An ergonomics action research demonstration: integrating human factors into assembly design processes.

In action research (AR), the researcher participates 'in' the actions in an organisation, while simultaneously reflecting 'on' the actions to promote learning for both the organisation and the researchers. This paper demonstrates a longitudinal AR collaboration with an electronics manufacturing firm where the goal was to improve the organisation's ability to integrate human factors (HF) proactively into their design processes. During the three-year collaboration, all meetings, workshops, interviews and reflections were digitally recorded and qualitatively analysed to inform new 'actions'. By the end of the collaboration, HF tools with targets and sign-off by the HF specialist were integrated into several stages of the design process, and engineers were held accountable for meeting the HF targets. We conclude that the AR approach combined with targeting multiple initiatives at different stages of the design process helped the organisation find ways to integrate HF into their processes in a sustainable way. PRACTITIONER SUMMARY: Researchers acted as a catalyst to help integrate HF into the engineering design process in a sustainable way. This paper demonstrates how an AR approach can help achieve HF integration, the benefits of using a reflective stance and one method for reporting an AR study.

Ergonomics action research II: a framework for integrating HF into work system design.

This paper presents a conceptual framework that can support efforts to integrate human factors (HF) into the work system design process, where improved and cost-effective application of HF is possible. The framework advocates strategies of broad stakeholder participation, linking of performance and health goals, and process focussed change tools that can help practitioners engage in improvements to embed HF into a firm's work system design process. Recommended tools include business process mapping of the design process, implementing design criteria, using cognitive mapping to connect to managers' strategic goals, tactical use of training and adopting virtual HF (VHF) tools to support the integration effort. Consistent with organisational change research, the framework provides guidance but does not suggest a strict set of steps. This allows more adaptability for the practitioner who must navigate within a particular organisational context to secure support for embedding HF into the design process for improved operator wellbeing and system performance. PRACTITIONER SUMMARY: There has been little scientific literature about how a practitioner might integrate HF into a company's work system design process. This paper proposes a framework for this effort by presenting a coherent conceptual framework, process tools, design tools and procedural advice that can be adapted for a target organisation.

Assessing whole body vibration exposure for use in epidemiological studies of back injuries: measurements, observations and self-reports.

Improved assessment of whole body vibration exposure is needed for epidemiological studies investigating the causes of low back disorders. Vibration was measured on 54 worker-days in five heavy industries, with data collected on observed and self-reported driving conditions, demographics, and vehicle characteristics. Variables significant at p < 0.1 in simple linear regressions (20 of 34) were retained for mixed effects multiple regressions to determine the best prediction of rms vibration level and 8-h equivalent vibration exposure. Vibration was measured, on average, for 205 min per work shift (SD 105). Means and standard deviations in m · s⁻² were: x-axis 0.35 (0.19); y-axis 0.34 (0.28); z-axis 0.54 (0.23); vector sum 0.90 (0.49); and 8-h equivalent vector sum 0.70 (0.37). The final three regression models retained only 2 or 3 of the 34 variables (driving speed (<20 km/h and/or 20-40 km/h) and industry and/or vehicle type and explained up to 60% of the variance (R² = 0.26-0.6). PRACTITIONER SUMMARY: The purpose of the project was to create a model that can predict whole body vibration exposure from a number of observed or self-reported variables. This could eliminate the need for costly and time-consuming field measurements of WBV in epidemiological studies. Despite a large number of variables included in the model (34) and 54 worker-days of WBV measurement, the final models contained only two or three variables, and explained 60% of the variance. While this is an improvement over use of job title in epidemiological studies, it still leaves a considerable amount of WBV variance unexplained.

Quantifying tasks, ergonomic exposures and injury rates among school custodial workers.

A job exposure matrix of ergonomics risk factors was constructed for school custodial workers in one large school district in the province of British Columbia using 100 h of 1-min fixed-interval observations, participatory worker consensus on task durations and existing employment and school characteristic data. Significant differences in ergonomics risk factors were found by tasks and occupations. Cleaning and moving furniture, handling garbage, cleaning washrooms and cleaning floors were associated with the most physical risks and the exposure was often higher during the summer vs. the school year. Injury rates over a 4-year period showed the custodian injury rate was four times higher than the overall injury rate across all occupations in the school district. Injury rates were significantly higher in the school year compared with summer (12.2 vs. 7.0 per 100 full-time equivalents per year, p < 0.05). Custodial workers represent a considerable proportion of the labour force and have high injury rates, yet ergonomic studies are disproportionately few. Previous studies that quantified risk factors in custodial workers tended to focus on a few tasks or specific risk factors. This study, using participatory ergonomics and observational methods, systematically quantifies the broad range of musculoskeletal risk factors across multiple tasks performed by custodial workers in schools, adding considerably to the methodological literature.

Development and evaluation of an observational Back-Exposure Sampling Tool (Back-EST) for work-related back injury risk factors.

