Ergonomics and workplace design: application of Ergo-UAS System in Fiat Group Automobiles

Since 2008 Fiat Group Automobiles has introduced Ergo-UAS system for the balancing of production lines and to detect ergonomic issues. Ergo-UAS system integrates 2 specific methods: MTM-UAS for time measurement and EAWS as ergonomic method to evaluate biomechanical effort for each workstation. Fiat is using a software system to manage time evaluation and ergo characterization of production cycle (UAS) to perform line balancing and obtain allowance factor in all Italian car manufacturing plant. For new car models, starting from New Panda, FGA is applying Ergo-UAS for workplace design since the earliest phase of product development. This means that workplace design is based on information about new product, new layout, new work organization and is performed by a multidisciplinary team (Work Place Integration Team), focusing on several aspects of product and process: safety, quality and productivity. This allows to find and solve ergonomic threats before the start of production, by means of a strict cooperation between product development, engineering and design, manufacturing. Three examples of workstation design are presented in which application of Ergo-UAS was determinant to find out initial excessive levels of biomechanical load and helped the process designer to improve the workstations and define limits of acceptability. Technical activities (on product or on process), or organizational changes, that have been implemented in order to solve the problems are presented. A comparison between "before" and "new" ergonomic scores necessary to bring workstations in acceptable conditions were made.     

Ergonomic considerations in school environments - the need for widening the scope

Behaviour patterns specific to children pose them at greater risk of environmental hazards than adults. Ergonomics is the science of matching human interaction with the proximate environment. Conventionally ergonomic principles were applied on adult work places to ensure safety of the working environment. With emerging scientific evidence, school environments are being a focus to apply ergonomic principles. Children spend more time within schools during critical developmental stages of their life. Everybody feels that the schools are safe places, but they are not. A multitude of ergonomic hazards have been identified in school settings. Widespread mismatches between anthropometry and school furniture, heavy schoolbag carriage and unhealthy bag behaviour are significant. Negative effects range from general tiredness, musculoskeletal pains, spinal deviations, shoulder level shifts, injuries and psychological disturbances. There are fragmented efforts to widen ergonomic concepts to health care professionals and other stakeholders of child health. Addressing ergonomic issues will ensure that children, the future productive generation contributing to economic growth and development of a country, are provided with opportunities in a healthy environment. This paper emphasizes the need for a concerted effort on widening the scope of ergonomics to cater for the evolving demand.     

Needs of ergonomic design at control units in production industries

During the last decades, an increasing use of innovative technologies in manufacturing areas was monitored. A huge amount of physical workload was replaced by the change from conventional machine tools to computer-controlled units. CNC systems spread in current production processes. Because of this, machine operators today mostly have an observational function. This caused increasing of static work (e.g., standing, sitting) and cognitive demands (e.g., process observation). Machine operators have a high responsibility, because mistakes may lead to human injuries as well as to product losses - and in consequence may lead to high monetary losses (for the company) as well. Being usable often means for a CNC machine being efficient. An intuitive usability and an ergonomic organization of CNC workplaces can be an essential basis to reduce the risk of failures in operation as well as physical complaints (e.g. pain or diseases because of bad body posture during work). In contrast to conventional machines, CNC machines are equipped both with hardware and software. An intuitive and clear-sighted operating of CNC systems is a requirement for quick learning of new systems. Within this study, a survey was carried out among trainees learning the operation of CNC machines.     

Analysis of the implementation of ergonomic design at the new units of an oil refinery

Ergonomic design is the adaptation of working conditions to human limitations and skills in the physical design phase of a new installation, a new working system, or new products or tools. Based on this concept, the purpose of this work was to analyze the implementation of ergonomic design at the new industrial units of an oil refinery, using the method of Ergonomic Workplace Assessment. This study was conducted by a multidisciplinary team composed of operation, maintenance and industrial safety technicians, ergonomists, designers and engineers. The analysis involved 6 production units, 1 industrial wastewater treatment unit, and 3 utilities units, all in the design detailing phase, for which 455 ergonomic requirements were identified. An analysis and characterization of the requirements identified for 5 of the production units, involving a total of 246 items, indicated that 62% were related to difficult access and blockage operations, while 15% were related to difficulties in the circulation of employees inside the units. Based on these data, it was found that the ergonomic requirements identified in the design detailing phase of an industrial unit involve physical ergonomics, and that it is very difficult to identify requirements related to organizational or cognitive ergonomics.     

