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By: Sonderegger (8 month(s) ago)

This presentation have very interesting information to start my ergo program do you allow me to download Iwill appreciate a lot

 

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the presentation s really informative, more pictures can be added

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Basic Industrial Ergonomics: 

Basic Industrial Ergonomics An EASEworks® Manufacturing Tutorial START

Scope of this Tutorial: 

Scope of this Tutorial This tutorial will give Industrial and Manufacturing Engineers an understanding of the basic concepts of ergonomics, known risk factors, methods of analyzing tasks, and suggested ways of reducing risk in an industrial or warehousing environment. Ergonomics is an ‘inexact science’ and the results of some method analyses can be open to interpretation. However ‘a little common sense’ goes a long way.

Contents: 

Contents What is Ergonomics Understanding Ergonomic Risk Analyzing & Recognizing Ergonomic Problems Reducing the Risk Work Station & Tool Check Lists New Product Design EASE Contact Information

What is Ergonomics?: 

What is Ergonomics? A study of the relation between people and their work environment. Is used to prevent injuries and illnesses associated with the design of physical work. Is used to increase employee safety and comfort and to optimize work performance and quality.

What is Ergonomics?: 

What is Ergonomics? The term ‘ergonomics’ comes from the Greek words ergon (work) and nomos (law). Too often ergonomics is only applied because of the ‘Law’. Ergonomics should be seen as a ‘win/win’ opportunity to improve productivity and quality while increasing employee safety and morale.

What is Ergonomics?: 

What is Ergonomics? Reactive Ergonomics – is where you respond to a work place complaint or injury. Reactive Ergonomics – is where you respond to a work place complaint or injury. Proactive Ergonomics – is where you analyze a proposed task at design time to prevent an injury. A real world ergonomics program should include both analyses. But due to constraints of time and staffing not every task can or indeed needs to be analyzed. Good work station & tool design will prevent a lot of problems whatever the task.

What is Ergonomics?: 

Stretching to reach Repeated heavy lifting High pinch forces Handling objects that are sharp, very hot, or very cold. Working with hands above shoulders Long periods of work without a change in body posture. Examples of work requirements that can cause discomfort, fatigue, injury, and illness are: What is Ergonomics?

What is Ergonomics?: 

Is to make the work fit the operator, not make the operator fit the work. The Goal of Ergonomics What is Ergonomics?

What is Ergonomics?: 

Fatigue Pain Illness – sprains, back ache, etc Low morale Frustration & Irritation Poor Quality Absenteeism Higher costs Higher employee turnover & training Effects on the Operator Effects on the Company And why do we need it? What is Ergonomics?

What is Ergonomics?: 

Higher productivity Higher Quality Reduced operator injury Increased morale Greater job satisfaction Lower medical & insurance costs Reduced lost time Lower absenteeism Less employee turnover And what is the benefit? What is Ergonomics?

Understanding Ergonomic Risk: 

Understanding Ergonomic Risk Physical Activity Fatigue Physical Exertion Fatigue & Recovery Overexertion & Cumulative Trauma Body Type

Understanding Ergonomic Risk: 

Understanding Ergonomic Risk It is important to note that occasional exposure to a risk factor is not usually harmful. Significant exposure to a risk factor may be harmful to sections of the population. You can’t specify the physique, age, sex of the operator. Ergonomic analysis tools are going to be based on 95% of the working population being able to do the work.

Understanding Ergonomic Risk: 

Understanding Ergonomic Risk Our bodies use energy from the food we eat to meet two kinds of physical demands. Internal demands are the processes which maintain life and growth within our bodies. External demands are the physical activities which we perform during our waking hours Internal: Cell Growth: Digestion: Circulation: Respiration etc. External: Walking: Lifting: Standing: Exercising: etc How the Body uses Energy Physical Activity

Understanding Ergonomic Risk: 

Understanding Ergonomic Risk If activities exceed our personal limits of stamina or strength (and this varies from person to person), then two kinds of fatigue may result Localized fatigue:- effects the particular part of the body that is working, for example the arms. Whole – body fatigue occurs when several body parts are over exerted. Fatigue

Understanding Ergonomic Risk: 

