Human Capabilities and Ergonomics

Presented by:Cindy Roth

Ergonomic Technologies CorporationSyosset, NY

AnthropometryAnthropometry

The study of the physical attributesThe study of the physical attributesof the human bodyof the human body

Human Capabilities at Work✦✦ AnthropometryAnthropometry

•• Measurements of the various Measurements of the various aspects of the human bodyaspects of the human body

•• Physical CharacteristicsPhysical Characteristics•• StrengthStrength•• Capacity for WorkCapacity for Work

AnthropometryAnthropometryStructural or StaticStructural or Static

¦ simple dimensions of the human body, stature, linklengths, breadths, depths, circumferences andweight of body structures

¦ simple dimensions of the human body stature, linklengths, breadths, depths, circumferences andweight of body structures

AnthropometryAnthropometryFunctional or Dynamic

•measures related to the capabilities of the humanbody including reach, range of joint motion andstrength

•measures related to the capabilities of the humanbody including reach, range of joint motion andstrength

Assume that the data for a given population for a single

variable will be normally distributed

Assume that the data for a given population for a single

variable will be normally distributed

Ergonomics Goals

■■ Optimizing the work systems Optimizing the work systems effectiveness and productivityeffectiveness and productivity

■■ Removing barriersRemoving barriers■■ Assuring the workers health, safety and Assuring the workers health, safety and

well beingwell being

PercentilesPercentiles% of Pop’n expected to have a

dimension of a given size or smaller% of Pop’n expected to have a

dimension of a given size or smaller

¦ 5th Percentile ¦ 50th Percentile ¦ 95th Percentile

¦ 5th Percentile ¦ 50th Percentile ¦ 95th Percentile

TOOL TESTING METHODOLOGYExperimental Design Steps

Assumptions

■■ Subjects are selected Subjects are selected from a population that is from a population that is normally distributednormally distributed

■■ Subjects represent Subjects represent independent random independent random samples of the populationsamples of the population

Types of DataTypes of DataAnthropometric data may be presented

in various formsAnthropometric data may be presented

in various forms

¦ as a value or range of values (mean ± sd) ¦ as an equation which can be applied to a known

easily measured variable ¦ as a % of another variable

¦ as a value or range of values (mean ± sd) ¦ as an equation which can be applied to a known

easily measured variable ¦ as a % of another variable

Application to Design

■■ For whom are we designing ?For whom are we designing ?■■ What are the population characteristics ?What are the population characteristics ?■■ Have we considered ?Have we considered ?

◆◆ StrengthStrength◆◆ Range of MotionRange of Motion◆◆ HeightHeight◆◆ ClearanceClearance◆◆ ReachReach

StrengthStrength

1st Class Lever (Neck)

1st Class Lever (Neck)

2nd Class Lever (Standing on Toes)2nd Class Lever

(Standing on Toes)

3rd Class Lever (Biceps)3rd Class Lever (Biceps)

ForceForce WeightWeight

FF

FF FF

WW

WW WW

Ergonomics Decision Model■■ DesignDesign--equipment and methodsequipment and methods■■ QuantifyQuantify--requirements for userequirements for use■■ PredictPredict--capabilities of the populationcapabilities of the population■■ CompareCompare--standards and guidelinesstandards and guidelines■■ DecideDecide--acceptable or unacceptableacceptable or unacceptable

Benefits of an Ergonomics Program

■■ Reduction of Reduction of musculoskeletalmusculoskeletal recordablesrecordables■■ Reduction in lost workdaysReduction in lost workdays■■ Reduction in lost Reduction in lost worktimeworktime■■ Reduction in absenteeism and turnoverReduction in absenteeism and turnover■■ Reduction of regulatory non complianceReduction of regulatory non compliance■■ Reduction in negative labor relationsReduction in negative labor relations■■ Reduction in “Crisis Management” issuesReduction in “Crisis Management” issues■■ Reduction in redo work and wasteReduction in redo work and waste■■ Reduction in production and quality issuesReduction in production and quality issues

MUSCULOSKELETAL INJURIES■■ Acute Disorders Acute Disorders

◆◆ Injuries which occur instantaneously due to a Injuries which occur instantaneously due to a known or specific cause/incidentknown or specific cause/incident

