Participatory ergonomic intervention for prevention of low back pain: assembly line redesign case

This paper gives an overview of a participatory ergonomic intervention aimed at reducing low back pain cases in the dispatch department of a catalogue and e-commerce retail company. Based on the findings of the ergonomic analysis and design committee, the company's own employees redesigned the assembly line's layout. As a result of these changes two job tasks that involved manual material handling of boxes, identified by the revised NIOSH equation as posing an increased risk for lifting-related low back pain, were totally eliminated, and the employees responsible for moving boxes from the end of the assembly line to pallets on the ground were given more control over their jobs, and these jobs were also enriched with a new, less heavy task. These results demonstrate that participatory ergonomic interventions are a viable and effective strategy to reduce the exposure to work-related physical and psychosocial risk factors for low back pain.     

Comparison of the Rapid Entire Body Assessment and the New Zealand Manual Handling 'Hazard Control Record', for assessment of manual handling hazards in the supermarket industry

This is a case study comparing the use of two different assessment tools (Rapid Entire Body Assessment versus New Zealand Manual Handling Hazard Control Record) to assess, plan and implement changes in manual handling practices in the supermarket industry. Existing manual handling practices being used within these supermarkets were assessed using each of these tools. The most hazardous tasks were revised to improve work methods and reviewed again using both tools, to determine the usefulness and effectiveness of these tools. The process generated considerable discussion regarding the benefits and drawbacks of each tool. The usefulness of each tool appears dependant on the reason for assessment and the anticipated outcome. REBA may be more useful if specific ergonomic or biomechanical changes are being implemented to decrease risk of work-related injury (particularly if an objective numeric score is required for re-assessment following modifications, to determine their effectiveness). The New Zealand Code of Practice for Manual Handling 'Hazard Control Record' Risk Score analysis process lacks specificity and objectivity, however it is less reductionistic and takes into account many factors other than biomechanics and ergonomics. It directs the user toward implementing controls, which are thorough, multi-factorial and useful to control hazards relating to several other areas, including task, load, environment, people and management factors.     

EADS - Ergonomics Affinity Design System

The Ergonomics Affinity Design System (EADS) is a systematic problem-solving tool used to analyze and solve ergonomics issues. The basis of EADS is the identification and ranking of affinities or relationships that exist among the factors that influence job performance in the workplace. The five-step system can be applied to the workplace at varying levels of complexity based on need. It can be used at the design phase or in a redesign/modification application. Applicable for use in any work environment, the system can be an important part of the overall ergonomics process.     

The ergonomics approach for thin film transistor-liquid crystal display manufacturing process

The thin film transistor-liquid crystal display (TFT-LCD) has been used all over the world. Although the manufacture process of TFT-LCD was highly automated, employees are hired to do manual job in module assembly process. The operators may have high risk of musculoskeletal disorders because of the long work hours and the repetitive activities in an unfitted work station. The tools of this study were questionnaire, checklist and to evaluate the work place design. The result shows that the participants reported high musculoskeletal disorder symptoms in shoulder (59.8%), neck (49.5%), wrist (39.5%), and upper back (30.6%). And, to reduce the ergonomic risk factors, revising the height of the work benches, chairs and redesigning the truck to decrease the chance of unsuitable positions were recommended and to reduce other ergonomics hazards and seta good human machine interface and appropriate job design.     

Prevention of MSD by means of ergonomic risk assessment (tools) in all phases of the vehicle development process

In industrialized countries musculoskeletal disorders (MSD) play an import role and are often responsible for almost one third of the total sick leave. The changes in the demographic profiles, i.e. aging work forces might even worsen this situation in the future. For a highly productive and sustainable use of human resources in production systems, ergonomics offers high potentials. In the recent years the authors have developed several ergonomic risk assessment tools, especially for the use in automotive industries. These methods may be used during the planning phases in the Tech Centers as well as during the production phase at shop floor level. The tools might also be used for a standardized communication in between the Tech Center and the plants to improve the effects of "lessons learned" for the design and layout of workstations and processes and the optimization of vehicle components. This paper describes suitable risk assessment tools as well as the integration of these tools into the vehicle development process. It introduces a comprehensive management approach for the integration of ergonomics into the management of production systems.     

