ISYE6190 - PPT3-W3-S4-PJJ TD (Final)

Facility Planning and Safety
Engineering
Topic 3-Week 3-Session 4
Ergonomic and The Principles of

Motion Economy
Learning Outcome
LO 1: Apply some engineering analysis and techniques in designing

the facility and flow interaction
LO 2: Analyze the floor space requirement, machine and facility
requirement based on layout optimization models
LO 3: Utilize basic knowledge Safety, Health and Environment to control
workplace hazards to prevent injuries, illness and property damage
LO 4: Analyze safety management in a TQM (Total Quality Management)
environment on manufacturing/service company
ERGONOMIC AND THE PRINCIPLES
OF MOTION ECONOMY
Workstation Design
• Design the workstation so that the task fits the person rather than
forcing the human body to fit the job.
• Improper workstation design costs the American industry millions of
dollars annually in lost productivity, health, and job related injuries and
accidents.
The result of ergonomics and workstation design is a workstation layout,

and the workstation layout determines the space requirements. The
manufacturing department’s total space requirements are just a total of
individual space requirements plus a contingency (a little extra) factor.
Workstation Design
The following information

must be included in any
workstation design:
1. Worktable, machines, and

facilities
2. Incoming materials (material
packaging and quantity must be
considered)
3. Outgoing material (finished
product)
4. Operators’ space and access to
equipment Fig. Workstation layout.
5. Location of waste and rejects
6. Fixture and tools
7. Scale of drawing
Ergonomics and the Principles
of Motion Economy
• Effectiveness is doing the right job.

• Efficiency is doing the job right.
• Safety and efficiency should be the goals of every workstation designer.
• Ergonomics and the principles of motion economy should be
considered for every job.
• Hand Motions
• Basic Motion Types
• Location of Parts and Tools
• Freeing the Hands from as Much Work as Possible
• Gravity
• Operator Safety and Health Considerations
Hand Motions
• Principles of motion economy related to hand motions :

1. Eliminate as many hand motions as possible.
2. Combine motions to eliminate other motions.
3. Make motions as short as possible, and discourage learning because
of excessive reaching.
4. Reduce the force required as much as possible.
5. Keep both hands equally busy.
6. Use mirror image moves.
7. Do not use the hand as a holding device.
8. Located frequently used tools and materials closer to the point of
use, and tools and materials used less often farther away. The weight
of tools and materials should also influence their closeness to the
point of use. Place heavy material closer to the point of use.
Basic Motion Types
• Ballistic motions are fast motions created by putting one set of

muscles in motion and not trying to stop those motions by using
other muscles.
• Controlled or restricted motions are the opposite of ballistic motions
and require more control especially at the end of the motion.
• Continuous motions are curved motions and much more natural
than straightline motionsm which tend to be controlled or restricted
motions.
Location of Parts and Tools
• A toolmaker’s toolbox is laid out so that the toolmaker knows where

every tool is and can retrieve it without looking. This should be a goal
in every workstation tthat planners design.
• Real creativity is required to minimize reaches.
• Here is a summary of the location of parts and tools :
1.Have a fixed location for everything

2.Place everything as close as possible to the point of use.
Freeing the Hands from as
Much Work as Possible
• As started earlier, the hand is the most expensive fixturre that a

designer could use. Fixtures and jigs are designed to hold parts so
that the worker can use both hands.
• Foot-operated control devices can be designed to activate
equipment to relieve the hands for work.
• Conveyors can move parts past operators so that they don’t have to
get or set aside the base unit.
Operator considerations
Fig. Operator considerations
Fixture design is easy and only your knowledge of the part and needed
processes are required to design fixtures
Gravity
Gravity is
free power.
Use it!
• Gravity can move parts closer to the operator.

• Gravity can also be used to remove finished parts from the workstation.
• Gravity is everywhere, so gravity can be used into your workstation everywhere.
Operator Safety and Health
Considerations
• Keep safety hazards in mind and anticipate emergency action

requirements while designing the workstation.
• Design a workstation to eliminate straining of the neck to look at
things, to eliminate stoopig or bending, to eliminate turning sideways
or turning atound, and to eliminate excessive reaches and moves.
• Operators become efficient and stay healthy if :
1. They are allowed to work at the right height
2. Given the opportunity to work while both sitting or standing
3. Given enough light to work by
4. Given adequate space to perform their tasks.
Space Determination
• The space determination for most production departments starts

with the workstation design.
• Multiplying the total workstation design square feet by 150% allows
for extra space for the aisle, work in process, and a small amount of
miscellaneous extra room.
• It does not include restrooms, lunchrooms, first aid, tool rooms,
maintenance, offices, stores, warehouse, shipping or receiving.
Summary
• Ergonomics is the science of preventing musculoskeletal injuries in

the workplace.
• Design the workstation so that the task fits the person.
• First of all hand motions should be eliminated as much as possible.
Let a machine do it.
• If hand tools are used they must be designed ergonomically, and they
must be easily adapted to both left-handed and right-handed people.
Over 10% of the people are left-handed.
• Controlled restricted motions require more control especially at the
end of the motion. Controlled motions are to be considered first for
elimination because they are costly, fatiguing, and unsafe.
Summary
• Have a fixed place for all parts and tools and have everything as close to
the point of use as possible.
• The correct work height is elbow height. Light work can be 2 inches
above elbow height, whereas heavy work should be 2 inches below
elbow height.
• Operator space should be 3 x 3 feet. Three feet off the aisle is adequate
for safety and 3 feet from side to side allows parts to be placed
comfortably next to the operator. If machines need maintenance and
cleanup, a 2 foot access should be allowed around the machine.
• Multiplying the total workstation design square feet by 150% allows for
extra space for the aisle, work in process, and a small amount of
miscellaneous extra room.
• It does not include restrooms, lunchrooms, first aid, tool rooms,
maintenance, offices, stores, warehouse, shipping or receiving.
References
• Stephens, Matthew P., & Meyers, F. E. (2013). Manufacturing

facilities design and material handling. Purdue University Press.
ISBN-13: 978-1-55753-650-1
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Facility Planning and Safety

Ergonomic and The Principles of

LO 1: Apply some engineering analysis and techniques in designing

The result of ergonomics and workstation design is a workstation layout,

The following information

1. Worktable, machines, and

• Effectiveness is doing the right job.

• Principles of motion economy related to hand motions :

• Ballistic motions are fast motions created by putting one set of

• A toolmaker’s toolbox is laid out so that the toolmaker knows where

• Here is a summary of the location of parts and tools :

1.Have a fixed location for everything

• As started earlier, the hand is the most expensive fixturre that a

Fig. Operator considerations

• Gravity can move parts closer to the operator.

• Keep safety hazards in mind and anticipate emergency action

• The space determination for most production departments starts

• Ergonomics is the science of preventing musculoskeletal injuries in

• Stephens, Matthew P., & Meyers, F. E. (2013). Manufacturing

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