Practical Application of Ergonomics

8/7/2019 Practical Application of Ergonomics

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Practical Application of Practical Application of ErgonomicsErgonomics

Hal W. Hendrick, Ph.D., CPEHal W. Hendrick, Ph.D., CPE

Practical Application of Practical Application of ErgonomicsErgonomics

Hal W. Hendrick, Ph.D., CPEHal W. Hendrick, Ph.D., CPE


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HFES Strategic Planning StudyHFES Strategic Planning StudyHFES Strategic Planning StudyHFES Strategic Planning Study

Reviewed ergonomics research and practiceReviewed ergonomics research and practicearound the world to determine commonaround the world to determine commoncharacteristics, purpose, and scope of characteristics, purpose, and scope of ergonomicsergonomics

Some important findings and conclusions areSome important findings and conclusions areas followsas follows

Reviewed ergonomics research and practiceReviewed ergonomics research and practicearound the world to determine commonaround the world to determine commoncharacteristics, purpose, and scope of characteristics, purpose, and scope of ergonomicsergonomics

Some important findings and conclusions areSome important findings and conclusions areas followsas follows


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Ergonomics is a ScientificallyErgonomics is a ScientificallyBased DisciplineBased DisciplineErgonomics is a ScientificallyErgonomics is a ScientificallyBased DisciplineBased Discipline

ScienceScience

Study human performance capabilities andStudy human performance capabilities andlimitations.limitations.

Apply our scientific knowledge of humansApply our scientific knowledge of humansto developingto developing ergonomics technologyergonomics technology

PrinciplesPrinciples

GuidelinesGuidelinesSpecificationsSpecificationsMethodsMethodsToolsTools

ScienceScience

Study human performance capabilities andStudy human performance capabilities andlimitations.limitations.

Apply our scientific knowledge of humansApply our scientific knowledge of humansto developingto developing ergonomics technologyergonomics technology

PrinciplesPrinciples

GuidelinesGuidelinesSpecificationsSpecificationsMethodsMethodsToolsTools


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Ergonomics is a ScientificallyErgonomics is a ScientificallyBased DisciplineBased DisciplineErgonomics is a ScientificallyErgonomics is a ScientificallyBased DisciplineBased Discipline

Practice*Practice*Apply ergonomics technology to the design, analysis, testApply ergonomics technology to the design, analysis, test

and evaluation, and standardization of systems.and evaluation, and standardization of systems.

Purpose*Purpose*To improve the quality of human lifeTo improve the quality of human life

HealthHealthSafetySafetyComfortComfort

productivityproductivity

** HFES Directory and Yearbook HFES Directory and Yearbook : Strategic Plan: Strategic Plan

Practice*Practice*Apply ergonomics technology to the design, analysis, testApply ergonomics technology to the design, analysis, test

and evaluation, and standardization of systems.and evaluation, and standardization of systems.

Purp

ose*Purpose*To improve the quality of human lifeTo improve the quality of human life

HealthHealthSafetySafetyComfortComfort

productivityproductivity



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The Technology of Ergonomics isThe Technology of Ergonomics isHumanHuman- -System Interface Technology*System Interface Technology*The Technology of Ergonomics isThe Technology of Ergonomics isHumanHuman- -System Interface Technology*System Interface Technology*

HumanHuman- -System Interface TechnologySystem Interface Technology-- HumanHuman- -Machine :Machine : Hardware ErgonomicsHardware Ergonomics

-- HumanHuman- -Environment : Environmental ErgonomicsEnvironment : Environmental Ergonomics-- HumanHuman- -Software :Software : Cognitive ErgonomicsCognitive Ergonomics-- HumanHuman- -Job :Job : Work Design ErgonomicsWork Design Ergonomics-- HumanHuman- -Work System :Work System : MacroergonomicsMacroergonomics


HumanHuman- -System Interface TechnologySystem Interface Technology-- HumanHuman- -Machine :Machine : Hardware ErgonomicsHardware Ergonomics

-- HumanHuman- -Environment : Environmental ErgonomicsEnvironment : Environmental Ergonomics-- HumanHuman- -Software :Software : Cognitive ErgonomicsCognitive Ergonomics-- HumanHuman- -Job :Job : Work Design ErgonomicsWork Design Ergonomics-- HumanHuman- -Work System :Work System : MacroergonomicsMacroergonomics



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Good Ergonomics is Good EconomicsGood Ergonomics is Good EconomicsGood Ergonomics is Good EconomicsGood Ergonomics is Good EconomicsPoor ErgonomicsPoor Ergonomics V iolates ergonomics technologyV iolates ergonomics technology

and/or and/or IsIs notnot cost effectivecost effective

Good ErgonomicsGood Ergonomics Appropriately applies sound ergonomics technologyAppropriately applies sound ergonomics technology

andand IsIs cost effectivecost effective

Poor Erg

onomicsPoor Ergonomics V iolates ergonomics technologyV iolates ergonomics technology

and/or and/or IsIs notnot cost effectivecost effective

Good ErgonomicsGood Ergonomics Appropriately applies sound ergonomics technologyAppropriately applies sound ergonomics technology

andand IsIs cost effectivecost effective


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ERGONOMICS Must Be COST EFFECTIV

EERGONOMICS Must Be COST EFFECTIV



E

The language of business isThe language of business is m oney! m oney!

Managers have to justify any expenditure inManagers have to justify any expenditure interms of the costterms of the cost- - benefit ratio : How thebenefit ratio : How theproject will affect theproject will affect the bottom line.bottom line.

Must express ergonomic project proposalsMust express ergonomic project proposalsinin financial termsfinancial terms. .

The language of business isThe language of business is m oney ! m oney!

Managers have to justify any expenditure inManagers have to justify any expenditure interms of the costterms of the cost- - benefit ratio : How thebenefit ratio : How theproject will affect theproject will affect the bottom line.bottom line.

Must express ergonomic project proposalsMust express ergonomic project proposalsinin financial termsfinancial terms. .


