Ergonomic Analysis Research Articles

Assessment of Adequacy of Product Appearance Attributes to the Design Objective

A new method for assessment of product aesthetics („Assessment of adequacy of product appearance attributes to the design objective and to values of market segment”, Adequacy Method, in short) was developed by the author. The method is based on the need to assess product aesthetics against the design objective and the human values / goals of the target market segment. In a pre-test, eight products (from four classes) with the most different design were chosen for testing the method. Then, in an experimental study, the products were assessed using the proposed method by students from a technical university. After statistically analysing the assessment results, it was found that the method criteria and the method itself proved to be reliable, efficient, and clear. The proposed method was also tested by comparison with a complex method (FTESE – Functional, Technical, Ergonomic, Significance and Esthetic Analysis). The same products used in the paper presenting the FTESE method were assessed using the proposed method and lead to the same ordering of products according to their aesthetics. But the comparison also indicated that the proposed method allows for a superior refinement.

Ergonomic risk analysis with the use of ergonomic guides

Ergonomic risk analysis with the use of ergonomic guides

Study on Static Biomechanical Model of Whole Body Based on Virtual Human.

Material handling tasks often lead to skeletal injury of workers. The whole-body static biomechanical modeling method based on virtual humans is the theoretical basis for analyzing the human factor index in the lifting process. This paper focuses on the study of humans' body static biomechanical model for virtual human ergonomics analysis: First, the whole-body static biomechanical model is constructed, which calculates the biomechanical data such as force and moment, average strength, and maximum hand load at human joints. Secondly, the prototype model test system is developed, and the real experiment environment is set up with the inertial motion capture system. Finally, the model reliability verification experiment and application simulation experiment are designed. The comparison results with the industrial ergonomic software show that the model is consistent with the output of the industrial ergonomic software, which proves the reliability of the model. The simulation results show that under the same load, the maximum joint load and the maximum hand load are strongly related to the working posture, and the working posture should be adjusted to adapt to the load. Upright or bent legs have less influence on the maximum load capacity of the hand. Lower hand load capacity is due to forearm extension, and the upper arm extension greatly reduces the load capacity of the hand. Compared with a one-handed load, the two-handed load has a greater load capacity.

Revolutionizing Workplace Safety Through Innovative Ergonomic Solutions in Indonesia

General Background: Workplace accidents significantly impact employee health, productivity, and organizational efficiency, necessitating effective safety and health management strategies. Specific Background: The study investigates the use of the Macro Ergonomic Analysis and Design (MEAD) method at PT Esprobags to improve occupational health and safety measures. Knowledge Gap: PT Esprobags faces challenges in effectively addressing employee health concerns, especially regarding health insurance and workplace conditions, despite increasing demand for safety protocols. Aims: This research aims to identify key health and safety issues affecting employees, utilizing MEAD to analyze and design solutions that mitigate workplace accidents and improve overall employee well-being. Results: The findings indicate that inadequate health insurance and infrequent health checks, along with insufficient drinking water quality and room cleanliness, are primary concerns among employees. The analysis reveals that environmental factors significantly influence employee safety, health, and performance, contributing to a 60.7% variance in the work environment's impact on safety and performance. Novelty: This study introduces a structured ergonomic approach tailored to the unique needs of the manufacturing sector, emphasizing the importance of holistic workplace assessments. Implications: PT Esprobags' implementation of the MEAD methodology can improve employee satisfaction, productivity, and safety, contributing to a broader understanding of workplace ergonomics and occupational health. Highlights: Health Concerns: Inadequate health insurance and checks impact employee well-being. Environmental Impact: Workplace conditions significantly affect safety and productivity. Implementation Benefits: MEAD enhances satisfaction and reduces workplace accidents. Keywords: workplace safety, ergonomic analysis, employee health, Macro Ergonomic Analysis and Design, occupational safety

Ergonomic Risk Analysis of Working Postures for a Textile Factory Worker

The textile sector significantly contributes to total employment and exports in our country. At the same time, it has a production structure that is labor-intensive and where most of the work is done manually and repetitively. As a result of shift work and long working hours in textile production, some musculoskeletal disorders occur in employees due to non-ergonomic posture and repetitive movements. Untreated and neglected musculoskeletal disorders cause more serious problems for employees in the long term. In this study, ergonomic risk assessment was conducted using the Rapid Entire Body Assessment Method for the working postures of textile workers working in the weaving department of a textile factory. Thus, potential risk factors and ergonomic strain levels exposed to employees were determined. As a result of the research, it was determined that the employee was exposed to high risk, and precautions needed to be taken quickly. In addition, some recommendations were made to prevent musculoskeletal disorders and loss of productivity in the business through some precautions.

