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.     

Prospective ergonomics: origin, goal, and prospects

So far ergonomics has been concerned with two categories of activities: correction and design. We propose to add a third category: prospection, and by so doing, we introduce a new series of activities that opens up the future of ergonomics. Corrective ergonomics relates to the past and comes with a demand and a client. It is turned towards the correction of existing situations and aims to reduce or eliminate problems. Here, after delimiting and defining the problem, the challenge is to find the best solution. Ergonomics for design relates to the present and also comes with a demand and a client. It is turned towards the design of new artefacts that have already been identified by a client, and that will allow users to do some activity and attain their goals. Here, after defining the scope of the project and the functional requirements, the challenge is to do the best design. Finally, prospective ergonomics relates to the future and does not come with a demand and a client. It is turned towards the creation of future things that have not been identified yet. Here the challenge is to detect existing user needs or anticipate future ones, and imagine solutions. These three categories of activities overlap and are not exclusive of each other. In this paper we define prospective ergonomics and compare it with corrective ergonomics and ergonomics for design. We describe its origin, goal, and prospects, we analyze its impacts on education and practice, and we emphasize the need of new collaboration between ergonomics and other disciplines.     

Ergonomics at Volkswagen Brasil. Multidisciplinary work to equalize health, productivity and quality

Following the technological developments and presented to the multidisciplinary processes as automakers, Volkswagen Brazil, represented by its ergonomists, through this paper, shows the importance of ergonomic efficiency of management applied to various levels of life of a product, since its creation to its final implementation on production lines.The preventive work of ergonomists during the processes leading to production of a vehicle is accomplished through assessments on a simulated system called the Digital Factory. Since the initial stages to final product delivery there is a need for a multidisciplinary aligning the concepts of ergonomics, productivity and quality of product. Industrial Engineering, Process Engineering, ergonomists and workers are involved in the analysis made through the Workshop's showing the importance of discussion between the various users of the systems. The processes of series are also equipped with a set of certifications flow of job and planned audits on items that describe processes and applied ergonomics.     

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.     

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.     

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.     

Successful integration of ergonomics into continuous improvement initiatives

Process improvement initiatives are receiving renewed attention by large corporations as they attempt to reduce manufacturing costs and stay competitive in the global marketplace. These initiatives include 5S, Six Sigma, and Lean. These programs often take up a large amount of available time and budget resources. More often than not, existing ergonomics processes are considered separate initiatives by upper management and struggle to gain a seat at the table. To effectively maintain their programs, ergonomics program managers need to overcome those obstacles and demonstrate how ergonomics initiatives are a natural fit with continuous improvement philosophies.     

Impact of increasing productivity on work content and psychosocial work characteristics in Chaku-Chaku assembly lines - a follow-up study in a German automotive manufacturing company

The current study aims at evaluating the reorganization of work processes on the basis of studies of three assembly lines in a well known component manufacture of the German automotive industry. It is of particular interest to evaluate the impact of the introduction of Chaku-Chaku assembly lines on the production goals, distribution of activities during one typical work day and psychosocial characteristics of the work environment. Findings indicate that the Chaku-Chaku assembly lines could represent a successful production strategy in order to enhance the output levels of work systems. However, the data show that interviewed assembly workers have spent more time on value added activities than before. The intensive perception of the time spent on main work activities (direct value added activities) and a simultaneous decrease of available discretionary time between work tasks seem to be related to the low level of the reported psychosocial work characteristics.     

Promoting ergonomics in Algeria: activities of "the research and training laboratory" in the University of Oran

The growing need in Algeria to develop ergonomics knowledge and practice in industry was behind the initiative to develop a training and research project within the ergonomics laboratory at Oran University. Since 2005 the laboratory team is running an academic option master in work design and ergonomics. The evaluation of the academic master in 2010 revealed the acute need of the local industry for professional competences in ergonomic and work psychology. A professional training master program in "ergonomics & work psychology" was then developed in partnership with local industry, five European Universities and six Universities from three Maghreb countries. Research projects were initiated around the two training programs, in conjunction with a number of ergonomics dissemination and promotion activities. Preliminary results of the project are presented and discussed in relation to the local context, and in the light of similar cases in Industrially Developing Countries.     