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MeasuringMeasuring the Economic Costs andthe Economic Costs andBenefitsBenefits of of ErgonomicErgonomic InterventionsInterventionsMeasuringMeasuring the Economic Costs andthe Economic Costs andBenefitsBenefits of of ErgonomicErgonomic InterventionsInterventionsCostsCosts Personnel, training, equipment, materials,Personnel, training, equipment, materials,

reduced productivity, and overhead.reduced productivity, and overhead.

BenefitsBenefits Personnel savings : Less lost time, less training,Personnel savings : Less lost time, less training,

lower skill levels required, increased output per lower skill levels required, increased output per person, fewer people required, greater individualperson, fewer people required, greater individual

or team effectiveness.or team effectiveness. Material savings : Reduced scrap, fewer rejects,Material savings : Reduced scrap, fewer rejects,

fewer parts.fewer parts.

CostsCosts Personnel, training, equipment, materials,Personnel, training, equipment, materials,

reduced productivity, and overhead.reduced productivity, and overhead.

BenefitsBenefits Personnel savings : Less lost time, less training,Personnel savings : Less lost time, less training,

lower skill levels required, increased output per lower skill levels required, increased output per person, fewer people required, greater individualperson, fewer people required, greater individual

or team effectiveness.or team effectiveness. Material savings : Reduced scrap, fewer rejects,Material savings : Reduced scrap, fewer rejects,

fewer parts.fewer parts.


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MeasuringMeasuring the Economic Costs andthe Economic Costs andBenefitsBenefits of of ErgonomicErgonomic InterventionsInterventionsMeasuringMeasuring the Economic Costs andthe Economic Costs andBenefitsBenefits of of ErgonomicErgonomic InterventionsInterventionsSource of informationSource of information

Much of the cost and pricing information isMuch of the cost and pricing information isavailable through either your human resourcesavailable through either your human resourcesor accounting departments, including overheador accounting departments, including overheadpercentage.percentage.

Projected benefits can be gained through theProjected benefits can be gained through theliterature and looking at similar projects in other literature and looking at similar projects in other organizations.organizations.

Source of informationSource of information

Much of the cost and pricing information isMuch of the cost and pricing information isavailable through either your human resourcesavailable through either your human resourcesor accounting departments, including overheador accounting departments, including overheadpercentage.percentage.

Projected benefits can be gained through theProjected benefits can be gained through theliterature and looking at similar projects in other literature and looking at similar projects in other organizations.organizations.


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MeasuringMeasuring the Economic Costs andthe Economic Costs andBenefitsBenefits of Ergonomic Interventionsof Ergonomic InterventionsMeasuringMeasuring the Economic Costs andthe Economic Costs andBenefitsBenefits of Ergonomic Interventionsof Ergonomic Interventions

Example : Tractor Forwarding Units, SouthExample : Tractor Forwarding Units, SouthAfrican Forestry IndustryAfrican Forestry IndustryOriginal UnitOriginal Unit : Poor operator seating and visibility: Poor operator seating and visibility

Example : Tractor Forwarding Units, SouthExample : Tractor Forwarding Units, SouthAfrican Forestry IndustryAfrican Forestry IndustryOrig inal UnitOriginal Unit : Poor operator seating and visibility: Poor operator seating and visibility


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ExampleExample : : Tractor Tractor- -Trailer Forwarding UnitsTrailer Forwarding UnitsSouth African Forestry IndustrySouth African Forestry Industry

Redesigned UnitRedesigned Unit : Good operator : Good operator seating and visibilityseating and visibility

Examp leExample : : Tractor Tractor- -Trailer Forwarding UnitsTrailer Forwarding UnitsSouth African Forestry IndustrySouth African Forestry Industry

Redesigned UnitRedesigned Unit : Good operator : Good operator seating and visibilityseating and visibility


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ExampleExample :: Tractor Tractor- -Trailer Forwarding Units,Trailer Forwarding Units,South African Forestry IndustrySouth African Forestry Industry

CostCost-- 23 Units modified @ $300 per unit : $6,90023 Units modified @ $300 per unit : $6,900

BenefitBenefit-- Reduced accident damage by $2000 per unit per year Reduced accident damage by $2000 per unit per year

or $46,000 per year.or $46,000 per year.

-- Extraction increased by one load per day per vehicleExtraction increased by one load per day per vehiclefor total increase of $19,000 per yr for total increase of $19,000 per yr -- TOTAL CostTOTAL Cost- -BenefitBenefit : $58,100 or 1 to 9.4 C: $58,100 or 1 to 9.4 C- -B ratio.B ratio.

Examp leExample :: Tractor Tractor- -Trailer Forwarding Units,Trailer Forwarding Units,South African Forestry IndustrySouth African Forestry Industry

CostCost-- 23 Units modified @ $300 per unit : $6,90023 Units modified @ $300 per unit : $6,900

BenefitBenefit-- Reduced accident damage by $2000 per unit per year Reduced accident damage by $2000 per unit per year

or $46,000 per year.or $46,000 per year.

-- Extraction increased by one load per day per vehicleExtraction increased by one load per day per vehiclefor total increase of $19,000 per yr for total increase of $19,000 per yr -- TOTAL CostTOTAL Cost- -BenefitBenefit : $58,100 or 1 to 9.4 C: $58,100 or 1 to 9.4 C- -B ratio.B ratio.


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Measuring the Economic BenefitsMeasuring the Economic Benefitsof Ergonomic Interventionsof Ergonomic InterventionsMeasuring the Economic BenefitsMeasuring the Economic Benefitsof Ergonomic Interventionsof Ergonomic Interventions

Less Tangible BenefitsLess Tangible Benefits

Increased Employee Satisfaction and Commitment :Increased Employee Satisfaction and Commitment :

Leads to good citizenship behavior. Can reduceLeads to good citizenship behavior. Can reducegrievances, improve productivity, and improvegrievances, improve productivity, and improvetrooptroop- -community relationscommunity relations all of which can have aall of which can have apositive financial impact.positive financial impact.

