Technological Institute of the Philippines

College of Engineering and Architecture

Industrial Engineering Department

Laboratory Manual

IE 009 – PHYSICAL ERGONOMICS LABORATORY

(Ergonomics 1)

Engr. Yoshiki B. Kurata, MSc.IE, CIE, AAE

Copyright 2020

PHYSICAL ERGONOMICS LABORATORY

(Ergonomics 1)
ENGR. YOSHIKI B. KURATA, CIE, AAE, MSc.IE

Doctor of Philosophy in Industrial Engineering, De La Salle

University Manila (on-going)

Master of Science in Industrial Engineering (Major in Human

Factors and Ergonomics and Production Systems), University
of the Philippines Diliman

Bachelor of Science in Industrial Engineering, University of

Santo Tomas, Manila

Certified Industrial Engineer (CIE), Philippine Institute of

Industrial Engineers

Associate ASEAN Engineer (AAE), ASEAN Federation of

Engineering Organizations

PREFACE

Ergonomics is everywhere – from one way or another, it impacts everyone. The discipline of human
factors and ergonomics has been an interesting discipline in the field of industrial engineering, as human
sciences and technology is systematically designed to improve human safety, health, comfort and
performance. The formal definition of ergonomics, according to International Ergonomics Association
(IEA), reads as follows:

Ergonomics (or human factors) is the scientific discipline concerned with understanding of the
interactions among humans and other elements of a system, and the profession that applies theory,
principles, data and methods to design, in order to optimize human well-being and overall system
performance.

This laboratory manual is the first-part of the human factors and ergonomics manual made with specific
focus on physical ergonomics for industrial engineering majors. It encompasses laboratory exercises that
will define humans through anatomical, anthropometric, physiological and biomechanical characteristics.

The author’s objective of this workbook is to provide the Industrial Engineering students taking up
Human Factors Engineering (Ergonomics) with a study guide and it hopes to establish a better
perspective and appreciation in understanding the ergonomics as a discipline and as a future endeavor
for industrial engineering graduates.

- THE AUTHOR

TABLE OF CONTENTS
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Experiment # Title Page

1 Body Mass Index 5

2 Visual Displays: Ishihara Test 10

3 Physical Environment: Light Measurement 15

4 Physical Environment: Indication and Temperature Reading 23

5 Engineering Anthropometry 29

6 Back Flexibility Assessment 40

7 Hand Strength Assessment 50

8 Motor Dexterity and Coordination 57

9 Manual Material Handling: NIOSH Lifting Exercises 67

10 Postural Analysis: Rapid Upper Limb Assessment 70

11 Postural Analysis: Rapid Entire Body Assessment 76

12 Physical Ergonomics: Design of Experiments 76

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 ACCEPTABLE USE POLICY FOR LABORATORY AND SHOP USERS
(Students and Faculty Members)

1. Faculty members shall always inform the technician of his intent to use a laboratory room. The
Laboratory Custody Form for the room shall properly accomplish.

2. Students shall not be allowed to do a laboratory or shop activity without the supervision of a faculty
member. Faculty members shall not leave their classes while students are doing the laboratory or shop
works.

3. No equipment shall be operated without the permission of the faculty member.

4. No equipment shall be transferred to other locations without the consent of the laboratory and shop
officer.

5. Students shall not be allowed to stay in the laboratory or shop rooms beyond the laboratory class
schedule.

6. Students and Faculty Members shall always observe the 5S program of the school inside the laboratory
and shop rooms.

7. Faculty members shall see to it that the machine or equipment is clean and also switch off before leaving
the laboratory or shop rooms. Also, all borrowed tools and devices must be returned to the tool stock room.

8. In case of damage or losses of tool / devices / machines / equipment, the borrower shall be held
responsible.

9. Eating, drinking and bringing in foods and drinks insider the laboratory or shop rooms are strictly
prohibited.

10. Safety shall always be observed and practiced inside the laboratory.

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 Laboratory Exercise No. 9

NIOSH Lifting Exercises

Course : IE 009 – Ergonomics 1 Experiment No. : 9

Group No. : Section : IE31S1
Group Members : 1. Berroya, Eula Date Performed : September 24,2020
2. Cumpa, Andrea Date Submitted : September 25, 2020
3. Martin, Angela Instructor : Engr. Yoshiki B. Kurata
4. Rivera, Justin
5. Salvante, Kenneth
1. Objective(s)

To understand and comprehend on different manual working tasks using NIOSH Lifting Equation.

