Manual Work Design: From: Niebel's Methods, Standards, and Work Design, Twelfth Edition
Manual Work Design: From: Niebel's Methods, Standards, and Work Design, Twelfth Edition
Physiology
Physiology - a branch of biology concerned with the vital processes of living organisms and how their constituent tissues and cells function. Important for Human Factors because work requires the expenditure of physical energy.
Anthropometry
Anthropometry a branch of anthropology concerned with the dimensions of the human body, such as height and reach. Important for Human Factors because the dimensions of the human body affect the capabilities of the worker.
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Skeletal Muscles
Approximately 400 skeletal muscles. 40 percent of human body weight. Provide power for force and motion in the musculoskeletal system. Blood vessels and nerves distributed throughout muscle tissue to deliver fuel and provide feedback.
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
Muscle Types
Smooth: found in stomach and intestines, blood vessel, urinary bladder, and uterus. Involved in the digestion of food and the regulation of the internal environment of the body. The contraction of smooth muscles is not normally under conscious control. Cardiac: heart muscle. It is not normally under direct conscious control.
Muscle Types
Skeletal or striated: attached to the bones and skeleton, accounts for 40 percent of the body weight. Its control enables bones to act like levers. The contraction of most skeletal muscles is under direct conscious control, and the movements produced by skeletal muscles make physical work possible.
Muscle Structure
Each skeletal muscle is made up of thousands of cylindrical elongated muscle fibers. Fibers are surrounded by a network of connective tissues through which blood vessels and nerve fibers pass to the muscle fibers. Each fiber consists of many cylindrical elements called myofibrils, each of which is divided into a number of sarcomeres, which are the contractile unit of skeletal muscle.
Muscle Structure
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
Muscle Structure
From: An Introduction to Human Factors Engineering by Christopher Wickens, John Lee, Yili Liu, and Sallie Gordon Becker
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
5. Use larger muscles for tasks requiring strength. Leg and trunk muscles should be used in heavy lead lifting, rather than weaker arm muscles.
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
Endurance Time
How long would a worker be able to sustain a force level of 30 percent of maximum strength?
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
8. Design tasks so that most workers can do them. There is a considerable range of strength in the normal, healthy adult population, due to individual factors: gender, age, handedness, and fitness/training.
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
Muscle Recruitment
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
10. Do not attempt precise movements or fine control immediately after heavy work. This principle is violated when operators load their workstations before their shift or replenish parts during a shift. Use less-skilled workers to restock bins on a regular basis.
11. Use ballistic movements for speed. Speed-accuracy tradeoff: In a short, gross, voluntary motion, the agonist is activated and the antagonist is inhibited to reduce counterproductive muscle contractions. For precise movements, feedback control from both set of muscles is utilized, increasing motion time.
12. Begin and end motions with both hands simultaneously. When the right and left hands of the operator are working in their normal areas, a feeling of balance tends to induce a rhythm in the operators performance, which leads to maximum productivity.
13. Move the hands symmetrically and simultaneously to and from the center of the body. Deviations from symmetry in a two-handed workstation result in slow, awkward movements of the operator.
14. Use the natural rhythms of the body. The natural frequency of the system is essential to the smooth and automatic performance of a task. Read examples of manual tasks work tempos.
15. Use continuous curved motions. It is easier for humans to produce curved motions, i.e., to pivot around a joint. Straight-line motions involving sudden and sharp changes in direction require more time and are less accurate.
Classifications of Movements
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
17. Work with both hands and feet simultaneously. It is economical to relieve the hands of work that can be done by the feet, only if this work is performed while the hands are occupied. The operator should be seated when operating a foot pedal.
18. Minimize eye fixations. Primary visual targets should be located within the primary visual field, about +/- 15 degrees around the line of sight. Within this area no head movements are needed and eye fatigue is minimized.
From: An Introduction to Human Factors Engineering by Christopher Wickens, John Lee, Yili Liu, and Sallie Gordon Becker
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
Physical work is possible only when there is energy to support muscular contraction. The energy required for muscular contraction comes in the form of high-energy phosphate compounds know as ATP (adenosine triphosphate) and CP (creatine phosphate). These components are derived from metabolism of nutrients and the creation of high-energy phosphate compounds.
Metabolism
Sum of the biochemical reactions that occur in the cells of living organisms. Functions: 1. Provide energy for vital processes and activities, including muscle contraction. 2. Assimilate new organic material into the body.
