Oxygen consumption prediction models for individual and combination materials handling tasks

An experiment was conducted to develop models to predict oxygen consumption of males and females engaged in common materials handling tasks including lifting, lowering, pushing, pulling, (de)palletising and combination tasks involving lifting or lowering a box and carrying it a set distance and lifting or lowering it to the destination. Nineteen male and 19 female subjects participated in the study. A psychophysical approach was used to set load limits for individual subjects for the oxygen consumption protocol. The 8398 oxygen consumption values collected were entered into the initial regression analyses and 168 potential outliers were removed before the final models were run. In addition to relevant task variables, body weight was a significant predictor variable in all models. The r(2) values for the final models ranged from 0.54 to 0.82 and the root mean square errors ranged from 90.2 ml to 294.8 ml.     

Prediction accuracy in estimating joint angle trajectories using a video posture coding method for sagittal lifting tasks

This study investigated prediction accuracy of a video posture coding method for lifting joint trajectory estimation. From three filming angles, the coder selected four key snapshots, identified joint angles and then a prediction program estimated the joint trajectories over the course of a lift. Results revealed a limited range of differences of joint angles (elbow, shoulder, hip, knee, ankle) between the manual coding method and the electromagnetic motion tracking system approach. Lifting range significantly affected estimate accuracy for all joints and camcorder filming angle had a significant effect on all joints but the hip. Joint trajectory predictions were more accurate for knuckle-to-shoulder lifts than for floor-to-shoulder or floor-to-knuckle lifts with average root mean square errors (RMSE) of 8.65°, 11.15° and 11.93°, respectively. Accuracy was also greater for the filming angles orthogonal to the participant's sagittal plane (RMSE = 9.97°) as compared to filming angles of 45° (RMSE = 11.01°) or 135° (10.71°). The effects of lifting speed and loading conditions were minimal. To further increase prediction accuracy, improved prediction algorithms and/or better posture matching methods should be investigated.

Statement of Relevance: Observation and classification of postures are common steps in risk assessment of manual materials handling tasks. The ability to accurately predict lifting patterns through video coding can provide ergonomists with greater resolution in characterising or assessing the lifting tasks than evaluation based solely on sampling with a single lifting posture event.     

Oxygen consumption prediction models for individual and combination materials handling tasks

An experiment was conducted to develop models to predict oxygen consumption of males and females engaged in common materials handling tasks including lifting, lowering, pushing, pulling, (de)palletising and combination tasks involving lifting or lowering a box and carrying it a set distance and lifting or lowering it to the destination. Nineteen male and 19 female subjects participated in the study. A psychophysical approach was used to set load limits for individual subjects for the oxygen consumption protocol. The 8398 oxygen consumption values collected were entered into the initial regression analyses and 168 potential outliers were removed before the final models were run. In addition to relevant task variables, body weight was a significant predictor variable in all models. The r² values for the final models ranged from 0.54 to 0.82 and the root mean square errors ranged from 90.2 ml to 294.8 ml.     

Manual materials handling capabilities in non-standard postures

Research efforts to establish manual materials handling (MMH) capabilities of individuals and populations have been conducted for many years. Most of the previous efforts have explored ‘standard postures’, utilizing two-handed, symmetric, sagittal plane MMH using unrestricted postures. Recognizing that many industrial MMH activities do not utilize ‘standard postures’, recent research projects have explored psychophysicaly determined MMH capacities in a variety of non-standard postures. Among the non-standard postures examined were: twisting while lifting or lowering, lifting and lowering from lying, sitting, kneeling, and squatting positions, and carrying loads under conditions of constricted ceiling heights. This paper presents the results of a series of previous research efforts at Texas Tech University. The results are presented in the form of population capabilities of both males and females for 99 MMH tasks using ‘non-standard postures’. The data tables contain means and standard deviations of the data, as well as percentile distributions for the subject populations. Sample sizes for the experimental populations ranged from 45 to 50 subjects of each sex in the first three experiments to 20 subjects of each sex in the fourth set of experiments.     