Is either dynamic or static. Dynamic exertion is where there is visible movement of the body. Static exertion is where the body or part of the body is held in place. Static exertion is often more tiring because the muscles have no chance to recover. Understanding Ergonomic Risk Physical Exertion

Understanding Ergonomic Risk: 

The amount of force you use in an exertion and the length of the exertion both effect how soon and how much fatigue will set in. Localized fatigue is best relieved by changing activities to rest working muscle groups or by resting the working limb. Whole body fatigue is best reduced by reducing the level of body activity or by resting the body. Understanding Ergonomic Risk Fatigue and Recovery

Understanding Ergonomic Risk: 

If an operator works in an activity that exceeds their strength or stamina, then overexertion injuries and cumulative trauma injuries are possible. Overexertion can cause immediate injuries to muscles, tendons and ligaments. Such as sprains, strains and tears. Cumulative Trauma injuries are of the ‘wear and tear’ type and include damage to hands, wrists, shoulders, elbow and some back disorders Understanding Ergonomic Risk Overexertion

Understanding Ergonomic Risk: 

Stamina Strength Height Weight The working population varies in age, sex, health and size. In most western countries you can’t specify the age, sex, fitness or size of the operator. Proportions Vision Hearing Understanding Ergonomic Risk

Slide19: 

Frequent Hand Use Arms Extended Bending & Twisting Static Body Posture Using Force Vibration Contact Stress Temperature Noise Fatigue Understanding Ergonomic Risk Risk Factors

Slide20: 

Risk Activities may occur at work, and may occur at home. Consider the body posture, force requirement and hand grip when bowling or hanging washing on a line. When walking a factory, you can often tell the physically demanding tasks by the operators performing them. Big, buff, men! But consider who will get the blame (and cost) for operator injury if ‘Big Bill’ hurt his back at home, and now has to do his physically demanding tasks? The work has to fit the operator, not the operator the work! Things to consider Understanding Ergonomic Risk

Slide21: 

Tasks often have multiple Risk Factors To analyze the task, multiple assessments have to be done to cover Force, Repetition, Posture, Fatigue The task time is important. If risk is found, any proposed solutions must take into account manufacturing cycle time requirements, and of course COST. Things to consider Understanding Ergonomic Risk

Analyzing Tasks: 

Analyzing Tasks Posture Force Repetition We need to know how much force is involved for each body posture, how often is it repeated, for how long is it held, how often is the total task repeated and for how long the task is worked. Ergonomic Analysis Methods Fatigue & Recovery Employee Survey Recognizing Problems

Analyzing Tasks: 

Analyzing a video of the task is the best way to make ergonomic analyses of a task Analyzing Tasks Recognizing Problems

Analyzing Tasks: 

Since you obviously can’t assemble anything without the use of hands and fingers we have to be concerned with the position of the hands, the type of grip forces involved, vibration, pressure, temperature and the number of repetitions. Posture - Constant Use of Hands and Fingers Recognizing Problems Analyzing Tasks

Analyzing Tasks: 

Pronation – thumb down, turning the wrist over 45 degrees Supination – thumb out, palm up. Turning the hand palm up over 20 degrees Ulnar Deviation – twisting hand outwards over 15 degrees Exceeding these angles may cause problems when used in conjunction with high repetition and/or force. Posture - Constant Use of Hands and Fingers Recognizing Problems Analyzing Tasks

Analyzing Tasks: 

Radial Deviation – twisting the hand inwards over 10 degrees Flexation – bending hand forward over 45 degrees Extension – raising hand backward over 40 degrees Posture - Constant Use of Hands and Fingers Recognizing Problems Analyzing Tasks

Analyzing Tasks: 

Keep the hand in a neutral posture. Minimize forces required to operate. Minimize vibration Have padded handles Tool design is crucial. Tools need to be designed to: Posture - Constant Use of Hands and Fingers Recognizing Problems Analyzing Tasks

Analyzing Tasks: 

A wrap or power grip is best. Pinch forces over 7lbs can cause injury. Hook and contact grasps expose the operator to the potential of contact stress with sharp, or hard objects. Using the hand(or any body part) to strike objects obviously isn’t recommended, but you do see it, as an operator ‘slaps’ something into place. Recognizing Problems Posture - Constant Use of Hands and Fingers Analyzing Tasks

