Ergonomic development work: co-education as a support for user participation at a car assembly plant. A case study

This study deals with the design, trials and evaluation of a co-education programme at the Volvo Uddevalla plant in Sweden. Involving operators, manufacturing engineers and managers, the programme served as a support for the creation of a participatory ergonomics process, intended for continuous use at the plant. It consisted of a basic ergonomics knowledge package, and a dialogue model defining the roles and relations of actors involved. As a practical part of the programme, trial development projects were also carried out by the participants. The main and long term objective of the project was to start the participants cooperating in a continuous change and development process on the shop-floor.

The outcome of the co-education programme was evaluated immediately after the first two regular courses, and, as a longterm follow-up, after seven subsequent courses shortly after the closing of the Uddevalla plant. The co-education programme was shown to be successful. Later on, the expertize of both operators and manufacturing engineers became obvious to everyone at the plant, and the cooperation between operators and manufacturing engineers increased steadily. The main conclusion drawn was that the co-education programme is a good starting point for a process of participation and industrial change work. However, in order to get a permanent impact, the whole organization must nurse and nourish the further development, and implementation of the process.     

Integrating ergonomics into engineering: Empirical evidence and implications for the ergonomists

Engineering design is a strong determinant of workplace ergonomics. A survey among 680 engineers in 20 Danish enterprises indicated that engineers are not aware that they influence the work environment of other people. Ergonomics had a low rating among engineers, perhaps because neither management nor safety organizations expressed any expectations in this area. The study further indicated that effects of ergonomics training in engineering schools were very limited. The engineering cultures in enterprises, together with other organizational factors, are suggested to be of greater importance than the professional training. The implications for industrial ergonomists might be an acknowledgement of the role as change agent when trying to integrate ergonomics into engineering. In doing so, they need also to acknowledge that engineers are widely different. They have different backgrounds and a “sensitivity” to ergonomics depending on their current engineering domain, tasks, organizational position, and the industrial branch of their organization. © 2007 Wiley Periodicals, Inc. Hum Factors Man 17: 353–366, 2007.     

Specifications, Design and Evaluation of an Advanced Human-Adapted Supervisory System

Supervision of highly automated processes is an interdisciplinary research area. Knowledge in the fields of automation, process knowledge, machine engineering, ‘work post’ ergonomics, cognitive ergonomics, working psychology, sociology and so on is necessary to design efficient supervisory systems. This is because supervision is an activity in which man, despite the increasing automation of recent years, is still present. Our research concerns monitoring tasks and diagnosis tasks in continuous processes. In this paper we propose specifications for an advanced human-adapted supervisory system (AHASS) integrating representation characteristics of the production system, such as functional, structural and behavioural aspects based on cognitive engineering models, with the use of advanced algorithms of detection and location. The main idea is to design a supervisory system well balanced between human and technical aspects. Indeed, man–machine system-centred approaches can deal to another extreme like purely technical approaches. These specifications have been used to design an AHASS for a nuclear fuel reprocessing system that has been evaluated through experiments with experienced operators. The results show that the approach is interesting because the boarder between support and assistantship is never crossed.     

Time--a key issue for musculoskeletal health and manufacturing

Time is a key issue for both ergonomists and engineers when they engage in production system interventions. While not their primary purpose, the actions of engineers have major effects on biomechanical exposure; possibly of much greater magnitude than many ergonomics interventions. This paper summarises the aims, actions and tools of engineers and ergonomists, emphasising time-related outcomes. Activities of the two groups when attempting to manipulate time aspects of work may be contradictory; engineers wishing to improve production and ergonomists aiming at better health as well as contributing to production. Consequently, tools developed by ergonomists for assessing time aspects of work describe rest patterns, movement velocities or daily duration of exposures, while engineering tools emphasise time-efficient production. The paper identifies measures that could be used to communicate time-relevant information between engineers and ergonomists. Further cooperation between these two stakeholders as well as research on the topic are needed to enable ergonomists to have a larger impact on the design of production systems.     