A novel optimization model for predicting trunk muscle forces during asymmetric lifting tasks

Low back pain (LBP) is a social and economic problem throughout industry. Repetitive asymmetric postures frequently occur in manual materials handling tasks and such asymmetric lifting has been epidemiologically linked to LBP. Therefore, biomechanical lifting models must be developed to predict muscle forces during asymmetric lifting tasks. This paper proposes an optimization model that was revised to take into account the activities of trunk muscles during asymmetric lifting tasks. Also, three optimization models (minimize maximum muscle intensity: MIN_I_MAX, minimize sum of magnitudes of the muscle forces raised to power 3: MIN_F³, and minimize sum of the muscle intensities raised to power 3: MIN_I³) are compared under various asymmetric lifting conditions. The revised model not only reflects the twisting effect of muscle force vectors for eight primary trunk muscles when trunk rotation is involved, but also accurately predicts the forces of left erector spinae, left latissimus dorsi and left external oblique muscles when compared with EMG signals obtained from experiments. Furthermore, MIN_I_MAX exhibits the best prediction capability among the three optimization models.Relevance to industryA novel optimization model proposed herein considers the twisting effect of muscle force vectors for eight trunk muscles when trunk rotation is involved. An accurate biomechanical model which reflects the asymmetric lifting conditions would significantly facilitate the evaluation of job and workplace design as well as provide a practical clinical evaluation technique.     

Manual materials handling capabilities in non-standard postures.

Research efforts to establish manual materials handling (MMH) capabilities of individuals and populations have been conducted for many years. Most of the previous efforts have explored 'standard postures', utilizing two-handed, symmetric, sagittal plane MMH using unrestricted postures. Recognizing that many industrial MMH activities do not utilize 'standard postures', recent research projects have explored psychophysically determined MMH capacities in a variety of non-standard postures. Among the non-standard postures examined were: twisting while lifting or lowering, lifting and lowering from lying, sitting, kneeling, and squatting positions, and carrying loads under conditions of constricted ceiling heights. This paper presents the results of a series of previous research efforts at Texas Tech University. The results are presented in the form of population capabilities of both males and females for 99 MMH tasks using 'non-standard postures'. The data tables contain means and standard deviations of the data, as well as percentile distributions for the subject populations. Sample sizes for the experimental populations ranged from 45 to 50 subjects of each sex in the first three experiments to 20 subjects of each sex in the fourth set of experiments.     

The effect of handle angle on MAWL, wrist posture, RPE, and heart rate

In manual material handling tasks, the handle serves as the interface between the human operator and the box (the materials). Handle angle design can affect both wrist posture and lifting ability. This study was designed to evaluate the effect of handle angle on maximal acceptable weight of lifting (MAWL), perceived whole-body exertion, whole-body workload, wrist posture, and perceived wrist exertion. The results indicate that handle angle had a significant effect on wrist posture and wrist rating of perceived exertion (RPE). A box with a 0 degrees handle angle induced the greatest ulnar deviation and the highest wrist RPE. A 75 degrees handle angle induced the greatest radial deviation and a relatively high wrist RPE. A 30 degrees handle angle resulted in the greatest MAWL and the lowest level of wrist RPE. Overall, these findings suggest that 30 degrees and 45 degrees handle angles can provide favorable coupling conditions for the cutout-type handhold container handle. Actual or practical applications include the ergonomic design of container handles for manual material handling tasks industry.     

Simulating Human Lifting Motions Using Fuzzy-Logic Control

Human motion simulation is an ill-posed problem. In order to predict unique lifting motion trajectories, a motion simulation model based on fuzzy-logic control is presented. The human body was represented by a 2-D five-segment model, and the neural controller was specified by fuzzy logic. Fuzzy rules were defined with their antecedent part describing the fuzzy variables of scaled positional error and velocity, and with their consequent part describing scaled angular velocity. These rules were generated according to certain trends in the fuzzy variable trajectories observed from actual lifting motions. An optimization procedure was performed to specify the parameters of the membership functions by minimizing the differences between the simulated and actual final postures. Simulations were obtained for 14 novel lifting motions from seven participants. Overall, results indicated that the presented model simulated lifting motions with an accuracy that was at least comparable to some previous human motion simulation models. The accuracy of the simulations differed between joints and was highest near the beginning and end of the motions. Strengths and limitations of the modeling approach are discussed. The use of fuzzy-logic control appears to be a fruitful basis for future simulations of lifting and other human tasks.      