Improved Organizational Image :Improved Organizational Image : Can result in lessCan result in lessgovernmental scrutiny & better community relationsgovernmental scrutiny & better community relations

all of which can have a positive financial impact.all of which can have a positive financial impact.

Less Tangible BenefitsLess Tangible Benefits

Increased Employee Satisfaction and Commitment :Increased Employee Satisfaction and Commitment :

Leads to good citizenship behavior. Can reduceLeads to good citizenship behavior. Can reducegrievances, improve productivity, and improvegrievances, improve productivity, and improvetrooptroop- -community relationscommunity relations all of which can have aall of which can have apositive financial impact.positive financial impact.

Improved Organizational Image :Improved Organizational Image : Can result in lessCan result in lessgovernmental scrutiny & better community relationsgovernmental scrutiny & better community relations

all of which can have a positive financial impact.all of which can have a positive financial impact.


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Cost Effective ErgonomicsCost Effective ErgonomicsCost Effective ErgonomicsCost Effective ErgonomicsThe earlier ergonomics is used in design, theThe earlier ergonomics is used in design, thecheaper the cost and greater the benefit*cheaper the cost and greater the benefit*

System DevelopmentSystem Development Proportion of DesignProportion of DesignDesign StageDesign Stage Engineering Cost___Engineering Cost___Conceptual/Early DesignConceptual/Early Design 1.0%1.0%-- 2+%2+%BlueprintBlueprint 1.5%1.5%-- 3+%3+%ConstructionConstruction 2.0%2.0%-- 6+%6+%CommissioningCommissioning 4.0%4.0%--10+%10+%OperationalOperational 5.0%5.0%--12+%12+%

*Auburn Engineers, Inc. findings; reported at the April 2002*Auburn Engineers, Inc. findings; reported at the April 2002DoD Ergonomics Conference.DoD Ergonomics Conference.

The earlier ergonomics is used in design, theThe earlier ergonomics is used in design, thecheaper the cost and greater the benefit*cheaper the cost and greater the benefit*

System DevelopmentSystem Development Proportion of DesignProportion of DesignDesig n StageDesign Stage Engineering Cost___Engineering Cost___Conceptual/Early DesignConceptual/Early Design 1.0%1.0%-- 2+%2+%BlueprintBlueprint 1.5%1.5%-- 3+%3+%ConstructionConstruction 2.0%2.0%-- 6+%6+%CommissioningCommissioning 4.0%4.0%--10+%10+%OperationalOperational 5.0%5.0%--12+%12+%

*Auburn Engineers, Inc. findings; reported at the April 2002*Auburn Engineers, Inc. findings; reported at the April 2002DoD Ergonomics Conference.DoD Ergonomics Conference.


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Cost Effective ErgonomicsCost Effective ErgonomicsCost Effective ErgonomicsCost Effective ErgonomicsTypical CostTypical Cost- -Benefit Ratio of HFE ProgramsBenefit Ratio of HFE Programs

Between 1 to 2 and 1 to10+Between 1 to 2 and 1 to10+ (direct cost(direct costsavings only)savings only) based on analysis of 27based on analysis of 27projects (Hendrick, 1997*).projects (Hendrick, 1997*).

Life cycle cost savings can make the costLife cycle cost savings can make the cost- -benefit ratiobenefit ratio in excess of 1 to 50in excess of 1 to 50 (Hendrick,(Hendrick,1979; 1997).1979; 1997).

**G ood Ergono m ics is G ood Econo m icsG ood Ergono m ics is G ood Econo m ics (available in pdf (available in pdf format at no cost at http : //hfes.org).format at no cost at http : //hfes.org).

Typical CostTypical Cost- -Benefit Ratio of HFE ProgramsBenefit Ratio of HFE Programs

Between 1 to 2 and 1 to10+Between 1 to 2 and 1 to10+ (direct cost(direct costsavings only)savings only) based on analysis of 27based on analysis of 27projects (Hendrick, 1997*).projects (Hendrick, 1997*).

Life cycle cost savings can make the costLife cycle cost savings can make the cost- -benefit ratiobenefit ratio in excess of 1 to 50in excess of 1 to 50 (Hendrick,(Hendrick,1979; 1997).1979; 1997).

**G ood Ergono m ics is G ood Econo m icsG ood Ergono m ics is G ood Econo m ics (available in pdf (available in pdf format at no cost at http : //hfes.org).format at no cost at http : //hfes.org).


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CC--141 Aircraft Development Program141 Aircraft Development ProgramCC--141 Aircraft Development Program141 Aircraft Development ProgramFour Engine USAF Cargo AircraftFour Engine USAF Cargo Aircraft

Converts to different configurations viaConverts to different configurations viainstallation of kits :installation of kits : Cargo aerial deliveryCargo aerial delivery ParatroopParatroop Passenger aircraftPassenger aircraft Medical air evacuationMedical air evacuation

Four Engine USAF Cargo AircraftFour Engine USAF Cargo Aircraft

Converts to different configurations viaConverts to different configurations viainstallation of kits :installation of kits : Cargo aerial deliveryCargo aerial delivery ParatroopParatroop Passenger aircraftPassenger aircraft Medical air evacuationMedical air evacuation


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CC--141 Aircraft Development Program141 Aircraft Development ProgramCC--141 Aircraft Development Program141 Aircraft Development ProgramSaved $2.5 million in original priceSaved $2.5 million in original price

Kits smaller, lighter, easier to store andKits smaller, lighter, easier to store and

could be installed faster with fewer peoplecould be installed faster with fewer peopleSaved storage cost and reducedSaved storage cost and reducedpersonnel requirements.personnel requirements.

Reduced actual aircraft operational weightReduced actual aircraft operational weightand related fuel costs for entire fleet of and related fuel costs for entire fleet of over 200 aircraft over 35+ year period.over 200 aircraft over 35+ year period.