Intermediary objects in the workspace design process: means of experience transfer in the offshore sector

The aim of this paper is to discuss the use of intermediary objects in the workspace design process of offshore accommodations module. The integration of ergonomics in the design process can lead to better work conditions, more effectiveness in the work process and less health and safety issues. Moreover, it is more efficient in terms of cost if ergonomics is considered from the initial phases of the project, as the potential costs of the redesign, the possible losses and the down-time in the operation of the platform would be more increased. The goal, then, is to discuss the integration of ergonomics and users involvement in the design process of accommodations modules, focusing on the transfer of information from reference situations by the use of intermediary objects during the process. In this paper we will present two tools developed to be used as intermediary object(s) aiming at transferring the experience from the use to the design in the specific field of offshore accommodations module.     

Ergonomic analysis of the use of open-plan offices in Brazilian public sector offices

The open-plan office is a layout used in government offices in Brazil aimed at saving on space occupied and integrating employees. However, the design of these work-stations must follow the characteristics of tasks and their interrelationships, since adverse physical and organizational conditions may have a negative impact on work productivity. From this perspective, this study sought to identify, from the viewpoint of the ergonomics of the built environment, the adequacy of the open-plan government offices for financial auditing accounts and analyzing documents. Use was made of the Ergonomic Methodology for Evaluating the Built Environment--MEAC (in Portuguese) which systematically analyzes the physical space, by using a mix of physical-spatial assessments and tools for identifying how the environment is perceived. The MEAC was employed in three analytical phases of the physical aspects, namely: an analytical phase of the user's perception; a diagnostic phase; and a final phase of propositions.     

Musculoskeletal injuries associated with selected university staff and faculty in an office environment

A research team with backgrounds in occupational therapy, rehabilitation, policy and rulemaking, and prevention programs affecting occupational health and safety designed, validated, and analyzed an ergonomics survey of university staff and faculty. The purpose of the study was to validate identified risk factors from the literature contributing to work-related musculoskeletal disorders (WRMDs) in an office setting within a university setting. The study was also designed to determine differences between faculty and staff in the university setting and their exposure to physical risk factors to WRMDs. The results suggest faculty have their keyboard in awkward positions more frequently than staff, and staff had more experience with mechanical stress than faculty. The researchers recommend parameters for the design of a university ergonomics program based on employee and education, management commitment, medical case management, problem job identification, and development of solutions.     

Ergonomic design of crane cabins: a case study from a steel plant in India

The study, carried out at the Batch Annealing Furnace (BAF) shop of Cold Rolling Mill (CRM) at an integrated steel plant of India, concerns ergonomic evaluation and redesign of a manually-operated Electrical Overhead Travelling (EOT) crane cabin. The crane cabin is a complex worksystem consisting of the crane operator and twelve specific machine components embedded in a closed workspace. A crane operator has to perform various activities, such as loading and unloading of coils, setting and removal of convector plates, and routine maintenance work. Initially, an operator had to work in standing posture with bent back most of the time. Ergonomically poor design of the chair and the controls, awkward work postures, and insufficient vision angle resulting in musculoskeletal disorders (MSDs) are some of the critical problems observed.. The study, conceived as an industry-academia joint initiative, was undertaken by a design team, the members of which were drawn from both the company concerned and the institute. With the project executed successfully, a number of lessons, such as how to minimize the anthropometric mismatch, how to improve the layout of the components and controls within enclosed workspace, and how to improve work posture minimizing risk of MSDs have been learned.     

Ergonomic design intervention strategy for work tools development for women agro based workers in Northeast India

Strategy for finding the appropriate strategy for work tool development has become a crucial issue in occupational wellness of varied nature of women workforce of Northeast India. This paper deals with ergonomics intervention through sustainable work tool design development process. Workers who frequently shift to different activities quite often in unorganised small-scale fruit processing units where productivity is directly related to the harvesting season require different work tools relevant to specific tasks and mostly workers themselves manage work tools of their own with available local resources. Whereas in contrast the tea-leaf pluckers are engaged in a single task throughout the year, and the work schedule and work equipment is decided and supplied to them based on the corporate decision where the workers do not have any individual control. Observations confirm the need for organising participatory workshops specific to trade based occupational well-being and different work tools for different tasks in mostly private owned unorganised sector. Implementation of single variety work tool development that supports a crucial component in tea-leaf plucking for which they are engaged in full time employment; and through a corporate decision a single design with its number of users makes a good effect.     

Blueprint for ergonomics

Worker safety and health, and productivity and efficiency on the job can be greatly impacted by the application of ergonomics. This article outlines the decision making process for implementing ergonomic change in the workplace. Ergonomic principles, as well as risk factors for the upper extremity and low back are identified. Three ergonomic measurement methods are presented including the National Institute for Occupational Safety and Health (NIOSH) 1991 Revised Lifting Guidelines, Rodgers's Functional Job Analysis Technique, and the Moore and Garg Strain Index. Ergonomic solutions are discussed and additional factors to consider when designing ergonomic changes are identified.     