Development of a software package for ergonomic assessment of manufacturing industry

A computer software package has been developed to be used as a self-assessment tool to evaluate ergonomic improvement potential of production systems by engineers, managers and safety professionals. Production managers of manufacturing industries with no prior knowledge of ergonomics were able to identify ergonomic deficiencies successfully (81%) in the shop floors as a result of the application of the ergonomic assessment tool. This enabled them to formulate intervention strategies to improve ergonomic conditions in their industries. The software package is user friendly, self-explanatory and provides relevant information, data and guidelines. It is unique, as the users will have access to necessary ergonomics information, which is often lacking in the manufacturing industries, especially in developing countries.     

The integration of ergonomics into design—A review

Abstract

This paper examines the role of ergonomics in product and systems design. Market requirements as well as legislation have increased the use of ergonomics in design. This has increased the demands upon both ergonomists and designers. The ergonomist must learn to participate in the product development team. In return the design team must find the time and resources necessary for the inclusion of ergonomics in the development programme. This paper discusses the different roles played by the ergonomist in each stage of product and systems design. The need to give designers, engineers and management a fundamental education in ergonomics is highlighted as is the need for the ergonomist to consider the financial consequences of his work.     

Eyestrain and visual display units: a review

A review is presented of current knowledge about the nature, incidence and causes of eyestrain or visual fatigue among VDU operators. It is suggested that fatigue and discomfort may result from visual, postural, environmental, work design and personal factors. However, it is concluded that all these problems can be overcome by sufficient attention to ergonomics in the design, implementation and use of VDUs.     

Bulgarian ergonomics revisited

In his earlier and more intensive review of ergonomics in Bulgaria, the author concluded that this discipline was highly developed and enjoyed strong government support. It was found that the network of ergonomics activities across national, regional, and local industrial plant levels was perhaps the most highly organised and comprehensive extension of ergonomics concerns of any country in the world. The brief revisit described in this report revealed that ergonomics continues to enjoy a very high measure of respectability. As also noted earlier, the field of ergonomics is still largely the province of physiologists and engineers. Some psychologists that are associated with design organisations are involved in ergonomics activities but, for the most part, psychologists deal primarily with more traditional topics that fall under the heading of industrial or work psychology.     

The integration of ergonomics into design—A review

This paper examines the role of ergonomics in product and systems design. Market requirements as well as legislation have increased the use of ergonomics in design. This has increased the demands upon both ergonomists and designers. The ergonomist must learn to participate in the product development team. In return the design team must find the time and resources necessary for the inclusion of ergonomics in the development programme. This paper discusses the different roles played by the ergonomist in each stage of product and systems design. The need to give designers, engineers and management a fundamental education in ergonomics is highlighted as is the need for the ergonomist to consider the financial consequences of his work.     

Control Strategies of Experienced and Novice Controllers with a Zero-Energy Nuclear Reactor

The objective of this paper is to describe how and why ergonomics should be promoted in total quality management (TQM). Ergonomics and TQM activities are compared. An approach is proposed to apply ergonomics in TQM using ergonomics circles. An eight-step approach is introduced for applying ergonomics using ergonomics circles and a study that employed this approach in Korea is discussed. In applying this approach, all processes were first evaluated by workers. Processes that were identified as problematic were analysed by a company-wide committee to set priorities for improvement. An ergonomics improvement team consisting of safety and health personnel, process engineers and management innovation personnel then worked on the processes using a low-cost approach. It was found that applying ergonomics using ergonomics circles as quality circles in TQM was effective in improving workplaces and resulted in increasing productivity, cost saving and improved safety.     

