Design and implementation of a participatory ergonomics program for machine sewing tasks

A participatory ergonomics program was designed and implemented to control and reduce workers' compensation costs within an automobile products manufacturing company. Pareto analysis identified a substantial number of musculoskeletal disorders (MSD) associated with manual, machine sewing of canvas automobile accessory products. This case study will discuss the elements of the participatory ergonomics program, describe its implementation, highlight intervention measures, and present program results. Specifically, during the period of 1993 to 1996, the participatory ergonomics program played a significant part in reducing the number of MSD claims by approximately 85%, and contributed to an overall reduction in workers' compensation incurred loss costs by approximately 42%.     

ErgoVSM: A Tool for Integrating Value Stream Mapping and Ergonomics in Manufacturing

Value stream mapping (VSM) is a lean tool aiming at waste reduction. Previous research suggests that the use of VSM may result in work intensification and thus an increased risk for the workers of developing work‐related musculoskeletal disorders (MSD). In the current study, VSM was developed to also consider physical exposure in the analyzed production system (ErgoVSM). As the VSM, ErgoVSM is based on a participatory approach. ErgoVSM was tested in a Swedish manufacturing company. The results suggest that ErgoVSM catalyzes change processes to include intervention proposals emphasizing ergonomics in addition to waste reduction. Thus, ErgoVSM appeared useful for the investigated target group of production engineers and experienced operators. The performance improvements suggested when using the ordinary VSM seemed not to be hampered by adding the ergonomics complement. However, the use of ErgoVSM was somewhat more time consuming than the use of VSM. In conclusion, ErgoVSM is suggested as a feasible tool to be used by production engineers and experienced operators for including ergonomics considerations in the rationalization process.     

Effectiveness of participatory ergonomic interventions on health outcomes: a systematic review

The objective of this study was to conduct a systematic review of the literature on the effectiveness of participatory ergonomic (PE) interventions for improving workers' health. The search strategy targeted six electronic databases and identified 442 potential articles. Each article was examined by pairs of reviewers for relevance (assessed a participative ergonomic workplace intervention, with at least one health outcome, published in English in peer reviewed literature). Twenty-three articles met relevance criteria and were then appraised for methodological strength. Using a best evidence synthesis approach, 12 studies that were rated as 'medium' or higher provided partial to moderate evidence that PE interventions have a positive impact on: musculoskeletal symptoms, reducing injuries and workers' compensation claims, and a reduction in lost days from work or sickness absence. However, the magnitude of the effect requires more precise definition.     

Evaluation of a participatory ergonomic intervention process in kitchen work

We evaluated a participatory ergonomic intervention process applied in 59 municipal kitchens. In groups of three to five kitchens, the workers participated in eight workshops, and generated and evaluated solutions to optimize musculoskeletal load in their work. An ergonomist initiated and supported the process. By the end, 402 changes were implemented. Evaluative data were collected using research diaries, questionnaires, and focus group interviews. The intervention model proved feasible and the participatory approach was mostly experienced as motivating. The workers’ knowledge and awareness of ergonomics increased, which improved their ability to tackle ergonomic problems by themselves. The changes in ergonomics were perceived to decrease physical load and improve musculoskeletal health. As hindering factors for implementation, lack of time and motivation, and insufficient financial resources were mentioned. In addition, the workers expressed a wish for more support from the management, technical staff, and ergonomists.     

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.     

Process and implementation of participatory ergonomic interventions: a systematic review

Participatory ergonomic (PE) interventions may vary in implementation. A systematic review was done to determine the evidence regarding context, barriers and facilitators to the implementation of participatory ergonomic interventions in workplaces. In total, 17 electronic databases were searched. Data on PE process and implementation were extracted from documents meeting content and quality criteria and synthesised. The search yielded 2151 references. Of these, 190 documents were relevant and 52 met content and quality criteria. Different ergonomic teams were described in the documents as were the type, duration and content of ergonomic training. PE interventions tended to focus on physical and work process changes and report positive impacts. Resources, programme support, ergonomic training, organisational training and communication were the most often noted facilitators or barriers. Successful PE interventions require the right people to be involved, appropriate ergonomic training and clear responsibilities. Addressing key facilitators and barriers such as programme support, resources, and communication is paramount.

Statement of Relevance: A recent systematic review has suggested that PE has some effect on reducing symptoms, lost days of work and claims. Systematic reviews of effectiveness provide practitioners with the desire to implement but do not provide clear information about how. This article reviews the literature on process and implementation of PE.     