2. Intended Learning Outcomes (ILOs)

At the end of the exercise, the students are expected:

1. To demonstrate the skills in gathering the NIOSH lifting measurements;

2. To apply knowledge in conceptualizing the importance and the use of gathered NIOSH lifting data;
and

3. To establish good working relationship with the other groups and develop his/her interpersonal
relationships.

3. Discussion

A decade after the first NIOSH lifting guide, NIOSH revised the technique for assessing overexertion
hazards of manual lifting. The new document no longer contains two separate weight limits (Action Limit
(AL) and Maximum Permissible Limit (MPL)) but has only one Recommended Weight Limit (RWL). It
represents the maximal weight of a load that may be lifted or lowered by about 90% of American industrial
workers, male or female, physically fit and accustomed to physical labor.

This new equation resembles the 1981 formula for AL, but includes new multipliers to reflect asymmetry
and the quality of hand-load coupling. The 1991 equation allows as maximum a “Load Constant (LC)” –
permissible under the most favorable circumstances with a absolute value of 23 kgs (51 lbs).

Recommended Weight Limit=LC x HM x VM x DM x AM x FM x CM

Notes:
 LC – load constant of 23 kgs or 51 lbs.
 Horizontal Multiplier (HM) – the horizontal distance of the hands from the ankles (the midpoint of
the ankles).

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  Vertical Multiplier (VM) – the vertical location (height) of the hands above the floor at the start and
end points of the lift.
 Distance Multiplier (DM) – vertical travel distance from the start and end points of the lift.
 Asymmetry Multiplier (AM) – angle of asymmetry, (e.g. the angular displacement of the load from
the medial (mid-saggital plane) which forces the operator to twist the body. It is measured at the
start and end points of the lift).
 Frequency Multiplier (FM) – frequency rate of lifting, expressed in lifts per minute.

 Coupling Multiplier (CM) – indicates the quality of coupling between hand and load.

Using the NIOSH lifting equation, perform an analysis of the lift below the same person and then perform
the same analysis for the second person. Calculate the RWL and LI for the origin and destination of both
lifts.

Load
Lifting Index ( LI )=
Recommended Weight Limit

4. Materials and Equipment

 Ergonomics Laboratory Equipment

 Paper
 Pen
 Internet Sources
 Ergonomics Reference Books

5. Procedure

Look for an actual worker who does lifting tasks in general. Observe the worker as he do the lifting task and
measure the necessary details in order for you to solve the RWL and LI. For the laboratory report, you are
to present the following (with actual pictures):

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1. Description of each task
2. List any necessary assumptions
3. Explain the values for each of the parameters from the NIOSH lifting equation
4. Do the task requirements seem excessive? Explain.
5. Compare and contrast the results of the tasks.

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Figure 6.1. Graphic Representation of Hand Location

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Figure 6.2. Graphic Representation of Angle of Asymmetry

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Figure 6.3. Loading Punch Press Stock

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 Hand to Container Coupling Notes

1. An optimal handle design has 0.75 – 1.50 inches (1.90 to 3.80 cm) diameter, 1 4.5 inches (1 1.5 cm)
length, 2 inches (5 cm) clearance, cylindrical shape and a non-slip surface.

2. An optimal handhold cut-out has the following approximate characteristics:

 1.5 inch (3.8 cm) height

 4.5 inch (11.5 cm) length
 semi-oval shape
 5 inch (12 cm) clearance
 smooth non-slip surface
 > 0.25 inches (0.60 cm) container thickness (e.g. double thickness cardboard)

3. An optimal container design has 16 inches (40 cm) frontal length, < 12 inches (30 cm) height, and a
smooth non-slip surface.

4. A worker should be capable of clamping the fingers at nearly 90 degrees under the container as required
when lifting a cardboard box from the floor.

5. A container is considered less than optimal if it has a frontal length of > 16 inches (40 cm), height of >12
inches (30 cm), rough and slippery surfaces, sharp edges, asymmetric center of mass, unstable contents or
requires the use of gloves.

6. A worker should be able to comfortably wrap the hand around the object without cawing excessive wrist
deviations or awkward postures, and the grip should not require excessive force.

