk
Overexertion
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
Understanding
Ergonomic Risk
Risk
Body
Body Type
Type
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.
o
Stamina
Strength
Height
Weight
o Proportions
o Vision
o Hearing
Understanding
Ergonomic Risk
Risk
Risk
Risk Factors
Factors
Frequent Hand Use

Arms Extended
Bending & Twisting
Static Body Posture
Using Force
Vibration
Contact Stress
Temperature
Noise
Fatigue
Injury Investigation
Time employee began workday

Time of event
What 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?
Suggestions
FIRST:
Create a spreadsheet
Use spreadsheet to track/organize information
Share information with managers & employees
THEN:
Injury Data Analysis
Create
charts and graphs to look for trends

Modify standard operating procedures
Improve employee training programs
How do you fix something?
Hammer
Nails
Level
Tape measure
Screw driver
Screws
Tape
And more
Evaluate Work Environment
Tools
Qualitative
Semi-Quantitative
Quantitative
Checklists
STEP 1: Understanding Ergonomics risk/problems
Implement Improvements
JUSTIFICATION:
Improving the safety of the workplace
Cost-benefit analysis
BENEFITS:
Delivering on commitments
Reducing injury risk
Reducing potential injury costs
Tool-task design
Consider the orientation of the tool and task

BAD
BETTER
Facility 8
Bending to get a part
Basket with parts on a

lift/tilt table
Workstation 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
Engage Employees/Workers
Involve workers in the decision process and ask for input
Example: 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 basis
Example:
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 reinforcement
Reward
good ideas, for example, a gift card for the local

movie theater for the best ergonomics/safety idea.
IMPROVEMENT PROCESS CIRCLE
Evaluate, re-evaluate and follow up
Training feedback questionnaire
Post training evaluation test
Follow up on the training effectiveness in the

next 3-4 months
Top 3 Office Safety Issues

Back Safety
Safe 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 Falls
Wires 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.
Copyright @ 2008 by ERGO
Additional Office Safety Issues:
File Cabinet Safety

File cabinets that are not secured to the wall can tip when heavy top
drawers are opened.
Fire and Electrical Safety
It is unsafe to plug a power strip into an extension cord. Use extension
cords only for temporary power
Chemical Safety
Are 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 Training
Periodic office safety training is recommended to heighten employees'
safety awareness.
Office
ergonomics
Seated posture
If 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.
Seating basics
Supported 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 surface
Position the keyboard in front of you and the monitor directly in front
of the keyboard
Place the mouse next to the keyboard
Position the chair up close to the work surface This will reduce
excessive reaching
Relax your shoulders and keep elbows close to the body
Place your thighs and forearms somewhat parallel to the floor
Clear obstacles from under the desk
Change positions frequently to avoid stiffness and to keep blood
circulating
Adjusting your computer workstation

1. Backs and legs
Sit 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
comfort
Sit with head above shoulders, shoulders above hips
Keep your feet supported on the floor or with a footrest
Your 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 legs
Allow for optimal movement of legs under the desk by keeping
the area clear of obstacles

2. Head and Eyes
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 below
Make 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 away
The best distance is when you can view the screen clearly without
leaning forward
No-No: Potential for neck strain
Ergo : Headset reduced risk for neck strain

2. Head and Eyes (cont.)
Increase 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 up
If you have vision challenges, ask
your eye care specialist about using
computer reading glasses
Take regular, short posture and vision breaks
If you use the phone for extended periods of time, hold the receiver
rather than cradling it against your shoulder
Use a headset to allow you to use your hands while talking

2. Head and Eyes (cont.)
Eliminate 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
screen
20 to 40 inches
Preferred viewing distance is 20 to 40 inches