We developed and evaluated an observational Back-Exposure Sampling Tool. A literature review suggested 53 exposure variables; these were reduced to 20 following field trials. Kappas for agreement beyond chance between six observers assessing exposures in 72 photos ranged from 0.21 to 1.0, with the highest values for posture type, trunk angle, manual materials handling, hands on item, and load weight. Intraclass correlations for agreement between pairs observing 17 workers once per minute for a full-shift were >0.74 for most postural, trunk angle, and manual materials handling variables. In validity testing, the proportions of shifts in flexion/extension and lateral bending observed for 169 full-shifts were compared to inclinometer measurements. Pearson correlations were 0.42 for 45-60 degrees flexion and 0.9 for >60 degrees flexion, but only 0.11-0.19 for lateral bending and trunk flexion less than 45 degrees . When lower flexion angles were collapsed to include trunk extension, correlations increased to >0.5.

Electromyography as a measure of peak and cumulative workload in intermediate care and its relationship to musculoskeletal injury: an exploratory ergonomic study.

Injury rates in Intermediate Care (IC) facilities are high and the factors related to these injuries are unclear. The objectives of this exploratory sub-study, which is part of a large multi-faceted study in 8 IC facilities are to: (1) evaluate EMG measured over a full-shift in the back and shoulders of 32 care aides (CAs) as an indicator of peak and cumulative workload (n = 4 x 8 facilities); investigate the relationship between EMG measures and injury indicators; and explore the relationship between EMG measures and other workload measurements. Lumbar EMG was converted to predicted cumulative spinal compression and ranged in CAs from 11.7 to 22.8 MNs with a mean of 16.4 MNs. Average compression was significantly different during different periods of the day (p < 0.001) with highest compression during pre-breakfast when CAs assist most with activities of daily living. Significant differences were found in average compression between low and high injury facilities for 3 of 5 periods of the day (p < 0.010). Peak compressions exceeding 3400 N occurred for very little of the workday (e.g. 11.25s during the 75 min period pre-breakfast). Peak neck/shoulder muscle activity is low (99% APDF ranged from 8.33% to 28% MVC). Peak and cumulative spinal compression were significantly correlated with lost-time and musculoskeletal injury rates as well as with total tasks observed in the CAs (p < 0.01). Perceived exertion was only correlated with peak compressions (p < 0.01). Facilities with low injury rates provided significantly more CAs (p < 0.01) to meet resident needs, and subsequently CAs performed fewer tasks, resulting in less peak and cumulative spinal loading over the day.

Biomechanical comparison of carpet-stretching devices.

Peak impact forces, measured from seven male carpetlayers using a knee-kicker over 39 trials were 2933 N (SD 397), taking 9.5 ms (SD +/- 1.1) to reach peak. The knee-kicking cycle involved high knee decelerations of 880 m.s-2 (SD +/- 271). Angles at peak force for the knee (63 degrees SD +/- 10 degrees) and hip (80 degrees SD +/- 35 degrees) showed considerable variation between individuals. Kneeling forces on the non-kicking leg during the kick cycle were 894 N: comparative forces were 368 N and 476 N measured during use of the power stretcher and crab re-stretcher, respectively. Under dynamic conditions the effective mechanical advantage of the knee-kicker was less than 1.0. In comparison, the mechanical advantage of the power stretcher was approximately 14 times greater over the stretch action. When tested with a crab re-stretcher, the breaking strength of the smooth-edge to which the carpet attaches averaged 2384 N (SD +/- 245). Design guidelines for an improved carpet stretching device are provided.

Whole-body vibration in underground load-haul-dump vehicles.

Whole-body vibrations (WBV) were measured at the seatpan of load-haul-dump (LHD) vehicles of 3.5-, 5-, 6- and 8-yard capacity at two underground mines. Twenty-two sets of measurements were made involving 11 vehicles, 8 operators and 4 work locations. In each set frequency-weighted rms and peak accelerations were measured in the x, y and z directions, as defined by the ISO (1982), during mucking, driving full, dumping and driving empty. Significant differences in rms accelerations were found between vehicle sizes and between operational tasks (less than or equal to 0.05). The smallest (3.5 yd) vehicle produced the greatest accelerations in the x and z directions. Accelerations in the x and z directions were also greater when driving full and empty than when mucking and dumping. The highest frequency-weighted rms accelerations of 2.0 to 2.8 m/s-2 were recorded in the z (longitudinal) direction. Peak accelerations ranged from 1.2 to greater than or equal to 20 m/s2, resulting in crest-factor ratios in excess of six. The exposure periods for each task were used to calculate mean daily acceleration exposures (m/s2). Of the 22 sets of measurements, 20 exceeded the International Standards Organization (ISO) six-hour daily exposure limit in the z direction of acceleration, and 9 exceeded the six-hour daily exposure limits in all three directions. Acceleration exposure ratios calculated using resultant acceleration vectors as described in ISO (1982), were found to exceed the ISO exposure limit for health or safety in all 22 cases. One-third octave band frequency analysis of the weighted signals indicated that the dominant frequencies were usually 1.6 to 3.15 Hz, except when the vehicles were idling and higher frequencies predominated.