Monocular 3D Multi-Person Pose Estimation for On-Site Joint Flexion Assessment: A Case of Extreme Knee Flexion Detection.

Work-related musculoskeletal disorders (WMSDs) represent a significant health challenge for workers in construction environments, often arising from prolonged exposure to ergonomic risks associated with manual labor, awkward postures, and repetitive motions. These conditions not only lead to diminished worker productivity but also incur substantial economic costs for employers and healthcare systems alike. Thus, there is an urgent need for effective tools to assess and mitigate these ergonomic risks. This study proposes a novel monocular 3D multi-person pose estimation method designed to enhance ergonomic risk assessments in construction environments. Leveraging advanced computer vision and deep learning techniques, this approach accurately captures and analyzes the spatial dynamics of workers' postures, with a focus on detecting extreme knee flexion, a critical indicator of work-related musculoskeletal disorders (WMSDs). A pilot study conducted on an actual construction site demonstrated the method's feasibility and effectiveness, achieving an accurate detection rate for extreme flexion incidents that closely aligned with supervisory observations and worker self-reports. The proposed monocular approach enables universal applicability and enhances ergonomic analysis through 3D pose estimation and group pose recognition for timely interventions. Future efforts will focus on improving robustness and integration with health monitoring to reduce WMSDs and promote worker health.

Ergonomic optimization in forestry harvesting: analysis of indicators and workstation layout for machine operators

The planted tree sector in Brazil plays a significant role in the national economy, driven by technological advancements in forestry machines, especially in harvesting. The interaction between operators and machines has become essential for improving performance and ensuring occupational health. This study analyzed forest harvesting machine operators, focusing on anthropometric surveys and proposing indicators for ergonomic satisfaction and cabin layout. Conducted between May 2022 and July 2023 in a northeastern Brazilian forestry company, data were collected during mechanized harvesting of a six-year-old Eucalyptus spp. stand using the cut-to-length system. A questionnaire was applied to 111 employees to assess their ergonomic satisfaction and health. Two indices were created: the Ergonomic Satisfaction Coefficient and the Occupational Health Coefficient. The anthropometric analysis evaluated operators’ percentiles and BMI, revealing that 77.77% were overweight, highlighting the need for health protection measures. The ergonomic indices proved effective in assessing operator satisfaction. The study also determined an adequate workstation layout for the sample group. From the Ergonomic Work Analysis perspective, FW2 and HV3 machines received a good rating based on the adopted parameters.

Inertial Motion Capture-Driven Digital Human for Ergonomic Validation: A Case Study of Core Drilling.

In the evolving realm of ergonomics, there is a growing demand for enhanced comfortability, visibility, and accessibility in the operation of engineering machinery. This study introduces an innovative approach to assess the ergonomics of a driller's cabin by utilizing a digital human. Through the utilization of inertial motion capture sensors, the method enables the operation of a virtual driller animated by real human movements, thereby producing more precise and realistic human-machine interaction data. Additionally, this study develops a simplified model for the human upper limbs, facilitating the calculation of joint forces and torques. An ergonomic analysis platform, encompassing a virtual driller's cabin and a digital human model, is constructed using Unity 3D. This platform enables the quantitative evaluation of comfortability, visibility, and accessibility. Its versatility extends beyond the current scope, offering substantial support for product development and enhancement.

