Development of an ergonomics guideline for the furniture manufacturing industry

Industry-specific ergonomics guidelines are an important component in the four-pronged approach to workplace ergonomics currently pursued by the United States Occupational Safety and Health Administration. The American Furniture Manufacturers Association has taken the initiative of developing such a guideline for its members. The result of this effort is the "AFMA Voluntary Ergonomics Guideline for the Furniture Manufacturing Industry", a document that includes basic information about ergonomics program components as well as a compilation of work-proven, ergonomics best practices as submitted by members of the furniture manufacturing community. This guideline was developed through an industry-research-government partnership and made strategic use of the unique attributes that each sector brought to this effort. Outlined in this paper are some of the characteristics of this partnership including, the roles played by each, the different motivations for pursuing the guideline, the challenges faced during the development of the document, the successes experienced in this process, as well as a proposed outline for measuring the effectiveness of this effort. The hope is that this summary, and some of the lessons learned contained herein, would be helpful to others considering the prospect of developing such a guideline for their industry.     

A multilayered ergonomic intervention program on reducing musculoskeletal disorders in an industrial complex: A dynamic participatory approach

Work-related musculoskeletal disorders (WMSDs) are closely identified with common complaints in different workplaces. This study aimed to implement an intervention program through which ergonomic measures were dynamically localized in industry. An interventional study, including three basic layers, namely, training workshops, participatory ergonomics (PE), and workstation redesign was fulfilled in an Iranian steel manufacturing complex from 2017 to 2020. A steering committee (SC) was formed following several meetings held for clarification of the project to the management team. The SC members then attended four organized workshops managed by an ergonomics specialist. Afterwards, the basics of ergonomics were transferred to action groups. After developing ergonomic assessment tools, the ergonomic problems were prioritized and numerous positive changes were made by the action groups. The findings of the tailored checklists revealed a load of WMSDs risk factors. All the three layers of the program were implemented as initiated. Ergonomics training workshops were then held and significant differences were observed between the participants' pre/posttest mean scores in all workshops (p < 0.001). Moreover, PE measures were exercised at all levels of the organization inducing enthusiastic motivation of the workforce to consider ergonomic requirements in the workplace. Consequently, the workers' innovative ideas and the managerial support yielded diverse workstation redesigns due to a growth in either the workers' ergonomics awareness or participatory culture grounding. A multilayered ergonomic intervention was implemented in this study. In conclusion, a multifaceted long-term follow-up intervention program could be applied to enhance workers’ health status and to raise system productivity.     

DASH questionnaire for the analysis of musculoskeletal symptoms in industry workers: a validity and reliability study

Purpose

The disabilities of the arm, shoulder and hand (DASH) questionnaire is a self-administered region-specific outcome instrument developed as a measure of self-rated upper-extremity disability and symptoms. The aim of this study was to evaluate the reliability and the construct validity of the DASH questionnaire by establishing its correlation to the Medical Outcomes Study Short Form-36 (SF-36) in industry workers. Also we aimed to investigate whether the DASH can be used as a standardized questionnaire to evaluate the work-related musculoskeletal disorders (WMSDs) in upper extremity in industrial settings and epidemiological studies.

Material and methods

The Turkish version's reliability and construct validity were evaluated in 240 industry workers with upper-extremity musculoskeletal complaints. Workers were asked to complete a packet that included the DASH and the SF-36. Test-retest reliability was assessed in all workers who filled in the DASH questionnaire 15 days later. Construct validity was evaluated by comparing the overall and work component DASH scores with SF-36 summary and subscales.

Results

The mean DASH score for the textile workers whose duties were confection, dyeing, sewing, quality control and packaging was calculated as 65, 55, 68, 54 and 67, respectively. As a result of this study, pain intensity in shoulder, wrist and hand was significantly associated with the DASH score (p<0.05). Internal consistency of the DASH was high (Cronbach alpha 0.91). Test-retest reliability was excellent for the overall DASH (intraclass correlation coefficient (ICC) 0.92). Moderate correlations (p<0.05) were found between the overall and work component DASH and the SF-36 summary scales. Pearson correlation coefficients of the overall and work component DASH to the SF-36 subscales ranged from −0.33 to −0.82.

Conclusion

These results support that DASH is a reliable and valid instrument to measure functional disability and investigate the ergonomic risk factors in textile workers with upper-extremity musculoskeletal complaints.     

Citation analysis and impact factor trends in the Ergonomics Journal List, 1975–2007

The current study sought to investigate and analyze citation‐based trends in the field of human factors and ergonomics over a relatively long period of time. Journals were selected from the Ergonomics Journal List (EJL), originally formulated by Dul and Karwowski in 2004. Data were extracted from the Thomson Reuters Journal Citation Reports via a custom order in 2008. Various bibliometric indicators were examined and analyzed, including total citation counts, cited half‐lives, immediacy indices, and journal impact factors. Overall, the results suggest that, although citation counts have increased in recent years, trends were less clear regarding cited half‐lives and immediacy indices. Impact factors rose over time, however, with individual journals increasing their scores between 200% and 613%, with an overall increase of 416% for the EJL between 1975 and 2007. © 2009 Wiley Periodicals, Inc.     