Saved $2.5 million in original priceSaved $2.5 million in original price

Kits smaller, lighter, easier to store andKits smaller, lighter, easier to store and

could be installed faster with fewer peoplecould be installed faster with fewer peopleSaved storage cost and reducedSaved storage cost and reducedpersonnel requirements.personnel requirements.

Reduced actual aircraft operational weightReduced actual aircraft operational weightand related fuel costs for entire fleet of and related fuel costs for entire fleet of over 200 aircraft over 35+ year period.over 200 aircraft over 35+ year period.


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CC--141 Aircraft Development141 Aircraft DevelopmentProgram : Total HFE CostProgram : Total HFE Cost- -BenefitBenefitCC--141 Aircraft Development141 Aircraft DevelopmentProgram : Total HFE CostProgram : Total HFE Cost- -BenefitBenefit

Over 100 ergonomic improvements toOver 100 ergonomic improvements tooriginal engineering designoriginal engineering design

Direct savings of over $5 million for HFEDirect savings of over $5 million for HFEprogram cost of $500,000program cost of $500,000 a 1 to 10 costa 1 to 10 costbenefit ratio.benefit ratio.

Life cycle savings from ergonomicLife cycle savings from ergonomicimprovements : At least 1 to 50 costimprovements : At least 1 to 50 cost- -benefitbenefit

Over 100 ergonomic improvements toOver 100 ergonomic improvements tooriginal engineering designoriginal engineering design

Direct savings of over $5 million for HFEDirect savings of over $5 million for HFEprogram cost of $500,000program cost of $500,000 a 1 to 10 costa 1 to 10 costbenefit ratio.benefit ratio.

Life cycle savings from ergonomicLife cycle savings from ergonomicimprovements : At least 1 to 50 costimprovements : At least 1 to 50 cost- -benefitbenefit


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CC--141 Aircraft Development141 Aircraft DevelopmentProgram : Total HFE CostProgram : Total HFE Cost- -BenefitBenefitCC--141 Aircraft Development141 Aircraft DevelopmentProgram : Total HFE CostProgram : Total HFE Cost- -BenefitBenefit

Good example of what ergonomicsGood example of what ergonomics

can do when integrated withcan do when integrated withengineering design early in theengineering design early in thedevelopment program.development program.

Good example of what ergonomicsGood example of what ergonomics

can do when integrated withcan do when integrated withengineering design early in theengineering design early in thedevelopment program.development program.


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Ergonomics CostErgonomics Cost- -BenefitBenefitTradeTrade- -Off DiamondOff DiamondErgonomics CostErgonomics Cost- -BenefitBenefitTradeTrade- -Off DiamondOff Diamond

HumanHuman- -System Interface DesignSystem Interface Design

TrainingTraining SelectionSelection

Job Performance AidsJob Performance Aids

HumanHuman- -System Interface DesignSystem Interface Design

TrainingTraining SelectionSelection

Job Performance AidsJob Performance Aids


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Ergonomics CostErgonomics Cost- -BenefitBenefitTradeTrade- -Off DiamondOff DiamondErgonomics CostErgonomics Cost- -BenefitBenefitTradeTrade- -Off DiamondOff Diamond

Often overlook ergonomic design andOften overlook ergonomic design and

job aids. job aids.

Managers & commanders tend toManagers & commanders tend tooveremphasize training and selectionoveremphasize training and selection

as the cureas the cure doesdoes notnot eliminate poor eliminate poor ergonomic design!ergonomic design!

Often overlook ergonomic design andOften overlook ergonomic design and

job aids. job aids.

Managers & commanders tend toManagers & commanders tend tooveremphasize training and selectionoveremphasize training and selection

as the cureas the cure doesdoes notnot eliminate poor eliminate poor ergonomic design!ergonomic design!


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Ergonomics CostErgonomics Cost- -Benefit TradeBenefit Trade- -Off Off Diamond : Job Aid SolutionDiamond : Job Aid SolutionErgonomics CostErgonomics Cost- -Benefit TradeBenefit Trade- -Off Off Diamond : Job Aid SolutionDiamond : Job Aid Solution

Example : IBM Displaywriter Packing LineExample : IBM Displaywriter Packing Line

Frequent errors in packing caused customer setFrequent errors in packing caused customer set- -up of the product to fail.up of the product to fail.

Ergonomist analyzed problem and developedErgonomist analyzed problem and developedlarge story board aid for each packing station.large story board aid for each packing station.

Boards detailed & illustrated specific packingBoards detailed & illustrated specific packingsteps.steps.

Example : IBM Displaywriter Packing LineExample : IBM Displaywriter Packing Line

Frequent errors in packing caused customer setFrequent errors in packing caused customer set- -up of the product to fail.up of the product to fail.

Ergonomist analyzed problem and developedErgonomist analyzed problem and developedlarge story board aid for each packing station.large story board aid for each packing station.

Boards detailed & illustrated specific packingBoards detailed & illustrated specific packingsteps.steps.


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Ergonomics CostErgonomics Cost- -Benefit TradeBenefit Trade- -Off Off Diamond : Job Aid SolutionDiamond : Job Aid SolutionErgonomics CostErgonomics Cost- -Benefit TradeBenefit Trade- -Off Off Diamond : Job Aid SolutionDiamond : Job Aid Solution

Example : IBM Displaywriter Example : IBM Displaywriter

Packing Line StoryboardsPacking Line Storyboards

Example : IBM Displaywriter Example : IBM Displaywriter

Packing Line StoryboardsPacking Line Storyboards


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Management Awareness is CriticalManagement Awareness is CriticalManagement Awareness is CriticalManagement Awareness is Critical

Study by Ed Jones and myself of DoD Major Study by Ed Jones and myself of DoD Major System Development Programs.System Development Programs.

-- Evaluated major DoD system developmentEvaluated major DoD system developmentprograms over a 10 year period in terms of whether programs over a 10 year period in terms of whether they had a good or poor ergonomics developmentthey had a good or poor ergonomics developmenteffort.effort.

