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The
Advanced Ergonomics Manual
The Advanced
Ergonomics Manual Table of Contents
A. What
is Ergonomics?............................................................................................ 3 -
Definition -
Goal B. Developing
and Implementing an Ergonomics Program.................................. 5 -
Introduction o
What is
an Ergonomics Program? -
Components of an
Ergonomics Program -
Health and Risk
Factor Surveillance o
Discussion
Passive Surveillance o
Passive
Surveillance - Does a Problem Exist? o
Active Surveillance o
Active Surveillance
When to Use? -
Job Analysis and
Design -
Medical Management o
Roles and
Responsibilities o
Job Familiarity o
Early Reporting o
Access to
Health Care Providers (HCPs) o
Evaluation
of the Worker by the HCP o
Treatment
of the Worker o
Follow-Up
and Referral o
Job Placement
Evaluations -
Training -
Program Documentation
and Evaluation o
Is the Program
Successful? -
Starting the Program o
Process
Steps o
Management
Commitment o
Setting
Up the Ergonomics Team -
Maintaining the
Program o
Assessing
the Program o
Responsibilities
of the Ergonomics Committee o
Discussion -
Summary C. The Future
of Ergonomics..................................................................................
29 -
Introduction o
What is
the Direction of Ergonomics? -
Industry Guidelines o
Food Distribution o
Semiconductor
Industry o
The Benefits
of Industry Guidelines -
Design-Stage Ergonomics -
Team Ergonomics D. Ergonomics Standards and Guidelines.................
...............................32 -
Introduction o
Standards-Making
Organizations -
Guidelines and Standards o
Introduction E.
Ergonomic
Resources .............................................
.37 -
Resources References....................................................................................................................... 40 Attachment IA. Body Part
Discomfort Survey.............................................................. 42
A. Introduction............................................................................................................. 7 B. Determining Upper Extremity Risk...................................................................... 8 -
Introduction ·
Definition ·
Risk Factors 1. Repetition, Duration, and Recovery Time............................................. 11 -
Guidelines ·
Example of Use of ANSI Checklist 2. Force........................................................................................................ 15 -
Discussion -
Guidelines ·
Measuring Grip Forces ·
Factors Affecting Grip Strength 3. Postures of the Upper Extremities........................................................ 22 -
Discussion -
Neutral Postures -
Guidelines ·
Static Postures ·
Velocity and Acceleration of Motion ·
Strength/Posture Interaction ·
Awkward Postures How Much is Too
Much? 4. Environmental Risk Factors................................................................... 31 -
Introduction 5. Personal Risk Factors............................................................................ 31 -
Introduction 6. Summary - The Relationship Between Risk Factors and Injury/Illness..33 -
Evidence -
Rating Risk Factors 7. Checklists................................................................................................. 35 - Discussion C. Upper Extremity Task Design Principles.......................................................... 36 -
Introduction 1. Minimize Repetition................................................................................ 37 -
Guidelines 2. Minimize Force Requirements............................................................... 39 -
Guidelines 3. Minimize the Awkward Postures of Hands
and Arms......................... 43 -
Guidelines 4. Minimize Exposure to Environmental
Factors...................................... 47 -
Guidelines D. Determining Manual Material Handling
Risk.................................................... 49 -
Introduction -
Procedure ·
Data Collection ·
Task Variables 1. Selecting the Appropriate Analysis Tool.............................................. 51 -
Discussion
-
Using the Table 2. NIOSH Equation 1991 Draft................................................................... 53
-
Introduction
-
RWL
-
Equation
-
Variables
·
Horizontal Distance (H)
·
Asymmetry (A)
·
Frequency Multiplier (FM)
·
Coupling Multiplier (CM) -
Lifting Index (LI) -
Example of Use of the Equation ·
Description of Lifting Task ·
Determining Variables for Inclusion in the Equation ·
Calculating RWL -
Multi-Task Procedure ·
When to use the Multi-Task Procedure -