Corporate-internal vs. national standard – A comparison study of two ergonomics evaluation procedures used in automotive manufacturing

Manufacturing corporations sometimes use corporate-internal procedures to evaluate and monitor the ergonomic status of the workplace. This article describes an industrial case study in the Swedish automotive sector, where an internally developed evaluation procedure was compared with a procedure based on a Swedish national standard provision.It was found that the national standard procedure tended to give more severe ratings and statistical support shows that the two evaluation procedures are not equivalent. The ability of the methods to identify body segments at risk was also compared.The quantitative comparison was followed up with interviews, where the influence of professional tasks and objectives became evident, as well as the fact that evaluation criteria are quantified differently by the two procedures. The main finding is that unforeseen differences in analysis procedure, criteria of acceptability and levels of detail can cause use-related difficulties for different professional groups when methods are used interchangeably.

Relevance to industry

Industrial corporations wishing to monitor ergonomics consistently are advised by the authors to ensure that ratings from internal evaluations are interpreted the same way by all involved personnel, and that they at least have criteria levels equivalent to those of a national standard.     

Usage and evaluation of Supply Chain Management Software – results of an empirical study in the European automotive industry

Abstract. This paper presents an evaluation of Supply Chain Management Software. For this purpose, we conducted an empirical study in the European automotive industry among car manufacturers, suppliers, distributors, and logistic service providers from 25 countries. In particular, we analysed the objectives these companies are trying to achieve by using Supply Chain Management Software and evaluated to what extent these objectives have been accomplished. Our results show that the companies have been able to reduce both their costs and lead times and to improve their service levels. The survey also reveals, however, that until now, the cooperative potential of Supply Chain Management Software has not been utilized effectively.     

Vibration of portable orbital sanders and its impact on the development of work-related musculoskeletal disorders in the furniture industry

The wood furniture industry has a strong presence in Canada, where it employs over 100,000 workers. Because of the extensive number of manual tasks required in this industry, several studies have been undertaken to characterize the health and safety risk factors to which these workers are exposed, such as awkward postures, repetitive movements and the application of undue force. However, very little research has been done on workers’ exposure to vibration from portable orbital sanders, one of the most common tools used in this industry. Vibration is responsible for a specific occupational disease called vibration syndrome, but is also recognized as a risk factor that increases the prevalence of more common work-related musculoskeletal disorders (WMSDs). This study proposed to determine the level of vibration to which sanders of furniture parts are exposed, and to analyze its impact on the risk of WMSDs. The results show that the level of vibration to which the workers are exposed is well above acceptable levels defined by recognized standards and directives and that this vibration is combined with many other risk factors, thus representing a risk for the development of WMSDs.     

A case study of ISO 11064 in control centre design in the Norwegian petroleum industry

In 2006-2008 we performed a case study for the purpose of assessing the industrial application of the seven part Control Centre (CC) design standard ISO 11064 to identify positive and negative experiences among stakeholders in the Norwegian petroleum sector. We mainly focussed on ISO 11064 Part 1, because this was the most commonly used among the identified stakeholders. ISO 11064 is generally appreciated and applied in the industry, but we did observe a significant variance in use between the different parts of the standard. We also identified potential areas for improvements, like scope and application adaptation. Thus we suggest a more goal-based approach based on one normative part only.     

The deep structure of organizational online networking – an actor‐oriented case study

While research on organizational online networking recently increased significantly, most studies adopt quantitative research designs with a focus on the consequences of social network configurations. Very limited attention is paid to comprehensive theoretical conceptions of the complex phenomenon of organizational online networking. We address this gap by adopting a theoretical framework of the deep structure of organizational online networking with a focus on their emerging meaning for the employees. We apply and assess the framework in a qualitative case study of a large‐scale implementation of a corporate social network site (SNS) in a global organization. We reveal organizational online networking as a multi‐dimensional phenomenon with multiplex relationships that are unbalanced, primarily consist of weak ties and are subject to temporal change. Further, we identify discourse drivers and information retrievers as two mutually interdependent actor roles as an explanation for uneven levels of user contributions to the SNS. Based on our analysis, we elicit abstract order principles, such as topical discourses, and identify transactive memory theory as a potent explanation of the evolving interaction structures. We finally discuss how the deep structure framework can contribute to future research on organizational networks.     

