UNIT – VI

Ergonomics (7 Hours)
 CONTENTS
Unit-VI

• Ergonomics Basic principles of ergonomics

• Concurrent Engineering: Producibility, manufacturability, productivity
improvement.
• Total Quality Management: Just in time (JIT), total quality control, quality
circles, six sigma.
 Unit Outcomes

At the end of this unit, Students will be able to,

• Can get an idea about importance of Ergonomics in

Engineering.
• Predict the importance of concurrent engineering.
• Assess various modern philosophies like TQM, Six Sigma, etc.
 Fundamental
Ergonomic
Principles
Maintain Neutral Posture

Neutral postures are postures where the body is aligned and balanced while
either sitting or standing, placing minimal stress on the body and keeping
joints aligned.

Neutral postures minimize the stress applied to muscles, tendons, nerves and
bones and allows for maximum control and force production.

Ergo-Plus.com
Maintain Neutral Posture

The opposite of a neutral posture is an “awkward posture.” Awkward postures

move away from the neutral posture toward the extremes in range of motion.

This puts more stress on the worker’s musculoskeletal system, is a

contributing risk factor for Musculoskeletal Disorders (MSDs), and should
be avoided.

Ergo-Plus.com
Maintain Neutral Posture

Ergo-Plus.com Image
Source
Maintain Neutral Posture

Ergo-Plus.com Image
Source
Maintain Neutral Posture

Ergo-Plus.com Image
Source
Maintain Neutral Posture

Ergo-Plus.com Image
Source
 ERGONOMIC PRINCIPLE

Work in the
Power/Comfort Zone
Work in the Power/Comfort Zone

The power zone for lifting is close to the body, between mi-thigh
and mid-chest height. This zone is where the arms and back can lift
the mostwith the least amount of effort.

Working from the power / comfort / handshake zone ensures

that you are working from proper heights and reaches, which
reduces MSD risk factors and allows for more efficient and pain-
free work.

Ergo-Plus.com
Work in the Power/Comfort Zone

Working outside the

Power Zone = Risk!

Ergo-Plus.com
Work in the Power/Comfort Zone

Working outside the

Power Zone = Risk!

Ergo-Plus.com
Work in the Power/Comfort Zone

Working outside the

Power Zone = Risk!

Ergo-Plus.com
Work in the Power/Comfort Zone

Working outside the

Power Zone = Risk!

Ergo-Plus.com
Work in the Power/Comfort Zone

Working outside the

Power Zone = Risk!

Ergo-Plus.com
 ERGONOMIC PRINCIPLE

Allow for Movement and

Stretching
Allow for Movement and Stretching

Stretching reduces fatigue, improves muscular balance and

posture and improves muscle coordination. Everyone is an athlete
in life, so you need to prepare your body for work by warming
up to improve performance and lower injury risk.

A warm-up stretching regimen is a great way to prepare your

body for work.

It is also beneficial to take periodic stretch breaks over the course

of your work day to get your blood moving and restore your
energy.

Ergo-Plus.com
Allow for Movement and Stretching

Ergo-Plus.com
 ERGONOMIC PRINCIPLE

Reduce Excessive
Force
Reduce Excessive
Force
Excessive force is one of the primary ergonomic risk factors.
Many work tasks require high force loads on the human body.
Muscle effort increases in response to high force requirements
which increases fatigue and risk of an MSD.

There are numerous conditions that affect force, but the idea is
to recognize when a job or task requires excessive force and then
find ways to reduce that force.

Ergo-Plus.com
Reduce Excessive
Force
Eliminating excessive force requirements will reduce worker fatigue
and the risk of MSD formation in most workers. Using mechanical
assists, counter balance systems, adjustable height lift tables and
workstations, powered equipment and ergonomic tools will reduce
work effort and muscle exertions.

Ergo-Plus.com
Reduce Excessive
Force

Excessive force = Risk!

Ergo-Plus.com
Reduce Excessive
Force

Excessive force = Risk!

Ergo-Plus.com
 ERGONOMIC PRINCIPLE

Reduce Excessive
Motions
Reduce Excessive
Motions
Repetitive motion is another one of the primary ergonomic risk
factors. Many work tasks and cycles are repetitive in nature, and
are frequently controlled by hourly or daily production targets
and work processes.