-- Found those with a poor effort had major problemsFound those with a poor effort had major problemswhen they became operational.when they became operational.

-- Looked for what made the difference betweenLooked for what made the difference betweenthose with a good effort vs. those with a poor effort.those with a good effort vs. those with a poor effort.

Study by Ed Jones and myself of DoD Major Study by Ed Jones and myself of DoD Major System Development Programs.System Development Programs.

-- Evaluated major DoD system developmentEvaluated major DoD system developmentprograms over a 10 year period in terms of whether programs over a 10 year period in terms of whether they had a good or poor ergonomics developmentthey had a good or poor ergonomics developmenteffort.effort.

-- Found those with a poor effort had major problemsFound those with a poor effort had major problemswhen they became operational.when they became operational.

-- Looked for what made the difference betweenLooked for what made the difference betweenthose with a good effort vs. those with a poor effort.those with a good effort vs. those with a poor effort.


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Study by Ed Jones and myself of DoD Major Study by Ed Jones and myself of DoD Major System Development Programs.System Development Programs.Results :Results :

-- Major discriminating factor was ergonomicsMajor discriminating factor was ergonomicsawareness of the program director/commander.awareness of the program director/commander.

-- Aware commanders appreciated value added of Aware commanders appreciated value added of ergonomicsergonomics -- -- and so allocated personneland so allocated personnelresources and funding to ergonomics. Thoseresources and funding to ergonomics. Thoselacking knowledge of ergonomics didlacking knowledge of ergonomics did not not ..


-- Major discriminating factor was ergonomicsMajor discriminating factor was ergonomicsawareness of the program director/commander.awareness of the program director/commander.

-- Aware commanders appreciated value added of Aware commanders appreciated value added of ergonomicsergonomics -- -- and so allocated personneland so allocated personnelresources and funding to ergonomics. Thoseresources and funding to ergonomics. Thoselacking knowledge of ergonomics didlacking knowledge of ergonomics did not not ..


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-- Effective programs :Effective programs : Ergonomics was anErgonomics was anintegral part of the engineering design team.integral part of the engineering design team.

-- Ineffective programs :Ineffective programs : Ergonomics was treatedErgonomics was treatedas an ility, like reliability, maintainability,as an ility, like reliability, maintainability,etc.; only could make input after item wasetc.; only could make input after item wasalready designed (bandalready designed (band- -aid changes only).aid changes only).


-- Effective programs :Effective programs : Ergonomics was anErgonomics was anintegral part of the engineering design team.integral part of the engineering design team.

-- Ineffective programs :Ineffective programs : Ergonomics was treatedErgonomics was treatedas an ility, like reliability, maintainability,as an ility, like reliability, maintainability,etc.; only could make input after item wasetc.; only could make input after item wasalready designed (bandalready designed (band- -aid changes only).aid changes only).


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Study by Ed Jones and myself of DoD Major SystemStudy by Ed Jones and myself of DoD Major SystemDevelopment Programs.Development Programs.

LessonLessonEstablishing rapport with key managers and raisingEstablishing rapport with key managers and raisingtheir consciousness about ergonomics is essentialtheir consciousness about ergonomics is essentialto your longto your long- -term success.term success.

This often takes time and persistence!This often takes time and persistence!

Study by Ed Jones and myself of DoD Major SystemStudy by Ed Jones and myself of DoD Major SystemDevelopment Programs.Development Programs.

LessonLessonEstablishing rapport with key managers and raisingEstablishing rapport with key managers and raisingtheir consciousness about ergonomics is essentialtheir consciousness about ergonomics is essentialto your longto your long- -term success.term success.

This often takes time and persistence!This often takes time and persistence!


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Participatory Ergonomics is Essential!Participatory Ergonomics is Essential!Participatory Ergonomics is Essential!Participatory Ergonomics is Essential!

Participatory ergonomics :Participatory ergonomics : Involve employeesInvolve employeesat all levels to insure success.at all levels to insure success.

They know problems with their jobs best.They know problems with their jobs best.

They know what ergonomic alternatives will beThey know what ergonomic alternatives will bemost satisfying and acceptable to them.most satisfying and acceptable to them.

Get employee buyGet employee buy- -in to changes.in to changes.

Establishes a trueEstablishes a true ergonomic safety cultureergonomic safety culture the proven way to sustain improvement gains!the proven way to sustain improvement gains!

Particip atory ergonomics :Participatory ergonomics : Involve employeesInvolve employeesat all levels to insure success.at all levels to insure success.

They know problems with their jobs best.They know problems with their jobs best.

They know what ergonomic alternatives will beThey know what ergonomic alternatives will bemost satisfying and acceptable to them.most satisfying and acceptable to them.

Get employee buyGet employee buy- -in to changes.in to changes.

Establishes a trueEstablishes a true ergonomic safety cultureergonomic safety culture the proven way to sustain improvement gains!the proven way to sustain improvement gains!


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Example : Participatory ErgonomicsExample : Participatory Ergonomics

Food Service Stand Redesign : Dodger StadiumFood Service Stand Redesign : Dodger Stadium

Example : Participatory ErgonomicsExample : Participatory Ergonomics



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Example : Participatory ErgonomicsExample : Participatory ErgonomicsExample : Participatory ErgonomicsExample : Participatory Ergonomics


ResultsResults-- Ergonomists Andrew Imada and Gorge StawowyErgonomists Andrew Imada and Gorge Stawowy

redesigned two food service stands for a cost of redesigned two food service stands for a cost of $40,000 using participatory$40,000 using participatory ergonomics.ergonomics.

-- Reduced average customer transaction timeReduced average customer transaction timeby 8 seconds.by 8 seconds.


ResultsResults-- Ergonomists Andrew Imada and Gorge StawowyErgonomists Andrew Imada and Gorge Stawowy

redesigned two food service stands for a cost of redesigned two food service stands for a cost of $40,000 using participatory$40,000 using participatory ergonomics.ergonomics.