Optimizing the energy efficiency of chiller systems in the semiconductor industry through big data analytics and an empirical study

Big data analytics is playing a more and more prominent role in the manufacturing industry as corporations attempt to utilize vast amounts of data to optimize the operation of plants and factories to gain a competitive advantage. Since the advent of Industry 4.0, also known as smart manufacturing, big data analytics, combined with expert domain knowledge, is facilitating ever-greater levels of speed and automaticity in manufacturing processes. The semiconductor industry is a fundamental driver of this transformation; moreover, due to the highly complex and energy-consuming nature of the semiconductor manufacturing process, semiconductor fabrication facilities (fabs) can also benefit greatly from incorporating big data analytics to improve production and energy efficiency. This paper developed a big data analytics framework, along with an empirical study conducted in collaboration with a semiconductor manufacturer in Taiwan, to optimize the energy efficiency of chiller systems in semiconductor fabs. Chiller systems are one of the most energy-consuming systems within a typical modern fab. The developed big data analytics framework allows production managers to ensure that chiller systems operate at an optimized level of energy efficiency under dynamically changing conditions, while fulfilling the chilling demands. Compared to the commonly-used heuristics previously employed at the fab to tune chiller system parameters, by the utilization of big data analytics, it is shown that fabs can achieve substantial energy savings, greater than 12%. The developed framework and the lessons learned from the empirical study are not only generalizable but also useful for practitioners who are interested in applying big data analytics to optimize the performance of other equipment systems in fabs.     

Study protocol and baseline results for a quasi-randomized control trial: An investigation on the effects of ergonomic interventions on work-related musculoskeletal disorders,quality of work-life and productivity in knowledge-based companies

IntroductionWork-related musculoskeletal disorders (WMSDs) are the major causes of lost workdays, increased costs, and occupational diseases in all countries. The prevalence of WMSDs among the workers in small and medium-sized enterprises in Iran was reported as 73%. This paper aimed to describe the design of an interventional study to investigate the effects of ergonomic interventions on work-related musculoskeletal disorders, quality of work-life, and productivity among office workers of knowledge-based companies and introduce the results obtained from the baseline survey.Methods/designIt was a quasi-randomized control trial study on 313 participants with four parallel groups including ergonomic training intervention; management training and work changes intervention; ergonomic training, management training and work changes intervention; and non-interventional control group. The primary outcome was WMSDs, and the secondary outcomes were occupational stress factors, quality of work-life, and productivity. All primary and secondary outcomes were measured before the interventions, one, three, and six months after the interventions.ResultsAt this phase of study only baseline results were reported. 328 participants, with a mean age of 31.97 years (SD = 5.39), completed the baseline survey and entered the study. The highest prevalence of musculoskeletal disorders was found in neck (52.13%), right shoulder (41.16%) and right forearm (37.2%), respectively.ConclusionErgonomic interventions were conducted based on baseline data of the participants at individual and management levels. The focus of training program interventions was to reduce musculoskeletal disorders in upper limbs; in management training and work changes program, the focus was to increase social support.Trial registrationIRCT registration number: IRCT20181204041840N1 (date of registration: 2019-02-05).     

Modelling the influence of the gas to melt ratio on the solid fraction of the surface in spray formed billets

In this paper, the relationship between the Gas to Melt Ratio (GMR) and the solid fraction of an evolving billet surface is investigated numerically. The basis for the analysis is a recently developed integrated procedure for modelling the entire spray forming process. This model includes the atomisation stage taking thermal coupling into consideration and the deposition of the droplets at the surface of the billet taking geometrical aspects such as shading into account. The coupling between these two models is accomplished by ensuring that the total droplet size distribution of the spray is the summation of “local” droplet size distributions along the r-axis of the spray cone. The criterion for a successful process has been a predefined process window characterised by a desired solid fraction range at a certain distance from the atomizer. Inside this process window, the gas and melt flows have been varied and their influence on the solid fraction at the surface of the billet has been analysed.     

A national cross-sectional study in the Danish wood and furniture industry on working postures and manual materials handling

Musculoskeletal disorders constitute a major problem in the wood and furniture industry and identification of risk factors is needed urgently. Therefore, exposures to different work tasks and variation in the job were recorded based on an observation survey in combination with an interview among 281 employees working in wood working and painting departments. A questionnaire survey confirmed high frequencies of symptoms from the musculoskeletal system: The one-year prevalence of symptoms from the low back was 42% and symptoms from the neck/shoulder was 40%. The exposure was evaluated based on: (1) classification of work tasks, (2) work cycle time, (3) manual materials handling, (4) working postures, and (5) variation in die job. Among the employees 47% performed feeding or clearing of machines, 35% performed wood working or painting materials, and 18% performed various other operations. Among the employees 20% had no variation in their job while 44% had little variation. Manual materials handling of 375 different burdens was observed, which most often occurred during feeding or clearing of machines. The weight of burdens lifted was 0·5-87·0 kg, where 2% had a weight of more than 50 kg. Among the lifting conditions 30% were evaluated as implying a risk of injury. An additional risk factor was the high total tonnage lifted per day, which was estimated to range from 132 kg to 58 800 kg. Working postures implied a risk of injury due to prolonged forward and lateral flexions of the neck, which was seen most frequently during wood working or painting materials. These data substantiate the finding that work tasks mainly during feeding or clearing of machines imply a risk of injury to the low back and a risk of injury to the neck and shoulder area mainly during wood working or painting materials. Optimal strategies for job redesign may be worked out by using these data in order to prevent occupational musculoskeletal disorders.     