Do ergonomics improvements increase computer workers' productivity?: an intervention study in a call centre

This paper examines whether improving physical ergonomics working conditions affects worker productivity in a call centre with computer-intensive work. A field study was conducted at a catalogue retail service organization to explore the impact of ergonomics improvements on worker production. There were three levels of ergonomics interventions, each adding incrementally to the previous one. The first level was ergonomics training for all computer users accompanied by workstation ergonomics analysis leading to specific customized adjustments to better fit each worker (Group C). The second level added specific workstation accessories to improve the worker fit if the ergonomics analysis indicated a need for them (Group B). The third level met Group B requirements plus an improved chair (Group A). Productivity data was gathered from 72 volunteer participants who received ergonomics improvements to their workstations and 370 control subjects working in the same departments. Daily company records of production outputs for each worker were taken before ergonomics intervention (baseline) and 12 months after ergonomics intervention. Productivity improvement from baseline to 12 months post-intervention was examined across all ergonomics conditions combined, and also compared to the control group. The findings showed that worker performance increased for 50% of the ergonomics improvement participants and decreased for 50%. Overall, there was a 4.87% output increase for the ergonomics improvement group as compared to a 3.46% output decrease for the control group. The level of productivity increase varied by the type of the ergonomics improvements with Group C showing the best improvement (9.43%). Even though the average production improved, caution must be used in interpreting the findings since the ergonomics interventions were not successful for one-half of the participants.     

Trends in approaches to night and shiftwork and new international standards

This paper examines whether improving physical ergonomics working conditions affects worker productivity in a call centre with computer-intensive work. A field study was conducted at a catalogue retail service organization to explore the impact of ergonomics improvements on worker production. There were three levels of ergonomics interventions, each adding incrementally to the previous one. The first level was ergonomics training for all computer users accompanied by workstation ergonomics analysis leading to specific customized adjustments to better fit each worker (Group C). The second level added specific workstation accessories to improve the worker fit if the ergonomics analysis indicated a need for them (Group B). The third level met Group B requirements plus an improved chair (Group A). Productivity data was gathered from 72 volunteer participants who received ergonomics improvements to their workstations and 370 control subjects working in the same departments. Daily company records of production outputs for each worker were taken before ergonomics intervention (baseline) and 12 months after ergonomics intervention. Productivity improvement from baseline to 12 months post-intervention was examined across all ergonomics conditions combined, and also compared to the control group. The findings showed that worker performance increased for 50% of the ergonomics improvement participants and decreased for 50%. Overall, there was a 4.87% output increase for the ergonomics improvement group as compared to a 3.46% output decrease for the control group. The level of productivity increase varied by the type of the ergonomics improvements with Group C showing the best improvement (9.43%). Even though the average production improved, caution must be used in interpreting the findings since the ergonomics interventions were not successful for one-half of the participants.     

Ergonomics in total quality management: how can we sell ergonomics to management?

The objective of this paper is to describe how and why ergonomics should be promoted in total quality management (TQM). Ergonomics and TQM activities are compared. An approach is proposed to apply ergonomics in TQM using ergonomics circles. An eight-step approach is introduced for applying ergonomics using ergonomics circles and a study that employed this approach in Korea is discussed. In applying this approach, all processes were first evaluated by workers. Processes that were identified as problematic were analysed by a company-wide committee to set priorities for improvement. An ergonomics improvement team consisting of safety and health personnel, process engineers and management innovation personnel then worked on the processes using a low-cost approach. It was found that applying ergonomics using ergonomics circles as quality circles in TQM was effective in improving workplaces and resulted in increasing productivity, cost saving and improved safety.     

Ergonomic contribution of ABLE exoskeleton in automotive industry

In PSA Peugeot Citroen factories, high precision requirements of workstations make them being manual. One of the main goal of the car manufacturer is to minimize the pain of workers while maintaining high efficiency of production lines. Consequently, assisting operators with an exoskeleton is a potential solution for improving ergonomics of painful workstations while respecting industrial constraints. To determine ergonomic performances of an exoskeleton, human joint angles and torques, ground reaction forces, and duration of operations are analysed for eight subjects performing a representative screwing task. Experiments were performed using ABLE upper-limb exoskeleton, developed by the French Atomic Energy Commission (CEA), which has the functionality to compensate arm and tools loads. Results show a clear reduction of the sum of the joints torques, up to 38.9%, given by ABLE supply and invite to make concrete the use of exoskeletons in car assembly lines.     

