practical application of ergonomics hal w. hendrick, ph.d., cpe practical application of ergonomics...

Practical Application of Practical Application of Ergonomics Ergonomics

Hal W. Hendrick, Ph.D., CPEHal W. Hendrick, Ph.D., CPE

Practical Application of Practical Application of Ergonomics Ergonomics

Hal W. Hendrick, Ph.D., CPEHal W. Hendrick, Ph.D., CPE

HFES Strategic Planning StudyHFES Strategic Planning StudyHFES Strategic Planning StudyHFES Strategic Planning Study

Reviewed ergonomics research and practice Reviewed ergonomics research and practice around the world to determine common around the world to determine common characteristics, purpose, and scope of characteristics, purpose, and scope of ergonomicsergonomics

Some important findings and conclusions are Some important findings and conclusions are as followsas follows

Reviewed ergonomics research and practice Reviewed ergonomics research and practice around the world to determine common around the world to determine common characteristics, purpose, and scope of characteristics, purpose, and scope of ergonomicsergonomics

Some important findings and conclusions are Some important findings and conclusions are as followsas follows

Ergonomics is a Scientifically Ergonomics is a Scientifically Based DisciplineBased DisciplineErgonomics is a Scientifically Ergonomics is a Scientifically Based DisciplineBased Discipline

Science Science

–Study human performance capabilities and Study human performance capabilities and limitations.limitations.

–Apply our scientific knowledge of humans to Apply our scientific knowledge of humans to developing developing ergonomics technologyergonomics technology

PrinciplesPrinciples GuidelinesGuidelines SpecificationsSpecifications MethodsMethods ToolsTools

Science Science

–Study human performance capabilities and Study human performance capabilities and limitations.limitations.

–Apply our scientific knowledge of humans to Apply our scientific knowledge of humans to developing developing ergonomics technologyergonomics technology

PrinciplesPrinciples GuidelinesGuidelines SpecificationsSpecifications MethodsMethods ToolsTools

Ergonomics is a Scientifically Ergonomics is a Scientifically Based DisciplineBased DisciplineErgonomics is a Scientifically Ergonomics is a Scientifically Based DisciplineBased Discipline

Practice*Practice*Apply ergonomics technology to the design, analysis, test Apply ergonomics technology to the design, analysis, test

and evaluation, and standardization of systems.and evaluation, and standardization of systems.

Purpose*Purpose*To improve the quality of human lifeTo improve the quality of human life

HealthHealth SafetySafety ComfortComfort productivityproductivity

* * HFES Directory and YearbookHFES Directory and Yearbook: Strategic Plan: Strategic Plan

Practice*Practice*Apply ergonomics technology to the design, analysis, test Apply ergonomics technology to the design, analysis, test

and evaluation, and standardization of systems.and evaluation, and standardization of systems.

Purpose*Purpose*To improve the quality of human lifeTo improve the quality of human life

HealthHealth SafetySafety ComfortComfort productivityproductivity


The Technology of Ergonomics is The Technology of Ergonomics is Human-System Interface Technology*Human-System Interface Technology*The Technology of Ergonomics is The Technology of Ergonomics is Human-System Interface Technology*Human-System Interface Technology*

Human-System Interface TechnologyHuman-System Interface Technology- Human-Machine:- Human-Machine: Hardware Ergonomics Hardware Ergonomics

- Human-Environment: Environmental Ergonomics- Human-Environment: Environmental Ergonomics

- Human-Software:- Human-Software: Cognitive Ergonomics Cognitive Ergonomics

- Human-Job:- Human-Job: Work Design Ergonomics Work Design Ergonomics

- Human-Work System:- Human-Work System: Macroergonomics Macroergonomics


Human-System Interface TechnologyHuman-System Interface Technology- Human-Machine:- Human-Machine: Hardware Ergonomics Hardware Ergonomics

- Human-Environment: Environmental Ergonomics- Human-Environment: Environmental Ergonomics

- Human-Software:- Human-Software: Cognitive Ergonomics Cognitive Ergonomics

- Human-Job:- Human-Job: Work Design Ergonomics Work Design Ergonomics

- Human-Work System:- Human-Work System: Macroergonomics Macroergonomics


Good Ergonomics is Good EconomicsGood Ergonomics is Good EconomicsGood Ergonomics is Good EconomicsGood Ergonomics is Good Economics

Poor ErgonomicsPoor Ergonomics

– Violates ergonomics technologyViolates ergonomics technology and/orand/or

– Is Is notnot cost effective cost effective

Good ErgonomicsGood Ergonomics

– Appropriately applies sound ergonomics technologyAppropriately applies sound ergonomics technologyandand

– IsIs cost effective cost effective

Poor ErgonomicsPoor Ergonomics

– Violates ergonomics technologyViolates ergonomics technology and/orand/or

– Is Is notnot cost effective cost effective

Good ErgonomicsGood Ergonomics

– Appropriately applies sound ergonomics technologyAppropriately applies sound ergonomics technologyandand

– IsIs cost effective cost effective

ERGONOMICS Must Be COST EFFECTIVEERGONOMICS Must Be COST EFFECTIVE ERGONOMICS Must Be COST EFFECTIVEERGONOMICS Must Be COST EFFECTIVE

The language of business is The language of business is money!money!

Managers have to justify any expenditure in Managers have to justify any expenditure in terms of the cost- benefit ratio: How the terms of the cost- benefit ratio: How the project will affect the project will affect the bottom line.bottom line.

Must express ergonomic project proposals Must express ergonomic project proposals in in financial termsfinancial terms..

The language of business is The language of business is money!money!

Managers have to justify any expenditure in Managers have to justify any expenditure in terms of the cost- benefit ratio: How the terms of the cost- benefit ratio: How the project will affect the project will affect the bottom line.bottom line.

Must express ergonomic project proposals Must express ergonomic project proposals in in financial termsfinancial terms..

MeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of of ErgonomicErgonomic Interventions InterventionsMeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of of ErgonomicErgonomic Interventions Interventions

CostsCosts

– Personnel, training, equipment, materials, Personnel, training, equipment, materials, reduced productivity, and overhead.reduced productivity, and overhead.

BenefitsBenefits

– Personnel savings: Less lost time, less training, Personnel savings: Less lost time, less training, lower skill levels required, increased output per lower skill levels required, increased output per person, fewer people required, greater individual person, fewer people required, greater individual or team effectiveness.or team effectiveness.

–Material savings: Reduced scrap, fewer rejects, Material savings: Reduced scrap, fewer rejects, fewer parts. fewer parts.

CostsCosts

– Personnel, training, equipment, materials, Personnel, training, equipment, materials, reduced productivity, and overhead.reduced productivity, and overhead.

BenefitsBenefits

– Personnel savings: Less lost time, less training, Personnel savings: Less lost time, less training, lower skill levels required, increased output per lower skill levels required, increased output per person, fewer people required, greater individual person, fewer people required, greater individual or team effectiveness.or team effectiveness.

–Material savings: Reduced scrap, fewer rejects, Material savings: Reduced scrap, fewer rejects, fewer parts. fewer parts.

MeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of of ErgonomicErgonomic Interventions InterventionsMeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of of ErgonomicErgonomic Interventions Interventions

Source of informationSource of information

–Much of the cost and pricing information is available Much of the cost and pricing information is available through either your human resources or accounting through either your human resources or accounting departments, including overhead percentage.departments, including overhead percentage.

– Projected benefits can be gained through the Projected benefits can be gained through the literature and looking at similar projects in other literature and looking at similar projects in other organizations.organizations.

Source of informationSource of information

–Much of the cost and pricing information is available Much of the cost and pricing information is available through either your human resources or accounting through either your human resources or accounting departments, including overhead percentage.departments, including overhead percentage.

– Projected benefits can be gained through the Projected benefits can be gained through the literature and looking at similar projects in other literature and looking at similar projects in other organizations.organizations.

MeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of Ergonomic Interventions of Ergonomic InterventionsMeasuringMeasuring the Economic Costs and the Economic Costs and BenefitsBenefits of Ergonomic Interventions of Ergonomic Interventions

Example: Tractor Forwarding Units, South Example: Tractor Forwarding Units, South African Forestry IndustryAfrican Forestry Industry

Original UnitOriginal Unit: Poor operator seating and visibility: Poor operator seating and visibility

Example: Tractor Forwarding Units, South Example: Tractor Forwarding Units, South African Forestry IndustryAfrican Forestry Industry

Original UnitOriginal Unit: Poor operator seating and visibility: Poor operator seating and visibility


ExampleExample: : Tractor-Trailer Forwarding UnitsTractor-Trailer Forwarding Units

South African Forestry IndustrySouth African Forestry Industry

Redesigned UnitRedesigned Unit: Good operator : Good operator

seating and visibilityseating and visibility

ExampleExample: : Tractor-Trailer Forwarding UnitsTractor-Trailer Forwarding Units

South African Forestry IndustrySouth African Forestry Industry

Redesigned UnitRedesigned Unit: Good operator : Good operator

seating and visibilityseating and visibility


ExampleExample:: Tractor-Trailer Forwarding Units, Tractor-Trailer Forwarding Units, South African Forestry IndustrySouth African Forestry Industry

CostCost

- 23 Units modified @ $300 per unit: $6,900- 23 Units modified @ $300 per unit: $6,900

BenefitBenefit

- Reduced accident damage by $2000 per unit per year - Reduced accident damage by $2000 per unit per year or $46,000 per year.or $46,000 per year.

- Extraction increased by one load per day per vehicle - Extraction increased by one load per day per vehicle for total increase of $19,000 per yrfor total increase of $19,000 per yr

- - TOTAL Cost-BenefitTOTAL Cost-Benefit: $58,100 or 1 to 9.4 C-B ratio.: $58,100 or 1 to 9.4 C-B ratio.

ExampleExample:: Tractor-Trailer Forwarding Units, Tractor-Trailer Forwarding Units, South African Forestry IndustrySouth African Forestry Industry

CostCost

- 23 Units modified @ $300 per unit: $6,900- 23 Units modified @ $300 per unit: $6,900

BenefitBenefit

- Reduced accident damage by $2000 per unit per year - Reduced accident damage by $2000 per unit per year or $46,000 per year.or $46,000 per year.

- Extraction increased by one load per day per vehicle - Extraction increased by one load per day per vehicle for total increase of $19,000 per yrfor total increase of $19,000 per yr

- - TOTAL Cost-BenefitTOTAL Cost-Benefit: $58,100 or 1 to 9.4 C-B ratio.: $58,100 or 1 to 9.4 C-B ratio.

Measuring the Economic Benefits Measuring the Economic Benefits of Ergonomic Interventionsof Ergonomic InterventionsMeasuring the Economic Benefits Measuring the Economic Benefits of Ergonomic Interventionsof Ergonomic Interventions

Less Tangible BenefitsLess Tangible Benefits

– Increased Employee Satisfaction and Commitment :Increased Employee Satisfaction and Commitment : Leads to “good citizenship” behavior. Can reduce Leads to “good citizenship” behavior. Can reduce grievances, improve productivity, and improve grievances, improve productivity, and improve troop-community relations – all of which can have a troop-community relations – all of which can have a positive financial impact.positive financial impact.

– Improved Organizational Image:Improved Organizational Image: Can result in less Can result in less governmental scrutiny & better community relations governmental scrutiny & better community relations – all of which can have a positive financial impact.– all of which can have a positive financial impact.

Less Tangible BenefitsLess Tangible Benefits

– Increased Employee Satisfaction and Commitment :Increased Employee Satisfaction and Commitment : Leads to “good citizenship” behavior. Can reduce Leads to “good citizenship” behavior. Can reduce grievances, improve productivity, and improve grievances, improve productivity, and improve troop-community relations – all of which can have a troop-community relations – all of which can have a positive financial impact.positive financial impact.