Validation of the Equation -
NIOSH Equation Software
-
NIOSH Equation Cheat Sheets 3. Biomechanical Models........................................................................... 67 -
Introduction -
3D Static Strength Prediction Program -
Guidelines 4. Psychophysical Capacity Data.............................................................. 72
-
Introduction 5. Two-Hand Lift/Lower Data...................................................................... 73 -
Background -
Using the Tables ·
Example
·
Lift vs. Lower ·
Combination Tasks a. Adjustment Factors for Lifting Capacity
Data.......................... 78 -
Background -
Guidelines ·
Working Duration (hours) Multiplier
·
Limited Headroom Multiplier
·
Asymmetrical Lifting (Twisting) Multiplier
·
Couplings (Handles) Multiplier
·
Load Placement Clearance Multiplier
·
Load Asymmetry Multiplier
·
Heat Stress Multiplier
·
Multiple-Person (team) Lifting 6. One-Hand Lift Data................................................................................. 84 -
Background -
Using the Tables -
Guidelines 7. Two-Hand Carry Data............................................................................. 87 -
Using the Table ·
Source -
Guidelines 8. One-Hand Carry Data............................................................................. 89 -
Using the Table -
Guidelines 9. Two-Hand Push Data............................................................................. 90 -
Using the Table -
Guidelines 10. Two-Hand Pull Data............................................................................... 92 -
Using the Table -
Guidelines 11. One-Hand Push/Pull Forces................................................................. 94 -
Background -
Guidelines ·
One Hand Push
·
One Hand Pull 12. MMH Data for Awkward Postures.......................................................... 95 -
Background -
Using the Tables ·
Kneeling Tasks
·
Task Description ·
Seated Tasks ·
Task Description and Recommended Weight of Lift ·
Lying Tasks ·
Task Description and Recommended Weight of Lift E. Manual Material Handling Design
Principles................................................. 104
-
Introduction 1. Eliminate or Minimize MMH................................................................. 105 - Introduction a. Mechanization........................................................................... 105 - Guidelines ·
Example ·
Why Do Mechanical Assists Go Un-Used? ·
Cautionary Note Regarding Mechanization b. Eliminate or Reduce Rehandling............................................. 108 - Guidelines ·
Examples c. Increase Object Weight............................................................ 108 - Guidelines ·
Examples 2. Reduce Stress Associated with MMH................................................ 109 - Introduction a. Reduce Object Weight............................................................. 109 - Guidelines ·
Examples ·
Comment 2-Person Lifting b. Changing Handling Method..................................................... 111 - Guidelines c. Reducing Push/Pull Tasks....................................................... 112 - Guidelines d. Hand Truck / Cart / Caster Design.......................................... 113 - Guidelines ·
Hand Trucks and Carts ·
Casters ·
Weight of Load e. Container Design...................................................................... 117 - Guidelines ·
Types of Containers ·
Containers that are Manually Handled ·
Handle Design ·
Containers that are Loaded into or Unloaded From f. Handwheel Design.................................................................... 121 - Guidelines 3. Minimize Stressful Postures................................................................ 122 - Introduction a. Minimize Bending..................................................................... 123 - Guidelines b. Minimize Twisting...................................................................... 124 - Guidelines c. Reduce Extreme Horizontal Reaches..................................... 126 - Guidelines d. Reduce Above Shoulder Work................................................ 127 - Guidelines e Minimize Kneeling Tasks......................................................... 128 - Guidelines f. Provide Knowledge of Load
Characteristics......................... 128 - Introduction - Guidelines g. Avoid Extreme Hand/Arm Posture.......................................... 129 - Guidelines 4. Special Case: Patient Handling Tasks............................................... 130 - Introduction - Guidelines - Engineering
Controls a.
Work Environment b.
Work Organization
c.
Patient Handling
Lift Assists
d.