■■ Workplace Workplace Musculoskeletal Musculoskeletal Disorders Disorders ((WMSDsWMSDs) ) ◆◆ Injuries occurring over time due to repeated Injuries occurring over time due to repeated

exposure to various risk factors when no specific exposure to various risk factors when no specific incident is recognizedincident is recognized

◆◆ Happens when human capabilities are exceededHappens when human capabilities are exceeded

Ergonomic Injury Terms■■ Cumulative Trauma Disorder Cumulative Trauma Disorder CTDCTD■■ MusculoskeletalMusculoskeletal DisorderDisorder MSDMSD■■ Repetitive Strain InjuryRepetitive Strain Injury RSIRSI■■ Repetitive Motion InjuriesRepetitive Motion Injuries RMIRMI■■ SprainsSprains■■ Overuse Syndrome/fatigueOveruse Syndrome/fatigue■■ Back injuryBack injury

Musculoskeletal Disorders■■ May occur in all body partsMay occur in all body parts■■ Levels of severity depending on age, Levels of severity depending on age,

individual and damageindividual and damage■■ If untreated may become chronic or long If untreated may become chronic or long

term disabilityterm disability■■ Most disabling of all injuries to persons Most disabling of all injuries to persons

1818--40 yrs of age in the US40 yrs of age in the US

Fatigue■■ The reduction in The reduction in

performance ability performance ability caused by a period of caused by a period of excessive activity without excessive activity without adequate recovery timeadequate recovery time◆◆ not enough oxygen in the not enough oxygen in the

musclemuscle◆◆ waste products not waste products not

carried away fast enoughcarried away fast enough

Musculoskeletal Disorders

■■ This year 2000 over 50% of workers’ This year 2000 over 50% of workers’ compensation dollars will be as a result of compensation dollars will be as a result of cumulative trauma disorders… cumulative trauma disorders… US OSHAUS OSHA

Occupational Risk Factors for WMSDs

FrequencyFrequency

ForceForce

PosturePosture

EnvironmentEnvironment(temp., vibration, (temp., vibration,

noise)noise)++PersonalPersonal

riskriskfactorsfactors

Contact StressContact Stress

Symptoms of WMSDs■■ PainPain■■ DiscomfortDiscomfort■■ SwellingSwelling■■ Loss of mobility/range of motionLoss of mobility/range of motion■■ Diminished coordinationDiminished coordination

According to OSHA

■■ “U.S. Department of Labor, Occupational “U.S. Department of Labor, Occupational Health and Safety Administration (OSHA) has Health and Safety Administration (OSHA) has declared ergonomics to be one of the most declared ergonomics to be one of the most important issues of the 1990’s.”important issues of the 1990’s.”

■■ And they acted upon this statementAnd they acted upon this statement

WMSDs in the Workplace

■■ Cal OSHA Study 1992Cal OSHA Study 1992◆◆ Carpal Tunnel Syndrome in 49 different Carpal Tunnel Syndrome in 49 different

occupations and 42 different industry occupations and 42 different industry classificationsclassifications

◆◆ Frequently reported risk factorsFrequently reported risk factors✦✦ repetition= 84%repetition= 84%✦✦ awkward wrist postures = 59%awkward wrist postures = 59%✦✦ direct palm/wrist pressure = 44%direct palm/wrist pressure = 44%✦✦ pinch grip = 42%pinch grip = 42%

The TrendRepeated Trauma Cases

in Private Industry

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120160200240280320

83 84 85 86 87 88 89 90 91 92 93 94 95 96

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Incidence rate(cases per 100workers)

National Average = 0.33

Y2K Goals of Ergonomics

■■ Productivity GainsProductivity Gains■■ Lean ManufacturingLean Manufacturing■■ Quality AssuranceQuality Assurance■■ Injury PreventionInjury Prevention■■ Employee Health & Well Employee Health & Well

BeingBeing■■ Greater ProfitsGreater Profits

Issues for 2000 and Beyond■■ The aging of the population worldwideThe aging of the population worldwide■■ Manufacturing competitivenessManufacturing competitiveness■■ Maintaining the precious resource … People Maintaining the precious resource … People

◆◆ 19961996--2006 labor force increases by 11% vs. a 14% 2006 labor force increases by 11% vs. a 14% increase for period 1986increase for period 1986--1996 1996

■■ Global customer and employee baseGlobal customer and employee base■■ Government legislationGovernment legislation■■ Rising medical costsRising medical costs