– Improved Organizational Image:Improved Organizational Image: Can result in less Can result in less governmental scrutiny & better community relations governmental scrutiny & better community relations – all of which can have a positive financial impact.– all of which can have a positive financial impact.

Cost Effective ErgonomicsCost Effective Ergonomics Cost Effective ErgonomicsCost Effective Ergonomics

The earlier ergonomics is used in design, the The earlier ergonomics is used in design, the cheaper the cost and greater the benefit*cheaper the cost and greater the benefit*

System DevelopmentSystem Development Proportion of Proportion of DesignDesign

Design Stage Design Stage Engineering Engineering Cost___Cost___

Conceptual/Early DesignConceptual/Early Design 1.0%- 2+%1.0%- 2+%Blueprint Blueprint 1.5%- 3+%1.5%- 3+%Construction Construction 2.0%- 6+%2.0%- 6+%CommissioningCommissioning 4.0%-10+%4.0%-10+%OperationalOperational 5.0%-12+%5.0%-12+%

*Auburn Engineers, Inc. findings; reported at the April 2002 *Auburn Engineers, Inc. findings; reported at the April 2002 DoD Ergonomics Conference.DoD Ergonomics Conference.

The earlier ergonomics is used in design, the The earlier ergonomics is used in design, the cheaper the cost and greater the benefit*cheaper the cost and greater the benefit*

System DevelopmentSystem Development Proportion of Proportion of DesignDesign

Design Stage Design Stage Engineering Engineering Cost___Cost___

Conceptual/Early DesignConceptual/Early Design 1.0%- 2+%1.0%- 2+%Blueprint Blueprint 1.5%- 3+%1.5%- 3+%Construction Construction 2.0%- 6+%2.0%- 6+%CommissioningCommissioning 4.0%-10+%4.0%-10+%OperationalOperational 5.0%-12+%5.0%-12+%

*Auburn Engineers, Inc. findings; reported at the April 2002 *Auburn Engineers, Inc. findings; reported at the April 2002 DoD Ergonomics Conference.DoD Ergonomics Conference.


Average Cost of Effective HFE ProgramsAverage Cost of Effective HFE Programs

1.0% of engineering design/development budget1.0% of engineering design/development budget - - based on analysis of 10 major military system development based on analysis of 10 major military system development projects (Hendrick & Jones, 1981).projects (Hendrick & Jones, 1981).

1.0% of engineering design/development budget1.0% of engineering design/development budget – – based on analysis of 15 projects (Alaxander, 2000).based on analysis of 15 projects (Alaxander, 2000).

0.08% of acquisition cost of off shore platforms0.08% of acquisition cost of off shore platforms - -based on analysis of several platform development programs based on analysis of several platform development programs over 9 year period (Miller, 1999). over 9 year period (Miller, 1999).

Average Cost of Effective HFE ProgramsAverage Cost of Effective HFE Programs

1.0% of engineering design/development budget1.0% of engineering design/development budget - - based on analysis of 10 major military system development based on analysis of 10 major military system development projects (Hendrick & Jones, 1981).projects (Hendrick & Jones, 1981).

1.0% of engineering design/development budget1.0% of engineering design/development budget – – based on analysis of 15 projects (Alaxander, 2000).based on analysis of 15 projects (Alaxander, 2000).

0.08% of acquisition cost of off shore platforms0.08% of acquisition cost of off shore platforms - -based on analysis of several platform development programs based on analysis of several platform development programs over 9 year period (Miller, 1999). over 9 year period (Miller, 1999).


Typical Cost-Benefit Ratio of HFE ProgramsTypical Cost-Benefit Ratio of HFE Programs

Between 1 to 2 and 1 to10+ Between 1 to 2 and 1 to10+ (direct cost (direct cost savings only) – based on analysis of 27 savings only) – based on analysis of 27 projects (Hendrick, 1997*).projects (Hendrick, 1997*).

Life cycle cost savings can make the cost-Life cycle cost savings can make the cost-benefit ratio benefit ratio in excess of 1 to 50in excess of 1 to 50 (Hendrick, (Hendrick, 1979; 1997).1979; 1997).

**Good Ergonomics is Good Economics Good Ergonomics is Good Economics (available in pdf (available in pdf format at no cost at http://hfes.org).format at no cost at http://hfes.org).

Typical Cost-Benefit Ratio of HFE ProgramsTypical Cost-Benefit Ratio of HFE Programs

Between 1 to 2 and 1 to10+ Between 1 to 2 and 1 to10+ (direct cost (direct cost savings only) – based on analysis of 27 savings only) – based on analysis of 27 projects (Hendrick, 1997*).projects (Hendrick, 1997*).

Life cycle cost savings can make the cost-Life cycle cost savings can make the cost-benefit ratio benefit ratio in excess of 1 to 50in excess of 1 to 50 (Hendrick, (Hendrick, 1979; 1997).1979; 1997).

**Good Ergonomics is Good Economics Good Ergonomics is Good Economics (available in pdf (available in pdf format at no cost at http://hfes.org).format at no cost at http://hfes.org).

Personal Example: C-141 Aircraft Personal Example: C-141 Aircraft System Development Program System Development Program Personal Example: C-141 Aircraft Personal Example: C-141 Aircraft System Development Program System Development Program

C-141 Aircraft Development ProgramC-141 Aircraft Development ProgramC-141 Aircraft Development ProgramC-141 Aircraft Development Program

Four Engine USAF Cargo Aircraft Four Engine USAF Cargo Aircraft

Converts to different configurations via Converts to different configurations via installation of kits:installation of kits:– Cargo aerial deliveryCargo aerial delivery

– ParatroopParatroop

– Passenger aircraftPassenger aircraft

–Medical air evacuationMedical air evacuation

Four Engine USAF Cargo Aircraft Four Engine USAF Cargo Aircraft

Converts to different configurations via Converts to different configurations via installation of kits:installation of kits:– Cargo aerial deliveryCargo aerial delivery

– ParatroopParatroop

– Passenger aircraftPassenger aircraft

–Medical air evacuationMedical air evacuation


Conducted macroergonomic analysis Conducted macroergonomic analysis of operational work system.of operational work system.