Prediction of human initial operation situation in confined space with a multi-task deep neural network

Most large manufacturing fields still rely on manual operations, requiring operators to enter the Confined Space (CS) to conduct assembly and maintenance tasks. The ergonomics analysis combined with the Digital Human Model (DHM) can provide valuable suggestions and guidance for product structure design and process planning. Due to the particularity of CS, the current algorithms applied to DHM operation planning are not suitable for CS operations. To address this challenge, we introduce a novel approach to predict the initial operation situation in CS. The Restriction State Expression Model for Bi-Directional Confined Space (RSEMfBDCS) is introduced to quantify the restricted degree, and a novel multi-task deep neural network, as the Human Operation Situation Prediction Network in CS (HOSPNiCS) is developed to predict the initial operation situation in CS, which includes operation reachability, the initial OPI, and the initial OPII of the operators. Training and Verifying by the data collected from the real operation cases, HOSPNiCS distinguishes whether the manual operation is reachable with an average accuracy of 0.996, and the average accuracy for initial OPI prediction can reach 0.957. For initial OPII prediction, HOSPNiCS has an average distance error of 0.036 m and an average angle error of 0.395°. Based on the proposed approach, the engineering designers can swiftly ascertain operation reachability and get the initial OPI and OPII of DHM with the help of the prediction results. In light of this, the human operation simulation would be more practical for future human factor analysis.

Simulation model to analyze the impact of work on absenteeism

AbstractShoe manufacturing companies often use overtime work but neglect the impacts and importance of physical recovery time. Ergonomic methods aim to analyze this, but they focus on deterministic aspects, which limits their ability to evaluate working conditions amid variations over time. This research explores how a simulation model can mitigate these limitations and enhance analysis of overtime and physical recovery on worker absenteeism. The objective was developed a simulation model using System Dynamics (SD) to represent working conditions and assess the influence of overtime and recovery time in Brazil's footwear industry. An Ergonomic Analysis of Work was conducted in a large company's production cell. Using SD, were constructed a causal and simulation model to analyze three scenarios. An additional hour of work increased physical overload by 44%, leading to 5, 4 leave requests, and 48 days of absenteeism per year. Increasing recovery time by 15 min reduced overload to 38,96%, resulting in 4, 9 leave requests and 13,68 days of absenteeism. The SD simulation model mitigated the limitations of ergonomic methods in understanding the dynamic relationships over time, emphasizing the importance of actively managing overtime and physical recovery time.

ErgoReality: A Virtual Reality Simulations Software for Ergonomic Analysis of Workstation Design

Traditional tools for ergonomic assessments of workstation designs often involve ergonomists using Digital Human Modeling (DHM) software to simulate worker motions. However, these tools can be limited by posture prediction algorithms that fail to capture the full range and variability of human behavior. Virtual Reality (VR) offers an alternative by enabling workers to perform tasks within simulated workspaces, where their movements are captured using motion tracking systems. This approach generates kinematic data that can overcome the shortcomings of DHM tools, facilitating improved accuracy in the ergonomic evaluation of workstation design. Building multiple alternative virtual workstations is not only quicker but also more cost-effective than building physical prototypes. In this paper, we introduce a VR application, ErgoReality, and discuss its three main components: simulation development, data collection, and ergonomic analysis. We also explore further research areas to enhance the tool, address potential limitations, and propose strategies to mitigate these challenges.

Influence of extended working hours and physical recovery on absenteeism in the footwear industry from a system dynamics model

Objectives. Work-related musculoskeletal disorders (WMSDs) are recurrent in the footwear industry, resulting in absenteeism. This study aimed to quantitatively analyze the influence of overtime work and physical recovery time on the occurrence of WMSD-related absenteeism using a system dynamics model. As ergonomic methods have limitations in quantitatively simulating the behavior of these relationships, the integration of computational modeling techniques has emerged as a methodological alternative to bridge this gap. Methods. An ergonomic work analysis (EWA) was developed in a production cell of a large company. A model of causal relationships (causal loop diagram) and a simulation model (flow and stock diagram) were then developed, where three scenarios for overtime and physical recovery time were analyzed. Results. Working an additional hour resulted in a 42% increase in physical overload, leading to 7.62 leave requests per year and 78.7 days of employee absenteeism. Increasing the physical recovery time by 15 min reduced the overload to 36.5%, resulting in 6.8 leave requests per year and 71.1 days of employee absenteeism. Conclusions. Properly managing excess workload and providing adequate physical recovery for professionals is necessary to mitigate the productivity impacts of absenteeism in the footwear industry.