The development of a model to predict the effects of worker and task factors on foot placements in manual material handling tasks

Accurate prediction of foot placements in relation to hand locations during manual materials handling tasks is critical for prospective biomechanical analysis. To address this need, the effects of lifting task conditions and anthropometric variables on foot placements were studied in a laboratory experiment. In total, 20 men and women performed two-handed object transfers that required them to walk to a shelf, lift an object from the shelf at waist height and carry the object to a variety of locations. Five different changes in the direction of progression following the object pickup were used, ranging from 45° to 180° relative to the approach direction. Object weights of 1.0 kg, 4.5 kg, 13.6 kg were used. Whole-body motions were recorded using a 3-D optical retro-reflective marker-based camera system. A new parametric system for describing foot placements, the Quantitative Transition Classification System, was developed to facilitate the parameterisation of foot placement data. Foot placements chosen by the subjects during the transfer tasks appeared to facilitate a change in the whole-body direction of progression, in addition to aiding in performing the lift. Further analysis revealed that five different stepping behaviours accounted for 71% of the stepping patterns observed. More specifically, the most frequently observed behaviour revealed that the orientation of the lead foot during the actual lifting task was primarily affected by the amount of turn angle required after the lift (R(2) = 0.53). One surprising result was that the object mass (scaled by participant body mass) was not found to significantly affect any of the individual step placement parameters. Regression models were developed to predict the most prevalent step placements and are included in this paper to facilitate more accurate human motion simulations and ergonomics analyses of manual material lifting tasks. STATEMENT OF RELEVANCE: This study proposes a method for parameterising the steps (foot placements) associated with manual material handling tasks. The influence of task conditions and subject anthropometry on the foot placements of the most frequently observed stepping pattern during a laboratory study is discussed. For prospective postural analyses conducted using digital human models, accurate prediction of the foot placements is critical to realistic postural analyses and improved biomechanical job evaluations.     

Dynamic biomechanical modelling of symmetric and asymmetric lifting tasks in restricted postures

This article describes investigations of dynamic biomechanical stresses associated with lifting in stooping and kneeling postures. Twelve subjects volunteered to participate in two lifting experiments each having two levels of posture (stooped or kneeling), two levels of lifting height (350 or 700 mm), and three levels of weight (15,20, or 25 kg). One study examined sagitally symmetric lifting, the other examined an asymmetric task. In each study, subjects lifted and lowered a box every 10 s for a period of 2 min in each treatment combination. Electromyography (EMG) of eight trunk muscles was collected during a specified lift. The EMG data, normalized to maximum extension and flexion exertions in each posture, was used to predict compression and shear forces at the L3 level of the lumbar spine. A comparison of symmetric and asymmetric lifting indicated that the average lumbar compression was greater in sagittal plane tasks; however, both anterior-posterior and lateral shear forces acting on the lumbar spine were increased with asymmetric lifts. Analysis of muscle recruitment indicated that the demands of lifting asymmetrically are shifted to ancillary muscles possessing smaller cross-sectional areas, which may be at greater risk of injury during manual materials handling (MMH) tasks. Model estimates indicated increased compression when kneeling, but increased shear forces when stooping. Increasing box weight and lifting height both significantly increased compressive and shear loading on the lumbar spine. A multivariate analysis of variance (MANOVA) indicated complex muscle recruitment schemes—each treatment combination elicited a unique pattern of muscle recruitment. The results of this investigation will help to evaluate safe loads for lifting in these restricted postures.     

The development of a model to predict the effects of worker and task factors on foot placements in manual material handling tasks

Accurate prediction of foot placements in relation to hand locations during manual materials handling tasks is critical for prospective biomechanical analysis. To address this need, the effects of lifting task conditions and anthropometric variables on foot placements were studied in a laboratory experiment. In total, 20 men and women performed two-handed object transfers that required them to walk to a shelf, lift an object from the shelf at waist height and carry the object to a variety of locations. Five different changes in the direction of progression following the object pickup were used, ranging from 45° to 180° relative to the approach direction. Object weights of 1.0 kg, 4.5 kg, 13.6 kg were used. Whole-body motions were recorded using a 3-D optical retro-reflective marker-based camera system. A new parametric system for describing foot placements, the Quantitative Transition Classification System, was developed to facilitate the parameterisation of foot placement data. Foot placements chosen by the subjects during the transfer tasks appeared to facilitate a change in the whole-body direction of progression, in addition to aiding in performing the lift. Further analysis revealed that five different stepping behaviours accounted for 71% of the stepping patterns observed. More specifically, the most frequently observed behaviour revealed that the orientation of the lead foot during the actual lifting task was primarily affected by the amount of turn angle required after the lift (R ² = 0.53). One surprising result was that the object mass (scaled by participant body mass) was not found to significantly affect any of the individual step placement parameters. Regression models were developed to predict the most prevalent step placements and are included in this paper to facilitate more accurate human motion simulations and ergonomics analyses of manual material lifting tasks.