ResultsResults Original design: Kits had many parts Original design: Kits had many parts

that would never be removed from that would never be removed from aircraft.aircraft.

Redesigned kits to only include items Redesigned kits to only include items that would not be left in aircraftthat would not be left in aircraft

Conducted macroergonomic analysis Conducted macroergonomic analysis of operational work system.of operational work system.

ResultsResults Original design: Kits had many parts Original design: Kits had many parts

that would never be removed from that would never be removed from aircraft.aircraft.

Redesigned kits to only include items Redesigned kits to only include items that would not be left in aircraftthat would not be left in aircraft


Saved $2.5 million in original priceSaved $2.5 million in original price

Kits smaller, lighter, easier to store and Kits smaller, lighter, easier to store and could be installed faster with fewer peoplecould be installed faster with fewer people

Saved storage cost and reduced Saved storage cost and reduced personnel requirements.personnel requirements.

Reduced actual aircraft operational weight Reduced actual aircraft operational weight and related fuel costs for entire fleet of and related fuel costs for entire fleet of over 200 aircraft over 35+ year period.over 200 aircraft over 35+ year period.

Saved $2.5 million in original priceSaved $2.5 million in original price

Kits smaller, lighter, easier to store and Kits smaller, lighter, easier to store and could be installed faster with fewer peoplecould be installed faster with fewer people

Saved storage cost and reduced Saved storage cost and reduced personnel requirements.personnel requirements.

Reduced actual aircraft operational weight Reduced actual aircraft operational weight and related fuel costs for entire fleet of and related fuel costs for entire fleet of over 200 aircraft over 35+ year period.over 200 aircraft over 35+ year period.

C-141 Aircraft Development C-141 Aircraft Development Program: Total HFE Cost-BenefitProgram: Total HFE Cost-BenefitC-141 Aircraft Development C-141 Aircraft Development Program: Total HFE Cost-BenefitProgram: Total HFE Cost-Benefit

Over 100 ergonomic improvements to Over 100 ergonomic improvements to original engineering designoriginal engineering design

Direct savings of over $5 million for HFE Direct savings of over $5 million for HFE program cost of $500,000 – a 1 to 10 cost program cost of $500,000 – a 1 to 10 cost benefit ratio.benefit ratio.

Life cycle savings from ergonomic Life cycle savings from ergonomic improvements: At least 1 to 50 cost-benefitimprovements: At least 1 to 50 cost-benefit

Over 100 ergonomic improvements to Over 100 ergonomic improvements to original engineering designoriginal engineering design

Direct savings of over $5 million for HFE Direct savings of over $5 million for HFE program cost of $500,000 – a 1 to 10 cost program cost of $500,000 – a 1 to 10 cost benefit ratio.benefit ratio.

Life cycle savings from ergonomic Life cycle savings from ergonomic improvements: At least 1 to 50 cost-benefitimprovements: At least 1 to 50 cost-benefit

C-141 Aircraft Development C-141 Aircraft Development Program: Total HFE Cost-BenefitProgram: Total HFE Cost-BenefitC-141 Aircraft Development C-141 Aircraft Development Program: Total HFE Cost-BenefitProgram: Total HFE Cost-Benefit

Good example of what ergonomics Good example of what ergonomics can do when integrated with can do when integrated with engineering design early in the engineering design early in the development program.development program.

Good example of what ergonomics Good example of what ergonomics can do when integrated with can do when integrated with engineering design early in the engineering design early in the development program.development program.

Ergonomics Cost-Benefit Ergonomics Cost-Benefit Trade-Off DiamondTrade-Off DiamondErgonomics Cost-Benefit Ergonomics Cost-Benefit Trade-Off DiamondTrade-Off Diamond

Human-System Interface DesignHuman-System Interface Design

TrainingTraining SelectionSelection

Job Performance AidsJob Performance Aids

Human-System Interface DesignHuman-System Interface Design

TrainingTraining SelectionSelection

Job Performance AidsJob Performance Aids

Ergonomics Cost-Benefit Ergonomics Cost-Benefit Trade-Off DiamondTrade-Off DiamondErgonomics Cost-Benefit Ergonomics Cost-Benefit Trade-Off DiamondTrade-Off Diamond

Often overlook ergonomic design and Often overlook ergonomic design and job aids.job aids.

Managers & commanders tend to Managers & commanders tend to overemphasize training and selection overemphasize training and selection as the cure – does as the cure – does notnot eliminate poor eliminate poor ergonomic design!ergonomic design!

Often overlook ergonomic design and Often overlook ergonomic design and job aids.job aids.

Managers & commanders tend to Managers & commanders tend to overemphasize training and selection overemphasize training and selection as the cure – does as the cure – does notnot eliminate poor eliminate poor ergonomic design!ergonomic design!

Ergonomics Cost-Benefit Trade-Off Ergonomics Cost-Benefit Trade-Off Diamond: Job Aid SolutionDiamond: Job Aid SolutionErgonomics Cost-Benefit Trade-Off Ergonomics Cost-Benefit Trade-Off Diamond: Job Aid SolutionDiamond: Job Aid Solution

Example: IBM Displaywriter Packing LineExample: IBM Displaywriter Packing Line

– Frequent errors in packing caused customer set-Frequent errors in packing caused customer set-up of the product to fail.up of the product to fail.

– Ergonomist analyzed problem and developed Ergonomist analyzed problem and developed large story board aid for each packing station.large story board aid for each packing station.

– Boards detailed & illustrated specific packing Boards detailed & illustrated specific packing steps.steps.

Example: IBM Displaywriter Packing LineExample: IBM Displaywriter Packing Line

– Frequent errors in packing caused customer set-Frequent errors in packing caused customer set-up of the product to fail.up of the product to fail.