Analyzing Tasks: 

Twisting or Bending of the Wrists – effects the median nerve passing through the carpal tunnel which can lead to carpal tunnel syndrome. Repetitive Hand & Wrist Motions – effects the tendons passing through the carpal tunnel which can lead to tendinitis/tenosynovitis. Vibration – effects the blood vessels in the fingers which can lead to Raynaud’s Phenomenon. Pinch grips can lead to contact stress and overexertion of the hands. Recognizing Problems Posture - Constant Use of Hands and Fingers Analyzing Tasks

Analyzing Tasks: 

Arms Extended Working with the arms above the shoulder can lead to the compression and entrapment of nerve in the shoulder. It also causes fatigue to the muscles of the shoulder and arm. Recognizing Problems Arms and Shoulders Analyzing Tasks

Analyzing Tasks: 

ARM AND SHOULDER Working with the elbows abducted at an angle of 25 degrees or more can lead to the compression and entrapment of nerves in the shoulder. It is also causes fatigue to the muscles of the shoulder and arm. Recognizing Problems Arms and Shoulders Analyzing Tasks

Analyzing Tasks: 

Horizontal reach over 25 inches (62.5cm) is greater than the reach of 5% of the female population without bending. A vertical reach of over 70 inches(175cm) is above the reach of 5% of the female population The longer the reach, the greater effect of any weight involved. The more off center the reach, the greater effect of any weight involved. Recognizing Problems Arms and Shoulders Analyzing Tasks

Slide33: 

The best position for assembly work is with the arms to the front, elbows close to the body, at a vertical height between the operators chest and thigh. Moving the arm across the midline of the body should be avoided. Analyzing Tasks Recognizing Problems Arms and Shoulders

Slide34: 

The lower the reach, the greater effect of any weight involved. The more off center the reach, the greater effect of any weight involved. Analyzing Tasks Recognizing Problems Bending and Twisting

Slide35: 

In general twisting, bending and leaning of the torso should be avoided. Repetition with weight in a poor body posture may cause injury in a significant percentage of the population. The risk angles are leaning more than 5 degrees, twisting more than 15, and bending more than 60. Analyzing Tasks Recognizing Problems Bending and Twisting

Slide36: 

Bending & Twisting also applies to the neck. In general neck side bending or held in a twisted position is to be avoided. Bending the neck back further than 5 degrees or forward further than 20 should also be avoided Use of head protection such as a welding mask needs to be accounted for in any fatigue assessment Analyzing Tasks Recognizing Problems Bending and Twisting

Slide37: 

The operator needs to be in a balanced posture. The effects of repetition and force will be increased detrimentally due to poor posture! Analyzing Tasks Recognizing Problems Posture

Slide38: 

Methods that analyze body posture include:- Analyzing Tasks Recognizing Problems Posture RULA – Rapid Upper Limb Assessment. REBA – Rapid Entire Body Assessment. NIOSH 91 – Takes Body Posture into Account. There are other methodologies. The screens shown earlier are based on RULA. Note: This tutorial does not explain how to use RULA.

Slide39: 

Analyzing Tasks Recognizing Problems Posture . The task shown here has two RULA action level 4’s, meaning that an immediate change in method is suggested

Slide40: 

Lifting Pushing Pulling Carrying Pinch Force Holding in place Analyzing Tasks Recognizing Problems Force

Slide41: 

The most frequently used lifting analysis in the USA is the NIOSH91 guide. This has a maximum weight of 51 lbs (23kg) It mainly uses weight and body posture to determine a lifting index for the 5% female. This screen shows input for NIOSH91, as well as for the Alpha analysis Analyzing Tasks Recognizing Problems Lifting

Slide42: 

An index of 1 or less is ideal, but may be unrealistic. What % of your workforce are 5% female Some companies are OK with a 2 or below This screen shows the results of a NIOSH91 analysis of a given lift Analyzing Tasks Recognizing Problems Force

Slide43: 

Whilst NIOSH91 focuses on the entire body, the analysis shown here gives results for strength, fatigue and recovery by back, shoulder, elbow and hand. A 4 means that 95% of the working population can’t do the task without risk of injury. Analyzing Tasks Recognizing Problems Force