Ergonomic Analysis of Small-Scale Palm Sugar Starch Processing Industry in Rancakalong Village, Sumedang Regency

Rancakalong village, Sumedang Regency, has been known for its small-scale palm sugar starch processing industry since 2013. This industry produces starch from palm trees, which is crucial for food and beverages. Generally, the processes involved in processing palm sugar starch include (i) splitting of the palm, (ii) grating, (iii) coarse fiber screening, (iv) fine fiber screening, (v) harvesting, and (vi) drying. Initial evaluations indicated that the workers experienced physical discomfort during their work. Therefore, this study aimed to analyze the ergonomic aspects of processing palm sugar starch, including the working posture, standard time, workload, noise, and vibration. Based on the analysis, the risk level for each work element in processing palm sugar starch fell into the high-risk (score 8-10) and very high-risk (score 11-15) categories. These risks cause discomfort due to inappropriate work posture and duration, necessitating significant changes. The standard time required for each work element was as follows: 212.88±28.43 seconds/kg (palm splitting), 363.45±12.90 seconds/kg (grating), 95.08±9.74 seconds/kg (coarse fiber screening), 192.05±21.27 seconds/kg (fine fiber screening), 35.57±5.78 seconds/kg (harvesting), and 1821.01±41.09 seconds/kg (drying). Regarding workload analysis, processing palm sugar starch activities fell into the moderate category with total energy cost (TEC) values ranging from 92.66±1.50 265.55±3.88 kcal/hour. Regarding noise and vibration analysis, the grating work element was identified as the station with the highest exposure, i.e., 96.00±0.82 dB and 1.6±0.05 m/s2, respectively. The results of this study could be used as a basis for developing more efficient work procedures, maintaining health, and improving safety in the processing of palm sugar starch.

Ergonomic evaluation of assembly line work activity in the automotive industry: a case study

The automotive industry is growing worldwide with new technologies and seeking maximum cost savings. This sector is essential for the economic development of the country, with modern industries that invest in technological innovations and control of the activities of the production process. With this, the workstations become increasingly dynamic and characterized in the logic of productivity. Therefore, this study aimed to evaluate the work activity of operators of an assembly line of automotive components, from the ergonomic analysis. Through a descriptive and exploratory field study, the work activity of 30 operators of an assembly line of metallic components of the automotive industry was evaluated. Using instruments such as sociodemographic questionnaire; Nordic questionnaire; open interview, with collective questions about the development of the function, listed in an ergonomic demand items (EDIs) ranking; and complementary application of the NIOSH and OCRA methods. As a result, all respondents were male, with an average age of 30.13 ± 8.57 years, most had completed high school (76.7%), with an average working time in the company of almost two years (21.93 ± 12 months). Regarding relationships with coworkers, it was observed that the sector has a great relationship during the activities, with both colleagues and the boss. This study demonstrated a lower frequency of musculoskeletal symptoms in operators when compared to other studies. Symptoms that caused work leave were neck (3.3%), shoulders (3.3%), upper (6.7%) and lower back (6.7%), and hips/thighs (6.7%), ankle/foot (6.7%) were reported.

Ergonomics, Health, and Perceptions about Remote Domestic Workposts: Study in Areas of City of João Pessoa, Paraíba, Brazil.

Home office (HO) stands out as one of the most promising and popular forms of teleworking, especially after the COVID-19 pandemic. Therefore, many companies want to implement or maintain this working method, given its numerous advantages. However, there are adverse effects that are mainly related to physical and mental health. This article presents ergonomic analyses of HOs in neighborhoods considered heat islands. Temperature levels, extreme low-frequency non-ionizing radiation (ELF-NIR), illuminance, physical layout characteristics, and physiological parameters of teleworkers were measured. The results reveal that 92% of these professionals work 6 to 8 h daily with an ambient temperature between 25 and 30 °C, illumination levels in the range 11.20-290 Lux, and ELF-NIR > 0.4 µT. The majority of teleworkers are overweight (BMI > 24.9), and some of them have blood pressure higher than average values (129 mmHg for systolic and 84 mmHg for diastolic) in addition to a reduction in the number of red blood cells and hematocrits. Symptoms such as burning sensation, dryness, tired eyes, redness, itching, and photophobia (light sensitivity) show a 68.95% similarity. These HOs do not meet the required ergonomic and health standards.