Implementing Engineering
Controls - Administrative / Training Controls -
Effectiveness of Ergonomic Controls F. Physiologically Demanding Tasks.................................................................. 134 - Introduction 1. Methods to Measure Energy Expenditure.......................................... 135 - Introduction a. Rating of Perceived Exertion................................................... 135 - Introduction - Using the
Scale b. Measurement of Heart Rate..................................................... 137 - Introduction - Categorizing
Work Based on Heart Rate - Guidelines 2. Factors Influencing Metabolic Demand.............................................. 138 - Introduction a. Frequency of Movement, Posture and Task
Duration........... 138 - Guidelines b. Heat Stress................................................................................ 140 -
Introduction
-
Measurement
-
Heat Stress Criteria
-
Guidelines References.................................................................................................................... 145
A. Introduction............................................................................................................. 7 B. Applying Anthropometry to Workstation
Design................................................ 8 -
Introduction -
Guidelines ·
Principles ·
Anthropometric Data 1. Anthropometric Adjustment Factors for
Clothing................................. 12 - Introduction - Guidelines ·
Shoes ·
Hard Hat ·
Work Gloves ·
Clothing 2. Additional Anthropometry Sources....................................................... 14 -
Sources C. Workstation Design Guidelines......................................................................... 15 -
Introduction ·
Definition ·
Goals ·
Types -
Selection ·
Procedure ·
Example -
General Principles of Workstation Design ·
Provide Adequate Room for All Work Materials ·
Accommodate the Neutral Posture ·
Accommodate the Primary Viewing Area ·
Slanted Workstations (Angled Worksurfaces) ·
Adjustability ·
Distribution of Workload ·
Minimize Reaches ·
Layout 1. Standing Workstation Design Guidelines............................................ 25 -
Guidelines ·
Workstation Dimensions ·
Functional Working Height ·
Clearances at Standing Workstations ·
Anti-Fatigue Mats ·
Platforms ·
Footrests ·
Summary Standing for Extended Periods ·
Standing Reach Distances 1.1
Special Case Grocery Checkstand Design -
Guidelines 1.2
Standing Computer Workstation -
Guidelines 2. Sit/Stand Workstation Design Guidelines............................................ 42 -
Guidelines ·
Workstation Dimensions ·
·
Sit/Lean Devices 3. Seated Workstation Design Guidelines............................................... 46 -
Guidelines ·
Workstation Dimensions ·
Reach Distances ·
Sharp Edges ·
Wrist Rests ·
Chair Design Guidelines ·
Caster Design ·
Chair Adjustment Features ·
Arm Rests - Yes or No?
·
Back Rest ·
Lumbar Pads ·
Foot Rests ·
The Seat Pan ·
Comment: Kneeling Chairs ·
Comment: Dynamic (Massaging) Chairs ·
Evaluating Seat Comfort ·
Sitting How Long is Acceptable? 4. Visual Guidelines for Workstations....................................................... 65 -
Introduction -
Guidelines ·
Recommended Viewing Angles 5. Special Case - VDT Work Area Design
Principles............................ 68 -
Guidelines
·
Clearances and
·
Monitor Position
·
Vertical Placement of Monitor
·
Horizontal Placement of Monitor (Viewing Distance)
·
Document Holders
·
Telephone Headsets ·
Illuminance ·
Acoustic Noise ·
Thermal Environment ·
VDT Work Breaks ·
Laptop Computers 6. Special Case Seated Microscope and
Sewing Workstations....... 77 -
Microscope Workstations -
Sewing Workstations 7. Shelving and Passageways................................................................... 80 -
Guidelines ·
Shelving ·
Passageways D. Ladders/Stairs/Ramps....................................................................................... 82 -
Introduction 1. Ladder Design......................................................................................... 83 -
Introduction -
Guidelines ·
Vertical ·
Non-Vertical ·
Safety 2. Stair Design............................................................................................. 87 -
Introduction -
Guidelines ·
Stair Tread ·
Discussion ·
Flights 3. Ramp Design........................................................................................... 90 -
Introduction -
Guidelines ·
Grade ·
Cleats ·
Handrail ·
Wheelchair E. Control Guidelines............................................................................................... 93 -
Introduction -
Definition 1. Control Selection..................................................................................... 94 - Guidelines 2. Recommended Physical Dimensions for
Controls.............................. 95 -
Guidelines -
Handwheels
-
Valves and Levers 3. Ergonomic Guidelines for Controls..................................................... 103 -
Guidelines ·
General ·
Control Location ·
Control/Display Relationship 4. Keyboards and Other Data Entry Devices......................................... 107 -
Guidelines ·
Keyboards
·
Training Issue
·
Keyboard Slope
·
Segmented Keyboard Designs
·
General Alternate Input Devices
·
Ball Controls (e.g., Trackballs)
·
Comment Trackball Design
·
Mouse Controls
·
Comment Incorporating the Mouse/Trackball into an Existing Workstation ·
Touchpads
·
Comment - Mouse versus Trackball versus Touchpad
·
Light Pens
·
Voice Recognition Systems (VRS) F. Display Guidelines............................................................................................ 123 -
Introduction -
Guidelines
·
Types of Displays ·
Display Use ·
Lighting of Displays ·
Location of Displays ·
Character Size 1. Design
Guidelines for Analog Displays.............................................. 127 -
Introduction -
Guidelines 2. Special Case: VDT Display Characteristics.................................... 128 -
Introduction -
Guidelines
·
Monitor Type (Technology)
·
Refresh Rate
·
Resolution
·
Brightness and Contrast
·
Characters
·
Polarity
·
Color
·
Glare ·
Lighting, Glasses and Visual Comfort o
Full-Spectrum Lighting o
Task Lighting o
Flicker from Lighting Systems o
Glasses o
Measuring Visual Fatigue ·
Reading from a VDT versus Paper 3. Illuminated Indicators............................................................................ 139 -
Introduction -
Guidelines ·
Color Coding 4. Grouping and Coding Display Information......................................... 141 -
Introduction -
Guidelines ·
Grouping Display Information ·
Coding Display Information
5. Auditory Displays.................................................................................. 144 -
Introduction -
Guidelines G. Warning Signs and Labels...............................................................................
