Design and implementation of ergonomic performance measurement system at a steel plant in India

Management of Tata Steel, the largest steel making company of India in the private sector, felt the need to develop a framework to determine the levels of ergonomic performance at its different workplaces. The objectives of the study are manifold: to identify and characterize the ergonomic variables for a given worksystem with regard to work efficiency, operator safety, and working conditions, to design a comprehensive Ergonomic Performance Indicator (EPI) for quantitative determination of the ergonomic status and maturity of a given worksystem. The study team of IIT Kharagpur consists of three faculty members and the management of Tata Steel formed a team of eleven members for implementation of EPI model. In order to design and develop the EPI model with total participation and understanding of the concerned personnel of Tata Steel, a three-phase action plan for the project was prepared. The project consists of three phases: preparation and data collection, detailed structuring and validation of EPI model. Identification of ergonomic performance factors, development of interaction matrix, design of assessment tool, and testing and validation of assessment tool (EPI) in varied situations are the major steps in these phases. The case study discusses in detail the EPI model and its applications.     

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.