Women as a Percent of the Civilian Labor Force

4142434445464748

1982 1995 2005

Year

% Women

■■ Females possess Females possess approximately approximately 70% the 70% the strength of a strength of a malemale

Age Breakdown of Hourly Workers in the Big Three Auto Companies

18-20 21-30 31-40 41-50 51-60 61-65 65+05

1015202530354045

% of Total

18-20 21-30 31-40 41-50 51-60 61-65 65+

19851995

The Elderly

■■ Over 65Over 65■■ Hand Strength Reduced by 16Hand Strength Reduced by 16--40%40%■■ Arm Strength Reduced by 50%Arm Strength Reduced by 50%■■ Leg Strength Reduced by 50%Leg Strength Reduced by 50%

Secular Variability

■■ Populations have been increasing in Populations have been increasing in stature at a rate of approximately 2cm stature at a rate of approximately 2cm per decade since the 1920sper decade since the 1920s

Costs of MusculoskeletalDisorders■■ Health & SafetyHealth & Safety■■ Morale and Labor Morale and Labor

RelationsRelations■■ TurnoverTurnover■■ AbsenteeismAbsenteeism■■ Productivity/EfficiencyProductivity/Efficiency■■ Product QualityProduct Quality■■ LawsuitsLawsuits■■ Citations/FinesCitations/Fines

Costs of WMSDs

Average Workers’ Compensation Claim Costs by Body Part

(95th Percentile)

(99th Percentile)

Body Part Average Low Median High High

Left Hand/Wrist

9,590 1,700 3,400 38,580 81,390

Right Hand/Wrist

9,590 1,700 3,400 38,580 81,390

Left Elbow 14,830 2,830 5,660 57,970 104,210 Right Elbow 14,830 2,830 5,660 57,970 104,210 Left Shoulder 14,830 2,830 5,660 57,970 104,210 Right Shoulder 14,830 2,830 5,660 57,970 104,210 Back 13,790 2,490 4,990 60,570 105,600 Neck 24,130 2,870 5,370 66,350 345,170 Legs 8,320 1,940 3,890 31,530 58,460

Milliman & Robertson, Inc., Actuaries & Consultants, 1993.

“This nation cannot afford to wait any longer to address the serious issues of work-related musculoskeletal disorders…”

3/4/99 Statement by Charles 3/4/99 Statement by Charles JeffressJeffressAsst. Secretary of Labor Asst. Secretary of Labor

U.S. Legislative InitiativesFederalFederal

■■ Ergonomic Protection Standard Ergonomic Protection Standard published for comment Feb. 99published for comment Feb. 99

■■ Occupational Safety & Health Act, Occupational Safety & Health Act, General Duty Clause (1970)General Duty Clause (1970)

■■ NIOSH Work Practices Guide for NIOSH Work Practices Guide for Manual Materials Handling (1981, 1991)Manual Materials Handling (1981, 1991)

■■ OSHA 3123 Ergonomics Guidelines for OSHA 3123 Ergonomics Guidelines for Meatpacking 1991Meatpacking 1991

■■ ANSIANSI--Z365 Ergonomics Standard (in Z365 Ergonomics Standard (in progress)progress)

Ergonomic PenaltiesGeneral Duty Clause

OSHA Act Public Law 91OSHA Act Public Law 91--596, 596, Section 17Section 17

■■ Willful or repeated violations (other Willful or repeated violations (other than serious)than serious)◆◆ $5,000 $5,000 -- $70,000 per violation$70,000 per violation

■■ Willful or repeated violations (serious)Willful or repeated violations (serious)◆◆ $25,000 $25,000 -- $70,000 per violation$70,000 per violation

■■ Violations not abatedViolations not abated◆◆ $7,000 per violation$7,000 per violation

Ergonomic Protection StandardErgonomic Protection StandardAn OverviewAn Overview

Proposed Ergonomics Standard

■■ Published in the Published in the Federal Register Federal Register in in November, 1999November, 1999

■■ OSHA’s OSHA’s goal is to take public comments, goal is to take public comments, hold hearings in several cities beginning hold hearings in several cities beginning February 2000 and publish the final rule February 2000 and publish the final rule at the end of the year 2000at the end of the year 2000