Statement of Relevance: This study proposes a method for parameterising the steps (foot placements) associated with manual material handling tasks. The influence of task conditions and subject anthropometry on the foot placements of the most frequently observed stepping pattern during a laboratory study is discussed. For prospective postural analyses conducted using digital human models, accurate prediction of the foot placements is critical to realistic postural analyses and improved biomechanical job evaluations.     

Development of a microcomputer-based expert system for the analysis of manual materials handling tasks in industrial settings

This paper discusses the framework of a comprehensive knowledge-based expert system (M-LIFTAN) for analysis and design of manual materials handling tasks. The system, built using an expert system shell: ES / P ADVISOR written in Prolog 2, is implemented on a IBM AT® microcomputer. The knowledge base of M-LIFTAN allows the user to perform five different types of job analysis: (1) determination of maximum weights that can be handled manually by industrial workers for a variety of tasks, (2) determination of the NIOSH-based lifting recommendations, (3) prediction of maximum acceptable loads for lifting, (4) evaluation of the risk of overexertion injury while lifting loads under specified conditions, and (5) to seek advice for design/evaluation of complex manual handling tasks. An example of the consultation session illustrates the system's capabilities.     

Ergonomic job design in frequent manual lifting tasks: A microcomputer-based model

The main objective of this paper is to generate ergonomic software that can be used in the design and evaluation of manual materials handling tasks so as to minimize the risk of injury. Specifically, this study is aimed at developing a microcomputer-based model for the design of frequent manual lifting tasks based ont he concept of job saverity index. The microcomputer-based software package is intended to be used by non-experts in the field of MMH. Possible engineering and administrative controls are implemented in the software in case if human lifting abilities are exceeded. The software was written in AutoLISP for the IBM personal computer. The knowledge base of the software is built upon a set of two models which were developed in the present study. The models were based on 2,736 observations.     

Manual materials handling: a survey of risks,and the selection and training of workers in Singapore

A survey of 83 plants employing safety officers indicated that in 66% of them, workers were involved in manual lifting. The average number of manual lifting tasks was three per plant. Only about 6% of the total workforce were involved in manual lifting. Using the NIOSH Lifting Guidelines, the survey revealed that 30% of the lifting tasks were above the Maximum Permissible Limit, 50% were between the Maximum Permissible Limit and the Action Level, and only 20% were below the Action Level. A majority of the plants used a self-selection method to match a worker to the physical demands of a given manual lifting task. Training of workers in manual materials handling was provided by 76% of the plants. The principal methods of training included a poster campaign and demonstration of lifting techniques. The basic handling skills were taught in 90% of the plants. The content of training was incomplete, however, and further improvement was necessary.     

Lifting in four restricted lifting conditions: psychophysical, physiological and biomechanical effects of lifting in stooped and kneeling postures

Many underground coal mines are less than 1.2 m in height, and require that manual lifting tasks be performed in restricted postures (usually stooped or kneeling). Unfortunately, little is known about how these postures affect the underground coal miner's capabilities to perform such work. A previous Bureau of Mines study indicated that lifting capacity is greater when stooped than kneeling when lifting under a 1.2 m roof height (Gallagher et al, 1988). However, many low-seam coal mines present even more restricted headroom than 1.2 m. Therefore, a study was conducted to: (1) examine the psychophysical lifting capacity of low-seam coal miners under four restricted lifting conditions, (2) investigate the associated metabolic costs, and (3) analyse the electromyography (EMG) of trunk muscles when lifting in these restricted positions. Subjects were 12 coal miners accustomed to handling materials in restricted postures (mean age = 35.9 yrs +/- 6.4 SD). Results of this study indicated that lifting capacity was greater when the subjects could assume a stooped posture than when kneeling (p < 0.01). Furthermore, the metabolic cost was greater in the kneeling posture for heart rate (p < 0.001), oxygen consumption (p < 0.001), minute ventilation (p < 0.05] ), and respiratory exchange ratio (p < 0.05), despite the fact that miners lifted less weight in this posture. Analysis of the EMG data indicated increased activity of the electores spinae when kneeling (p < 0.001), but higher latissimus dorsi activity when stopped (p < 0.001). The findings of this study indicate that the weight of supply items should be reduced approximately 14-18% when the kneeling posture must be used for lifting.     

