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Ergonomics

ERGONOMICS AND EFFICIENT WORK DESIGN

Mike Dixon, PhD

In the continuous quest for operational excellence and waste reduction, ergonomics plays a pivotal role in enhancing productivity and safeguarding employee well-being. Ergonomics, the science of designing work environments to fit the capabilities and limitations of workers, directly addresses motion waste by optimizing tasks and workspaces for efficiency and safety. This reading explores how ergonomics contributes to reducing motion waste and delves into the principles of designing tasks and workspaces that promote efficiency, prevent injuries, and improve overall job satisfaction.

Introduction to Ergonomics

Definition and Importance of Ergonomics in the Workplace

Ergonomics, derived from the Greek words “ergon” (work) and “nomos” (law), is the scientific discipline concerned with understanding the interactions between humans and other elements of a system. In the workplace, ergonomics focuses on designing or modifying work to fit the worker, rather than forcing the worker to fit the work. This involves considering the physical capabilities and limitations of employees to ensure that tasks, equipment, information, and the environment suit each worker.

The importance of ergonomics in the workplace cannot be overstated. Proper ergonomic design can prevent repetitive strain injuries and musculoskeletal disorders, which can develop over time and lead to long-term disability. By enhancing comfort and reducing physical strain, ergonomics contributes to improved productivity, quality of work, and employee satisfaction.

The Relationship Between Ergonomics, Motion Waste, and Standardized Work

Ergonomics is intrinsically linked to motion waste and standardized work. By applying ergonomic principles, organizations can minimize unnecessary movements (motion waste) that do not add value to the product or service. Ergonomics complements standardized work by ensuring that the standardized processes are not only efficient but also safe and sustainable for employees.

Standardized work defines the most efficient method to perform a task, and ergonomics ensures that this method aligns with human capabilities. Together, they create a harmonious work environment where efficiency does not compromise employee health, and safety does not hinder productivity.

Principles of Ergonomic Work Design

Implementing ergonomic principles in work design involves understanding how the human body interacts with the physical aspects of the workplace. The following key principles guide the creation of work environments that support efficiency and safety.

Neutral Body Postures

Designing Tasks to Keep Joints Naturally Aligned

Neutral body posture refers to a comfortable working position where the joints are naturally aligned, reducing stress on muscles, tendons, and skeletal structures. In this posture, the spine is aligned, shoulders are relaxed, elbows are at the side, wrists are straight, and knees are slightly bent.

Minimizing Strain on Muscles and Joints

Designing tasks to maintain neutral postures minimizes the strain on the body. This can be achieved by adjusting the height of work surfaces, positioning tools and materials within easy reach, and providing adjustable chairs or stools. For example, when assembling small parts, a workbench at the appropriate height prevents the worker from bending over, reducing back strain.

Minimizing Excessive Movements

Reducing Unnecessary Bending, Reaching, and Twisting

Excessive movements such as bending, reaching, and twisting place additional stress on the body and contribute to fatigue and injuries. Ergonomic work design aims to minimize these movements by:

    • Adjusting Workstations: Positioning work surfaces and equipment at optimal heights and angles.
    • Organizing Layouts: Arranging tools and materials so that workers can access them without excessive movements.
    • Mechanical Aids: Using equipment like lift tables, conveyors, or adjustable shelves to reduce manual handling.

For instance, placing frequently used tools on a pegboard directly in front of the worker at shoulder height can eliminate the need for reaching or bending.

Proper Tool and Equipment Placement

Positioning Frequently Used Items Within Easy Reach

Tools and materials that are used frequently should be within the primary work zone—an area within easy reach without the need to stretch or lean. This reduces the physical effort required and the time spent retrieving items. The use of extendable arms or sliding shelves can aid in bringing items closer to the worker.

Organizing Tools to Match the Sequence of Tasks

Arranging tools and materials in the order in which they are used supports an efficient workflow and minimizes unnecessary motions. This principle ensures that as the worker progresses through the task, the required tools are readily available, eliminating pauses and movements to search for items.

An example is a surgeon’s tray in an operating room, where instruments are laid out in the order they will be used, allowing smooth transitions between steps.

Ergonomic Risk Factors

Identifying and addressing ergonomic risk factors is essential to prevent injuries and improve efficiency. The main risk factors include:

  1. Repetitive Motions

Performing the same motion repeatedly over prolonged periods can lead to fatigue and overuse injuries such as tendinitis or carpal tunnel syndrome. Tasks should be designed to allow for variability in movements, and where possible, automation can reduce the need for repetitive manual actions.

2. Forceful Exertions

Tasks that require significant physical effort, such as lifting heavy objects or applying force to tools, increase the risk of injury. Ergonomic solutions include mechanical lifting aids, power tools, or redesigning the task to reduce the required force.

3. Awkward Postures

Working in non-neutral postures, such as reaching overhead, bending forward, or twisting the torso, places strain on the body. Adjusting work heights, angles, and positions can help workers maintain neutral postures.

4. Contact Stress

Contact stress occurs when a hard or sharp object presses into soft tissues, such as leaning against a hard edge or gripping tools with narrow handles. Padding, rounded edges, and ergonomically designed tools can alleviate contact stress.

5. Environmental Factors

Environmental conditions such as poor lighting, excessive noise, and extreme temperatures can impact comfort and safety.

