Practical

Practical Application
Application of
of
Ergonomics
Ergonomics

Hal
Hal W.
W. Hendrick,
Hendrick, Ph.D.,
Ph.D., CPE
CPE
HFES
HFES Strategic
Strategic Planning
Planning Study
Study

 Reviewed
Reviewed ergonomics
ergonomics research
research and
and practice
practice
around
around the
the world
world to
to determine
determine common
common
characteristics,
characteristics, purpose,
purpose, and
and scope
scope of
of
ergonomics
ergonomics

 Some
Some important
important findings
findings and
and conclusions
conclusions are
are
as
as follows
follows
 Ergonomics
Ergonomics is
is aa Scientifically
Scientifically
Based
Based Discipline
Discipline
 Science
Science
––Study
Study human
human performance
performance capabilities
capabilities and
and
limitations.
limitations.
––Apply
Apply our
our scientific
scientific knowledge
knowledge of
of humans
humans to
to
developing
developing ergonomics
ergonomics technology
technology
 Principles
Principles
 Guidelines
Guidelines
 Specifications
Specifications
 Methods
Methods
 Tools
Tools
 Ergonomics
Ergonomics is
is aa Scientifically
Scientifically
Based
Based Discipline
Discipline
 Practice*
Practice*
Apply
Apply ergonomics
ergonomics technology
technology to
to the
the design,
design, analysis,
analysis, test
test
and
and evaluation,
evaluation, and
and standardization
standardization of
of systems.
systems.
 Purpose*
Purpose*
To
To improve
improve the
the quality
quality of
of human
human life
life
 Health
Health
 Safety
Safety
 Comfort
Comfort
 productivity
productivity

** HFES
HFES Directory
Directory and
and Yearbook
Yearbook:: Strategic
Strategic Plan
Plan
 The
The Technology
Technology of
of Ergonomics
Ergonomics is
is
Human-System
Human-System Interface
Interface Technology*
Technology*
Human-System
Human-System Interface
Interface Technology
Technology
-- Human-Machine:
Human-Machine: Hardware
Hardware Ergonomics
Ergonomics
-- Human-Environment:
Human-Environment: Environmental
Environmental Ergonomics
Ergonomics
-- Human-Software:
Human-Software: Cognitive
Cognitive Ergonomics
Ergonomics
-- Human-Job:
Human-Job: Work
Work Design
Design Ergonomics
Ergonomics
-- Human-Work
Human-Work System:
System: Macroergonomics
Macroergonomics

** HFES
HFES Directory
Directory and
and Yearbook
Yearbook:: Strategic
Strategic Plan
Plan
Good
Good Ergonomics
Ergonomics is
is Good
Good Economics
Economics
 Poor
Poor Ergonomics
Ergonomics
–– Violates
Violates ergonomics
ergonomics technology
technology
and/or
and/or
–– Is
Is not
not cost
cost effective
effective
 Good
Good Ergonomics
Ergonomics
–– Appropriately
Appropriately applies
applies sound
sound ergonomics
ergonomics technology
technology
and
and
–– Is
Is cost
cost effective
effective
 ERGONOMICS
ERGONOMICS Must
Must Be
Be COST
COST EFFECTIVE
EFFECTIVE

The
The language
language of
of business
business is
is money!
money!

 Managers
Managers have
have toto justify
justify any
any expenditure
expenditure in
in
terms
terms of
of the
the cost-
cost- benefit
benefit ratio:
ratio: How
How the
the
project
project will
will affect
affect the
the bottom
bottom line.
line.

 Must
Must express
express ergonomic
ergonomic project
project proposals
proposals
in
in financial
financial terms
terms..
 Measuring the
Measuring the Economic
Economic Costs
Costs and
and
Benefits of
Benefits Ergonomic Interventions
of Ergonomic Interventions
 Costs
 Costs
–– Personnel,
Personnel, training,
training, equipment,
equipment, materials,
materials, reduced
reduced
productivity,
productivity, and
and overhead.
overhead.