-- Reduced average customer transaction timeReduced average customer transaction timeby 8 seconds.by 8 seconds.


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Example : Participatory ErgonomicsExample : Participatory ErgonomicsExample : Participatory ErgonomicsExample : Participatory Ergonomics


Results (continued)Results (continued)

-- Increased productivity was $1,200 per baseballIncreased productivity was $1,200 per baseballgame, resulting in payback period of 33 games.game, resulting in payback period of 33 games.

-- Payback period for modifying the other 50 standsPayback period for modifying the other 50 standswill be 20 games.will be 20 games.


Results ( continued)Results (continued)

-- Increased productivity was $1,200 per baseballIncreased productivity was $1,200 per baseballgame, resulting in payback period of 33 games.game, resulting in payback period of 33 games.

-- Payback period for modifying the other 50 standsPayback period for modifying the other 50 standswill be 20 games.will be 20 games.


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OSHA Guidelines* are the Key toOSHA Guidelines* are the Key to

an Effective Ergonomics Programan Effective Ergonomics Program

OSHA Guidelines* are the Key toOSHA Guidelines* are the Key to

an Effective Ergonomics Programan Effective Ergonomics Program

Are based on extensive researchAre based on extensive research

When OSHA ergonomics programWhen OSHA ergonomics programelementselements notnot present, ergonomics &present, ergonomics &safety program invariablysafety program invariably not not adequate.adequate.

*See OSHA 3123 E*See OSHA 3123 E rgono m ics Progra m Manage m ent rgono m ics Progra m Manage m ent Gu idelines for Meatpacking PlantsGu idelines for Meatpacking Plants

Are based on extensive researchAre based on extensive research

When OSHA ergonomics programWhen OSHA ergonomics programelementselements notnot present, ergonomics &present, ergonomics &safety program invariablysafety program invariably not not adequate.adequate.

*See OSHA 3123 E*See OSHA 3123 E rgono m ics Progra m Manage m ent rgono m ics Progra m Manage m ent Gu idelines for Meatpacking PlantsGu idelines for Meatpacking Plants


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OSHA Guidelines are the Key to anOSHA Guidelines are the Key to an

Effective ErgonomicsEffective Ergonomics ProgramProgram


Effective ErgonomicsEffective Ergonomics ProgramProgramOSHA GuidelinesOSHA Guidelines

I. Management Commitment & EmployeeI. Management Commitment & EmployeeInvolvementInvolvement

A. Commitment by Top ManagementA. Commitment by Top Management - -deeds, not just wordsdeeds, not just words

B. Written ProgramB. Written ProgramC. Employee InvolvementC. Employee InvolvementD. Regular Program Reviews & EvaluationD. Regular Program Reviews & Evaluation

OSHA GuidelinesOSHA Guidelines

I. Management Commitment & EmployeeI. Management Commitment & EmployeeInvolvementInvolvement

A. Commitment by Top ManagementA. Commitment by Top Management - -deeds, not just wordsdeeds, not just words

B. Written ProgramB. Written ProgramC. Employee InvolvementC. Employee InvolvementD. Regular Program Reviews & EvaluationD. Regular Program Reviews & Evaluation


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II.II. OSHA Program ElementsOSHA Program Elements

A. Worksite AnalysisA. Worksite Analysis

B. Hazard Prevention and ControlB. Hazard Prevention and Control Engineering ControlsEngineering Controls Work Practice ControlsWork Practice Controls

Personal Protective EquipmentPersonal Protective Equipment Administrative ControlsAdministrative Controls

II.II. OSHA Prog ram ElementsOSHA Program Elements

A. Worksite AnalysisA. Worksite Analysis

B. Hazard Prevention and ControlB. Hazard Prevention and Control Engineering ControlsEngineering Controls Work Practice ControlsWork Practice Controls

Personal Protective EquipmentPersonal Protective Equipment Administrative ControlsAdministrative Controls


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Effective ErgonomicsEffective Ergonomics ProgramProgramIIII.. OSHA Program Elements (Cont.)OSHA Program Elements (Cont.)

C. Medical ManagementC. Medical Management

D. Training and EducationD. Training and Education General TrainingGeneral Training JobJob--Specific TrainingSpecific Training Training for SupervisorsTraining for Supervisors

Training for ManagementTraining for Management Training for Engineers & MaintenanceTraining for Engineers & MaintenancePersonnelPersonnel

IIII.. OSHA Prog ram Elements (Cont.)OSHA Program Elements (Cont.)

C. Medical ManagementC. Medical Management

D. Training and EducationD. Training and Education General TrainingGeneral Training JobJob--Specific TrainingSpecific Training Training for SupervisorsTraining for Supervisors

Training for ManagementTraining for Management Training for Engineers & MaintenanceTraining for Engineers & MaintenancePersonnelPersonnel


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Effective ErgonomicsEffective Ergonomics ProgramProgramOSHA GuidelinesOSHA Guidelines

Poor Example : Some warehouse RetailPoor Example : Some warehouse RetailStoresStores Program elements largelyProgram elements largelymissing; many customer injuries.missing; many customer injuries.

Good Example : Redwing ShoesGood Example : Redwing Shoes

OSHA GuidelinesOSHA Guidelines

Poor Example : Some warehouse RetailPoor Example : Some warehouse RetailStoresStores Program elements largelyProgram elements largelymissing; many customer injuries.missing; many customer injuries.

Good Example : Redwing ShoesGood Example : Redwing Shoes


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Insuring Effective ErgonomicsInsuring Effective ErgonomicsInsuring Effective ErgonomicsInsuring Effective Ergonomics

OSHA GuidelinesOSHA Guidelines : Redwing Shoes: Redwing Shoes

Implemented OSHA guidelines components.Implemented OSHA guidelines components.

ResultsResults From 1989 to 1995, workers compensationFrom 1989 to 1995, workers compensation

dropped by 70% for a $3.1 million savings.dropped by 70% for a $3.1 million savings.

