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ErgonomicsErgonomicsErgonomics for People

at Work

Yassierli, PhDyassierli@mail.ti.itb.ac.id

Institut Teknologi Bandung

ErgonomicsErgonomicsforfor

OSH ManagementOSH Management

• KK Manajemen Industri – Teknik Industri• PhD in Industrial & Systems Engineering, Ergonomics & Human Factors

Engineering option, Virginia Tech, USA

Ya s s i e r l iYa s s i e r l i , P h D, P h D

• Adjunct Faculty at Virginia Tech, USA• Faculty at ITB since 1998• Research Interest:

– Fatigue Management– Fit to work– Transportation Safety– Ergonomic Assessment– E‐learning– Usability Engineering– Ergonomics in organization– Safety Culture & Safety Management

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Research Overview• 2010:  Ergonomic Intervention using Blue Light for Enhancing 

Worker Awareness , Hibah Alumni ITB

• 2010. Pengembangan alat monitor kelelahan berdasarkan Flicker Fusion Critical Frequency Hibah Kompetensi DIKTIFusion Critical Frequency, Hibah Kompetensi DIKTI

• 2010, Effects of secondary task while driving: An effort to reduce accident rate in Indonesia, Asahi Glass Foundation Grant, Japan

• 2009, Sistem Cerdas Deteksi Kantuk pada Pengemudi Kendaraan, Riset Insentif Kementrian Riset dan Teknologi

• 2008 Utilities of fatigue measures during overhead construction• 2008, Utilities of fatigue measures during overhead construction work, Hibah Alumni ITB

• 2008‐2009, Perancangan Alat Genggam Elektronik untuk EvaluasiKeselamatan Kerja di Industri, Hibah Bersaing DIKTI 

Interventions

• ErgoSH: a  PDA‐based Assessment for Ergonomics & S f t& Safety

• Portable Fatigue Monitor: Flicker‐based• Driving Simulator

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• Ergonomics (Greek):

>>Definition

– Ergon : work (kerja )– Nomos : laws (aturan)

Another term : Human Factors Engineering

‘’ A discipline that studies human capabilities and limitations, and applies the information in

designing and evaluating work systems ‘’‘’

>> Basic Concepts

ERGONOMI

b t k j l bih d h t i g d‘’

• Fit the task to the person, not the person to

membuat kerja lebih aman, mudah, cepat, ringan danberkualitas baik ‘’

the task• Human-Centered Design

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• Personal and fatigue allowances are too high

>>Indicators of need for Ergonomics

• Employees frequently complain at musculoskeletal• Operators are making frequent mistakes on the jobs• Production output is unacceptably low• Absenteeism is unacceptably high• Product quality is lowq y

Human-related problems

Courses in Ergonomics• Occupational Biomechanics• Work Physiology• Human Information Processing• Research Design in Ergonomics• Usability Engineering• Human Factors System Design• Macro‐ergonomics• Industrial Ergonomics• Work Environmental Design

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Financial/Business

>>Why Ergonomics ?

Increased ProductivityImproved work methods

(Easier for workers)Increased efficiencyLess fatigueF

Decreased medical costsDecreased compensation costsIncreased productivityFewer lost work day cases

Fewer errors Quality of Working LifeFewer injuriesLess fatigue and stressImproved employee morale

• Musculoskeletal– Overload of muscles and skeletal system

>>Micro-Ergonomics Problems

– Overload of muscles and skeletal system• Anthropometric

– Dimensional conflicts between functional space geometry and the human body

• Cardiovascular– Overload of metabolic (energy production) system

• Environmental– Excessive exposure to environmental stress (e.g. heat, vibration)

• Cognitive– Information overload; memory demands

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• Lack of motivation• Lack of worker involvement

>>Macro-Ergonomics Problems

• Lack of worker involvement• Coordination & communication problems• Human error• Safety culture

>>Misconceptions

• It is luxury• It is always expensivey p• It is just common sense• It is about design a chair• It is about low-back pain• It is solved by checklist

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Issues in Industries

1. In‐ergonomics product/machine/display2. Musculoskeletal disorders 3. Human error & Human factors4. Fatigue5. Safety culture

Issue 1

www.baddesigns.com

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Issue 1 (Cont’d)

Issue 1 (Cont’d)

• Other cases:– Too small/Too big– Too high/Too short– Etc

• Safety & Health Consequences?Safety & Health Consequences?• Solutions:

– Ergonomics role in design

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>>Issue 2

Risk of musculoskeletal disorders due to strenuous physical activities:

- Lifting - Pulling/Pushing- Handling

Disorders: Low back pain, shoulder pain, neck pain, etc

Event: %: (Billions) 2002- 2003 1999- 2003

Overexertion 26 4% $13 4 -0 03% 15 1%

>> Cost $$$ ?www.libertymutual.com

Overexertion 26.4% $13.4 0.03% 15.1%Falls on the Same Level 13.7% $6.9 10.4% 32.3%Bodily Reaction 10.2% $5.1 -4.7% 20.3%Falls to Lower Level 9.0% $4.6 -1.9% 8.8%Struck by Object 8.5% $4.3 -3.4% 12.2%Repetitive Motion 5.9% $3.0 3.4% -2.2%Highway Incidents 5 8% $3 0 12 8% 9 2%Highway Incidents 5.8% $3.0 12.8% 9.2%Struck Against Object 4.4% $2.2 -6.1% 5.2%

