INDUSTRIAL ERGONOMICS

MAIN 2028

Sergio A. Caporali Filho, Ph.D., CSP

Email: scaporali@rcm.upr.edu

Agenda
„ Introduction
„ Relevant Injury Statistics
„ Upper Extremities
„ Risk Factors
„ Design Principles
„ Exposure Assessment
„ Effective Ergonomics Program

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 Ergonomics
„ It is a multidisciplinary science that
studies the interactions between man
and his total working environment
„ Office
„ Manufacturing
„ Service
„ Health care
„ The objective is to fit the job to the
worker

Injuries and Illnesses Distribution

Cases with days away from work
Source Bureau of Labor Statistics, 2006 data

Contact with object, equipment

11%
Fall to lower level
2%
0%
28% Fall on same level
5%

Slips, trips
5%
Ergonomics (Overexertion, Repetitive Motion)

Exposed to harmful substance

6% Transportation accidents

27% Fires, explosions

13% Assault, violent act

3%
All other

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 Ergonomic-related Injuries
„ Types of injuries: „ Injuries typically
„ Acute involve:
„ Chronic „ Bones
„ Muscles
„ Joints
„ Tendons
„ Ligaments
„ Nerves

Symptoms of injuries are:

„ Painful joints
„ Pain, tingling or numbness in hands/feet
„ Pain in upper and lower extremities
„ Decreased blood irrigation
„ Swelling or inflammation
„ Stiffness
„ Weakness or clumsiness in hands
„ Burning sensations

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 Back:How it works!

Biomechanical Leverage

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 Biomechanical Leverage

1 ft 1 ft 1 ft 10 ft

? ?
10 lb 10 lb 100 lb 10 lb

Biomechanical Leverage
2” 20”

50 lb
70 lb
?
50 lb
20” 500 lb

620 lb
70 lb
Upper body

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 Biomechanical Leverage

8”
30°

7 80
lb
2”
70 lb
b
50 lb 4l
10 50 lb
840
lb 70 lb

20”
20”

Herniated Disk

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 Wrist: How it works!

Shoulder: How it works!

Collar Bone Shoulder Blade
(Clavicle) (Scapula)

Upper Arm Bone

(Humerus)

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Neck: How it works!

Elbow: How it works!

Common Flexor Tendon

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 Ergonomic Risk Factors

„ Physical Workload
„ Repetition/no rest
„ Awkward postures
„ Forceful exertions/
Contact stresses
„ Extreme temp
„ Vibration

Ergonomic Risk Factors

„ Psychosocial Factors
„ Work organization factors
„ Individual work-related factors

„ Individual characteristics

„ Extra-work environmental factors

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 Repetition/Lack of rest
„ Fatigue buildup
„ Poor recovery from micro injuries
„ Stress buildup
„ Poor muscle control

Repetition

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 Awkward Postures
„ Greater muscular force required
„ Static postures contribute to muscle and
tendon fatigue, and joint soreness
„ Greater forces exerted on the spine

Awkward Postures

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 Awkward Postures

Awkward Postures: Back Flexion

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Awkward postures: Back Flexion

Awkward Postures:
Static Postures

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 Awkward Postures:
Shoulder Abduction

Forceful Exertions/Contact Stresses

„ Decreased muscle circulation

„ Recovery time increases significantly
„ Potential soft tissue injuries due to
„ Insufficient recovery time
„ Greater contact stress
„ Quick fatigue buildup

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 Contact Stress

Extreme Temperatures

„ Extreme Temperatures
„ Heat Stress
„ Cold Stress

„ Vibration
„ Hand-arm

„ Whole body

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 Hand Tool Design Principles
„ Be consistent with
employee capabilities
„ Size, Age, Gender,
Dominant hand

„ Minimize awkward
postures

Grip Design Principles

„ Avoid tissue compression stress

„ Avoid repetitive finger action
„ Provide round handle 0.75 to 1.5”
diameter, 4 to 5” long
„ Incorporate two handles when possible
„ Minimize vibration transmission

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 Workstation Design Principles

„ Keep elbows flexed at 90°

„ Reduce repetition

„ Reduce static work

„ Utilize body strengths

„ Avoid awkward postures

„ Account for individual differences

(Age, gender, size, and force capabilities)

Workstation Design - Back Stress

„ Avoid lifting at floor/above shoulders
levels
„ Eliminate unnecessary material handling
„ Replace vertical by horizontal handling
„ Minimize reaching distance
„ Keep frequently used objects closer
„ Use gravity in employee’s favor
„ Keep force requirements within limits

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 Workstation Design (Standing)

„ Provide foot rest

„ Provide mats and floor coverings
„ Provide a stool or support where suitable
„ Provide opportunities to change positions
or move around
„ Place materials to be handled at waist
height

Workstation Design (Sitting)

„ Provide arm, elbow, and wrist rests
„ Provide adjustable chair
„ Provide adjustable work bench
„ Provide for arched back support
„ Provide space for legs under table
„ Avoid placing objects above shoulder
height sitting
„ Minimize the need to twist while sitting

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Interventions

Interventions

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 How to Reduce Injury?
„ Provide healthy work environment
„ Eliminate bending, twisting, & other
awkward movements
„ Locate frequently-used materials in
front of the worker, at waist height
„ Heavier objects should not be placed
overhead or on the floor
„ Use mechanical lifting equipment
„ Motivate stretching and exercise

Exposure Control

„ Engineering
„ Administrative
„ Work practice
„ Personal protective equipment

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 Exposure Assessment

„ Material Handling
„ 1981 NIOSH lifting guide
„ 1991 Revised NIOSH equation
„ Psychophysical data
„ 2D/3D static models
„ Multiple muscle system models
„ EMG assisted multiple muscle system models

Exposure Assessment

„ Whole Body Vibration

„ ISO 2631, 1985
„ ACGIH, 1996
„ Hand Arm Vibration
„ ISO 5349, 1986; ISO/FDIS 5349-1, 2001
„ ANSI, 1986
„ NIOSH, 1989

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 Exposure Assessment

„ Repetition limits for different body parts

„ Oxygen consumption measurement
„ Heart rate monitoring
„ Thermal stress monitoring
„ Goniometry
„ Anthropometry

Exposure Assessment

„ Job risk factors checklists

„ Workstation layout
„ Task analysis
„ Hand tool analysis
„ Materials handling
„ Computer workstation

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 Effective Ergonomics Program

„ Appropriately identifies and systematically

controls or eliminates WMSD's hazards
„ Looking for signs of potential problems
„ Showing management commitment and
motivating worker involvement
„ Training to build in-house expertise

Effective Ergonomics Program

„ Gathering data to identify problem jobs

„ Identifying effective controls
„ Establishing health care management
„ Creating a proactive Ergonomics program

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