– Ergonomist analyzed problem and developed Ergonomist analyzed problem and developed large story board aid for each packing station.large story board aid for each packing station.

– Boards detailed & illustrated specific packing Boards detailed & illustrated specific packing steps.steps.

Ergonomics Cost-Benefit Trade-Off Ergonomics Cost-Benefit Trade-Off Diamond: Job Aid SolutionDiamond: Job Aid SolutionErgonomics Cost-Benefit Trade-Off Ergonomics Cost-Benefit Trade-Off Diamond: Job Aid SolutionDiamond: Job Aid Solution

Example: IBM Displaywriter Example: IBM Displaywriter

Packing Line StoryboardsPacking Line Storyboards

Example: IBM Displaywriter Example: IBM Displaywriter

Packing Line StoryboardsPacking Line Storyboards

Management Awareness is CriticalManagement Awareness is CriticalManagement Awareness is CriticalManagement Awareness is Critical

Study by Ed Jones and myself of DoD Major Study by Ed Jones and myself of DoD Major System Development Programs.System Development Programs.

- Evaluated major DoD system development - Evaluated major DoD system development programs over a 10 year period in terms of whether programs over a 10 year period in terms of whether they had a good or poor ergonomics development they had a good or poor ergonomics development effort.effort.

- Found those with a poor effort had major problems - Found those with a poor effort had major problems when they became operational.when they became operational.

- Looked for what made the difference between - Looked for what made the difference between those with a good effort vs. those with a poor those with a good effort vs. those with a poor effort.effort.


- Evaluated major DoD system development - Evaluated major DoD system development programs over a 10 year period in terms of whether programs over a 10 year period in terms of whether they had a good or poor ergonomics development they had a good or poor ergonomics development effort.effort.

- Found those with a poor effort had major problems - Found those with a poor effort had major problems when they became operational.when they became operational.

- Looked for what made the difference between - Looked for what made the difference between those with a good effort vs. those with a poor those with a good effort vs. those with a poor effort.effort.



Results:Results:

- Major discriminating factor was ergonomics - Major discriminating factor was ergonomics awareness of the program director/commander.awareness of the program director/commander.

- Aware commanders appreciated value added of - Aware commanders appreciated value added of ergonomics -- and so allocated personnel ergonomics -- and so allocated personnel resources and funding to ergonomics. Those resources and funding to ergonomics. Those lacking knowledge of ergonomics did lacking knowledge of ergonomics did notnot . .


Results:Results:

- Major discriminating factor was ergonomics - Major discriminating factor was ergonomics awareness of the program director/commander.awareness of the program director/commander.

- Aware commanders appreciated value added of - Aware commanders appreciated value added of ergonomics -- and so allocated personnel ergonomics -- and so allocated personnel resources and funding to ergonomics. Those resources and funding to ergonomics. Those lacking knowledge of ergonomics did lacking knowledge of ergonomics did notnot . .



Results:Results:

-- Effective programs:Effective programs: Ergonomics was an Ergonomics was an integral part of the engineering design integral part of the engineering design

team.team.

- Ineffective programs:- Ineffective programs: Ergonomics was treated Ergonomics was treated as an “ility”, like reliability, maintainability, as an “ility”, like reliability, maintainability, etc.; only could make input after item was etc.; only could make input after item was already designed (band-aid changes only).already designed (band-aid changes only).


Results:Results:

-- Effective programs:Effective programs: Ergonomics was an Ergonomics was an integral part of the engineering design integral part of the engineering design

team.team.

- Ineffective programs:- Ineffective programs: Ergonomics was treated Ergonomics was treated as an “ility”, like reliability, maintainability, as an “ility”, like reliability, maintainability, etc.; only could make input after item was etc.; only could make input after item was already designed (band-aid changes only).already designed (band-aid changes only).


Study by Ed Jones and myself of DoD Major System Study by Ed Jones and myself of DoD Major System Development Programs.Development Programs.

LessonLesson

Establishing rapport with key managers and raising Establishing rapport with key managers and raising their consciousness about ergonomics is essential their consciousness about ergonomics is essential to your long-term success. to your long-term success.

This often takes time and persistence!This often takes time and persistence!

Study by Ed Jones and myself of DoD Major System Study by Ed Jones and myself of DoD Major System Development Programs.Development Programs.

LessonLesson

Establishing rapport with key managers and raising Establishing rapport with key managers and raising their consciousness about ergonomics is essential their consciousness about ergonomics is essential to your long-term success. to your long-term success.

This often takes time and persistence!This often takes time and persistence!

Participatory Ergonomics is Essential!Participatory Ergonomics is Essential!Participatory Ergonomics is Essential!Participatory Ergonomics is Essential!

Participatory ergonomics:Participatory ergonomics: Involve employees Involve employees at all levels to insure success.at all levels to insure success.

They know problems with their jobs best.They know problems with their jobs best.

They know what ergonomic alternatives will be They know what ergonomic alternatives will be most satisfying and acceptable to them.most satisfying and acceptable to them.

Get employee “buy-in” to changes. Get employee “buy-in” to changes.

Establishes a true Establishes a true ergonomic safety cultureergonomic safety culture – – the proven way to sustain improvement gains!the proven way to sustain improvement gains!

Participatory ergonomics:Participatory ergonomics: Involve employees Involve employees at all levels to insure success.at all levels to insure success.

They know problems with their jobs best.They know problems with their jobs best.

They know what ergonomic alternatives will be They know what ergonomic alternatives will be most satisfying and acceptable to them.most satisfying and acceptable to them.

Get employee “buy-in” to changes. Get employee “buy-in” to changes.

Establishes a true Establishes a true ergonomic safety cultureergonomic safety culture – – the proven way to sustain improvement gains!the proven way to sustain improvement gains!