The impact of poor assembly ergonomics on product quality: A cost–benefit analysis in car manufacturing

The study aimed at analyzing the relationship between assembly ergonomics, assemblability (“ease of assembly”), and product quality and at quantifying these relationships in economic terms. This was in order to better to support the development of more ergonomic product and assembly solutions, particularly at early stages of the car development process. The assembly of 24,443 cars was studied for 8 weeks in an assembly plant and for another 16 weeks as factory‐complete vehicles. The results show increased risks for quality errors of 3.0 and 3.7 times and total action costs that were 8.7 times and 8.2 times higher for high and medium physical load assemblies compared to low physical load assemblies for 55 tasks assessed. © 2009 Wiley Periodicals, Inc.     

Use of a simulation game in delivering blended lifelong learning in the construction industry – Opportunities and Challenges

Continuing professional development (CPD) and life-long learning are vital to both individual and organisational success. For higher education, the intensive resource requirements requisite in the development of e-learning content and the challenges in accommodating different learning styles, developing an e-learning program can be a resource intensive exercise. A blended learning program has been developed in Ireland in an attempt to address the CPD needs of Irish construction professionals. This initiative attempts to strike a balance between the considerable resources required in the development of an e-learning initiative while addressing staff concerns in integrating technology in the delivery of programs. This pilot explores the issues encountered in integrating a simulation game, called MERIT, on a module as part of this blended learning program. The key finding from this research indicates that simulation games can play a very effective role in the delivery of lifelong learning opportunities aimed at the construction industry. However, management of the integration of a simulation game into a program requires careful planning, establishing key milestone dates and encouraging online collaboration through assigning of marks for effort and use of voice over IP communications.     

Implementation procedure of an advanced supervisory and control strategy in the pharmaceutical industry

This paper describes the different steps followed in implementing a temperature controller and a supervisory controller in a Supervisory Control And Data Acquisition (SCADA) system to control a 60 and 160 l reactor in a pharmaceutical factory. These reactors are used to produce the initial quantities of drugs needed to perform clinical tests. The chemical reactions involved are often changed (several times a week). The different steps of the project will be presented:

• design of a new heating–cooling system,

• design of the predictive and Supervisory Control Algorithm (SCA),

• connection of the SCA to the SCADA system,

• experimental validation according to Good Manufacturing Practice (GMP).

This SCA has been in daily use as the standard control system for more than 2 years.     

Development of an expert system for tackling the public''s perception to climate-change impacts on petroleum industry

Climate change could cause significant impacts on human activities, which is especially true for regions that are of high latitude such as Canada. Petroleum industry is a main economic sector in Canada's prairie, where a number of its production and processing practices are vulnerable to the fluctuations of climatic conditions. In this study, an expert system (ES) for integrated climate-change impact assessment within the prairie's petroleum sector was developed. Interactive relationships among climate change, natural-condition variations, industrial activities, environmental concerns and economic objectives, as well as the related policy implications, were comprehensively examined and incorporated within the ES. A series of questionnaire surveys were conducted for acquiring knowledge about the interrelationships between the climate change and the petroleum-related activities. Processes that were vulnerable to climate change were analyzed, followed by an integrated impact assessment. The results indicated that the impacts of increased temperature and natural hazards would be very significant on most of the petroleum-related processes. Also, the petroleum industry would be quite sensitive to changed precipitation patterns. The developed ES can be used for both acquiring knowledge of climate-change impacts on the petroleum industry and supporting formulation of the relevant adaptation policies.     

Job characteristic perceptions of manual drafting and CADD: A field study of the effects of computerization on drafting & design personnel

The introduction of CADD equipment into an engineering department provided the opportunity to identify job characteristic perceptions of drafters and designers. Drafters and designers responded to a job characteristic questionnaire which asked them to describe their job twice, first when using manual drafting and second when using CADD. Because the CADD equipment was phased in over time, the questionnaire sampled personnel with varying experience levels. The job perceptions are compared between job technologies and across experience levels. Information on changes in job characteristic perceptions may be useful in designing systems which improve employee motivation, performance and satisfaction.