Types of Metabolism
Basal metabolism energy used only to sustain the vital circulatory and respiratory functions. Activity metabolism energy associated with physical activity. Digestive metabolism energy used for digestion. Daily metabolic rates: TMRd = BMRd + AMRd + DMRd
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
Metabolism of basic foods: carbohydrates, fats, and protein. Aerobic metabolism: processing nutrients in the presence of oxygen. Anaerobic metabolism: processing nutrients without oxygen. Aerobic metabolism is more efficient than anaerobic metabolism, but is relatively slow.
Sources of Energy
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
Anaerobic metabolism produces lactic acid as a waste product. Lactic acid increases the acidity of the muscle tissue and causes muscle pain and fatigue. The removal of lactic acid requires oxygen. If there is an oxygen debt, oxygen will be consumed after muscle contraction is stopped, in the cooling down period.
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
Aerobic metabolism produces carbon dioxide as a waste byproduct, which must be removed from the tissues by the circulatory and the respiratory systems.
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Cardiovascular System
Arteries - deliver oxygen, glucose, & other nutrients from lungs and digestive tract to muscle tissue and organs. Veins - deliver carbon dioxide & waste products to lungs, kidneys, and liver. Capillaries - small blood vessels between arteries and veins to exchange nutrients and waste between blood and tissue.
Respiratory System
Nasal cavity (nose) - inhales air (oxygen) and exhales carbon dioxide. Air passageway connecting nasal cavity and lungs. Lungs - consist of alveoli (air-containing cells) that provide for exchange of gases in the blood circulating through them. 200 to 600 million alveoli in adult human lungs. Surface area = 70 to 90 m2 (750 to 970 ft2).
From: Work Systems and the Methods, Measurement, and Management of Work by Mikell Groover
From: An Introduction to Human Factors Engineering by Christopher Wickens, John Lee, Yili Liu, and Sallie Gordon Becker
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
The energy expended on a task can be estimated by assuming that most of the energy is produced through aerobic metabolism and measuring the amount of oxygen consumed by the worker. The amount of inspired air is measured with a flow meter and the expired oxygen is also measured with an oxygen meter.
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
E(kcal/min) = 4.9xV(0.21 EO2) where E: energy expenditure(kcal/min) V: volume of air inspired (L/min) EO2: fraction of Oxygen (O2) in expired air.
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
The energy expended on a task depends on: Type of task being performed. Posture maintained during the task. Type of load carriage.
From: An Introduction to Human Factors Engineering by Christopher Wickens, John Lee, Yili Liu, and Sallie Gordon Becker
Energy expenditure, heart rate, and oxygen consumption for several categories of work activity
From: Work Systems and the Methods, Measurement, and Management of Work by Mikell Groover
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
Physical demands of work according to the energy expenditure requirements: Light: under 2.5 kcal/min Moderate: about 2.5 to 5.0 kcal/min Heavy: between 5.0 to 7.5 kcal/min Very Heavy: between 7.5 to 10.0 kcal/min Extremely Heavy: greater than 10 kcal/min
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
It usually takes about 1 to 3 minutes for the circulatory and respiratory systems to adjust to the increased metabolic demands and reach the level at which energy requirements of work are met. The oxygen deficit incurred at the start of work must be repaid at some time, either during work or during the recovery period immediately after work ceases.
From: An Introduction to Human Factors Engineering by Christopher Wickens, John Lee, Yili Liu, and Sallie Gordon Becker
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
Acceptable limit for energy expenditure for an 8-hr workday: 5.33 kcal/min for average US male. 4 kcal/min for average US female.
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
Rest allocation guideline: R = (W 5.33)/(W 1.33) where R: time required for rest (% of total time) W: average energy expenditure during work (kcal/min) 1.33 kcal/min energy expenditure during rest
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
What are the rest period requirements for a sawing wood operation performed by healthy male and female workers on an 8-hour shift basis?
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
4.4 Manual Work and Design Guidelines Energy Expenditure and Workload Guidelines
The total rest time should be divided into several short breaks distributed throughout the 8-hr work shift rather than taken as few long breaks. The use of frequent, short work/rest cycles is highly recommended.