Example: Participatory ErgonomicsExample: Participatory Ergonomics

Food Service Stand Redesign: Dodger StadiumFood Service Stand Redesign: Dodger Stadium

Example: Participatory ErgonomicsExample: Participatory Ergonomics


Example: Participatory ErgonomicsExample: Participatory Ergonomics Example: Participatory ErgonomicsExample: Participatory Ergonomics


ResultsResults

- Ergonomists Andrew Imada and Gorge Stawowy- Ergonomists Andrew Imada and Gorge Stawowy

redesigned two food service stands for a cost of redesigned two food service stands for a cost of

$40,000 using participatory $40,000 using participatory ergonomics.ergonomics.

- Reduced average customer transaction time - Reduced average customer transaction time

by 8 seconds.by 8 seconds.


ResultsResults

- Ergonomists Andrew Imada and Gorge Stawowy- Ergonomists Andrew Imada and Gorge Stawowy

redesigned two food service stands for a cost of redesigned two food service stands for a cost of

$40,000 using participatory $40,000 using participatory ergonomics.ergonomics.

- Reduced average customer transaction time - Reduced average customer transaction time

by 8 seconds.by 8 seconds.

Example: Participatory ErgonomicsExample: Participatory Ergonomics Example: Participatory ErgonomicsExample: Participatory Ergonomics


Results (continued)Results (continued)

- Increased productivity was $1,200 per baseball- Increased productivity was $1,200 per baseball

game, resulting in payback period of 33 games.game, resulting in payback period of 33 games.

- Payback period for modifying the other 50 stands - Payback period for modifying the other 50 stands

will be 20 games.will be 20 games.


Results (continued)Results (continued)

- Increased productivity was $1,200 per baseball- Increased productivity was $1,200 per baseball

game, resulting in payback period of 33 games.game, resulting in payback period of 33 games.

- Payback period for modifying the other 50 stands - Payback period for modifying the other 50 stands

will be 20 games.will be 20 games.

OSHA Guidelines* are the Key to OSHA Guidelines* are the Key to an Effective Ergonomics Programan Effective Ergonomics Program

OSHA Guidelines* are the Key to OSHA Guidelines* are the Key to an Effective Ergonomics Programan Effective Ergonomics Program

Are based on extensive researchAre based on extensive research

When OSHA ergonomics program When OSHA ergonomics program elements elements notnot present, ergonomics & present, ergonomics & safety program invariably safety program invariably notnot adequate. adequate.

*See OSHA 3123 E*See OSHA 3123 Ergonomics Program Management rgonomics Program Management Guidelines for Meatpacking PlantsGuidelines for Meatpacking Plants

Are based on extensive researchAre based on extensive research

When OSHA ergonomics program When OSHA ergonomics program elements elements notnot present, ergonomics & present, ergonomics & safety program invariably safety program invariably notnot adequate. adequate.

*See OSHA 3123 E*See OSHA 3123 Ergonomics Program Management rgonomics Program Management Guidelines for Meatpacking PlantsGuidelines for Meatpacking Plants

OSHA Guidelines are the Key to anOSHA Guidelines are the Key to an Effective ErgonomicsEffective Ergonomics ProgramProgram

OSHA Guidelines are the Key to anOSHA Guidelines are the Key to an Effective ErgonomicsEffective Ergonomics ProgramProgram

OSHA GuidelinesOSHA Guidelines

I. Management Commitment & EmployeeI. Management Commitment & Employee

InvolvementInvolvement

A. Commitment by Top Management -A. Commitment by Top Management -deeds, not just wordsdeeds, not just words

B. Written ProgramB. Written Program C. Employee InvolvementC. Employee Involvement D. Regular Program Reviews & EvaluationD. Regular Program Reviews & Evaluation


I. Management Commitment & EmployeeI. Management Commitment & Employee

InvolvementInvolvement

A. Commitment by Top Management -A. Commitment by Top Management -deeds, not just wordsdeeds, not just words

B. Written ProgramB. Written Program C. Employee InvolvementC. Employee Involvement D. Regular Program Reviews & EvaluationD. Regular Program Reviews & Evaluation

OSHA Guidelines are the Key to anOSHA Guidelines are the Key to an Effective Ergonomics Effective Ergonomics ProgramProgram


II. II. OSHA Program ElementsOSHA Program Elements

A. Worksite AnalysisA. Worksite Analysis

B. Hazard Prevention and ControlB. Hazard Prevention and Control

–Engineering ControlsEngineering Controls

–Work Practice ControlsWork Practice Controls

–Personal Protective EquipmentPersonal Protective Equipment

–Administrative Controls Administrative Controls

II. II. OSHA Program ElementsOSHA Program Elements

A. Worksite AnalysisA. Worksite Analysis

B. Hazard Prevention and ControlB. Hazard Prevention and Control

–Engineering ControlsEngineering Controls

–Work Practice ControlsWork Practice Controls

–Personal Protective EquipmentPersonal Protective Equipment

–Administrative Controls Administrative Controls



IIII. . OSHA Program Elements (Cont.)OSHA Program Elements (Cont.)

C. Medical ManagementC. Medical Management

D. Training and EducationD. Training and Education–General TrainingGeneral Training–Job-Specific TrainingJob-Specific Training–Training for SupervisorsTraining for Supervisors–Training for ManagementTraining for Management–Training for Engineers & Maintenance Training for Engineers & Maintenance

PersonnelPersonnel

IIII. . OSHA Program Elements (Cont.)OSHA Program Elements (Cont.)

C. Medical ManagementC. Medical Management

D. Training and EducationD. Training and Education–General TrainingGeneral Training–Job-Specific TrainingJob-Specific Training–Training for SupervisorsTraining for Supervisors–Training for ManagementTraining for Management–Training for Engineers & Maintenance Training for Engineers & Maintenance

PersonnelPersonnel




– Poor Example: Some warehouse Retail Poor Example: Some warehouse Retail

Stores – Program elements largely Stores – Program elements largely missing; many customer injuries. missing; many customer injuries.

– Good Example: Redwing ShoesGood Example: Redwing Shoes


– Poor Example: Some warehouse Retail Poor Example: Some warehouse Retail

Stores – Program elements largely Stores – Program elements largely missing; many customer injuries. missing; many customer injuries.