Development of an evidence-based swimming representative military task to assess swimming competency in the British Army.

There is a requirement for British Army personnel to operate in/around water. Assessing role-related swimming/water competence will support personnel to conduct their job-roles safely and effectively. To undertake a Job-Task Analysis (JTA) of British Army personnel when working in/around water and use this information to develop a Swimming Representative Military Task (RMT) to assess swimming/water competence. Workshops, surveys, and observations were used to conduct a JTA, which identified and described job-tasks conducted by British Army personnel in/around water. Ergonomic analysis of these job-tasks identified seven water-based physical actions, which were considered fundamental for all personnel to be competent in performing. These seven actions guided design of a Swimming RMT, which was subsequently conducted twice by 103 serving personnel (89 men, 11 women) and once by 65 recruits (49 men, 16 women). The RMT comprised of entering the water in combat fatigues and webbing, removing webbing, swimming 50 m, and staying afloat for up to 10 minutes. During RMT trials, in trial 1, 85% of serving personnel and 74% of recruits successfully completed the RMT, which increased to 93% in serving personnel for trial 2. Across trials 1 and 2, all three timed RMT elements showed moderate-high correlational reliability (ICC range: 0.462-0.791). On average, serving personnel were quicker to complete the 50 m swim phase compared to recruits (91±24 s vs. 100±26 s; U = 2575.0, rb = -0.192, p = 0.039). The JTA-informed Swimming RMT provides an assessment of the minimum role-related swimming/water competence standard for British Army personnel.

Modal, Structural, and Comfort Analyses for Improving Customized Bicycles for Recreational Ridings of People with Disabilities

Leisure activities are known to be especially important for the health of people with disabilities. In Belém, PA, an Amazonian city in Brazil, a nonprofitable organization has promoted leisure ridings in bicycles for those people in Utinga State Park, a large green area for physical and leisure activities. The handcrafted bikes have a sidecar attached for users with disabilities which are ridden by trained volunteers. Since such bikes have been empirically manufactured, they require some minor improvements in safety, comfort, and handling, and verification of structural strength. Therefore, ergonomic, modal, and forced vibration analyses assessed the user’s comfort and safety and a structural analysis with the use of strain gauges evaluated the bicycle’s structural strength. Initially, a numerical modal analysis was performed using the finite element method, and the modal model obtained was validated by an experimental modal analysis employing shaker excitation. ISO-2631-based evaluations of forced vibration and human body comfort were conducted regarding whole-body vibration in vehicles and mechanical equipment. Vibration measurements at the position of the rider and sidecar occupant were obtained during rides on the bicycle and, according to the results, in general, when subjected to loads, the bicycle showed low stress levels far from the yield stress of the material, promoting an excellent safety factor in relation to its structural integrity. The modal, comfort, and forced vibration analyses revealed a mode of vibration in the sidecar that caused discomfort to the back of the users. Ergonomics analysis pointed out changes in the handlebars, the bicycle seat, the coupling between the sidecar and the bike, and the dimensions of the sidecar will provide greater comfort and safety. This paper presents and discusses the proposed modifications to both bicycle and sidecar.