Automatic ergonomic work analysis

To reduce occupational-related diseases, injuries and impairments to the musculo-skeletal systems, an ergonomics analysis of the work process is necessary. The authors describe a project to develop an automatic ergonomic work analysis method using existing and developed models of work stress factors. It was designed to record the work accurately without disrupting activities, and describe the situation so that production engineers and designers can be supplied with basic information for ameliorative measures. The system determines such parameters as the position and movement of 14 parts of the body, and such measurements as force exerted, range of movement and static stress. A pilot study with a prototype of the system has been completed and tested with simple work sequences.     

A comparative analysis of participatory ergonomics programs in U.S. and Japan manufacturing plants

The use of a participative approach to ergonomics is growing in countries throughout the world. This paper compares and contrasts Participatory Ergonomics programs in two U.S. and two Japanese manufacturing plants. All four programs focused on the redesign of repetitive manufacturing jobs to reduce physical stress on workers. In all four cases, this traditional ergonomics concern was addressed in a non-traditional way-involving broad participation of many manufacturing functions who worked together as an ergonomics team and direct input from operators whose jobs were redesigned.

The participatory ergonomics programs were successful in making significant numbers of job changes in both countries. A comparison of the ergonomics programs across countries revealed some significant differences in structure and process. An overarching difference was in how participation was managed. In the Japan cases, participation was a carefully controlled process by which upper management and staff specialists worked through first-line supervisors to get input from workers meeting in quality (or safety) circles. In the U.S., multi-functional and multi-level task forces (including union and worker representatives) were formed and operators were invited to meetings to give input. The U.S. plants gave the task force a great deal of autonomy and virtually all decisions were group decisions. The differences suggest that effective participatory ergonomics programs can take many forms. The best program for any particular plants in differing countries depends on their own unique history, structure, and culture.     

RULA: a survey method for the investigation of work-related upper limb disorders

RULA (rapid upper limb assessment) is a survey method developed for use in ergonomics investigations of workplaces where work-related upper limb disorders are reported. This tool requires no special equipment in providing a quick assessment of the postures of the neck, trunk and upper limbs along with muscle function and the external loads experienced by the body. A coding system is used to generate an action list which indicates the level of intervention required to reduce the risks of injury due to physical loading on the operator. It is of particular assistance in fulfilling the assessment requirements of both the European Community Directive (90/270/EEC) on the minimum safety and health requirements for work with display screen equipment and the UK Guidelines on the prevention of work-related upper limb disorders.     

Corporate ergonomics programme at BCM Airdrie. Boots Contract Manufacturing

The production processes at the BCM Airdrie site range from manual loading tasks in the manufacturing areas to high frequency packaging assembly tasks on the production lines. Both are jobs that are known to carry risk to musculoskeletal health, so an ergonomist was appointed to design and co-ordinate an ergonomics programme for the site to control these risks. This paper details the programme that has evolved to proactively manage musculoskeletal risks in the design of both new and existing equipment and processes. The ergonomics procedures described primarily involve the engineers from all areas of the factory, and the process for ergonomics involvement with engineering design projects is described. Shop-floor personnel involvement is considered to be an essential part of the programme and 'Ergonomics Champions' are being trained on the packing lines to monitor the risks that are sometimes introduced with the different designs of product packaging.     

A corporate workplace model for ergonomic assessments and improvements

Several companies have developed their own company-specific models for ergonomic improvements. This study aims to describe and identify factors supporting and hindering the implementation and application of one such corporate model for ergonomic assessment and improvement. The model has been developed by Volvo Car Corporation and implemented at an assembly plant in G?teborg, Sweden. The model is unique as it is intended to be used by production engineers and safety representatives in cooperation. The process for assessment of musculoskeletal risks is standardised and participatory, which also supports identification of solutions. Interviews, questionnaires, observation and document studies were used to evaluate the use of the model. The model was found to improve participation and collaboration among stakeholders; provide a more effective ergonomic improvement process; visually represent the ergonomics situation in the company; and give legitimacy to and awareness of ergonomics. However, the model was found to be rather resource demanding and dependent on support from management and unions. In particular, a substantial training programme and regular use of the model are needed.