OSHA reportable injuries dropped from ratio of OSHA reportable injuries dropped from ratio of 75 per 100 employees working per year, to 19.75 per 100 employees working per year, to 19.

OSHA GuidelinesOSHA Guidelines : Redwing Shoes: Redwing Shoes

Implemented OSHA guidelines components.Implemented OSHA guidelines components.

ResultsResults From 1989 to 1995, workers compensationFrom 1989 to 1995, workers compensation

dropped by 70% for a $3.1 million savings.dropped by 70% for a $3.1 million savings.

OSHA reportable injuries dropped from ratio of OSHA reportable injuries dropped from ratio of 75 per 100 employees working per year, to 19.75 per 100 employees working per year, to 19.


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Macroergonomics : The Key toMacroergonomics : The Key to

Dramatic ImprovementsDramatic Improvements


Dramatic ImprovementsDramatic ImprovementsMacroergonomic interventions can dramatically improve health,Macroergonomic interventions can dramatically improve health,safety, and productivity (50%safety, and productivity (50% - - 90% or more).90% or more).

Theoretical BasisTheoretical Basis

-- Systems theory :Systems theory : All complex systems areAll complex systems aresynergistic : When harmonized, whole moresynergistic : When harmonized, whole more than thethan thesum of its parts.sum of its parts.

-- Sociotechnical systems thus are more than the sumSociotechnical systems thus are more than the sumof their parts.of their parts.

-- Therefore, macroergonomics can dramaticallyTherefore, macroergonomics can dramaticallyimprove theimprove the effectiveness sociotechnical systems.effectiveness sociotechnical systems.

Macroergonomic interventions can dramatically improve health,Macroergonomic interventions can dramatically improve health,safety, and productivity (50%safety, and productivity (50% - - 90% or more).90% or more).

Theoretical BasisTheoretical Basis

-- Systems theory :Systems theory : All complex systems areAll complex systems aresynergistic : When harmonized, whole moresynergistic : When harmonized, whole more than thethan thesum of its parts.sum of its parts.

-- Sociotechnical systems thus are more than the sumSociotechnical systems thus are more than the sumof their parts.of their parts.

-- Therefore, macroergonomics can dramaticallyTherefore, macroergonomics can dramaticallyimprove theimprove the effectiveness sociotechnical systems.effectiveness sociotechnical systems.


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MacroergonomicsMacroergonomics

-- ConceptuallyConceptually : A top: A top--down sociotechnicaldown sociotechnicalsystems approach to work system designsystems approach to work system design

-- In PracticeIn Practice : It is top: It is top- -down, middledown, middle- -out, andout, andbottombottom- -up (via participatory ergonomics).up (via participatory ergonomics).

Macroerg onomicsMacroergonomics

-- ConceptuallyConceptually : A top: A top--down sociotechnicaldown sociotechnicalsystems approach to work system designsystems approach to work system design

-- In PracticeIn Practice : It is top: It is top- -down, middledown, middle- -out, andout, andbottombottom- -up (via participatory ergonomics).up (via participatory ergonomics).


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Dramatic ImprovementsDramatic ImprovementsGoalGoal : : Achieve a fully harmonized work systemAchieve a fully harmonized work system

1. Design a work systems structure and processes to1. Design a work systems structure and processes tobe compatible with the key characteristics of itsbe compatible with the key characteristics of its-- Personnel subsystemPersonnel subsystem-- Technological SubsystemTechnological Subsystem-- External EnvironmentExternal Environment

Empirical models exist that enable us to accomplish this.Empirical models exist that enable us to accomplish this.

2. Design jobs, human2. Design jobs, human- -machine, humanmachine, human- -software, andsoftware, andhumanhuman- -environment interfaces to fully harmonize withenvironment interfaces to fully harmonize withthe over the over- -all work system designall work system design

GoalGoal : : Achieve a fully harmonized work systemAchieve a fully harmonized work system

1. Design a work systems structure and processes to1. Design a work systems structure and processes tobe compatible with the key characteristics of itsbe compatible with the key characteristics of its-- Personnel subsystemPersonnel subsystem-- Technological SubsystemTechnological Subsystem-- External EnvironmentExternal Environment

Empirical models exist that enable us to accomplish this.Empirical models exist that enable us to accomplish this.

2. Design jobs, human2. Design jobs, human- -machine, humanmachine, human- -software, andsoftware, andhumanhuman- -environment interfaces to fully harmonize withenvironment interfaces to fully harmonize withthe over the over- -all work system designall work system design


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Dramatic ImprovementsDramatic ImprovementsMacroergonomic interventions possible when :Macroergonomic interventions possible when :

A major change in equipment, facilities or A major change in equipment, facilities or

processes is to take place.processes is to take place. The organization is in real trouble.The organization is in real trouble. There is an enlightened managementThere is an enlightened management

regarding ergonomics.regarding ergonomics.

MicroMicro--ergonomic successes have gainedergonomic successes have gainedyou managements confidence.you managements confidence.

Macroergonomic interventions possible when :Macroergonomic interventions possible when :

A major change in equipment, facilities or A major change in equipment, facilities or

processes is to take place.processes is to take place. The organization is in real trouble.The organization is in real trouble. There is an enlightened managementThere is an enlightened management

regarding ergonomics.regarding ergonomics.

MicroMicro--ergonomic successes have gainedergonomic successes have gainedyou managements confidence.you managements confidence.


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Dramatic ImprovementsDramatic ImprovementsResultResult

-- A fully harmonized work system.A fully harmonized work system.-- Whole thus is more than a simple sum of itsWhole thus is more than a simple sum of its

partsparts Synergistic Synergistic ..

--Consequently, dramatic improvements occur.Consequently, dramatic improvements occur.

ResultResult

-- A fully harmonized work system.A fully harmonized work system.-- Whole thus is more than a simple sum of itsWhole thus is more than a simple sum of its

partsparts Synergistic Synergistic ..