    • Lighting: Adequate lighting reduces eye strain and helps maintain alertness.
    • Noise: High noise levels can cause stress and impede communication.
    • Temperature: Extreme heat or cold affects comfort and can reduce manual dexterity.
Designing Workstations for Efficiency
Creating workstations that support ergonomic principles involves careful consideration of the physical setup and equipment used by employees.
Adjustability and Customization to Fit Individual Workers
Since workers vary in size, strength, and abilities, workstations should be adjustable to accommodate individual needs. Features such as height-adjustable desks, chairs with adjustable seat height and backrests, and movable monitor arms allow workers to customize their setup for optimal comfort.
Use of Ergonomic Furniture and Equipment
Investing in ergonomically designed furniture and equipment enhances comfort and reduces the risk of injury.
  • Chairs: Should provide lumbar support, adjustable seat height, and swivel functionality.
  • Keyboards and Mice: Ergonomic designs reduce strain on wrists and hands.
  • Anti-Fatigue Mats: For standing workstations, mats can reduce leg and back fatigue.
Importance of Proper Lighting and Visual Ergonomics
Visual ergonomics focuses on optimizing the visual environment to reduce eye strain and fatigue.
  • Lighting: Adequate illumination prevents squinting and leaning forward to see better . Adjustable task lighting allows workers to position the light where needed.
  • Glare Reduction: Using matte finishes, screen filters, and proper positioning of monitors can reduce glare.
  • Monitor Placement: Screens should be at eye level and at a comfortable viewing distance to prevent neck strain.
Impact on Health and Safety
Integrating ergonomic principles into work design has profound positive effects on employee health and safety.
Prevention of Musculoskeletal Disorders
By reducing ergonomic risk factors, the likelihood of developing musculoskeletal disorders decreases significantly. Workers experience fewer strains, sprains, and overuse injuries, leading to better long-term health outcomes.
Reduction in Workplace Injuries and Associated Costs
Ergonomic interventions lead to fewer workplace injuries, which in turn reduces costs associated with medical treatments, workers’ compensation, and lost productivity due to absenteeism. Organizations benefit financially from investing in ergonomics through lower insurance premiums and reduced legal liabilities.
Improvement in Employee Comfort and Job Satisfaction
When workers are comfortable and can perform their tasks without excessive physical effort or discomfort, job satisfaction increases. Comfortable employees are more engaged, productive, and less likely to experience burnout. This contributes to higher retention rates and a positive workplace culture.
Case Studies: Successful Ergonomic Interventions
To illustrate the practical application and benefits of ergonomics in the workplace, consider the following examples:
Manufacturing Assembly Line
A manufacturing company observed high instances of back strain among assembly line workers due to repetitive bending and lifting. By reconfiguring workstations with adjustable height tables and implementing mechanical lifts for heavy components, the company reduced physical strain. Additionally, tools and parts were reorganized to be within easy reach, eliminating unnecessary movements. As a result, the company saw a 40% reduction in reported injuries and a significant increase in productivity.
Office Environment
An organization noticed that employees complained of neck and shoulder pain. An ergonomic assessment revealed that monitors were positioned too low, causing employees to tilt their heads downward. By providing monitor risers and adjustable chairs, employees could maintain neutral neck postures. Paired with training on ergonomic posture, the company reduced discomfort complaints by 60% and noticed improved focus and efficiency among staff.
Integrating Ergonomics with Standardized Work and Continuous Improvement
Ergonomics should not be a one-time intervention but part of an ongoing process of continuous improvement.
Employee Involvement
Engaging employees in identifying ergonomic issues and developing solutions ensures that interventions address real needs and gain acceptance. Workers are more likely to adhere to standardized work practices when they are comfortable and see that their input is valued.
Regular Assessments
Routine ergonomic assessments help identify emerging risks and evaluate the effectiveness of implemented solutions. Adjustments can be made proactively to prevent injuries and maintain efficiency.
Training and Education
Providing training on ergonomic principles empowers employees to take responsibility for their own comfort and safety. Education should cover proper body mechanics, equipment adjustments, and the importance of reporting ergonomic concerns.
Conclusion
Ergonomics is a critical component of efficient work design, directly addressing motion waste and enhancing the well-being of employees. By integrating ergonomic principles into the design of tasks and workspaces, organizations can reduce unnecessary movements, prevent injuries, and improve productivity. Emphasizing ergonomics fosters a workplace environment where employees are valued, comfortable, and equipped to perform at their best, ultimately contributing to the organization’s success.
Discussion Questions
1. Reflect on a Workplace You Are Familiar With
    • Identify any ergonomic risk factors present.
    • How do these risk factors contribute to motion waste or employee discomfort?
    • What ergonomic interventions could be implemented to address these issues?
2. The Role of Ergonomics in Different Industries
    • How might ergonomic principles be applied differently in manufacturing versus office environments?
    • What unique challenges might arise in implementing ergonomics in various settings?
3. Employee Participation in Ergonomics
    • Why is it important to involve employees in ergonomic assessments and solutions?
    • How can organizations encourage employee engagement in ergonomics

Self-Assessment Questions

    1. Explain the Relationship Between Ergonomics and Motion Waste
    • How does applying ergonomic principles help reduce unnecessary movements?

2. List and Describe Three Ergonomic Risk Factors

    • Provide examples of each and how they might be mitigated.

3. How Do Proper Tool and Equipment Placement Improve Efficiency?

    • Explain the importance of positioning frequently used items within easy reach.

4. What Are the Benefits of Adjustability in Workstations?

    • Discuss how adjustable equipment accommodates individual workers and enhances comfort.

5. Describe the Impact of Ergonomics on Employee Health

    • How does ergonomics contribute to the prevention of musculoskeletal disorders and improve job satisfaction?

License

Introduction to Operational Excellence Copyright © by Mike Dixon. All Rights Reserved.

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