 Benefits
 Benefits
–– Personnel
Personnel savings:
savings: Less
Less lost
lost time,
time, less
less training,
training,
lower
lower skill
skill levels
levels required,
required, increased
increased output
output per
per
person,
person, fewer
fewer people
people required,
required, greater
greater individual
individual or
or
team
team effectiveness.
effectiveness.

–– Material
Material savings:
savings: Reduced
Reduced scrap,
scrap, fewer
fewer rejects,
rejects, fewer
fewer
parts.
parts.
 Measuring the
Measuring the Economic
Economic Costs
Costs and
and
Benefits of
Benefits Ergonomic Interventions
of Ergonomic Interventions
 Source
 Source of
of information
information

–– Much
Much of
of the
the cost
cost and
and pricing
pricing information
information is
is available
available
through
through either
either your
your human
human resources
resources oror accounting
accounting
departments,
departments, including
including overhead
overhead percentage.
percentage.

–– Projected
Projected benefits
benefits can
can be
be gained
gained through
through the
the literature
literature
and
and looking
looking at
at similar
similar projects
projects in
in other
other organizations.
organizations.
 Measuring the
Measuring the Economic
Economic Costs
Costs and
and
Benefits of
Benefits of Ergonomic
Ergonomic Interventions
Interventions
Example:
Example: Tractor
Tractor Forwarding
Forwarding Units,
Units, South
South
African
African Forestry
Forestry Industry
Industry
Original
Original Unit
Unit:: Poor
Poor operator
operator seating
seating and
and visibility
visibility
 Measuring the
Measuring the Economic
Economic Costs
Costs and
and
Benefits of
Benefits of Ergonomic
Ergonomic Interventions
Interventions
Example
Example:: Tractor-Trailer
Tractor-Trailer Forwarding
Forwarding Units
Units
South
South African
African Forestry
Forestry Industry
Industry

Redesigned
Redesigned Unit
Unit:: Good
Good operator
operator
seating
seating and
and visibility
visibility
 Measuring the
Measuring the Economic
Economic Costs
Costs and
and
Benefits of
Benefits of Ergonomic
Ergonomic Interventions
Interventions
Example
Example:: Tractor-Trailer
Tractor-Trailer Forwarding
Forwarding Units,
Units,
South
South African
African Forestry
Forestry Industry
Industry
Cost
Cost
-- 23
23 Units
Units modified
modified @ @ $300
$300 per
per unit:
unit: $6,900
$6,900
Benefit
Benefit
-- Reduced
Reduced accident
accident damage
damage by by $2000
$2000 perper unit
unit per
per year
year
or
or $46,000
$46,000 perper year.
year.
-- Extraction
Extraction increased
increased byby one
one load
load per
per day
day per
per vehicle
vehicle
for
for total
total increase
increase of
of $19,000
$19,000 per
per yr
yr
-- TOTAL
TOTAL Cost-Benefit
Cost-Benefit:: $58,100
$58,100 or
or 11 to
to 9.4
9.4 C-B
C-B ratio.
ratio.
 Measuring
Measuring the
the Economic
Economic Benefits
Benefits
of
of Ergonomic
Ergonomic Interventions
Interventions
 Less
Less Tangible
Tangible Benefits
Benefits
–– Increased
Increased Employee
Employee Satisfaction
Satisfaction andand Commitment
Commitment ::
Leads
Leads to
to “good
“good citizenship”
citizenship” behavior.
behavior. CanCan reduce
reduce
grievances,
grievances, improve
improve productivity,
productivity, andand improve
improve
troop-community
troop-community relations
relations –– all
all of
of which
which can
can have
have aa
positive
positive financial
financial impact.
impact.
–– Improved
Improved Organizational
Organizational Image:
Image: Can
Can result
result in
in less
less
governmental
governmental scrutiny
scrutiny &
& better
better community
community relations
relations
–– all
all of
of which
which can
can have
have aa positive
positive financial
financial impact.
impact.
 Cost
Cost Effective
Effective Ergonomics
Ergonomics
 The
The earlier
earlier ergonomics
ergonomics is
is used
used in
in design,
design, the
the
cheaper
cheaper the
the cost
cost and
and greater
greater the
the benefit*
benefit*
System
System Development
Development Proportion
Proportion of
of Design
Design
Design
Design Stage
Stage Engineering
Engineering
Cost___
Cost___
Conceptual/Early
Conceptual/Early Design
Design 1.0%-
1.0%- 2+%
2+%
Blueprint
Blueprint 1.5%-
1.5%- 3+%
3+%
Construction
Construction 2.0%-
2.0%- 6+%
6+%
Commissioning
Commissioning 4.0%-10+%
4.0%-10+%
Operational
Operational 5.0%-12+%
5.0%-12+%
*Auburn
*Auburn Engineers,
Engineers, Inc.
Inc. findings;
findings; reported
reported at
at the
the April
April 2002
2002
DoD
DoD Ergonomics
Ergonomics Conference.
Conference.
 Cost
Cost Effective
Effective Ergonomics
Ergonomics