Caught in or Compressed by 3.9% $2.0 1.4% 12.9%Assaults & Violent Acts 0.8% $0.4 -9.9% -8.5%All other 11.3% $5.8Total 100% $50 8 0 7% 11 4%

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• Maintenance shop: posture, excessive

>> Coal Mining>> Coal Mining

force, static loading, contact stress, vibration

>> Oil Industry>> Oil Industry

Well service: posture, excessive force, metabolic cost, night shift

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>> Manufacturing>> Manufacturing

posture excessive posture, excessive force, static loading, repetition, contact stress, lighting

>> Textile>> Textile

posture, repetition, contact stress, static loading, lighting

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Ergonomics Solutions for Risk of MSDs

• Musculoskeletal complaints survey• Ergonomic Assessment

– Risk factors evaluation– Risk quantification– Job priority– Controls/Interventions

• Engineering• Engineering• Administrative

• Health surveillance

>>Issue 2: Human Errors

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Human Error• Individual factors:

– Low skill & competence levels (?)– Tired staff (?)( )– Bored staff (?)

• Job factors:– Illogical design of equipment and instruments– Missing or unclear instructions– Poorly maintained equipment– High workloadg– Noisy condition

• Organization & Management factors:– Poor work planning– Poor management– Poor health & safety culture

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Ergonomic Solutions for Minimizing Human Error

• Human factors in risk assessment• Human factors in analyzing accidents, incidents, near‐missed

• Human factors in design & procurement• Human factors in SH management:

R i & i i– Recruitment & training– Work schedule & shift work

Issues in Industries

1. In‐ergonomics product/machine/display2. Musculoskeletal disorders 3. Human error & Human factors4. Fatigue5. Safety culture

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Company Issue Intervention Outcome

Window Manufacturing

- increasing musculoskeletal injuries - rise in WC costs

- ergonomic training- ergonomic demonstration

- 19% decrease in time loss injuries- 49.84% reduction in WC costs- 493 day reduction in time lost to injuries

>> Success Stories>> Success Stories

g WC costs demonstration projects

injuries- 6.9 day decrease in the average days lost per WC claim

Plastics Manufacturing

- back/shoulder RSIs- increase in WC costs

- ergonomic training- redesign of high risk machines- installation of new machinery

- $69,306 decrease in WC premiumIn single department (1994-98): - 95% decrease in RSIs- 100% decrease in lost hours- 20.4% increase in productivity- 19.9% increase in efficiency- 3.4% decrease in absenteeism- overall increase in worker morale

Nursing Home

- high numbers of musculoskeletal injuries,- high WC costs

- ergonomic training,- change in work practices to reduce MMH- new lift equipment

- $27,073.97 drop in WC claims costs- 44.8% decrease in RSIs- total days lost decreased by 505 days,- decrease in WC days lost by 43.3 days- decrease in average days lost per WC claim by 16.9 days.

Company Issue Intervention Outcome

• OSHA Recordable Rate for Ergonomics injuries=2.0.

•Ergonomics Program as part of development program

•Creating Company’s

• OSHA Recordable Rate for Ergonomics injuries=0.1

• Lost Day Case Return=0.03• Awarded “The Best Semiconductor

>> Success Stories…(2)>> Success Stories…(2)

Intel Corporation

ju es 0• Lost Day Case Rate

> 0.5.

C eat g Co pa y sErgonomics Team

•Ergonomics policy, including: management commitment; accident investigations; hazard analysis

a ded e est Se co ductoCompany” from Semiconductor Industry Association for Total Recordable Case Rate

• “Outstanding Achievement Award for improvements in productivity, ergonomics and measurement of work and workplaces” from IIE

• Cumulative trauma disorders (CTDs) up to 35% from total

•Developing ergonomic-based work quality improvement

•CTD incident rate decrease to 90%•Total accident rate decrease to 81%

Duracell

recordable injuries and illnesses for 4 years.

•Work-height adjustment, •Work stations redesign•Ergonomic chair•anti-fatigue floor mats

installation•Provide medical personnel•Ergonomic Training•Ergonomic Task Force•Ergonomic Survey

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Company Issue Intervention Outcome

Honda of America

• Increase productivity

•Fixture development in rear suspension production process

• Reduce pull force for releasing fixture from 133lbs to 2.2 lbs.

• Cycle time reduced by 10%• Scrap reduced by 96%

>> Success Stories…(3)>> Success Stories…(3)

America Manufacturing

• Scrap reduced by 96%• Increase employee morale• Reduce accidents or injuries• Injury avoidance saving $~1 million

Sun Microsystems, Inc

• WMSDs up to 300 cases

• Low Productivity

• Prolonged computer use problem

•Providing ergonomic furniture

•Personel training•Workstation

evaluation•Maintain neutral

posture at work

• 1992-2002, Repetitive Motion Injuries decreased drastically

• Total claim decreased from 300 in 1993, to less than 50 in 2002.

• Compasation cost decreased from $1.5 million to $100.000

• Cost-related MSDs decreased dracticallyp p yfrom $12.000 in 1992, to $ 2.500 in 2002.