Ergonomics of Welding

Ergonomics of Welding
Steven Rojo
Background of Field
➢ One of the largest parts of the construction industry

➢ Increased the Human-Machine relationship
➢ Wide variety in kinds of welding techniques and
welding specialties
➢ Integral to other manufacturing projects
➢ Over 400k jobs in the economy
2
Objective
▪ Recognize the ergonomic stresses that workers that

weld face on the job
▪ Compose solutions to address these problems to
▫ Decrease the odds of injury
▫ Possibly improve performance
3
Risks of the job
▪ Climate ▪ Inhalation
▪ Fire ▪ Electric Shock
▪ Noise ▪ Manual Loading
▪ Vibration ▪ Falling
4
Materials
▪ Guidance from experts in the field

▪ 3DSSPP software
▪ Direct line observation during process
▪ Literature from industry & research sources to answer
questions raised
5
Methods
REBA EEPP Biomechanical Analysis

An assessment of Measures appropriate Free-body diagram of a
postures that evaluates rest time that a worker worker and determines
specific body-parts to requires for a specific the effects of postures
find final score of risk task performed under
6
REBA
7
Energy Expenditure Prediction
Program (EEPP)
Based on the physical

capacity that a standard
worker has and the available
energy output
8
Biomechanical Analysis
Accounts for joint and

appendage forces &
estimates the % of pop. who
are viable to perform
9
Findings
Solving for the:
EEPP
REBA
10
Plasma Cutting
▪ EEPP found 38 minutes of REBA Score = 5

rest for 801 minutes of work ▪ Action level 2
▪ Based on pulling a 2 kg ▪ Medium Risk
torch across 0.5 meters of ▪ Further Assessment is
metal by shifting legs needed
11
REBA
Trunk 3 Upper Arm 1
Neck 2 Lower Arm 2
Legs 1 Legs 2
Table A 4 Table A 2
Table C 4 Activity +1
12
Task Joint Strength Demand (% Pop. Capable)
Elbow Shoulder Torso Ankle
100 100 98 97
Wrist Hip Knee
97 96 98
Est. L5/S1 Low Back Loads Leg Loads (%)

(lb)
Compression Shear Left Right
403.6 40 46 53
13
Sorting/ Selection
▪ EEPP found 19 minutes of REBA Score = 9

rest for 24.5 minutes of work ▪ Action level 3
▪ Based on moving 5 kg ▪ High Risk
bins/boxes/canisters on ▪ Assessment is necessary
ground level in a bent soon
position
14
REBA
Trunk 4 Upper Arm 4+1-1
Neck 2 Lower Arm 2
Legs 2+1 Legs 1+1
Table A 7 Table A 6
Table C 9 Activity 0
15
100 100 95 74
Wrist Hip Knee
97 85 78

(lb)
445.3 121 65 34
16
Welding
▪ EEPP found 50.5 minutes of REBA Score = 3

rest for 73 minutes of work ▪ Action level 1
▪ Based on holding a 3 kg ▪ Low Risk
piece in one hand and ▪ Additional assessment may
welding it in place in a be needed in the future
neutral position
17
REBA
Trunk 1 Upper Arm 2
Neck 1 Lower Arm 2
Legs 1 Legs 3
Table A 1 Table A 4
Table C 2 Activity +1
18
100 99 99 97
Wrist Hip Knee
98 97 98

(lb)
291.4 43 35 64
19
BIG DEAL
How are these findings addressed?
20
Plasma
Conclusion Suggestions
▪ EEPP found it to be accessible to the vast ➢ Implement arm rests on table
population ✓ Decreases back strain
▫ 38 min rest for 801 min worked ✓ Decreases neck strain
▪ REBA found a level 5/ moderate risk × Cumbersome workstation
▫ Strain in trunk and neck ➢ Angle the table
▪ 3DSSPP determined 403.6 lb ✓ Eases use
compression ✓ Reduces the range needed to reach
▫ Falls within range of vast use × Removes multi-use function
21
Sorting/ Selecting
▪ EEPP found task to induce fatigue ➢ Move supplies into storage shelving
▫ 19 min rest for 24.5 min worked ✓ Decreases back and neck strain
▪ REBA found a level 9/ high risk ✓ Less time spent looking
▫ Immediate assessment ➢ Teach workers how to lift properly
▪ 3DSSPP determined 445.3 lb ✓ Reduces strain on back
compression & 121 lb shear ✓ No equipment needs to be
▫ Concern over health of L5/S1 purchased
health × Time spent educating instead of
working
22
Welding
▪ EEPP found it to be accessible to the ➢ Implement worker assistance
larger population ✓ Decreases strain on worker
▫ 50 min rest for 73 min worked ✓ Focuses on the welds
▪ REBA found a level 3/ low risk × Doubles man hour for project
▫ Strain in trunk and neck during these periods
▪ 3DSSPP determined 291.4 lb ➢ Enforce table usage
compression & 43 lb shear ✓ Focuses on the welds
▫ Falls within safe use ✓ Reduces the range needed to reach
▫ ⅔ of load supported by right leg × Limitations based on situation
23
References
▪ Lincoln Electric PPE

▪ The Effects of Training on Back Pain from NCBI
▪ Science Citation Index
▪ The Welding Institute
▪ Bureau of Labor Statistics
24
Questions or Comments?
25

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Ergonomics of Welding

➢ One of the largest parts of the construction industry

▪ Recognize the ergonomic stresses that workers that

▪ Fire ▪ Electric Shock

▪ Noise ▪ Manual Loading

▪ Guidance from experts in the field

REBA EEPP Biomechanical Analysis

Based on the physical

Accounts for joint and

▪ EEPP found 38 minutes of REBA Score = 5

Trunk 3 Upper Arm 1

Neck 2 Lower Arm 2

Elbow Shoulder Torso Ankle

Wrist Hip Knee

Est. L5/S1 Low Back Loads Leg Loads (%)

Compression Shear Left Right

▪ EEPP found 19 minutes of REBA Score = 9

Trunk 4 Upper Arm 4+1-1

Neck 2 Lower Arm 2

Legs 2+1 Legs 1+1

Elbow Shoulder Torso Ankle

Wrist Hip Knee

Est. L5/S1 Low Back Loads Leg Loads (%)

Compression Shear Left Right

▪ EEPP found 50.5 minutes of REBA Score = 3

Trunk 1 Upper Arm 2

Neck 1 Lower Arm 2

Elbow Shoulder Torso Ankle

Wrist Hip Knee

Est. L5/S1 Low Back Loads Leg Loads (%)

Compression Shear Left Right

▪ Lincoln Electric PPE

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