High task repetition, when combined with other risks factors such
high force and/or awkward postures, can contribute to the
formation of MSD. A job is considered highly repetitive if the cycle
time is 30 seconds or less.

Ergo-Plus.com
Reduce Excessive
Motions
Excessive or unnecessary motions should be reduced if at all
possible. In situations where this is not possible, it is important
to eliminate excessive force requirements and awkward
postures.

Other control methods to consider are job enlargement, job

rotation and counteractive stretch breaks.

Ergo-Plus.com
Reduce Excessive
Motions

Excessive motion combined

with other risk factors = Risk!

Ergo-Plus.com
Reduce Excessive
Motions

Excessive motion combined

with other risk factors = Risk!

Ergo-Plus.com
 ERGONOMIC PRINCIPLE

Minimize Contact
Stress
Minimize Contact
Stress
According to OSHA, contact stress results from continuous contact
or rubbing between hard or sharp objects/surfaces and sensitive
body tissue, such as soft tissue of the fingers, palms, thighs and
feet. This contact creates localized pressure for a small area of the
body, which can inhibit blood, nerve function, or movement of
tendons and muscles.

Ergo-Plus.com
Minimize Contact
Stress
Examples of contact stress include resting wrists on the sharp
edge of a desk or workstation while performing tasks, pressing
of tool handles into the palms, especially when they cannot be
put down, tasks that require hand hammering, and sitting
without adequate space for the knees.

Ergo-Plus.com
Minimize Contact
Stress

Contact Stress = Risk!

Ergo-Plus.com
Minimize Contact
Stress

Contact Stress = Risk!

Ergo-Plus.com
 ERGONOMIC PRINCIPLE

Reduce Excessive
Vibration
Reduce Excessive Vibration

Multiple studies have shown that regular and frequent exposure

to vibration can lead to permanent adverse health effects, which
are most likely to occur when contact with a vibrating tool or
work
process is a regular and significant part of a person’s job.

Ergo-Plus.com
Reduce Excessive Vibration

Hand-arm vibration can cause a range of conditions collectively

known as hand-arm vibration syndrome (HAVS), as well as specific
diseases such as white finger or Raynaud’s syndrome, carpel
tunnel
syndrome and tendinitis. Vibration syndrome has adverse
circulatory and neural effects in the fingers. The signs and
symptoms include numbness, pain, and blanching (turning pale
and ashen).

Ergo-Plus.com
Reduce Excessive Vibration

Excessive Vibration = Risk!

Ergo-Plus.com
 ERGONOMIC PRINCIPLE

Provide Adequate Lighting

Provide Adequate Lighting

Poor lighting is a common problem in the workplace that can

affect a worker’s comfort level and performance. Too much or too
little light makes work difficult – just imagine trying to do your
job without sight!

Dimly lit work areas and glare can cause eye fatigue and
headaches and improperly lit areas put workers at greater risk for
all types of injuries.

Ergo-Plus.com
Provide Adequate Lighting

Providing workers with adjustable task lighting is often a simple

solution to lighting problems. At a computer workstation, take
steps to control screen glare, and make sure that the monitor is
not placed in front of a window or a bright background.

Ergo-Plus.com
 Industrial Engineering
PIONEERS OF INDUSTRIAL ENGINEERING
Taylor and Scientific Management –

3. Henry Towne and Henry Gantt, Frederick Halsey (1912)

Henry Gantt invented “Task and bonus system”.
Gantt chart: a systematic graphical procedure for planning and
scheduling activities that is still widely used in project
management.
 Concurrent Engineering
Introduction
Definition: “Integrated approach to product-design that takes into
account all stages of a product’s life cycle from design to disposal
– including costs, quality, testing, user needs, customer support,
and logistics”
OR
The simultaneous performance of product design and process
design. Typically, concurrent engineering involves the formation
of cross-functional teams. This allows engineers and managers of
different disciplines to work together simultaneously in developing
product and process design.”
Concurrent Engineering
 Concurrent Engineering
Benefits
It encourages multidisciplinary collaboration.
It makes the design process faster.
It reduces costs and increases quality by supporting the entire
project life cycle.
It increases productivity by stopping mistakes in their tracks.
It gives you a competitive advantage.
 Concurrent Engineering
Influencing areas
There are three influencing areas of concurrent
engineering
1. Man
2. Process
3. Technology
 Concurrent Engineering
Producibility

The quality or state of being producible.