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
4.4 Manual Work and Design Guidelines Subjective Ratings of Perceived Exertion
Simple subjective rating scales of physical workload. Borg RPE (Ratings of Perceived Exertion) scale requires workers to rate their perceived level of physical exertion on a scale of 6 to 20. 6: minimum heart beat rate of 60 beats/min 20: maximum heart beat rate of 200 beats/min
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
4.4 Manual Work and Design Guidelines Subjective Ratings of Perceived Exertion
Subjective measures are cheaper and easier to implement than physiological measures. Subjective measures may be influenced by other factors: Workers satisfaction with a workplace. Motivation. Other emotional factors. Preferable to use them along with physiological measures of workload.
4.4 Manual Work and Design Guidelines Low Back Compressive Forces
Human spine or vertebral column: S-shaped 25 bones or vertebrae, divided in 4 regions: 7 cervical vertebrae 12 thoracic vertebrae 5 lumbar vertebrae sacrum in pelvic area
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
4.4 Manual Work and Design Guidelines Low Back Compressive Forces
The spinal cord travels from the brain to the end of the vertebral column through the opening at the center of each vertebra. Spinal nerve roots separate from the spinal cord and pass between the vertebral bone out to extremities, heart, organs, and other parts. Vertebral bones are separated by the intervertebral disks that allow a large range of motion in the spine.
4.4 Manual Work and Design Guidelines Low Back Compressive Forces
Disks are composed of a gel-like center surrounded by layers of fibers. The lower back is the most vulnerable link of the musculoskeletal system in material handling because it is the most distant from the load handled by the hand. Significant stress occurs on the two lowest joints, L5/S1 disk and L4/L5 disk.
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
4.4 Manual Work and Design Guidelines Low Back Compressive Forces
The combined effect of aging and manual work exposure can weaken disks with time. Disks may release some of their gelatinous material and the disk space may narrow, allowing vertebral bones to come closer and touch, causing irritation and pain. Disk herniation or slipped disk may allow large amount of gel to extrude and impinge upon the nerve roots.
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
4.4 Manual Work and Design Guidelines Low Back Compressive Forces
From: An Introduction to Human Factors Engineering by Christopher Wickens, John Lee, Yili Liu, and Sallie Gordon Becker
4.4 Manual Work and Design Guidelines Low Back Compressive Forces
The simple model neglects the offset aligment of the disks, weight of the body segments, and other factors. Therefore, this model probably underpredicts the extremely high compressive forces typically obtained in the low back area. A compressive force of 770 lb should be considered the danger threshold.
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
2.
4.4 Manual Work and Design Guidelines General Guidelines: Manual Lifting
Safe lifting procedure. Avoid twisting and jerky motions. Avoid carrying uneven loads in both arms or an entire load in only one arm.
From: Niebels Methods, Standards, and Work Design by Andris Freivalds and Benjamin Niebel
Lifting Loads
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
Lifting Loads
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
Appropriate Height
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
Appropriate Height
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and KroemerElbert
From: An Introduction to Human Factors Engineering by Christopher Wickens, John Lee, Yili Liu, and Sallie Gordon Becker
Torso twisting should be minimized. Design lifting tasks to use both hands in front of the body and balance the load between the hands. Frequency of lifting should be minimized with lifting and work rest schedules. Use MHDs for frequent and heavy lifting. Loads and MHDs should be easy to grasp and handle.
From: An Introduction to Human Factors Engineering by Christopher Wickens, John Lee, Yili Liu, and Sallie Gordon Becker
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
Lifting Loads
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
Conveyors
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
Lift Tables
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
Forklift Truck
From: Ergonomics How to Design for Ease and Efficiency by Kroemer, Kroemer, and Kroemer-Elbert
References
Cal/OSHA Consultation Service. (2007) Ergonomic Guidelines for Manual Material Handling. California Department of Industrial Relations. Freivalds, A. and Niebel, B. (2009) Niebels Methods, Standards, and Work Design. Twelfth Edition. McGraw-Hill Higher Education. Groover, M. (2007) Work Systems and the Methods, Measurement, and Management of Work. Pearson Prentice Hall. Kroemer, K., Kroemer, H. and Kroemer-Elbert, K. (2001) Ergonomics How to design for Ease and Efficiency. Second Edition. Prentice Hall. Sanders, M. and McCormick, E. (1993) Human Factors in Engineering and Design. Seventh Edition. McGraw-Hill. Waters, T., Putz-Anderson, V. and Garg, A. (1997) Applications Manual for the revised NIOSH Lifting Equation. U.S. Department of Health and Human Services. Wickens, C., Lee, J., Liu, Y. and Gordon Becker S. (2004) An Introduction to Human Factors Engineering. Second Edition. Pearson Prentice Hall.