Who’s Affected?■■ All manufacturingAll manufacturing■■ All job requiring manual materials All job requiring manual materials

handlinghandling■■ Any job that has produced a Any job that has produced a

musculoskeletal musculoskeletal disorderdisorder■■ Exempt Exempt -- maritime, construction and maritime, construction and

agricultural activitiesagricultural activities

Problem jobs and some of the reasons for the Ergo Standard■■ Managing costsManaging costs■■ Managing peopleManaging people■■ Managing injuries/illnessesManaging injuries/illnesses■■ Managing competitionManaging competition■■ Managing regulationsManaging regulations

What are the Obligations?■■ Companies must setup an ergonomics program Companies must setup an ergonomics program

to prevent or reduce to prevent or reduce WMSD’sWMSD’s■■ Program components:Program components:

◆◆ Management leadership & employee participationManagement leadership & employee participation◆◆ Hazard identification & awarenessHazard identification & awareness◆◆ Job hazard analysis and hazard controlJob hazard analysis and hazard control◆◆ TrainingTraining◆◆ Medical managementMedical management◆◆ Program evaluationProgram evaluation

Ergonomics Process and Procedures

What Works

■■ A program that incorporates the major A program that incorporates the major OSHA prescribed componentsOSHA prescribed components

■■ Engineering is the driving force, well Engineering is the driving force, well supported by other departmentssupported by other departments

■■ Keeping it simpleKeeping it simple■■ Commitment to embedding concepts of Commitment to embedding concepts of

ergonomics into day to day operationsergonomics into day to day operations■■ Accountability!!!Accountability!!!

Ergonomics Committee Ergonomics Committee MembersMembers

■■ Executive Management Executive Management ■■ Employees Employees ■■ Engineering Engineering ■■ Safety & HealthSafety & Health■■ Medical DepartmentMedical Department■■ Workers’ CompensationWorkers’ Compensation

Ergonomics Program Reality

Pressure to Incorporate Ergonomics

Realistic Expectations & Goals

vs.vs.

¦ rising costs ¦ penalties¦ rising costs ¦ penalties

¦ awareness ¦ problem recognition

capabilities ¦ evaluation efforts ¦ development and

implementation of solutions

¦ awareness ¦ problem recognition

capabilities ¦ evaluation efforts ¦ development and

implementation of solutions

Realistic TimeframeRealistic Timeframe

Identifying & Solving Workplace Ergonomics Deficiencies

Identifying & Solving Workplace Ergonomics Deficiencies

Budgeting & Capital Investments

Budgeting & Capital Investments

Time to See Benefits in the Injury Data

Time to See Benefits in the Injury Data

Ergonomics Process

Keys to Successes

■■ Ability to manage processAbility to manage process■■ Ability to include all levels of employeesAbility to include all levels of employees■■ Ability to incorporate the process into the Ability to incorporate the process into the

corporate culturecorporate culture■■ Ability to cost justifyAbility to cost justify

Hazard Abatement Options

■■ Administrative ControlsAdministrative Controls◆◆ job rotation, employee training, prejob rotation, employee training, pre--placement placement

screeningscreening

■■ Work Practice ControlsWork Practice Controls◆◆ Job enlargement, cycle time modificationJob enlargement, cycle time modification

■■ Engineering ControlsEngineering Controls◆◆ Machine retrofits, new tool introductions, lift assists, Machine retrofits, new tool introductions, lift assists,

workstation design, job redesigns, DFM, DFAworkstation design, job redesigns, DFM, DFA

Manual Materials HandlingETC TechnologyHuman Modeling

Muscle Activity Testing (EMG)Assessment of Repetitive Lifting

0

50

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150

200

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300

350

400

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Upper Back (L)Upper Back (R)Low Back (L)Low Back (R)

Reach Reduction Using Human Modeling

Ergonomic Protection Standard■■ “After a long delay, U.S. plans to issue “After a long delay, U.S. plans to issue

Ergonomic Rules” 11/22/99, NY TimesErgonomic Rules” 11/22/99, NY Times■■ “ergonomics programs are cost effective “ergonomics programs are cost effective

and feasible”and feasible”■■ Currently enforced through OSHA Currently enforced through OSHA

General Duty clauseGeneral Duty clause■■ OSHA said employers to fix or redesign OSHA said employers to fix or redesign

4.5 million jobs the first year4.5 million jobs the first year■■ Changes would prevent 32,000 to 95,000 Changes would prevent 32,000 to 95,000

injuries each yearinjuries each year