The measure of the relative ease o of manufacturing.
 Concurrent Engineering
Manufacturability

To make or process (a raw material) into a finished

product, especially by means of a large
scale industrial operation.
To make or process (a product), especially with the use of in
dustrial machines.
 Concurrent Engineering
Productivity improvement
There can be many techniques of productivity
improvement. Few of them are

1. Review Your Existing Workflow.

2. Update Processes and Technology
3. Commit to Scheduled Maintenance
4. Train and Educate Employees
5. Organize the Workspace
6. Maintain Optimal Inventory
 Total Quality Management
Introduction
Total Quality Management (TQM) is enhancement to the
traditional way of doing business.

• Total:- Made up of whole or Involvement of all levels in the

organization
• Quality:-Degree of excellence a product or service provides or
Conformance to agreed upon requirements
• Management:- Act, art or manner of handling,
controlling, directing
 Total Quality Management
Introduction

TQM is defined as both philosophy and a set of guiding

principles that represent the foundation of continuously
improving organization.
Total Quality Management means that the organization's
culture is defined by and supports the constant attainment of
customer satisfaction through an integrated system of tools,
techniques, and training. This involves the continuous
improvement of organizational processes, resulting in high
quality products and services.
 Total Quality Management
TQM- Basic Principles

1. Management commitment to TQM principles and methods &

long term Quality plans for the Organization
2. Focus on customers
3. Quality at all levels of the work force.
4. Continuous improvement of the production/ Business process
5. Treating suppliers as partners
6. Establish performance measures for the processes.
 Total Quality Management
TQM- Origin

The roots of Total Quality Management (TQM) can be traced back

to early 1920s when statistical theory was first applied to
product quality control. This concept was further developed in
Japan in the 40s led by Americans, such as Deming, Juran and
Feigenbaum. The focus widened from quality of products to
quality of all issues within an organisation – the start of TQM.
 Total Quality Management
WHY TQM
Total quality management benefits and advantages: Strengthened
competitive position
Adaptability to changing or emerging market conditions and to
environmental and other government regulations
Higher productivity
Enhanced market image
Elimination of defects and waste
Reduced costs and better cost management
Higher profitability
 Total Quality Management
WHY TQM

Improved customer focus and satisfaction

Increased customer loyalty and retention
Increased job security
Improved employee morale
Enhanced shareholder and stakeholder value
Improved and innovative processes
 Six Sigma
An Overview

 Sigma is a statistical concept that represents the amount of

variation present in a process relative to customer requirements
or specifications.
 A statistical concept that measures a process in terms of
defects – at the six sigma level, there 3.4 defects per
million opportunities
 Commonly denoted as 6σ, 6 Sigma, or 6s
 Six Sigma
Why we should use Six Sigma?

Quality
Process Improvement
Time reduction
Customer Satisfaction
Growth
Money
 Six Sigma
History of Six Sigma

Bill Smith
Deming's methods became systematized into Six Sigma
at Motorola, a consumer electronics company battered by Japanese
competition. Bill Smith, an engineer, developed and named it in
1985, and CEO Bob Galvin made it a company-wide initiative
 Six Sigma
Six Sigma table
 Six Sigma

Measure Improve

Define Analyze Con

 Six Sigma
Phases of Six Sigma

1. Define: Define the project goals and customer (internal

and external) deliverables

2. Measure: Measure the process to determine current

performance

3. Analyze: Analyze and determine the root cause(s) of the

defects
 Six Sigma
Phases of Six Sigma

4. Improve: Improve the process by eliminating defects

5. Control: Control future process performance

 Six Sigma
Advantages of Six Sigma
1. Reduction in Operational Costs
A. Inspection Costs
B. Rework Costs
C. Customer complaints
2. Improve Efficiency or Timeliness
3. Improve Accuracy, Controls, and Policy Compliance
4. Improved Customer Service/ Satisfaction
5. Improved Cash Flow