Prevention of musculoskeletal disorders (MSDs) in office work: a case study

Twelve recently built office work stations, where jobs imply continued use of information and communication technologies, were analyzed for ergonomic risk factors. Based on a literature review of ergonomic recommendations for computer and general office work, a checklist was devised for assistance in identifying inadequate ergonomic situations, a process that was informed by pain complaints information. RULA (Rapid Upper Limb Assessment) was selected to estimate the risk of MSDs, considering the criteria of applicability and appropriateness to the case studied. This method was applied by an occupational health and safety technician to the most critical job observed in the workplace. Criticality was estimated through observations aided by the systematic use of a checklist tailored to the specific office scenario. Recommendations for change were provided for implementation in all workplaces in the office, in order to improve work conditions, and guide the setup of a MSD prevention training program.     

Global ergonomics strategy in Volkswagen: from the product construction, over the planning until the serial process

The Volkswagen Group operates and coordinates the activities of ergonomics from Wolfsburg in Germany and works with its contact persons of every plant and brand of the group towards an integrated proceeding relating to ergonomics. For the ergonomic process it is very important to consider the ergonomics in the whole production process, still from the beginning the conception and construction of the vehicle in the early phases. In these phases there is a big potential to work in the preventive ergonomics and avoid correcting the workstations after start of production. Therefore, it is important to have fluently information in all this phases and identify the potential in each of them. In order to attend these items, Volkswagen has defined different activity fields: coordination of ergonomic standards and the roll-out into all the plants, introducing the ergonomic items in the product development process (PEP), considering the constant improvement of the workplaces in the Volkswagen-Way (KVP and 3P Workshops), taking care of an adequate qualification concept in ergonomics and the intern and extern information exchange within the committees. This topic is established in the industrial engineering of the production area of the group. We are working interdisciplinary with the medical services, human resources, work council and the protection of labor.     

Evaluation of selected ergonomic assessment tools for use in providing job accommodation for people with inflammatory arthritis

Inflammatory arthritis (IA) is a leading cause of work disability, especially for those with jobs involving repetitive, hand-intensive or manual work. Ergonomic interventions may mediate against job loss. Our objective was to identify desirable features of an ergonomic tool for use in providing job accommodation for people with IA, and to evaluate a selection of ergonomic and rehabilitation tools against these features. Eight desirable features were compared across 16 assessment tools. None of the tools met all the pre-determined features. Ergonomic assessment tools should incorporate objective assessment of risk factors together with subjective perceptions of symptom aggravation, and identify risk factors that may not currently be causing problems, but may increase risk of aggravation or injury in the future. To accommodate the needs of people with IA, the tool should allow for evaluation of risks and generation of solutions without a worksite visit in situations where the client does not want to disclose their illness. Finally, an assessment tool needs to be applicable to a wide range of worksites, easy to use, valid, and reliable. Against these criteria, it appears that there is a lack of appropriate ergonomic assessment tools for use in people with IA.     

Ergonomic factors and production target evaluation in eucalyptus timber harvesting operations in mountainous terrains

There are several forest operations involved in Eucalyptus timber harvesting. This study was carried out during brush-cutting; tree felling, bucking, delimbing, piling and manual extraction operations, with the following objectives: a) analyzing, ergonomically, two systems of brush-cutting: one manual and the other semi-mechanized, using two different machines; b) ergonomically evaluating three different brands of pruner machines used in delimbing felled trees. c) determining the feasible target of productivity as a function of ergonomic factors relevant to establish the time of resting pauses for workers in manual and semi-mechanized timber harvesting systems in mountainous terrain. Brush-cutting, either manual or semimechanized, is an activity carried out prior to timber harvesting. It is usually a hard work, with low productivity when compared with mechanized systems. Pruner machines have been used by forest companies, due to the great possibilities to improve productivity, quality and the health of workers. Ergonomics is a discipline that promotes the adequacy of work to the physical and mental characteristics of human beings, seeking to design production systems and products considering relevant aspects, including social, organizational and environmental factors. Companies should consider the ergonomic factor in the determination of daily worker production targets.     

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.     

Ergonomic initiatives at Inmetro: measuring occupational health and safety

This work studies biomechanical hazards to which the workforce of Instituto Nacional de Metrologia, Qualidade e Tecnologia Industrial (Inmetro) is exposed. It suggests a model for ergonomic evaluation of work, based on the concepts of resilience engineering which take into consideration the institute's ability to manage risk and deal with its consequences. Methodology includes the stages of identification, inventory, analysis, and risk management. Diagnosis of the workplace uses as parameters the minimal criteria stated in Brazilian legislation. The approach has several prospectives and encompasses the points of view of public management, safety engineering, physical therapy and ergonomics-oriented design. The suggested solution integrates all aspects of the problem: biological, psychological, sociological and organizational. Results obtained from a pilot Project allow to build a significant sample of Inmetro's workforce, identifying problems and validating the methodology employed as a tool to be applied to the whole institution. Finally, this work intends to draw risk maps and support goals and methods based on resiliency engineering to assess environmental and ergonomic risk management.     