Average
Average Cost
Cost of
of Effective
Effective HFE
HFE Programs
Programs
 1.0%
1.0% of
of engineering
engineering design/development
design/development budget
budget --
based
based on
on analysis
analysis of
of 10
10 major
major military
military system
system development
development
projects
projects (Hendrick
(Hendrick && Jones,
Jones, 1981).
1981).

 1.0%
1.0% of
of engineering
engineering design/development
design/development budget
budget ––
based
based on
on analysis
analysis of
of 15
15 projects
projects (Alaxander,
(Alaxander, 2000).
2000).

 0.08%
0.08% of
of acquisition
acquisition cost
cost of
of off
off shore
shore platforms
platforms
-based
-based onon analysis
analysis of
of several
several platform
platform development
development programs
programs
over
over 99 year
year period
period (Miller,
(Miller, 1999).
1999).
 Cost
Cost Effective
Effective Ergonomics
Ergonomics
 Typical
Typical Cost-Benefit
Cost-Benefit Ratio
Ratio of
of HFE
HFE Programs
Programs

 Between
Between 11 to
to 22 and
and 11 to10+
to10+ (direct
(direct cost
cost
savings
savings only)
only) –– based
based on
on analysis
analysis of
of 27
27
projects
projects (Hendrick,
(Hendrick, 1997*).
1997*).

 Life
Life cycle
cycle cost
cost savings
savings can
can make
make the
the cost-
cost-
benefit
benefit ratio
ratio in
in excess
excess of
of 11 to
to 50
50 (Hendrick,
(Hendrick,
1979;
1979; 1997).
1997).
**Good
Good Ergonomics
Ergonomics is
is Good
Good Economics
Economics (available
(available in
in pdf
pdf
format
format at
at no
no cost
cost at
at http://hfes.org).
http://hfes.org).
Personal
Personal Example:
Example: C-141
C-141 Aircraft
Aircraft
System
System Development
Development Program
Program
C-141
C-141 Aircraft
Aircraft Development
Development Program
Program
 Four
Four Engine
Engine USAF
USAF Cargo
Cargo Aircraft
Aircraft