Hazard identification and pre-map with a simple specific tool: synthesis of application experience in handicrafts in various productive sectors

In August 2009, an international group was founded with the task of developing a "toolkit for MSD prevention" under the IEA and in collaboration with the World Health Organization.According to the ISO standard 11228 series and the new Draft ISO TR 12259 "Application document guides for the potential user", our group developed a preliminary "mapping" methodology of occupational hazards in the craft industry, supported by software (Excel?, free download on: www.epmresearch.org).The possible users of toolkits are: members of health and safety committees; health and safety representatives; line supervisors; foremen; workers; government representatives; health workers providing basic occupational health services; occupational health and safety specialists.The proposed methodology, using specific key enters and quick assessment criteria, allows a simple ergonomics hazards identification and risk estimation to be made. It is thus possible to decide for which occupational hazards a more exhaustive risk assessment will be necessary and which occupational consultant should be involved (occupational physician, safety engineer, industrial hygienist, etc.).The methodology has been applied in different situations of small and medium craftsmanship Italian enterprises: leather goods, food, technical dental work, production of artistic ceramics and stained glass, beekeeping activities. The results are synthetically reported and discussed in this paper.     

Understanding labour processes in global production networks: a case study of the football industry in Pakistan

ABSTRACT

Over the last few decades, the changing nature of global production and distribution processes has raised a number of critical questions regarding work and employment relations. Presenting a qualitative case study of the football industry in Pakistan as an example of the general mechanism of the social relations of re/production in a global system of industrial organization, this research highlights how and under what conditions informal workers are embedded in extended global production networks. By drawing on the integrated conceptual framework of the global production network (GPN) and labour process theory (LPT), this research sheds light on the working conditions and living realities of informal workers. A potential contribution of this paper is to extend the horizon of production network theory by analysing the work and employment conditions of informal workers, which are absent in existing discussions of these conceptual frameworks.     

Ergonomics and Kaizen as strategies for competitiveness: a theoretical and practical in an automotive industry

With increased international competitiveness in the automotive industry, came the concern of the companies save costs and lower production costs. For this purpose many ways are designed to reduce costs and waste of raw materials and reduce activities that do not aggregate value to manufacturing processes. In the early XVII appears the manufacturing system, which processes were hard with little concern for the health and safety of employees and conditions of the workplace. After the advent of the production system called lean manufacturing, a new paradigm in terms of production system capable of providing high levels of productivity and quality. It is based on waste elimination that occur during the production process. After began a new way of thinking, creating a culture of continuous improvement and lean process with no waste and reducing costs, without neglecting the welfare worker and improving the conditions of their work environment. This paper presents a reflection on the application of ergonomics in a lean production system of an automotive industry, using methodology based on the Kaizen (Continuous Improvement) to gain performance and improving the conditions of the workplace, also will be presented with positive and negative points in using this methodology in relation to ergonomics. The research will be conducted by collecting data 'in loco' and interviews with workers. Some studies show that in companies that are lean system and using the methodology of Kaizen, the results of product quality, levels of absenteeism and accidents are better than those obtained in companies that do not apply the same concept.     

New procedures of ergonomics design in a large oil company

This study presents the challenge involved in the negotiation and construction of a standard process in a major petroleum company that has the purpose of guiding the implementation of ergonomic studies in the development of projects, systemising the implementation of ergonomics design. The standard was created by a multi-disciplinary working group consisting of specialists in ergonomics, who work in a number of different areas of the company. The objective was to guide "how to" undertake ergonomics in all projects, taking into consideration the development of the ergonomic appraisals of work. It also established that all the process, in each project phase, should be accompanied by a specialist in ergonomics. This process as an innovation in the conception of projects in this company, signals a change of culture, and, for this reason requires broad dissemination throughout the several company leadership levels, and training of professionals in projects of ergonomics design. An implementation plan was also prepared and approved by the corporate governance, complementing the proposed challenge. In this way, this major oil company will implement new procedures of ergonomics design to promote health, safety, and wellbeing of the workforce, besides improving the performance and reliability of its systems and processes.     

Ergonomic analysis in cold storage rooms: a study of case

The human work possess a history and, in this dimension, the man is submitted to the conditions that confer it physical and psychological consequences. The activity of work in the present time imposes adverse labor conditions. The ergonomics is a science that it aims at to study the real activity of the work with sights its transformation. This study it was carried through in a sector of processing of meats in a Agroindustry, with the objective to analyze ergonomically the conditions of work and the possible risks it greets it of the workers. It was verified that in the accomplishment of the activities it had an overload of the musculature of superior members, where if it verified the requirement of repetitive movements during four working hours. Also observed the organization of the work, the position of the employees and way to carry through the activities. With the study we conclude that the ergonomic risks in the sector are related to the position during the accomplishment of the activities, requirement of repetitive movements, e the cold that affects the muscular control, reducing some motor abilities as the dexterity and the force.     