Research on the influence and evaluation of manual operation performance of multifunctional operation panel considering interaction effect

AbstractManual operations remain crucial in critical human‐machine interactions due to limitations in automatic control algorithms and technologies. While ergonomic analysis and evaluation techniques for interactive interfaces are advancing, recent approaches emphasize integrating graphical interface experiences with intuitive controls. Conventional methods often lack precision or overlook the interaction effect of different influencing factors, leading to inadequate assessment of essential manual operations for intricate interfaces, such as multifunctional operation panels. To address these challenges, this study aimed to investigate the interaction effects of various factors on the manual operation performance of operators when using a multifunctional operation panel and aims to develop a more comprehensive and broadly applicable evaluation model for such panels. An experiment was designed to consider the type, size, layout of controls, and operational task type as the main factors affecting manual operation performance. Multivariate analysis of variance was used to identify significant interaction effects among the operation factors. The findings underscored the importance of these interactions in evaluating manual operation performance. Multivariate linear regression further examined the influence of these factors, enhancing the evaluation methodology. The study emphasizes the critical role of understanding interaction effects in assessing the manual operation performance of multifunctional operation panels, particularly in improving the design of the panel or operation tasks.

Lower Back & Comfortability Analysis of Driving Posture to Mitigate Musculoskeletal Disorders: An Ergonomics Study using Digital Human Modelling in JACK Software

In this paper, the crucial aspect of driver comfort was explored by investigating the prevailing driving postures among individuals, aiming to discern their ergonomic implications and ascertain whether the commonly adopted postures are conducive to musculoskeletal health or pose potential risks. From the last decade vehicle like cars have become one of the common modes of personal transport. Car has high relevance in day-to-day activities like commuting, economic activities and sports etc. The continuous driving of vehicle can lead the driver prone to musculoskeletal disorders such as back pain, spine injury and posture issues. This study is conducted to address the ergonomic aspects of posture of the driver to highlight the risk of Musculoskeletal disorders (MSDs) and to optimize the driving posture. Lower Back Analysis (LBA) and Comfortability Analysis is performed in JACK Software to analyze the driving posture. A DHM (Digital Human Model) is created in JACK Simulation Software according to the collected anthropometric data of an average Pakistani man. A virtual Environment is created in JACK Simulation Software. The posture of the subject is analyzed by taking measurements of the subject’s angle of joints when they are sitting in a driving posture. For Ergonomic Analysis the Driving Posture is evaluated on JACK software to Mitigate Musculoskeletal Disorders. Results show that the subject is having low back compression force of 672 which is below the NIOSH Back Compression Action Limit of 3400N representing a nominal risk of low back injury.

Ergonomic analysis in nuclear decommissioning: A comprehensive path planning strategy for workers well-being

Recent studies on path planning in nuclear decommissioning focus on efficient algorithms, often overlooking workers’ physical and cognitive well-being. However, there is a need to consider the effect of the paths recommended by algorithms on workers’ health to prevent work-related musculoskeletal disorders. This study introduces a computational dynamic body map tool designed to assess and monitor musculoskeletal disorders (MSDs) among workers in high-risk decommissioning environments. Utilizing color-coded body maps, the study identifies key ergonomic risk factors and their impact on different body parts. The strategy begins by identifying job tasks requiring ergonomic assessment, distilling the tasks into different activities and the time spent on each activity, and using the result to dynamically compute the average pain severity experienced by workers across different body parts. Subsequent body mapping, hazard surveys, and structured interviews are used to rank workplace risks and worker-specific risk factors. The major contribution of this work is the development of a computational dynamic tool to regularly track worker body maps regularly, ensuring optimal performance. To evaluate the proposed strategy, the study utilized data from a 35-response online MSD questionnaire for safety professionals. To demonstrate the methodology across diverse roles, 10 worker examples were analyzed, aligning with 5 key IAEA nuclear decommissioning categories. Analysis of the computational dynamic body map data reveals specific pain distributions among workers. The most severe pain occurs in the lower back (13.08 %), followed by the right wrist/hand (10 %), the right shoulder, the left elbow (8.46 % each), the left shoulder, the upper back (7.69 % each), the neck and the left wrist/hand (6.92 % each). The findings further reveal that the 36–45 years age category experiences the most pain. In addition, awkward posture was found in the study to be the most likely ergonomic risk factor affecting workers. The results show that incorporating ergonomics into path planning aids risk-informed decision-making for ergonomic interventions and continuous monitoring to maintain a safe and healthier workplace. Integrating the tool presented in this work with a conventional path-planning algorithm provides a comprehensive path-planning strategy for nuclear decommissioning.