 Converts
Converts toto different
different configurations
configurations via
via
installation
installation of
of kits:
kits:
–– Cargo
Cargo aerial
aerial delivery
delivery
–– Paratroop
Paratroop
–– Passenger
Passenger aircraft
aircraft
–– Medical
Medical air
air evacuation
evacuation
C-141
C-141 Aircraft
Aircraft Development
Development Program
Program
 Conducted
Conducted macroergonomic
macroergonomic analysis
analysis
of
of operational
operational work
work system.
system.
Results
Results
 Original
Original design:
design: Kits
Kits had
had many
many parts
parts
that
that would
would never
never be
be removed
removed from
from
aircraft.
aircraft.
 Redesigned
Redesigned kits
kits to
to only
only include
include items
items
that
that would
would not
not be
be left
left in
in aircraft
aircraft
C-141
C-141 Aircraft
Aircraft Development
Development Program
Program
 Saved
Saved $2.5
$2.5 million
million in
in original
original price
price
 Kits
Kits smaller,
smaller, lighter,
lighter, easier
easier to
to store
store and
and
could
could be
be installed
installed faster
faster with
with fewer
fewer people
people
 Saved
Saved storage
storage cost
cost and
and reduced
reduced
personnel
personnel requirements.
requirements.
 Reduced
Reduced actual
actual aircraft
aircraft operational
operational weight
weight
and
and related
related fuel
fuel costs
costs for
for entire
entire fleet
fleet of
of
over
over 200
200 aircraft
aircraft over
over 35+
35+ year
year period.
period.
 C-141
C-141 Aircraft
Aircraft Development
Development
Program:
Program: Total
Total HFE
HFE Cost-Benefit
Cost-Benefit
 Over
Over 100
100 ergonomic
ergonomic improvements
improvements to
to
original
original engineering
engineering design
design

 Direct
Direct savings
savings of
of over
over $5
$5 million
million forfor HFE
HFE
program
program cost
cost of
of $500,000
$500,000 –– aa 11 to
to 10
10 cost
cost
benefit
benefit ratio.
ratio.

 Life
Life cycle
cycle savings
savings from
from ergonomic
ergonomic
improvements:
improvements: AtAt least
least 11 to
to 50
50 cost-benefit
cost-benefit
 C-141
C-141 Aircraft
Aircraft Development
Development
Program:
Program: Total
Total HFE
HFE Cost-Benefit
Cost-Benefit

 Good
Good example
example of
of what
what ergonomics
ergonomics
can
can do
do when
when integrated
integrated with
with
engineering
engineering design
design early
early in
in the
the
development
development program.
program.
Ergonomics
Ergonomics Cost-Benefit
Cost-Benefit
Trade-Off
Trade-Off Diamond
Diamond
Human-System
Human-System Interface
Interface Design
Design

Training
Training Selection
Selection

Job
Job Performance
Performance Aids
Aids
 Ergonomics
Ergonomics Cost-Benefit
Cost-Benefit
Trade-Off
Trade-Off Diamond
Diamond

 Often
Often overlook
overlook ergonomic
ergonomic design
design and
and
job
job aids.
aids.

 Managers
Managers & & commanders
commanders tendtend to
to
overemphasize
overemphasize training
training and
and selection
selection
as
as the
the cure
cure –– does
does not
not eliminate
eliminate poor
poor
ergonomic
ergonomic design!
design!
Ergonomics
Ergonomics Cost-Benefit
Cost-Benefit Trade-Off
Trade-Off
Diamond:
Diamond: Job
Job Aid
Aid Solution
Solution

 Example:
Example: IBM
IBM Displaywriter
Displaywriter Packing
Packing Line
Line

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

–– Ergonomist
Ergonomist analyzed
analyzed problem
problem and
and developed
developed large
large
story
story board
board aid
aid for
for each
each packing
packing station.
station.

–– Boards
Boards detailed
detailed &
& illustrated
illustrated specific
specific packing
packing
steps.
steps.
Ergonomics
Ergonomics Cost-Benefit
Cost-Benefit Trade-Off
Trade-Off
Diamond:
Diamond: Job
Job Aid
Aid Solution
Solution

 Example:
Example: IBM
IBM Displaywriter
Displaywriter
Packing
Packing Line
Line Storyboards
Storyboards
 Management
Management Awareness
Awareness is
is Critical
Critical
 Study
Study by
by Ed
Ed Jones
Jones and
and myself
myself of
of DoD
DoD Major
Major
System
System Development
Development Programs.
Programs.
-- Evaluated
Evaluated major
major DoD
DoD system
system development
development programs
programs
over
over aa 10
10 year
year period
period in
in terms
terms of
of whether
whether they
they had
had aa
good
good oror poor
poor ergonomics
ergonomics development
development effort.
effort.