– Good Example: Redwing ShoesGood Example: Redwing Shoes

Insuring Effective ErgonomicsInsuring Effective Ergonomics Insuring Effective ErgonomicsInsuring Effective Ergonomics

OSHA GuidelinesOSHA Guidelines: Redwing Shoes: Redwing Shoes

– Implemented OSHA guidelines components.Implemented OSHA guidelines components.

ResultsResults

– From 1989 to 1995, workers compensation From 1989 to 1995, workers compensation dropped by 70% for a $3.1 million savings.dropped by 70% for a $3.1 million savings.

– OSHA reportable injuries dropped from ratio of OSHA reportable injuries dropped from ratio of 75 per 100 employees working per year, to 19.75 per 100 employees working per year, to 19.

OSHA GuidelinesOSHA Guidelines: Redwing Shoes: Redwing Shoes

– Implemented OSHA guidelines components.Implemented OSHA guidelines components.

ResultsResults

– From 1989 to 1995, workers compensation From 1989 to 1995, workers compensation dropped by 70% for a $3.1 million savings.dropped by 70% for a $3.1 million savings.

– OSHA reportable injuries dropped from ratio of OSHA reportable injuries dropped from ratio of 75 per 100 employees working per year, to 19.75 per 100 employees working per year, to 19.

Macroergonomics: The Key to Macroergonomics: The Key to Dramatic ImprovementsDramatic Improvements Macroergonomics: The Key to Macroergonomics: The Key to Dramatic ImprovementsDramatic Improvements

Macroergonomic interventions can dramatically improve health, safety, and Macroergonomic interventions can dramatically improve health, safety, and productivity (50% - 90% or more).productivity (50% - 90% or more).

Theoretical BasisTheoretical Basis

- - Systems theory:Systems theory: All complex systems are All complex systems are synergistic: When harmonized, whole more synergistic: When harmonized, whole more than the than the

sum of its parts.sum of its parts.

- Sociotechnical systems thus are more than the sum - Sociotechnical systems thus are more than the sum of of their parts.their parts.

- Therefore, macroergonomics can dramatically - Therefore, macroergonomics can dramatically improve improve thethe effectiveness sociotechnical systems.effectiveness sociotechnical systems.

Macroergonomic interventions can dramatically improve health, safety, and Macroergonomic interventions can dramatically improve health, safety, and productivity (50% - 90% or more).productivity (50% - 90% or more).

Theoretical BasisTheoretical Basis

- - Systems theory:Systems theory: All complex systems are All complex systems are synergistic: When harmonized, whole more synergistic: When harmonized, whole more than the than the

sum of its parts.sum of its parts.

- Sociotechnical systems thus are more than the sum - Sociotechnical systems thus are more than the sum of of their parts.their parts.

- Therefore, macroergonomics can dramatically - Therefore, macroergonomics can dramatically improve improve thethe effectiveness sociotechnical systems.effectiveness sociotechnical systems.


MacroergonomicsMacroergonomics

- ConceptuallyConceptually: A top-down sociotechnical : A top-down sociotechnical systems approach to work system designsystems approach to work system design

- - In PracticeIn Practice: It is top-down, middle-out, and : It is top-down, middle-out, and bottom-up (via participatory ergonomics).bottom-up (via participatory ergonomics).

MacroergonomicsMacroergonomics

- ConceptuallyConceptually: A top-down sociotechnical : A top-down sociotechnical systems approach to work system designsystems approach to work system design

- - In PracticeIn Practice: It is top-down, middle-out, and : It is top-down, middle-out, and bottom-up (via participatory ergonomics).bottom-up (via participatory ergonomics).


GoalGoal: : Achieve a fully harmonized work systemAchieve a fully harmonized work system

1. Design a work system’s structure and processes to 1. Design a work system’s structure and processes to be compatible with the key characteristics of its be compatible with the key characteristics of its

- Personnel subsystem- Personnel subsystem- Technological Subsystem- Technological Subsystem- External Environment- External Environment

Empirical models exist that enable us to accomplish Empirical models exist that enable us to accomplish this.this.

2. Design jobs, human-machine, human-software, and 2. Design jobs, human-machine, human-software, and human-environment interfaces to fully harmonize with human-environment interfaces to fully harmonize with the over-all work system designthe over-all work system design

GoalGoal: : Achieve a fully harmonized work systemAchieve a fully harmonized work system

1. Design a work system’s structure and processes to 1. Design a work system’s structure and processes to be compatible with the key characteristics of its be compatible with the key characteristics of its

- Personnel subsystem- Personnel subsystem- Technological Subsystem- Technological Subsystem- External Environment- External Environment

Empirical models exist that enable us to accomplish Empirical models exist that enable us to accomplish this.this.

2. Design jobs, human-machine, human-software, and 2. Design jobs, human-machine, human-software, and human-environment interfaces to fully harmonize with human-environment interfaces to fully harmonize with the over-all work system designthe over-all work system design


Macroergonomic interventions possible when:Macroergonomic interventions possible when:

–A major change in equipment, facilities or A major change in equipment, facilities or processes is to take place.processes is to take place.

–The organization is in real trouble.The organization is in real trouble.

–There is an enlightened management There is an enlightened management regarding ergonomics.regarding ergonomics.

–Micro-ergonomic successes have gained Micro-ergonomic successes have gained you management’s confidence.you management’s confidence.

Macroergonomic interventions possible when:Macroergonomic interventions possible when:

–A major change in equipment, facilities or A major change in equipment, facilities or processes is to take place.processes is to take place.

–The organization is in real trouble.The organization is in real trouble.

–There is an enlightened management There is an enlightened management regarding ergonomics.regarding ergonomics.

–Micro-ergonomic successes have gained Micro-ergonomic successes have gained you management’s confidence.you management’s confidence.


ResultResult

- A fully harmonized work system. A fully harmonized work system.

- Whole thus is more than a simple sum of its Whole thus is more than a simple sum of its parts – parts – SynergisticSynergistic..