Paddling upstream: a contextual analysis of implementation of a workplace ergonomic policy at a large newspaper

Efforts to implement workplace ergonomic programs aimed at reducing the burden of work-related musculoskeletal disorders (WMSD) have to address multiple physical and psychosocial aspects of work environments yet often contextual factors limit their success. We describe the processes involved in an ergonomic program to reduce neck and upper limb WMSDs at a large Canadian newspaper. Using qualitative data collection and analysis methods, we illustrate the impact of key contextual characteristics of: (1) the program (management commitment, union involvement, experience and skill of program leaders, and researcher involvement); (2) the organization (drive for productivity, management control, organizational culture); and (3) the broader social context (economic climate, nature of newspaper work, technology and nature of WMSD). We argue for increased attention to identification and response to the contextual factors affecting program implementation in order to more successfully address upstream determinants of WMSD.     

Study of the effectiveness of a participatory ergonomics intervention in reducing worker pain severity through physical exposure pathways

A participatory ergonomics programme was implemented in an automotive parts manufacturing factory. An ergonomics change team was formed composed of members from management and the organized labour union. It was hypothesized that the physical change projects implemented as part of this process would result in decreased worker exposures to peak and cumulative physical demands and reduced worker perceptions of physical effort and pain severity. A quasi-experimental design was employed, utilizing a sister plant in the corporation as a referent group. A longitudinal questionnaire approach was used to document pre-post changes in worker perceptions. In general, the physical change projects were rated as improvements by workers and were successful at reducing peak and/or cumulative mechanical exposures. However, there were few systematic changes in perceived effort or pain severity levels. Explanations include the confounding effects of differential production rate and staffing changes at the intervention and referent plants and/or insufficient overall intervention intensity due to a relatively short intervention period, plant and team ambivalence towards the process and the low overall impact on exposure of the particular changes implemented.     

Time trends in ergonomic intervention research for improved musculoskeletal health and comfort in Latin America

Studies on ergonomic intervention research aiming at improved musculoskeletal health published in Latin America in the past 20 years were reviewed. The tendencies observed over time in these studies show that interventions carried out are trying to deal with the changes occurring in the production processes in this period. Thus, more participative approaches have been used, involving different parts interested in the process. The previous transversal projects, more focused on the physical aspects of the work, are now substituted by studies including organizational and longitudinal designs. Despite this, some negative or unchanged outcomes have been obtained. Therefore, good quality intervention studies are needed to provide more generalizable data and improve our understanding on planning, implementing and sustaining effective measures for controlling work-related musculoskeletal disorders.     

A tool for early workstation design for small and medium enterprises evaluated in five cases

Five case studies on production line design were described to study the effect of an early design support tool. Based on these case studies, the simple, interactive, real‐time, medium‐fidelity, mixed‐reality methodology was not only found to be a good early design stage evaluative tool for ergonomics and workflow, but a teaching tool as well. Despite some drawbacks, such as limited accuracy, mixed‐reality simulation appears to be a good compromise between cost and fidelity, especially for small to medium‐sized manufacturing enterprises, and gives important information on the layout focused on high efficiency and healthy postures. © 2010 Wiley Periodicals, Inc.     

Estimation of the relative risks of musculoskeletal injuries in the Andalusian manufacturing sector

BackgroundHigher injury rates of workers with specific characteristics can show areas of interest for intervention. Worker characteristics can be a risk factor because there is a differential distribution of exposure or because a particular worker characteristic affects the worker's behavior and the effects of work in the musculoskeletal system.ObjectiveTo estimate the relative risk for the most frequent accident mechanisms and to present the usefulness of the information from the Continuous Sample of Working Lives for a better estimation of the relative risk based on epidemiological analysis of specific types of accident controlling for possible confounders.Materials and methodsThe most frequent accident mechanisms were identified by analyzing the official accident notifications. To estimate the exposed workers, the Continuous Sample of Working Lives dataset is used. The dataset contains employment variables such as occupational levels, sector of activity, contract type and duration of employment. It also includes relevant variables related to demographics such as location, age, sex and nationality.ResultsAdjusted relative risk confirms that female workers, foreign, non-manual and older workers have lower injury rates.ConclusionsThe use of the Continuous Sample of Working Lives is useful in the analysis of the risk factors for particular types of accidents and allows a better estimation of the relative risks of accident.     