-- Found
Found those
those with
with aa poor
poor effort
effort had
had major
major problems
problems
when
when they
they became
became operational.
operational.

-- Looked
Looked forfor what
what made
made thethe difference
difference between
between those
those
with
with aa good
good effort
effort vs.
vs. those
those with
with aa poor
poor effort.
effort.
 Management
Management Awareness
Awareness is
is Critical
Critical
 Study
Study by
by Ed
Ed Jones
Jones and
and myself
myself of
of DoD
DoD Major
Major
System
System Development
Development Programs.
Programs.
Results:
Results:
-- Major
Major discriminating
discriminating factor
factor was
was ergonomics
ergonomics
awareness
awareness of of the
the program
program director/commander.
director/commander.

-- Aware
Aware commanders
commanders appreciated
appreciated value
value added
added ofof
ergonomics
ergonomics --
-- and
and so
so allocated
allocated personnel
personnel
resources
resources and
and funding
funding toto ergonomics.
ergonomics. Those
Those
lacking
lacking knowledge
knowledge ofof ergonomics
ergonomics did
did not
not ..
 Management
Management Awareness
Awareness is
is Critical
Critical
 Study
Study by
by Ed
Ed Jones
Jones and
and myself
myself of
of DoD
DoD Major
Major
System
System Development
Development Programs.
Programs.
Results:
Results:
-- Effective
Effective programs:
programs: Ergonomics
Ergonomics was
was an
an
integral
integral part
part of
of the
the engineering
engineering design
design team.
team.
-- Ineffective
Ineffective programs:
programs: Ergonomics
Ergonomics was was treated
treated
as
as an
an “ility”,
“ility”, like
like reliability,
reliability, maintainability,
maintainability,
etc.;
etc.; only
only could
could make
make input
input after
after item
item was
was
already
already designed
designed (band-aid
(band-aid changes
changes only).
only).
 Management
Management Awareness
Awareness is
is Critical
Critical
 Study
Study by
by Ed
Ed Jones
Jones and
and myself
myself of
of DoD
DoD Major
Major System
System
Development
Development Programs.
Programs.

Lesson
Lesson
Establishing
Establishing rapport
rapport with
with key
key managers
managers and
and raising
raising
their
their consciousness
consciousness about
about ergonomics
ergonomics is
is essential
essential
to
to your
your long-term
long-term success.
success.

This
This often
often takes
takes time
time and
and persistence!
persistence!
 Participatory
Participatory Ergonomics
Ergonomics is
is Essential!
Essential!

Participatory
Participatory ergonomics:
ergonomics: Involve
Involve employees
employees
at
at all
all levels
levels to
to insure
insure success.
success.
 They
They know
know problems
problems with
with their
their jobs
jobs best.
best.
 They
They know
know what
what ergonomic
ergonomic alternatives
alternatives will
will be
be
most
most satisfying
satisfying and
and acceptable
acceptable to
to them.
them.
 Get
Get employee
employee “buy-in”
“buy-in” to
to changes.
changes.
 Establishes
Establishes aa true
true ergonomic
ergonomic safety
safety culture
culture ––
the
the proven
proven way
way toto sustain
sustain improvement
improvement gains!
gains!
 Example:
Example: Participatory
Participatory Ergonomics
Ergonomics
Food
Food Service
Service Stand
Stand Redesign:
Redesign: Dodger
Dodger Stadium
Stadium
 Example:
Example: Participatory
Participatory Ergonomics
Ergonomics

 Food
Food Service
Service Stand
Stand Redesign:
Redesign: Dodger
Dodger Stadium
Stadium

Results
Results
-- Ergonomists
Ergonomists Andrew
Andrew Imada
Imada and
and Gorge
Gorge Stawowy
Stawowy
redesigned
redesigned two
two food
food service
service stands
stands for
for aa cost
cost of
of
$40,000
$40,000 using
using participatory
participatory ergonomics.
ergonomics.