Ergonomic risks in mining companies: a study in Paraiba/Brazil

The growing concern for the welfare of workers in the work environment, the importance of widespread use of ergonomics in the different sectors of industry. Yet most corporate practices that work with rudimentary or great need for human handling of materials is not fully in line with the ergonomic aspects. Given this, this article aims to identify ergonomic hazards in mining to later propose improvements in the process. After a series conducted plant visits, found that workers are exposed to various ergonomic risks, which entails the need for new healthy practices in the workplace. Finally, a series of proposals are submitted in order to avoid possible occupational diseases.     

Managing ergonomics in the development of rotation between workstations in the automotive industry. A balance between health and traceability of tasks

Abstract When the subject rotation between workstations (job rotation) is inside the organizations it's seemed that technically there are lots of restrictions to the development of an adequate system of rotation. We went from the need for an advanced ergonomic study and even possible restrictions of versatility and training of employees. The implementation of the ideal system of rotation passes through stages of development and research ergonomic study of the level of employee versatility, awareness and discussion with employees, implementation of the proposed system, feedback and audits for maintenance of the ideal sequence and time of rotation. For the success of the project there is a need for multidisciplinary involvement in the areas of manufacturing engineering, industrial engineering, human resources, medical services and manufacturing. Rotation between the tasks may mean that a worker should conduct two or more different activities in different parts of the day (ie. change between activity A and activity B "between 1 hours and 2 hours interval). An important consideration is to ensure that different activities do not present the same ergonomic risk for the same body part. The tracing of the execution of the activity is an important factor for production processes. Thus it is possible to conduct appropriate levels of training for employees and ensure safe and sustainable processes in terms of workers' health, productivity and quality.     

Multi dimensional system for evaluating preventive program for upper extremity disorders among computer operators

Typing is associated with musculoskeletal complaints (MSCs), caused by multiple risk factors. Although a wide variety of ergonomic intervention programs were conducted to reduce risk factors and MSC's, only few of them were found evidence based. This study aimed to test the efficacy of a workplace intervention in reducing MSC's among computer workers. 66 computer workers were assigned randomly to one of three intervention programs: ergonomic intervention including biofeedback, intervention without biofeedback and control group without intervention. The efficacy was tested by advanced assessment including; pain location and severity, posture at work, upper extremity 3D kinematics, muscle activity and psychosocial status. Working hypothesis; significant score differences will be found between the study groups which underwent ergonomic intervention and the control group on the following measures: pain complaints, upper extremity kinematics, muscle activity and psychosocial status. Significant differences were found between pre and post intervention and between research groups and the control group in pain, posture and motion. The ergonomic intervention with biofeedback had no unique contribution in comparison to other interventions. In conclusion; the proposed intervention program was found efficient for reducing pain among computer workers.     

Psychosocial risks: acting upon the organisation by ergonomic intervention

In this paper we discuss the possibilities of acting on psychosocial risk (PSR) factors by modifying the way in which an organisation operates. On the basis of an ergonomic intervention in an insurance company, we were able to show that the health problems observed by the operators were mainly the result of their inability to produce work of quality. Next, our analyses revealed the links between poor perceived quality, production difficulties and the rigidity of the organisational structure. After setting up working groups to deal with production difficulties, we were able to identify and test an organisational form that was better adapted to managing day-to-day production constraints and which was ultimately better able to be attentive to individual difficulties which had given rise, in the long term, to intrapsychic conflicts.     

Evaluation and control of ergonomics actions in federal public service: the case of FIOCRUZ-RJ

This article presents information about the development of the dissertation. Deals with the production of ergonomic diagnosis in the environments and work processes of an important center of research and development in Public Health, FIOCRUZ. Critically evaluates the performance of a team promoting and facilitating the process of implementing ergonomic changes suggested. Through analysis of documents and statements by some managers and representatives of Human Resources was possible to identify the factors that facilitate and hinder the implementation process, linking them to the organization of the institution and conduct of the agents involved. Finally, it makes a reflection on practice, results and developments involved in the processes of change initiated by the ergonomic actions, proposing its replication along with other institutes of the Civilian Personnel of Federal Public Administration.     