A toolkit for MSDs prevention--WHO and IEA context

Many simple MSD risk management tools have been developed by ergonomists for use by workers and employers with little or no training to undertake injury prevention programs in their workplace. However, currently there is no "toolkit" which places such tools within an holistic, participative ergonomics framework and provides guidance on how best to use individual tools. It is proposed that such an holistic approach should entail initial analysis and evaluation of underlying systems of work and related health and performance indicators, prior to focusing in assessment of MSD risks stemming from particular hazards. Depending on the context, more narrowly focused tools might then be selected to assess risk associated with jobs or tasks identified as problematic. This approach ensures that biomechanical risk factors are considered within a broad context of organizational and psychosocial risk factors. This is consistent with current research evidence on work- related causes of MSDs.     

Ergonomic evaluation of a wheelchair transportation securement system

The Americans with Disabilities Act (ADA) specifies guidelines covering the securement system and environment for wheeled mobility device (WhMD) passengers on the public bus system in the United States, referred to as the wheelchair tiedown and occupant restraint system (WTORS). The misuse or disuse of the WTORS system can be a source of injury for WhMD passengers riding the buses. The purpose of this study was to quantify the risks posed to the bus driver while performing the WTORS procedure using traditional ergonomic analysis methods. Four bus drivers completed the WTORS procedure for a representative passenger seated in three different WhMDs: manual wheelchair (MWC), scooter (SCTR), and power wheelchair (PWC). Potential work-related risks were identified using the four most applicable ergonomic assessment tools: PLIBEL, RULA, REBA, and iLMM. Task evaluation results revealed high levels of risk to be present to drivers during the WTORS procedure. The securement station space design and equipment layout were identified as contributing factors forcing drivers to adopt awkward postures while performing the WTORS task. These risk factors are known contributors to injury and the drivers could opt to improperly secure the passengers to avoid that risk.     

Design and implementation of a novel tool addresses the greatest cause of wrist injuries at Bayer Healthcare

Sanitary clamp wingnut manipulation is the fifth most frequent cause of injuries in the production areas of the Bayer Healthcare site in Berkeley, California. Task analysis showed that manual manipulation of clamp wingnuts had concurrent multiple risk factors, including: awkward postures, high forces, contact stresses, and high frequency. Task elimination was not an option. Several tools on the market were researched and tried but it was found that no existing tools would alleviate the associated ergonomics risk factors. An interim tool found on the market was used as a short term solution until an optimal design could be manufactured. A tool was designed, fabricated, and tested in-house at the Bayer machine shop. The tool was originally designed to fit all variations of clamp wingnuts, but then was found to fit too loosely for some. By using a comparison between inventory and cost benefit analysis it was decided to standardize the wingnuts types leaving the two most common types. A final prototype of the tool fit these two types of wingnuts. The efficient methods by which clamps were replaced and how tools were implemented in cleanroom manufacturing areas are described in this paper. This ten month project potentially eliminated all of the ergonomics risk factors associated with clamping.     

Ergonomics and the inclusion of disabled people in the Brazilian job market

The inclusion of persons with disabilities (PD) has been widely discussed in Brazil. The main purpose of this paper is to identify the contributions of ergonomics in the process of including disabled people in the job market and to discuss the situation in Brazil. It was found that ergonomics is an important tool within organizations. Using it allows space, work stations and tools to be matched workers' needs, including those with disabilities, on behalf of whom it is necessary to adjust the demands of work to their specific needs. However, further research is needed in Brazil on the existing methods of ergonomic intervention for this population in order to suit their needs and optimize potential.     

A collaborative effort to apply ergonomics to electric utility workers at generating stations

As part of a collaborative approach involving electric utility companies, university researchers, individual contractors and a not-for-profit research institute, two ergonomics teams consisting of skilled utility workers and trained ergonomists, were assembled. These teams were to identify tasks with risk factors for musculoskeletal disorders (MSDs) among workers in fossil-fueled generating stations and and to propose ergonomic interventions for these tasks. One team focused on tasks of electricians and the other focused on tasks of plant operators and mechanics. Several of the tasks were tested in an ergonomics laboratory and at one of the utility's generating stations. We present a sample of the recommended interventions in this paper. An anthropometric analysis of electrical box height recommended the appropriate height for electrical boxes. The results of a field experiment showed that low rolling resistance wheels decreased the forces to initiate and sustain pushing a cart. The same experiment also demonstrated that the forces required to turn a cart with six wheels were lower than the forces equired to turn a cart with four wheels. A collaborative approach to ergonomics proved to be an effective method to identify and assess tasks that are problematic for workers and to develop best practices for these tasks in the electric power industry. This method could be used by other industries in their attempt to decrease the incidence, cost and severity of workplace MSDs.     