-- Reduced
Reduced average
average customer
customer transaction
transaction time
time
by
by 88 seconds.
seconds.
 Example:
Example: Participatory
Participatory Ergonomics
Ergonomics

 Food
Food Service
Service Stand
Stand Redesign:
Redesign: Dodger
Dodger Stadium
Stadium

Results
Results (continued)
(continued)

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

-- Payback
Payback period
period for
for modifying
modifying the
the other
other 50
50 stands
stands
will
will be
be 20
20 games.
games.
OSHA
OSHA Guidelines*
Guidelines* are
are the
the Key
Key to
to
an
an Effective
Effective Ergonomics
Ergonomics Program
Program

 Are
Are based
based on
on extensive
extensive research
research

 When
When OSHA
OSHA ergonomics
ergonomics program
program
elements
elements not
not present,
present, ergonomics
ergonomics &&
safety
safety program
program invariably
invariably not
not adequate.
adequate.

*See
*See OSHA
OSHA 3123
3123 E
Ergonomics
rgonomics Program
Program Management
Management
Guidelines
Guidelines for
for Meatpacking
Meatpacking Plants
Plants
 OSHA
OSHA Guidelines
Guidelines are
are the
the Key
Key to
to an
an
Effective
Effective Ergonomics
Ergonomics Program
Program
OSHA
OSHA Guidelines
Guidelines

I.I. Management
Management Commitment
Commitment &
& Employee
Employee
Involvement
Involvement
 A.
A. Commitment
Commitment by by Top
Top Management
Management --
deeds,
deeds, not
not just
just words
words
 B. Written Program
B. Written Program
 C. Employee Involvement
C. Employee Involvement
 D. Regular Program Reviews & Evaluation
D. Regular Program Reviews & Evaluation
OSHA
OSHA Guidelines
Guidelines are
are the
the Key
Key to
to an
an
Effective
Effective Ergonomics
Ergonomics Program
Program

II.
II. OSHA
OSHA Program
Program Elements
Elements
 A.
A. Worksite
Worksite Analysis
Analysis
 B.
B. Hazard
Hazard Prevention
Prevention and
and Control
Control
––Engineering
Engineering Controls
Controls
––Work
Work Practice
Practice Controls
Controls
––Personal
Personal Protective
Protective Equipment
Equipment
––Administrative
Administrative Controls
Controls
OSHA
OSHA Guidelines
Guidelines are
are the
the Key
Key to
to an
an
Effective
Effective Ergonomics
Ergonomics Program
Program

IIII.. OSHA
OSHA Program
Program Elements
Elements (Cont.)
(Cont.)
 C.
C. Medical
Medical Management
Management
 D.
D. Training
Training and
and Education
Education
––General
General Training
Training
––Job-Specific
Job-Specific Training
Training
––Training
Training for
for Supervisors
Supervisors
––Training
Training for
for Management
Management
––Training
Training for
for Engineers
Engineers &
& Maintenance
Maintenance
Personnel
Personnel
 OSHA
OSHA Guidelines
Guidelines are
are the
the Key
Key to
to an
an
Effective
Effective Ergonomics
Ergonomics Program
Program
 OSHA
OSHA Guidelines
Guidelines

–– Poor
Poor Example:
Example: Some
Some warehouse
warehouse Retail
Retail
Stores
Stores –– Program
Program elements
elements largely
largely
missing;
missing; many
many customer
customer injuries.
injuries.

–– Good
Good Example:
Example: Redwing
Redwing Shoes
Shoes
 Insuring
Insuring Effective
Effective Ergonomics
Ergonomics

 OSHA
OSHA Guidelines
Guidelines:: Redwing
Redwing Shoes
Shoes
–– Implemented
Implemented OSHA
OSHA guidelines
guidelines components.
components.