Ergonomic evaluation of the preparation of cuttings and minicuttings for eucalyptus seedling production, with the use of scissors

This study was conducted in a nursery for eucalyptus seedling production in a forest Company, located in the southern state of Bahia, Brazil. It aimed to evaluate the ergonomic conditions of the preparation of cuttings and mini-cuttings with scissors for Eucalyptus seedling production to increase well-being, satisfaction and safety and minimizing the occurrence of occupational diseases, also improving the process efficiency and final product quality. Environmental conditions, levels of noise, postures, RSI risk and physical workload were assessed. The environmental conditions complied with the recommended norms, except at certain times of day, when workers should make compensation breaks. The workers that collect minicuttings presented postures classified as normal by OWAS. On the other hand, the posture of workers dealing with cutting preparation requires corrections in a short run. The workers were subjected to moderate RSI risk due to the high degree of repeatability found. The physical workload was classified as mild, with no need for ergonomic interventions.     

Features and limitations of digital human models--a new German guideline

In 2008 the Association of German Engineers (VDI) published the first part of the VDI 4499 guideline for methods and tools for the digital factory. Part 1 of this guideline deals with the fundamentals of the system and will be expanded by the addition of further parts on specific topics within the digital factory. Soon to be published is Part 4 which covers human models as tools of the digital factory. It describes the state of the art of current digital human models with regards to the methods and procedures implemented in German speaking countries. The structure of this part of the guideline is based on the different sections of engineering mechanics and outlines the opportunities for ergonomic assessments and the evaluation of work systems. During the writing of the guideline, the restrictions of the existing procedures also became evident thus showing the requirement for further development of such procedures. This is illustrated in this paper using examples from commercial software systems.     

The reality of the women who make our lives easier: experience in a company that assemblies electric motors in Venezuela

Objective: intervene a workline throughout ergonomic approach to diminish incidence of Carpal Tunnel Syndrome (CTS). Methods and Materials: an ergonomic intervention study was developed in workstations with highest index of musculoskeletal disorder (MED) associated to cumulative trauma. The Deparis method, Reba and Ocra check list methods were used, also morbility reviewes. National and international ethics criteria were carried out. Results: workers identified 3 fundamental issues using the Deparis method: repetitive activities, postures adopted and uncomfortable furniture. The analysis of the workstation with Reba and Ocra methods before the changes, evidenciated that 56% of postures adopted were high risk postures, the 44% remaining were medium and low-risk. Following the active pause program (APP), furniture changes and work rhythm decrease, was noted that the risk of suffering MED decreased. The morbility review, drop in consults of musculoskeletal system (MES) related to CTS observed. The APP was well accepted by women, but not initially men. Discussion: the research show that when the work rhythm decreases, the symptom of MES related to CTS have a remarkable decrease, also that changes in the furniture, generate great ergonomic differences and changes in the work environment are not possible if workers don't empower the tools to make-it.     

Ergonomic risk assessment with DesignCheck to evaluate assembly work in different phases of the vehicle development process

Occupational hazards exist, if the design of the work situation is not in accordance with ergonomic design principles. At assembly lines ergonomics is applied to the design of work equipment and tasks and to work organisation. The ignoring of ergonomic principles in planning and design of assembly work leads to unfavourable working posture, action force and material handling. Disorders of the musculoskeletal system are of a common occurrence throughout Europe. Musculoskeletal disorders are a challenge against the background of disabled workers. The changes in a worker's capability have to be regarded in the conception of redesigned and new assembly lines. In this way ergonomics becomes progressively more important in planning and design of vehicles: The objective of ergonomic design in different stages of the vehicles development process is to achieve an optimal adaptation of the assembly work to workers. Hence the ergonomic screening tool "Design Check" (DC) was developed to identify ergonomic deficits in workplace layouts. The screening-tool is based on the current ergonomic state of the art in the design of physical work and relevant EU legal requirements. It was tested within a federal German research project at selected work stations at the assembly lines at Dr.-Ing. h.c. F. Porsche AG / Stuttgart. Meanwhile the application of the screening-tool DC is transferred in other parts of the Porsche AG, Stuttgart. It is also realized as an ergonomic standard method to perform assembly work in different phases of the vehicle development process.     

An ergonomic approach to design hand tool for agricultural production

Hand tool mechanisms designed to reduce the risk factors have rarely been studied. In this paper it is analyze trowel firstly designing in CATIA and then its Finite Element Analysis has been carried out by ABAQUS. The main emphasis is on finding stresses by using this software, then removing them by suitable mechanical working on tool & ergonomic change in the design of handle to make it more comfortable. Body part discomfort score and overall discomfort rating experienced by the subjects had also been estimated. During the muscular activity workers physiological responses i.e. energy expenditure rate, oxygen consumption rate and heart rate increases. This increase in physiological responses is related to the type, intensity and duration of work and thus sets limits to the performance of heavy work. In this paper oxygen consumption rate and heart rate was used for physiological cost estimation. These parameters were measured by Computerized Ambulatory Metabolic Measurement System K4b2.