- Consequently, dramatic improvements occur.Consequently, dramatic improvements occur.

ResultResult

- A fully harmonized work system. A fully harmonized work system.

- Whole thus is more than a simple sum of its Whole thus is more than a simple sum of its parts – parts – SynergisticSynergistic..

- Consequently, dramatic improvements occur.Consequently, dramatic improvements occur.

Example: Large Petroleum Distribution Example: Large Petroleum Distribution Company in U.S.Company in U.S.Example: Large Petroleum Distribution Example: Large Petroleum Distribution Company in U.S.Company in U.S.

Macro- and Micro-ergonomic InterventionMacro- and Micro-ergonomic Intervention Macro- and Micro-ergonomic InterventionMacro- and Micro-ergonomic Intervention


Macroergonomic InterventionMacroergonomic Intervention

- Macroergonomic analysis of work system.Macroergonomic analysis of work system.

- Developed strategic plan for improving safety Developed strategic plan for improving safety & productivity.& productivity.

- Made changes to work system where indicated.Made changes to work system where indicated.

- Participation at all levels.Participation at all levels.

Macroergonomic InterventionMacroergonomic Intervention

- Macroergonomic analysis of work system.Macroergonomic analysis of work system.

- Developed strategic plan for improving safety Developed strategic plan for improving safety & productivity.& productivity.

- Made changes to work system where indicated.Made changes to work system where indicated.

- Participation at all levels.Participation at all levels.


Micro-ergonomic InterventionMicro-ergonomic Intervention

- Worker participation at all levels.Worker participation at all levels.

- Employees (with ergonomist facilitator/resource person) Employees (with ergonomist facilitator/resource person)

- developed and taught truck safety program developed and taught truck safety program

- selected new equipmentselected new equipment

- identified problems and proposed ergonomic design identified problems and proposed ergonomic design changes to equipment & procedures.changes to equipment & procedures.

Micro-ergonomic InterventionMicro-ergonomic Intervention

- Worker participation at all levels.Worker participation at all levels.

- Employees (with ergonomist facilitator/resource person) Employees (with ergonomist facilitator/resource person)

- developed and taught truck safety program developed and taught truck safety program

- selected new equipmentselected new equipment

- identified problems and proposed ergonomic design identified problems and proposed ergonomic design changes to equipment & procedures.changes to equipment & procedures.


Macro- and Micro-ergonomics Intervention*Macro- and Micro-ergonomics Intervention*

ResultsResults Reductions AfterReductions After2 years2 years 9 Years 9 Years

Motor Vehicle AccidentsMotor Vehicle Accidents 51%51% 63%63%Industrial AccidentsIndustrial Accidents 54%54% 70%70%Lost WorkdaysLost Workdays 94%94% 97%97%

$ 60,000 savings per year in petroleum delivery costs.$ 60,000 savings per year in petroleum delivery costs.

* Imada (2002)* Imada (2002)


ResultsResults Reductions AfterReductions After2 years2 years 9 Years 9 Years

Motor Vehicle AccidentsMotor Vehicle Accidents 51%51% 63%63%Industrial AccidentsIndustrial Accidents 54%54% 70%70%Lost WorkdaysLost Workdays 94%94% 97%97%

$ 60,000 savings per year in petroleum delivery costs.$ 60,000 savings per year in petroleum delivery costs.

* Imada (2002)* Imada (2002)

Example: Macroergonomic Approach Example: Macroergonomic Approach to Implementing TQM at L.L. Bean to Implementing TQM at L.L. BeanExample: Macroergonomic Approach Example: Macroergonomic Approach to Implementing TQM at L.L. Bean to Implementing TQM at L.L. Bean


- Company ergonomists read my writings on - Company ergonomists read my writings on

macroergonomics and saw it as a potential macroergonomics and saw it as a potential

methodology for implementing TQM.methodology for implementing TQM.

- Used methods similar to Imada’s in Petroleum- Used methods similar to Imada’s in Petroleum

distribution company example.distribution company example.


- Company ergonomists read my writings on - Company ergonomists read my writings on

macroergonomics and saw it as a potential macroergonomics and saw it as a potential

methodology for implementing TQM.methodology for implementing TQM.

- Used methods similar to Imada’s in Petroleum- Used methods similar to Imada’s in Petroleum

distribution company example.distribution company example.

Example: Macroergonomic Approach Example: Macroergonomic Approach to Implementing TQM at L.L. Bean to Implementing TQM at L.L. BeanExample: Macroergonomic Approach Example: Macroergonomic Approach to Implementing TQM at L.L. Bean to Implementing TQM at L.L. Bean


ResultsResults

- 70% reduction in lost time accidents and - 70% reduction in lost time accidents and injuries achieved in two year period in both injuries achieved in two year period in both production and distribution divisions.production and distribution divisions.

- Other benefits, such as greater employee satisfaction,- Other benefits, such as greater employee satisfaction, also realized.also realized.


ResultsResults

- 70% reduction in lost time accidents and - 70% reduction in lost time accidents and injuries achieved in two year period in both injuries achieved in two year period in both production and distribution divisions.production and distribution divisions.

- Other benefits, such as greater employee satisfaction,- Other benefits, such as greater employee satisfaction, also realized.also realized.

Practical Application of ErgonomicsPractical Application of ErgonomicsPractical Application of ErgonomicsPractical Application of Ergonomics

ConclusionConclusion::

Good Ergonomics Good Ergonomics isis Good Economics Good Economics

AndAnd

Is a Key to Optimizing the Effectiveness of Is a Key to Optimizing the Effectiveness of our Armed Forces. our Armed Forces.

ConclusionConclusion::

Good Ergonomics Good Ergonomics isis Good Economics Good Economics

AndAnd

Is a Key to Optimizing the Effectiveness of Is a Key to Optimizing the Effectiveness of our Armed Forces. our Armed Forces.

practical application of ergonomics hal w. hendrick, ph.d., cpe practical application of ergonomics...

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