Slide44: 

By using the tools available you can see areas of concern Rule of thumb – as you increase the weight of a lift (50 lb max) the more neutral you must keep the body posture. Analyzing Tasks Recognizing Problems Force

Slide45: 

Space constraints Available rest between lifts Capability of the employee skill in handling loads past injuries Note: The affectivity of safe lifting techniques has been questioned. “Proper lifting’ is not a substitute for a well engineered work place. Loads that can be lifted by the legs from a squat can exceed the capacity of the lower back. Other variables that can effect the degree of difficulty in lifting loads safely are: Size (bulk) of load Floor/shoe traction Stability of load Adequacy of grip Distance to carry Analyzing Tasks Recognizing Problems Force

Slide46: 

Pushing is better than pulling (less strain on back). Pushing can be split into whole body or arms only. Suggested standing force limits are 50lbf using 2 hands. A 2 wheel manual cart should not be loaded with >250lb or 114 kg. 3 or 4 wheel manual cart should not be loaded with >500lb or 228kg Pushing can be split into whole body or arms only Suggested force limits are 24lbf using 2 hands. Pushing Pulling Analyzing Tasks Recognizing Problems Force

Slide47: 

Pinch forces of over 2lbs (1 kilo) are generally considered to have injury potential Carrying loads greater than 50 lbs is to be avoided. The load should be kept close and near waist level The load should have handles Pinch Forces Carrying Analyzing Tasks Recognizing Problems Force

Slide48: 

Holding a force in place is very fatiguing as the muscles don’t get to rest and recover Hold in Place Analyzing Tasks Recognizing Problems Force

Slide49: 

Causing fatigue if insufficient recovery time Compounding the effects of force Compounding the effects of poor body posture A ‘no significant weight’ assembly task where all parts are under a pound can still have risk if the repetitions are high enough. In tasks with a less than 30 second cycle time, more than 1500-2000 similar hand motions per hour can lead to injury Repetition Affects by: Analyzing Tasks Recognizing Problems Force

Slide50: 

Localized fatigue can be analyzed as we have seen with tools like the Alpha analysis. Whole body fatigue can be analyzed by using a Kilo Calorie Analysis or an industrial engineering tool such as a PF&D (Personal Fatigue & Delay) analysis Analyzing Tasks Recognizing Problems Fatigue and Recovery

Slide51: 

Don’t ignore the operator. Not only will they tell you where a task causes discomfort, but often they have thought of ways of alleviating it. Analyzing Tasks Recognizing Problems Employee Survey

Slide52: 

Employee Survey Compare the results of your ergonomic analyses with the survey. Analyzing Tasks Recognizing Problems

Slide53: 

Design each work station – follow a checklist Use ergonomically designed tools – follow a checklist Have work instructions and ensure the operator follows them Do an analysis of the task The Basics Reducing the Risk

Slide54: 

Constant use of hands & fingers – rotate to jobs where hand use is lower. Arms extended & unsupported – alter the design of the work station to bring the work closer. Don’t work above shoulders, don’t require elbow abduction (elbows up). Bending & Twisting – reposition the objects to the front of the worker at an appropriate height Using significant force – reduce the weight of the load if possible, keep the body in neutral postures, use assisted lifts, reduce pinch forces, use power grips, minimize lift distance. Reducing the Risk

Slide55: 

Static body posture – alternate between standing and sitting, rest one foot on a support while standing Vibration – isolate body from vibration source, rotate to non vibrating job, use better designed tools Contact Stress – cushion exposed body parts (eg gloves), pad hard or sharp objects, round or smooth rough edges Heat/cold – limit exposure to temperature extremes, provide heating/cooling systems, provide protective clothing Noise – use hearing protection, reduce exposure to high noise levels. Reducing the Risk

Slide56: 

Lifting – provide handles, allow large containers to tilt or have collapsible sides, raise tote bins to appropriate height Holding in place – provide clamps or fixtures Reducing the Risk

Slide57: 

Can you cost justify it? Have you made productivity improvements? Is the new cycle time better or worse? Is that acceptable? But is management going to buy off on it? Reducing the Risk

Slide58: 