The importance of ergonomics to sustainability throughout a building's life cycle

Protecting and conserving environmental resources is a global concern. Over the past decade, a number of certification processes have emerged to help designers and operators of buildings assess the potential impact of a building on the environment. Certifications such as the Leadership in Energy and Environmental Design (LEED) consider the environmental impact through the lifecycle of a building, but may not be considering the people that construct and utilize it. It is important to remember the human factor. Considering the human factor throughout the lifecycle is crucial to ensure individuals are protected during construction and in operation in the built environment. The paper highlights how ergonomics can be integrated into the life cycle of a building to promote sustainability goals for both the human factor and the environment. A case study approach will be used to illustrate how ergonomics was integrated into a LEED renovation and expanded into its daily operations on a large university campus..     

Social responsibility and work conditions: building a reference label, Démarche T®

Corporate Social Responsibility (CSR) is now considered in large and global companies and the recent publication of the ISO 26000 standard clarifies the targets. Based on our consultancy's experience for fifteen years in ergonomics mainly in French small and medium enterprises, we developed a label to coax and value efforts of companies in dealing with health and safety at the work place as required by ISO 26000 paragraph 6.4. The formal approach of ISO describes what should be achieved but gives no cue on how actual conditions of work should be improved. The label, called Démarche T (ie Process W where W stands for work) aims the management of work conditions as a process, giving visibility and credit to companies for their continuous involvement in the matter. We describe the items and processes that are part of our assessment. We first conduct an ergonomic diagnosis including the analysis of records on health, physical and psychological well-being, observations at the workplace and interviews with the workers. This diagnosis is followed by recommendations. The fulfillment of these is assessed yearly. Items under assessment include: - ergonomics, health and safety in the companies statements and their impact in actual project management; - relations with workers through the committee for health and safety; - actual results on health, safety and work conditions. On a local level, we give the companies passing the label a competitive edge in recruiting better candidates motivated by good work conditions, and help them fulfill ISO 26000 requirements, an increasingly decisive advantage to benefit from public regional and European support. Our paper describes the diagnosis and follow-up process.     

Applying health determinants and dimensions in social work practice

Dimensions and determinants related to physical health, mental health and well-being can be used as tools in social work practice. These frameworks are useful for assessment, planning and intervention activities in complex client situations, alerting social workers to consider diverse features and processes that influence well-being in people's lives. They can be applied in social work with individuals, families, groups, and communities. In our view health and well-being need to be viewed holistically, broadly and in each unique situation, changing over time over the life course. Literature based on key word searches of concepts we use in our teaching and research and that has informed our conceptualisation of dimensions and determinants in physical health, mental health and well-being, is reviewed. A case illustration is presented to illustrate how the dimensions and determinants are used to inform practice and compare and apply alternative frameworks. Finally, the implications of these and other frameworks for social work, not only in health care settings, but also in other fields of social work practice, are discussed.     

Assessing human movement with accelerometry

The methods for measuring and evaluating human movement have advanced rapidly over the past 2 decades. The use of smaller, lighter, more powerful personal computers, digital video cameras and miniature, portable accelerometers have allowed the health professional, engineer, sports coach and scientist to very precisely record and quantify human movements on the sports field, in the business office, industrial setting and in the home. Most human motion analysis systems have evolved to meet the particular needs of the user. One such system that has developed over the past ten years in the Sport Science Laboratory at Dalhousie University is the Padlog series of accelerometer systems. This paper will discuss the development the Padlog systems at Dalhousie.     

ERGO-MTM model: an integrated approach to set working times based upon standardized working performance and controlled biomechanical load

ERGO-MTM is an innovative model to set standard times of manual tasks. MTM, developed in the forties by industrial engineers, assigns a basic time to execute a given motion based on the concept of normal performance (speed, effort and precision). The traditional models to set a standard time then add to the basic time a fatigue allowance, applied on each individual motion, depending generally on the type of posture and on the load/force implied in the motion. To the light of the most recent ISO/CEN standards dealing with biomechanical load, the traditional models do not meet the requirements any more: it becomes mandatory to consider the load generated by the overall assignment of working tasks to a workstation to be compliant with the new ergonomics standards. ERGO-MTM is the solution: it determines a fatigue allowance (named Ergonomic Allowance), which is applied on the total workstation basic MTM time to allow the necessary recovery periods, enough to keep the biomechanical load within safety limits. The final result is a standard time based on a norm level of performance and a work sequence with a controlled biomechanical load.