Bernardino Ramazzini's early observations of the link between musculoskeletal disorders and ergonomic factors

Bernardino Ramazzini (1633-1714) systematically studied the relationship between work and diseases. He realized that it was not possible to ascribe all workers' diseases to chemicals or physical agents and foresaw that other factors were involved. He observed that common diseases could originate following the maintenance either of prolonged stationary postures or of unnatural postures (e.g. bakers, workers who stand, sedentary worker, scribes, weavers) or following activities requiring heavy muscular performance (e.g. porters and woodworkers). Furthermore, Ramazzini recognized the need to undertake measures to prevent disorders from repetitive motions and manual lifting and anticipated the now accepted advice of moderation and recommendations of reduction of work duration for a number of hard jobs requiring a standing position or severe muscular effort. From his early writings therefore it is evident that Ramazzini realized the importance of assessing the ergonomic factors associated with the occurrence of work-related musculoskeletal disorders.     

Comparison of ergonomic risk assessment outputs from OWAS and REBA in forestry timber harvesting

Globally, work-related (musculoskeletal disorders (MSDs) are one of the most important health problems encountered by ergonomists. Forest work, especially logging harvesting, is traditionally recognized as one of the most difficult types of physical work and has distinct characteristics. Harvesting works in forestry are composed of the following work stages: logging, skidding, and loading. This study aimed to examine risk factors of MSDs associated with different work postures during harvesting under variable external conditions by comparing work stages using the Ovako Working posture Assessment System (OWAS) and Rapid Entire Body Assessment (REBA). A statistically significant difference was observed between the two methods. While the difference in risk to the musculoskeletal system was statistically significant in different work stages using REBA, logging and skidding were assigned to the same risk level using OWAS. Easy-to-use ergonomic hand tools should be developed that are suitable for working conditions and help reduce MSD risk in forestry workers.     

Cost‐effectiveness of ergonomic interventions in production

Early cost–benefit analysis of ergonomic interventions in manufacturing is in the interest of the production management and the ergonomics specialist. Because of the variety of factors and the complexity to quantify these factors, this task is not an easy one. In this article we present a case study that illustrates that the economic benefits of ergonomics may easily overwhelm the costs because of the gain in productivity and quality, not to the economic gain associated with improved health. Finally, we propose a decision tool that addresses the relevant factors in the cost–benefit analysis of ergonomics. It gives Internet support to company managers and human factor specialists to make an economic analysis prior to the start of an ergonomic intervention project. © 2010 Wiley Periodicals, Inc.     

Stakeholder perspectives on managing the occupational health of UK business drivers: a qualitative approach

Musculoskeletal disorders are one of leading causes of work related ill health and sickness absence. Those drive as part of their job may be at particular risk, with evidence suggesting that prolonged exposure to driving is associated with increased absence from work due to low back pain. Business drivers often work away from a traditional office environment. Such mobile working may pose greater risks to occupational health due to increased ergonomic risks, for example working from the car, longer working hours and a lack of concern amongst drivers about health and safety. It has been suggested that occupational health practices have not adapted to meet the needs of peripatetic workers. The current study explored how occupational health services are delivered to business drivers. Semi-structured interviews were carried out with a sample of 31 stakeholders in 4 organisations. Respondents included, health and safety professionals, occupational health nurses, fleet managers and high mileage business drivers. The interviews were transcribed and analysed using ‘Template Analysis’. The data revealed that, within these organisations, the provision of occupational health services was often fragmented and drivers and other key stakeholders were often unaware of the existing systems within their organisations. The peripatetic nature of business drivers meant that they were difficult for occupational health teams to reach. The paper concludes by presenting recommendations for occupational health professionals and researchers engaged with improving the health of peripatetic workers, namely that occupational health policies should be integrated in company strategy and widely disseminated to drivers and those with responsibility for managing their occupational health provision.     

Contextual factors affecting task distribution in two participatory ergonomic interventions: a qualitative study

This article provides an analysis of the evolution of the division of labour in participatory ergonomics (PE) programmes in two worksites. The analysis is based on interviews and field observations in the worksites. In both settings there was meaningful participation by both worker and management members of ergonomic change teams (ECTs) in the hazard assessment and solution identification stages, but as the teams moved to the implementation stage, worker representatives were marginalised and the participatory nature of the programmes was severely curtailed. The removal of workers from the process was the outcome of the interplay among the type of activities pursued in the implementation stage, the skills and knowledge required to carry out those activities, and workers’ limited influence in the organisational hierarchies. Findings highlight the salience of the social context in which participatory programmes are located and the importance of examining participatory programmes as they evolve over time.