This solution using a lifting arm while greatly reducing the risk has added 8 seconds to the cycle time Does it matter? Reducing the Risk

Work Station & Tool Check Lists: 

Work Station & Tool Check Lists The use of work station and tool design check lists will go a long way in alleviating ergonomic problems. If your answers are negative, fix them if possible

Work Station & Tool Check Lists: 

Does the work space accommodate the smallest employee reach to the largest employee clearance? (No=Bad) Are work surfaces and chairs adjustable? (No=Bad) Does the work keep the operator immobile? (Yes=Bad) Requires handling of large bulky materials regardless of weight? (Yes=Bad) Is the floor slippery? (Yes=Bad) Is matting provided? (No=Bad) Work Station & Tool Check Lists

Work Station & Tool Check Lists: 

Work Station & Tool Check Lists Does the work require eye focus at differing distances? (yes=bad) Is lighting adequate? (no=bad) Are noise levels less than 85 dbA for ambient and less than 140 dbA for impact? (no=bad) Is humidity in the range 20 to 85? (no=bad) Is temperature in the range of 66-79F for light work, 64-74F for medium and 60-68F for heavy? (no=bad)

Slide62: 

Are there peak loads of muscular effort? (yes=bad) Frequent or extreme lifting requirements? (yes=bad) Excessive pushing, pulling or carrying? (yes=bad) Is material manually moved over long distances? (yes=bad) Are there extended reaches? (yes=bad)

Work Station & Tool Check Lists: 

Work Station & Tool Check Lists

Work Station & Tool Check Lists: 

Work Station & Tool Check Lists

Work Station & Tool Check Lists: 

Work Station & Tool Check Lists Tool Design

New Product Design: 

New Product Design New products should not be designed solely for function, but also for assembly. Part of DFA (Design for Assembly) is accounting for ergonomics. EASE, Inc has integrated software modules that reflect this belief.

New Product Design: 

New Product Design New products are designed in a DFA module that uses standard touch labor data as part of the process. When a beta design is ready, it can be transferred to a routing system, standards in place by operation for the addition of material handling data (where parts are in relation to the work station & operator, that may not be known at design time) and input of manufacturing engineers.

New Product Design: 

The process plan is then transferred to line balancing to ensure that different production schedules can be met. Each station for a new process, should have an ergonomic review done proactively. If problems surface at this stage, the beta design can be sent back for revision. Once the design is acceptable, work instructions can be added to the routing, and we are ready for production. New Product Design

Slide71: 

Thank you for viewing this tutorial. For further information about EASE Inc, our clients, consulting services, software products and software customization, or to end this tutorial, please select from the buttons at left. EASE Inc. CLIENTS CONSULTING SOFTWARE CONTACT US EXIT HOME

Slide72: 

EASE Incorporated is an international corporation, founded in 1986. EASE is headquartered in Southern California with satellite offices in Europe and the United States. EASE Incorporated provides productivity improvement services through the application of the EASEworks® Software, training, consulting services and implementation support. Who is EASE Inc? HOME

Slide73: 

EASE Customers HOME

The Service: 

The Service Our major focus is to offer sustainable productivity improvements and cost reductions for our clients. We can provide you with consulting assistance for. . HOME Equipment Evaluation Facility Layout Establishing “Best Practices” Competitive Benchmarking Design Engineering Process Engineering Production Engineering Implementing Ergonomic Improvements Training and Training Support & Certification Improving Labor Efficiency Productivity Analysis Implementing Lean Manufacturing Manufacturing Engineering ISO 9000 Implementation Developing Work Standards Process Mapping EASE will provide engineers with extensive experience in YOUR industry. Your engineers will have the ability to take over, with confidence, where we leave off.

Software: 

Software EASEworks® Software modules cover: HOME Work Standards Product Cost Estimating Line Balancing Work Instructions Ergonomics Design For Assembly EASE Inc. provides full training, start up assistance and consulting services for all modules. Software customization services are also available.

Contact Information: 

Phone: Fax: E-Mail: Web: information@easeinc.com HOME (949) 348-7511 (949) 367-9906 www.easeinc.com HOME Contact Information EASE Inc. 27405 Puerta Real, #380 Mission Viejo, CA 92691