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 Figure 6.4. Frequency Multiplier

Figure 6.5. NIOSH Lifting Equation Job Analysis Worksheet

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6. Data and Results

Using the general report, answer the following questions:

1. In your own opinion, what is the valuable contribution of the worker’s condition to your group to the study
of ergonomics for industrial engineers?

2. Why is it necessary for industrial engineering students to determine the equipment that will be utilized in
the course of ergonomics at the start of the semester? What can it give to you as a student?

3. If you are to rate the laboratory activity (10 as the highest mark and 1 as the lowest mark), what would
you rate? Why?

7. Data Analysis and Conclusion

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The worker's posture during work helps the coed to investigate the NIOSH. With workers'
data supported their posture with this, the students can demonstrate the right application of the lifting
equation and procedures. The procedures provide a technique for determining the amount of physical
stress related to a particular set of lifting conditions and assist in identifying the contribution of every job-
related factor. The lifting equation and procedures presented during this document were designed to
spot ergonomic problems.

As industrial engineering students, this activity helps us to be experienced in identifying the contribution of

every job-related factor. The examples also guide in developing an ergonomic redesign strategy.
Specifically, for every example, employment description, job analysis, hazard assessment, redesign
suggestion, illustration, and completed worksheet are provided. These activities provide a  sample of lifting
jobs that applying to this equation was suitable.

9, with this activity we are now familiar to NIOSH lifting measurement, it taught us how to conceptualize the
importance of gathering NIOSH lifting data and understand the situation of the workers who experienced
difficulties during their wok, though this activity made during a pandemic time I think it will be more fun
when we conduct this activity together.

We can conclude based on the data we gathered from the worker and use NIOSH lifting measurement. The
result of a worker for his recommended weight limit is 20.20 lbs and the worker lifts a bucket with 22 lbs of
weight while the computed lifting index is 1.09. NIOSH revised the technique for assessing the overexertion
hazards of manual lifting; the worker lifts a bucket with the same data from its origin to his destination,
meaning the worker can lift the bucket without any difficulties.

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8. Reflection on the Attainment of Intended Learning Outcomes (ILOs):
Students met and achieved the three Intended Learning Outcomes (ILOs) in this activity. Now the
students can demonstrate the skills in gathering the NIOSH lifting measurements, applying knowledge in
conceptualizing the importance and the use of gathered NIOSH lifting data; and establishing a good
working relationship with the other groups, and develop his/her interpersonal relationships. This activity
helps us to realize the importance of computing NIOSH determining the level of physical stress
associated with a specific set of lifting conditions. We I realized that risk can be prevented if proper
execution and applicable work design, work equipment will be implemented. We can apply this
knowledge in our ongoing research as this will help us improve the condition of the workers we are
investigating.

9. Assessment Rubric

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BIBLIOGRAPHY

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Books

Blanchard, B.S., Fabryckry, W.J. (2002). Systems Engineering and Analysis (3 rd Edition). Prentice Hall
Publishing

Badiru, A.B. (2006). Handbook of Industrial and Systems Engineering. Taylor and Francis Group, LLC

Frievalds, A. (2009). Niebel’s Methods, Standards and Work Design (12 th Edition). McGraw-Hill Education
(Asia)

Gallwey, T.J., O’Sullivan, L.W. (2009). Ergonomics Laboratory Exercises. Taylor and Francis Group, LLC

Kanawaty, G. (1992). Introduction to Work Study (4th Edition). International Labour Organization

Kroemer, et.al. (2002). Ergonomics: How to Design for Ease and Efficiency (2 nd Edition). Prentice Hall
Publishing

Salvendy, G.S. (2006). Handbook of Human Factors and Ergonomics (3 rd Edition). John Wiley & Sons, Inc.

International Labour Organization. Introduction to Work Study (3rd Revised Edition)

Instrument’s Instruction Manual

Cardinal Scale Mfg. Co.

www.detectoscale.com

EXTECH Instrument
Model 407727 and Model 407730
www.extech.com

Lafayette Instrument
Email: info@lafayetteinstrument.com
www.lafayetteinstrument.com

Line Seiki Co., Ltd.

Email: webtrade@line.co.jp
www.line.co.jp

Oregon Scientific
Model EB312E

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