Results
Results
–– From
From 1989
1989 to
to 1995,
1995, workers
workers compensation
compensation
dropped
dropped by
by 70%
70% for
for aa $3.1
$3.1 million
million savings.
savings.
–– OSHA
OSHA reportable
reportable injuries
injuries dropped
dropped from
from ratio
ratio of
of
75
75 per
per 100
100 employees
employees working
working per
per year,
year, to
to 19.
19.
 Macroergonomics:
Macroergonomics: The
The Key
Key to
to
Dramatic
Dramatic Improvements
Improvements
Macroergonomic
Macroergonomic interventions
interventions can
can dramatically
dramatically improve
improve health,
health, safety,
safety, and
and
productivity (50% - 90% or more).
productivity (50% - 90% or more).
Theoretical
Theoretical Basis
Basis
-- Systems
Systems theory:
theory: All
All complex
complex systems
systems are
are
synergistic:
synergistic: When
When harmonized,
harmonized, whole
whole more
more than
than the
the sum
sum of
of
its
its parts.
parts.
-- Sociotechnical
Sociotechnical systems
systems thus
thus are
are more
more than
than the
the sum
sum of
of
their
their parts.
parts.
-- Therefore,
Therefore, macroergonomics
macroergonomics can
can dramatically
dramatically improve
improve the
the
effectiveness
effectiveness sociotechnical
sociotechnical systems.
systems.
 Macroergonomics:
Macroergonomics: The
The Key
Key to
to
Dramatic
Dramatic Improvements
Improvements

Macroergonomics
Macroergonomics
-- Conceptually
Conceptually:: A
A top-down
top-down sociotechnical
sociotechnical
systems
systems approach
approach to to work
work system
system design
design
-- In
In Practice
Practice:: It
It is
is top-down,
top-down, middle-out,
middle-out, and
and
bottom-up
bottom-up (via
(via participatory
participatory ergonomics).
ergonomics).
 Macroergonomics:
Macroergonomics: The
The Key
Key to
to
Dramatic
Dramatic Improvements
Improvements
Goal
Goal:: Achieve
Achieve aa fully
fully harmonized
harmonized work
work system
system
1.
1. Design
Design aa work
work system’s
system’s structure
structure and
and processes
processes to
to
be
be compatible
compatible with
with the
the key
key characteristics
characteristics of
of its
its
-- Personnel
Personnel subsystem
subsystem
-- Technological
Technological Subsystem
Subsystem
-- External
External Environment
Environment
Empirical
Empirical models
models exist
exist that
that enable
enable us
us to
to accomplish
accomplish this.
this.
2.
2. Design
Design jobs,
jobs, human-machine,
human-machine, human-software,
human-software, and
and
human-environment
human-environment interfaces
interfaces to
to fully
fully harmonize
harmonize with
with
the
the over-all
over-all work
work system
system design
design
 Macroergonomics:
Macroergonomics: The
The Key
Key to
to
Dramatic
Dramatic Improvements
Improvements
Macroergonomic
Macroergonomic interventions
interventions possible
possible when:
when:
––A
A major
major change
change inin equipment,
equipment, facilities
facilities or
or
processes
processes is
is to
to take
take place.
place.
––The
The organization
organization is
is in
in real
real trouble.
trouble.
––There
There is
is an
an enlightened
enlightened management
management
regarding
regarding ergonomics.
ergonomics.
––Micro-ergonomic
Micro-ergonomic successes
successes have
have gained
gained
you
you management’s
management’s confidence.
confidence.
 Macroergonomics:
Macroergonomics: The
The Key
Key to
to
Dramatic
Dramatic Improvements
Improvements
Result
Result