Manual handling of supplies in free and restricted headroom

The handling of mining supplies still involves manual lifting and carrying, some of which is, of necessity, carried out in restricted headroom conditions. Laboratory studies previously reported in the literature have shown that a reduction in ceiling height led to a progressive increase in truncal stress as measured by intra-abdominal pressure (IAP). However, such studies involved standard stylised lifting procedures. Whether such effects of restricted headroom occurred when free-style lifting, or if the operator compensated by change in lifting style for the restriction, was not known. The effect of reduced headroom was examined on two handling tasks carried out in a simulated underground roadway using eight mining instructors as subjects. Both handling tasks involved the loading, unloading and carrying of stonedust bags (25–30 kg) into different vehicle types.

The expected increase in IAP did not occur in the reduced headroom condition for one handling task and only a slight increase (average 3 mm Hg), corresponding to a 7% reduction in lifting capacity, was found for the second handling task. It appears that the subjects, who were free to adopt any posture and handling method, were able to compensate in some way for the effects of the restricted headroom. The vehicle type had a highly significant effect, both in free and restricted headroom conditions, which highlights the importance of design for manual handling tasks.     

Estimation of 3-D peak L5/S1 joint moment during asymmetric lifting tasks with cubic spline interpolation of segment Euler angles

Previous research proposed a method using interpolation of the joint angles in key frames extracted from a field-survey video to estimate the dynamic L5/S1 joint loading for symmetric lifting tasks. The advantage of this method is that there is no need to use unwieldy equipment for capturing full body movement for the lifting tasks. The current research extends this method to asymmetric lifting tasks. The results indicate that 4-point cubic spline interpolation of segment Euler angles combined with a biomechanical model can provide a good estimation of 3-D peak L5/S1 joint moments for asymmetric lifting tasks. The average absolute error in the coronal, sagittal, and transverse planes with respect to the local pelvis axes was 16Nm, 22Nm, and 11Nm, respectively. It was also found that the dynamic component of the peak L5/S1 joint moment was not monotonously convergent when the number of interpolation points was increased. These results can be helpful for developing applied ergonomic field-survey tools such as video bases systems for estimating L5/S1 moments of manual materials handling tasks.     

Using sitting as a component of job rotation strategies: Are lifting/lowering kinetics and kinematics altered following prolonged sitting

Workers are often required to perform manual materials handling tasks immediately following periods of prolonged sitting either as a secondary job component of as different tasks in a job rotation strategy. The goal of this investigation was to determine if changes to low-back kinetics and/or kinematics occurred during repetitive lifting/lowering exertions following extended seated exposures. Upper body kinematics, lumbar spine flexion angle, pelvic orientation and bilateral muscle activity from the external abdominal obliques and lumbar erector spinae were recorded for 8 males and 8 females while they alternated between sessions of repetitive lifting/lowering and prolonged sitting. Upper body kinematics were used as inputs to a linked segment model to compute low-back flexion/extension moments, compression, and shear. Peak lumbar flexion was reduced by 1.8° during the lifting/lowering exertions following the first hour of sitting which consequently led to a reduction of approximately 50 N in the reaction anteroposterior shear forces. Sitting postures were consistent with previously reported data. The reduced shear loads during repetitive lift/lower exertions following prolonged sitting may be a consequence of alterations in passive tissue properties which could alter the risk of low-back injury, although future research is required to examine the biomechanical significance of this finding. Changes to both kinematics and kinetics were minimal suggesting that using prolonged sitting as a component of a task series in job rotation does not alter the risk present when combined with repetitive lifting tasks.     

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.