145 - Introduction - Definition - Guidelines 1. Guidelines for Effective Warning Signs
and Labels.......................... 146 -
Introduction -
Guidelines ·
Format-Related
·
Content-Related ·
Mode of Presentation ·
General 2. Standard-Making
Organizations and Recommended Warning Systems...................................................... 154 -
Organizations -
Guidelines H. Illumination in the Workplace........................................................................... 158 -
Introduction 1. Illumination Measuring Techniques..................................................... 159 -
Introduction -
Guidelines ·
Procedure ·
Discussion 2. Determining Industrial Lighting
Requirements................................... 160 -
Introduction
·
Example -
Guidelines ·
Procedure 3. Illumination and Character Size........................................................... 165 -
Introduction -
Guidelines 4. Illumination Special Cases - VDT Work, Inspection Tasks................................................................................... 166 -
Introduction -
Guidelines
·
VDT Work ·
Inspection Tasks References.................................................................................................................... 167
A. Introduction.............................................................................................................. 4 -
Background -
Discussion
Force
Physical Dimensions
Air and Vibration
Task/Posture B. Force........................................................................................................................ 7 -
Introduction 1 Direction of Force....................................................................................... 7 -
Guidelines
Examples 2 Handle Grip Forces..................................................................................... 9 -
Guidelines
Repetitive Grip Forces
Definitions of Grip Types
Torque
Tool Weight
Feed Force
Powered Tools
Springs
Gloves
Triggers
Tool Balancers
Air Hoses
Reaction Force (kickback)
Vibration
Cold C Handle Features................................................................................................... 22 -
Introduction 1 Resting Hand............................................................................................ 23 -
Introduction -
Guidelines
Availability and Constraints 2 Left Handed Tools.................................................................................... 24 -
Introduction -
Guidelines 3. Surface Quality......................................................................................... 24 -
Introduction -
Guidelines 4. Handle Size.............................................................................................. 27 -
Introduction -
Guidelines
Enclosed Handle
Force/Torque Providing Different Sized Tools
based on Hand Size 5. Handle Shape........................................................................................... 31 -
Guidelines D Hand/Arm Postures.............................................................................................. 32 -
Introduction 1 Wrist Deviation......................................................................................... 32 -
Introduction -
Guidelines - Applications 2. Shoulder Abduction.................................................................................. 34 -
Introduction -
Guidelines 3. Forearm Rotation...................................................................................... 35 -
Introduction -
Guidelines E. Tool Maintenance................................................................................................. 36 -
Guidelines
Cutting Edges
Handles
Lubrication
Work Environment
Vibration F.