-- A
A fully
fully harmonized
harmonized work
work system.
system.
-- Whole
Whole thus
thus is
is more
more than
than aa simple
simple sum
sum of
of its
its
parts
parts –– Synergistic
Synergistic..
-- Consequently,
Consequently, dramatic
dramatic improvements
improvements occur.
occur.
Example:
Example: Large
Large Petroleum
Petroleum Distribution
Distribution
Company
Company in
in U.S.
U.S.
Macro-
Macro- and
and Micro-ergonomic
Micro-ergonomic Intervention
Intervention
 Example:
Example: Large
Large Petroleum
Petroleum Distribution
Distribution
Company
Company in
in U.S.
U.S.
Macroergonomic
Macroergonomic Intervention
Intervention
-- Macroergonomic
Macroergonomic analysis
analysis of
of work
work system.
system.
-- Developed
Developed strategic
strategic plan
plan for
for improving
improving safety
safety
&
& productivity.
productivity.
-- Made
Made changes
changes to
to work
work system
system where
where indicated.
indicated.
-- Participation
Participation at
at all
all levels.
levels.
 Example:
Example: Large
Large Petroleum
Petroleum Distribution
Distribution
Company
Company in
in U.S.
U.S.
Micro-ergonomic
Micro-ergonomic Intervention
Intervention
-- Worker
Worker participation
participation at
at all
all levels.
levels.

-- Employees
Employees (with
(with ergonomist
ergonomist facilitator/resource
facilitator/resource person)
person)
-- developed
developed and
and taught
taught truck
truck safety
safety program
program
-- selected
selected new
new equipment
equipment
-- identified
identified problems
problems and
and proposed
proposed ergonomic
ergonomic design
design
changes
changes to to equipment
equipment &
& procedures.
procedures.
 Example:
Example: Large
Large Petroleum
Petroleum Distribution
Distribution
Company
Company in
in U.S.
U.S.
Macro-
Macro- and
and Micro-ergonomics
Micro-ergonomics Intervention*
Intervention*

Results
Results
Reductions
Reductions After
After
22 years
years 99 Years
Years
Motor
Motor Vehicle
Vehicle Accidents
Accidents 51%
51% 63%
63%
Industrial
Industrial Accidents
Accidents 54%
54% 70%
70%
Lost
Lost Workdays
Workdays 94%
94% 97%
97%
$$ 60,000
60,000 savings
savings per
per year
year in
in petroleum
petroleum delivery
delivery costs.
costs.
** Imada
Imada (2002)
(2002)
Example:
Example: Macroergonomic
Macroergonomic Approach
Approach
to
to Implementing
Implementing TQM
TQM at
at L.L.
L.L. Bean
Bean
Macro-
Macro- and
and Micro-ergonomics
Micro-ergonomics Intervention*
Intervention*
-- Company
Company ergonomists
ergonomists read
read my
my writings
writings on
on
macroergonomics
macroergonomics and
and saw
saw it
it as
as aa potential
potential
methodology
methodology for
for implementing
implementing TQM.
TQM.

-- Used
Used methods
methods similar
similar to
to Imada’s
Imada’s in
in Petroleum
Petroleum
distribution
distribution company
company example.
example.
Example:
Example: Macroergonomic
Macroergonomic Approach
Approach
to
to Implementing
Implementing TQM
TQM at
at L.L.
L.L. Bean
Bean
Macro-
Macro- and
and Micro-ergonomics
Micro-ergonomics Intervention*
Intervention*

Results
Results

-- 70%
70% reduction
reduction in
in lost
lost time
time accidents
accidents and
and
injuries
injuries achieved
achieved in
in two
two year
year period
period in
in both
both
production
production and
and distribution
distribution divisions.
divisions.

-- Other
Other benefits,
benefits, such
such as
as greater
greater employee
employee satisfaction,
satisfaction,
also
also realized.
realized.
 Practical
Practical Application
Application of
of Ergonomics
Ergonomics

Conclusion
Conclusion::

Good
Good Ergonomics
Ergonomics is
is Good
Good Economics
Economics
And
And
Is
Is aa Key
Key to
to Optimizing
Optimizing the
the Effectiveness
Effectiveness of
of
our
our Armed
Armed Forces.
Forces.