Statement of Relevance: This article contributes to a growing literature on the process and implementation of PE programmes. The article's focus on social and organisational factors that affect the division of labour and attention to the evolution of involvement over time extend current understandings of participation in ergonomics programmes.     

Theory and practice for the implementation of ‘in-house’, continuous improvement participatory ergonomic programs

This paper presents a case study of an implementation of a participatory ergonomics program in a public service agency. The objective of the study was to develop a theoretical model and related design principles for the implementation of ‘in-house’, continuous improvement participatory programs. The proposed model is based on the behavioral cybernetic theory of learning (Smith and Smith, 1966, Cybernetic Principles of Learning and Educational Design held, Rhinehart and Winsten, New York) and emphasizes the concepts of action, feedback, feedback control, and individual learning as essential for a progression from external regulation (by outside experts) to internal regulation (by organizational members) of participatory programs. Results support the proposed model, but do suggest an expansion of the model to include macro-level organizational variables as additional factors necessary for developing internally regulated participatory programs. Results have led to the specification of several design principles for implementing ‘in-house’, continuous improvement participatory programs.     

Participatory ergonomics in design processes: the role of boundary objects

The aim of this paper is to introduce the concept of boundary objects in order to better understand the role of objects in participatory ergonomics (PE) design processes. The research question is: What characterizes boundary objects in PE processes? Based on two case studies, we identify eight characteristics of boundary objects and their use, which make them particularly useful in PE design processes. These characteristics go beyond the object itself and extend into the context of their use. We argue that the selection of boundary objects in PE processes is of great importance, since different objects enable workers’ participation and collaborative design in different ways. The framework developed may serve to provide criteria to guide practitioners and intervention researchers in the selection of objects to facilitate a PE process. The paper concludes with a list of recommendations for ergonomic practitioners that are based on the framework.     

Effectiveness of a participatory ergonomics intervention in improving communication and psychosocial exposures

A participatory ergonomics programme was implemented in an automotive parts manufacturing factory in which an ergonomics change team was formed, composed of members from management, the organized labour union and the research team. It was hypothesized that the participatory nature of this change process would result in enhanced worker perceptions of workplace communication dynamics, decision latitude and influence, which in conjunction with anticipated mechanical exposure reductions would lead to reduced worker pain severity. Utilizing a sister plant in the corporation as a referent group, a quasi-experimental design was employed with a longitudinal, repeat questionnaire approach to document pre-post intervention changes. Nine participatory activities (psychosocial interventions) were implemented as part of the process. Communication dynamics regarding ergonomics were significantly enhanced at the intervention plant compared to the referent plant. However, there were no significantly different changes in worker perceptions of decision latitude or influence between the two plants, nor did pain severity change. Possible explanations for these results include limited intervention intensity, context and co-intervention differences between the two plants, high plant turnover reducing the statistical power of the study and lack of sensitivity and specificity in the psychosocial measures used. Further research should include the development of psychosocial tools more specific to participatory ergonomic interventions and the assessment of the extent of change in psychosocial factors that might be associated with improvements in pain.     

A long-term evaluation of the stage of change approach and compensable injury outcomes – a cluster-randomised trial

Abstract

This study investigated the long-term injury outcomes for workers in companies from a range of industries which had been randomly allocated to receive ergonomics interventions tailored according to the stage of change (SOC) approach or standard ergonomics advice. Differences in compensable injury outcomes between the groups were analysed using logistic regression models. Questionnaire results from face-to-face interviews to assess musculoskeletal pain and discomfort (MSPD), job satisfaction and other factors were also analysed. Although not significant at the 0.05 level, after adjusting for workgroup clustering, workers in receipt of tailored advice were 55% (OR = 0.45, 95% CI = 0.19–1.08) less likely to report a compensable injury than those in receipt of standard ergonomics advice. Workload, job satisfaction and MSPD were significantly correlated with injury outcomes. The observed outcomes support the potential value of the SOC approach, as well as highlighting the need to consider workload, job satisfaction and MSPD when planning injury prevention programmes.

Practitioner Summary: This study investigated compensable injury outcomes for workers who had received ergonomics advice tailored according to the stage of change (SOC) approach compared with standard ergonomics advice. The results support the potential value of the SOC approach and highlight the need to consider workload, job satisfaction and musculoskeletal pain and discomfort when planning injury prevention interventions.