3. Shoulder and Arms
Keep shoulders relaxed with arms

comfortably at your sides
Adjust the work surface or the height of

your chair if your shoulders are elevated
Avoid 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 extended
Keep frequently used items within easy

reach
Armrests on the chair can offer support for

your arms and shoulders if used properly.
No-No: Excessive reach for the

mouse
No-No:
Work surface too high

4. Wrist and Hands
When 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 stress
No-No: Wrists bent
Ergo: Wrists straight by tilting keyboard

4. Wrist and Hands (cont.)
No-No: Bent Wrist and Fingers and Thumb
No-No: Bent Wrist and Fingers and Thumb
Ergo: Straight Wrist and Relaxed Fingers
Ergo: Straight wrist, air space under wrist, relaxed

fingers. Alternate use of hands to rest the dominant
one
Model Computer Workstation
Keyboard trays WITH wrist support.

Split "Natural" keyboards to
facilitate neutral wrist angle
Fully adjustable ergonomic chair
Document holder to minimize
head/eye & neck movements
Corner desk units to position
monitor directly in front of employee
Foot 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 ?
Change Postures
Frequently
Organize Your Workstation
Alternate Job Tasks
Avoid Eyestrain
Protect Your Back and
Hands
Change posture frequently

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
Ergo: Use an anti-fatigue mat
Ergo: Rest on a platform or box
Lifting and Carrying

Size 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 assistance
Plan the lift before you start. When team lifting, pick one
person to call the signals. Avoid walking backward
Check the route and be sure the path is clear
Get a firm footing. Keep your feet shoulder-width apart
and center yourself over the load
Keep your back in its natural S curve rather than
rounded in a C curve when you lift
Avoided:
Recommende
d:
Workstation 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?

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Human Factors/Ergonomics

K.H.E. Kroemer et al. (2001). Ergonomics-How to design for ease and

R.S. Bridger (1995). Introduction to Ergonomics. McGraw Hill.

Mark S. Sanders & Ernest J. McCormick (1992). Human Factor in

Benjamin Niebel & Andris Freivalds (2004). Methods, Standards and

Gerard J. Tortora & Sandra Reynolds Grabowski (2001). Introduction to

K.H.E.Kroemer (1997). Engineering Physiology. International Thomson

Konz & Johnson (2004). Work Design: Occupational Ergonomics.

Understand the basic concepts of ergonomics in

Various authors define ergonomics as:

What other definitions have you heard?

The term ergonomics comes from the Greek words

Early history-1900 Frank and Lillian Gilbreth began

Their work can be considered as one of the

Ergonomics and Human Factors

Human factors is the term used in

Ergonomics is more prevalent in

For all practical purposes the

The Goal of Ergonomics

To generate tolerable working condition that do not

.. is to make the work fit the operator,

Examples of work requirements that can cause discomfort,

Fatigue, pain, illness

Therefore Ergonomics is Important

The Importance of Ergonomics.

In Engineering and Manufacturing

High technology research

Safety and health

Risk factor and MSD

Study, research and experimentation to determine

Application and engineering designing tools,

Ergonomics focus on human being and their

The emphasis is on human beings and how the

In 1986, Goodyear established an ergonomics

Established ergonomics committee

Established an audit program

Fixed identified problems

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

GOODYEARs Accident Rates

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

Wisconsin Aluminum Foundry

Foundry has approx. 390 employees

Installed lift and tilt tables

Reduced bending and

Foundry Ergonomics Partnership Helps Employers Improve Safety and Efficiency.

How to start Ergonomics Program?

STEP 1: Understand Ergonomics risk/problems

STEP 2: Review injury history

STEP 3: Evaluate workplace

STEP 4: Implement improvements

STEP 5: Engage employees

STEP 6: Re-evaluate, measure improvements

Our bodies use energy from the

Internal demands are the processes

External demands are the physical

Internal: Cell Growth: Digestion:

External: Walking: Lifting:

If activities exceed our personal limits of stamina or

Localized fatigue - effects the particular part of the body

Whole body fatigue - occurs when several body parts

Is either dynamic or static.

Dynamic exertion is where there is visible movement of

Static exertion is where the body or part of the body is