Prevalence of musculoskeletal disorders among staffs in specialized healthcare centre

This study was conducted to investigate pervasiveness of the musculoskeletal disorder (MSD) among staffs in a specialized healthcare centre. Sixty-eight staffs from three departments namely Cardiovascular Lab (CVL), Nuclear Radiology, and General Radiography were recruited in this study. A modified Nordic Musculoskeletal Questionnaire (NMQ) was distributed among study population. The result shows that the prevalence of MSD was highest in lower back (88.2%), neck (76.5%) and shoulder (60.3%) for the past 12 months followed by lower back and elbow (44.1%), and wrist (39.1%) correspondingly, for the past 7 days. Present results suggest that healthcare professionals - radiographers, patient assistants and nurses incurs MSD risks through work tasks as well as psychosocial factors. These include awkward posture during patient handling, workload, work stress and time pressure. Therefore, an ergonomics improvement on the job design and workspace are needed in order to reduce the MSD risks.     

Occupational lifting tasks as a risk factor in low back pain: a case-control study in a Mexican population

The objective of this study was to quantify and assess whether lifting tasks in the workplace are a risk factor in lumbar spondyloarthrosis etiology. A case-control study was performed with 231 workers, 18-55 years old, insured by the Mexican Social Security Institute (IMSS, according to its designation in Spanish). A multivariate analysis using conditional logistical regression showed that lifting tasks, combined with driving tasks, are associated with this illness (OR = 7.3; 95% CI 1.7-31.4). The daily frequency of lifting as it interacts with work as a driver resulted in a greater risk (OR = 10.4; 95% CI 2.0-52.5). The load weight, daily task-hours and cumulative time showed a dose-response relationship. The attributable risk for lifting tasks was 0.83, suggesting that 83% of lumbar spondyloarthrosis development could be prevented if risk factors were eliminated by ergonomic redesign of the task.     

The gap between exposure and implementation of computer workstation ergonomics in the workplace

The population of people using computers is increasing in home, school and work environments [20,21]. Research suggests that more computer usage may lead to increased incidence of upper extremity cumulative trauma disorder (UECTD) and other work related musculoskeletal injuries [8]. Yet, proper computer workstation ergonomics training is not readily available. This pilot study attempts to better understand the gap between ergonomic interventions and the initiation of work-practice change. The pilot study used self-report through an anonymous Internet survey to explore university faculty and staff training in computer workstation ergonomics, assess UECTD and other computer-use related symptoms, and learn about the respondents' success implementing their knowledge of computer workstation ergonomics. The 55 respondents ranged in age from 21 to 65, and spent an average of 5.3 hours at the computer during a typical workday. Over 70% of respondents experienced symptoms associated with excessive computer use. Although 60% of respondents had exposure to computer workstation ergonomics information, less than 10% reported implementing their knowledge of computer workstation ergonomics in their tasks. This paper looks at organizational and individual issues preventing the implementation of computer workstation ergonomics in the workplace. The Transtheoretical Model for Health Behavior Change [25,27] is used to further evaluate effectiveness of ergonomic interventions. Recommendations for interventions and future evaluations are presented.     

30 years of ergonomics at 3M: a case study

The added value of the Ergonomics Program at 3M was found to be improved employee safety, compliance with regulations and reduction of work-related illness, increases in productivity, and quality and operating efficiency. This paper describes the thirty years of existence of this program. For the first twenty years, the program objectives were to: respond to requests for assistance related to work-related musculoskeletal disorder (WMSD) concerns, raise employee awareness of MSDs and ergonomics; educate engineers in ergonomics design; and develop ergonomics teams at manufacturing locations. Since the year 2000, 3M's Ergonomics Program has been in transition from a US-centric and corporate-based technical-expertled program to a global program applying participatory ergonomics strategies within a macroergonomics framework. During that transition, the existing program requirements were revised, new methods and program tools were created, and expectations for implementation at the manufacturing locations clarified. This paper focuses on the company's manufacturing ergonomics program activities during the past ten years and includes specifics of the program's objectives, risk assessment reduction process, and ergonomics technical expertise development. The main benefit achieved throughout the company is reducing employee injury while also increasing productivity and operating efficiency.