--Consequently, dramatic improvements occur.Consequently, dramatic improvements occur.


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Example : Large Petroleum DistributionExample : Large Petroleum Distribution

Company in U.S.Company in U.S.


Company in U.S.Company in U.S.MacroMacro-- and Microand Micro- -ergonomic Interventionergonomic InterventionMacroMacro-- and Microand Micro- -ergonomic Interventionergonomic Intervention


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Company in U.S.Company in U.S.Macroergonomic InterventionMacroergonomic Intervention

-- Macroergonomic analysis of work system.Macroergonomic analysis of work system.

-- Developed strategic plan for improving safetyDeveloped strategic plan for improving safety& productivity.& productivity.

-- Made changes to work system where indicated.Made changes to work system where indicated.

-- Participation at all levels.Participation at all levels.

Macroerg onomic InterventionMacroergonomic Intervention

-- Macroergonomic analysis of work system.Macroergonomic analysis of work system.

-- Developed strategic plan for improving safetyDeveloped strategic plan for improving safety& productivity.& productivity.

-- Made changes to work system where indicated.Made changes to work system where indicated.

-- Participation at all levels.Participation at all levels.


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Company in U.S.Company in U.S.MicroMicro--ergonomic Interventionergonomic Intervention

-- Worker participation at all levels.Worker participation at all levels.

-- Employees (with ergonomist facilitator/resource person)Employees (with ergonomist facilitator/resource person)

-- developed and taught truck safety programdeveloped and taught truck safety program-- selected new equipmentselected new equipment

-- identified problems and proposed ergonomic designidentified problems and proposed ergonomic designchanges to equipment & procedures.changes to equipment & procedures.

MicroMicro--erg onomic Interventionergonomic Intervention

-- Worker participation at all levels.Worker participation at all levels.

-- Employees (with ergonomist facilitator/resource person)Employees (with ergonomist facilitator/resource person)

-- developed and taught truck safety programdeveloped and taught truck safety program-- selected new equipmentselected new equipment

-- identified problems and proposed ergonomic designidentified problems and proposed ergonomic designchanges to equipment & procedures.changes to equipment & procedures.


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Company in U.S.Company in U.S.MacroMacro-- and Microand Micro- -ergonomics Intervention*ergonomics Intervention*

ResultsResults

Reductions After Reductions After 2 years2 years 9 Years9 Years

Motor V ehicle AccidentsMotor V ehicle Accidents 51%51% 63%63%Industrial AccidentsIndustrial Accidents 54%54% 70%70%Lost WorkdaysLost Workdays 94%94% 97%97%

$ 60,000 savings per year in petroleum delivery costs.$ 60,000 savings per year in petroleum delivery costs.

* Imada (2002)* Imada (2002)

MacroMacro-- and Microand Micro- -ergonomics Intervention*ergonomics Intervention*

ResultsResults

Reductions After Reductions After 2 y ears2 years 9 Years9 Years

Motor V ehicle AccidentsMotor V ehicle Accidents 51%51% 63%63%Industrial AccidentsIndustrial Accidents 54%54% 70%70%Lost WorkdaysLost Workdays 94%94% 97%97%

$ 60,000 savings per year in petroleum delivery costs.$ 60,000 savings per year in petroleum delivery costs.

* Imada (2002)* Imada (2002)


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Example : Macroergonomic ApproachExample : Macroergonomic Approach

to Implementing TQM at L.L. Beanto Implementing TQM at L.L. Bean


to Implementing TQM at L.L. Beanto Implementing TQM at L.L. BeanMacroMacro-- and Microand Micro- -ergonomics Intervention*ergonomics Intervention*

-- Company ergonomists read my writings onCompany ergonomists read my writings on

macroergonomics and saw it as a potentialmacroergonomics and saw it as a potentialmethodology for implementing TQM.methodology for implementing TQM.

-- Used methods similar to Imadas in PetroleumUsed methods similar to Imadas in Petroleumdistribution company example.distribution company example.


-- Company ergonomists read my writings onCompany ergonomists read my writings on

macroergonomics and saw it as a potentialmacroergonomics and saw it as a potentialmethodology for implementing TQM.methodology for implementing TQM.

-- Used methods similar to Imadas in PetroleumUsed methods similar to Imadas in Petroleumdistribution company example.distribution company example.


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to Implementing TQM at L.L. Beanto Implementing TQM at L.L. Bean


to Implementing TQM at L.L. Beanto Implementing TQM at L.L. BeanMacroMacro-- and Microand Micro- -ergonomics Intervention*ergonomics Intervention*

ResultsResults

-- 70% reduction in lost time accidents and70% reduction in lost time accidents andinjuries achieved in two year period in bothinjuries achieved in two year period in bothproduction and distribution divisions.production and distribution divisions.

-- Other benefits, such as greater employee satisfaction,Other benefits, such as greater employee satisfaction,also realized.also realized.


ResultsResults

-- 70% reduction in lost time accidents and70% reduction in lost time accidents andinjuries achieved in two year period in bothinjuries achieved in two year period in bothproduction and distribution divisions.production and distribution divisions.

-- Other benefits, such as greater employee satisfaction,Other benefits, such as greater employee satisfaction,also realized.also realized.


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Practical Application of ErgonomicsPractical Application of ErgonomicsPractical Application of ErgonomicsPractical Application of Ergonomics

ConclusionConclusion ::

Good ErgonomicsGood Ergonomics is is Good EconomicsGood EconomicsAndAnd

Is a Key to Optimizing the Effectiveness of Is a Key to Optimizing the Effectiveness of our Armed Forces.our Armed Forces.

ConclusionConclusion ::

Good ErgonomicsGood Ergonomics is is Good EconomicsGood EconomicsAndAnd

Is a Key to Optimizing the Effectiveness of Is a Key to Optimizing the Effectiveness of our Armed Forces.our Armed Forces.

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Practical Application of Ergonomics