Ergonomic Tool Design Examples ................................................................. 37
- Introduction
-
Examples
Hand-Held Scanners
Spray Guns
Hammers
Shovels
Manual Saws
Pneumatic Nut Runners Pens / Writing Instruments
Screwdrivers
Syringes / Liquid Dispensing Systems
Tweezers
Knives
Power Drills
Orbital Sanders / Vibration-Producing Power Tools References....................................................................................................................... 50
A. Introduction 3 B. Noise in the Workplace ..4 Introduction · What is Noise? · Sources of Noise · Effects of Noise · The Ergonomists Role 1. Measuring Noise ..5 Introduction Instruments · Sound Level Meter · Dosimeter · Octave Band Analyzer Measurement Techniques · Personal Monitoring · Area Monitoring Procedures-General 2. Standards and Guidelines 7 OSHA Occupational Noise Exposure Standard (1983) · Introduction · Using the Standard · Employee Daily Noise Exposure Example Guidelines - Office Work Environment 3. Control Strategies .. .11 Introduction Strategies · General Procedures · Design of New Facilities for Noise Control · Controlling Noise in an Existing Facility - Control at the Source · Controlling Noise in an Existing Facility - Control Along the Path Sound Absorbing Materials Shields, Barriers, and Enclosures · Controlling Noise in an Existing Facility - Control at the Receiver Administrative Controls Personal Protective Equipment Types of Personal Protective Equipment · Controlling Noise in the Office C. Vibration .. 19 Introduction Definitions Effects Measurement 1. Whole Body Vibration 20 Guidelines Resonance Suspension 2. Segmental Vibration . 23 Guidelines D. Temperature . .26 Introduction 1. Heat Stress 27 Introduction Measurement Heat Stress Criteria Guidelines 2. Cold . .30 Introduction Guidelines 3. Thermal Comfort .33 Guidelines E. Indoor Air Quality .. .34 Introduction Definitions Health
Effects ( Design Guidelines . 35 Recommended Ventilation Rates Control Strategies . 36 F. Slip/Fall Risk .. .38 Guidelines References 41
A. Introduction............................................................................................................. 5 B. Design
for Maintainability and Assembly............................................................ 6 - Introduction 1. Troubleshooting......................................................................................... 7 - Introduction - Guidelines 2. Design
to Improve Accessibility............................................................... 8 - Introduction - Guidelines Clothing Access Openings / Clearances Visual Requirements Hinged Doors Drawers Safety Labeling 3. Designing
for Repair Issues................................................................... 18 - Introduction - Guidelines Maintenance Time Connectors / Fasteners Conductors Cables Piping Hand Tools Circuit Boards Labeling Legibility 4. Designing
Maintenance Job Aids......................................................... 23 - Introduction - Guidelines - Procedure 5 Designing
for Assembly......................................................................... 25 - Guidelines C. Design for the Disabled...................................................................................... 26 - Introduction Definition 1. Assessing
Capabilities.......................................................................... 27 - Procedure - Written Resources - Additional Resources 2. Design
Guidelines for Specific Cases................................................. 29 - Introduction a. Sight
Limitation............................................................................ 30 - Introduction - Guidelines b. Hearing
Limitation....................................................................... 32 - Introduction - Guidelines c. Information
Processing Impairment........................................... 33 - Introduction - Guidelines d. Sensation
Limitation................................................................... 34 - Introduction - Guidelines Wheelchairs e. Difficulty
in Manipulating............................................................. 36 -
Introduction -
Guidelines f. Difficulty
in Lifting, Reaching, Carrying..................................... 38 - Introduction - Guidelines D. Administrative
Controls...................................................................................... 39 - Introduction - When do we use Administrative Controls? 1. Job
Rotation............................................................................................. 40 - Introduction - Guidelines What Jobs do we Rotate Between? Example Additional Guidelines How Frequently Should
we Rotate? - Benefits
of Job Rotation - Drawbacks
of Job Rotation - Job
Enlargement 2. Microbreaks............................................................................................. 45 - Definition - Guidelines Types of Microbreaks Types of Microbreaks Discussion How often should the worker take a
microbreak? What should the worker do during the
Microbreak? Discussion Microbreak Software 3. Stretching,
Exercise and Work Hardening........................................... 49 - Introduction - Guidelines Selecting an Exercise Protocol How Often should we Stretch? - Do
Exercise Programs Work? - Work
Hardening - Wellness
Programs 4. Physical
Ability Testing (PAT)................................................................ 55 - Introduction - Legal Issues - Developing a PAT Program Is a PAT Program Warranted? Define the Physical Requirement of
the Job Develop Test Provide Validation Documentation -
Effectiveness of PAT Programs 5. Back
Belts, Wrist and Elbow Braces ..................................................... 59 - Introduction -
Back Belts How do back Belts Work? Do Back Belts reduce Injuries? - Wrist Braces - Elbow Braces 6 The
Psychosocial Environment ............................................................... 61 -
Introduction - Definition -
Measuring Stress -
Guidelines References....................................................................................................................... 66 ATTACHMENT A. ERGONOMIC CHECKLISTS GLOSSARY OF TERMS INDEX |