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Ferdinand Praeger Collection of Scores, circa 1829-1891
Mus. Arc. 46

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Mus. Arc. 46

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Ferdinand Praeger Collection of Scores, circa 1829-1891
Mus. Arc. 46

�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
Mus. Arc. 46

�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
Mus. Arc. 46

�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
Mus. Arc. 46

�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
Mus. Arc. 46

�State University of New York at Buffalo. Music Library
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Mus. Arc. 46

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�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
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�State University of New York at Buffalo. Music Library
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Ferdinand Praeger Collection of Scores, circa 1829-1891
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�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
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�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
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�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
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                  <text>&lt;p&gt;The Ferdinand Praeger Collection of Scores, circa 1829-1891, consists of 484 items, all but a few of which are manuscript scores. Due to the fragile condition of some of the scores, not every score was digitized. As a result, there are only 472 digitized scores in this digital collection. Two of the additional documents received with the collection were also digitized and the digital collection includes digital copies of documents, portraits, and correspondence about the Praeger family generously provided by the great, great grandson of Ferdinand Praeger, Andrew Leach.&lt;/p&gt;
&lt;p&gt;This is the largest collection of Praeger's musical manuscripts in the world. Nearly all the scores are in Praeger's own hand. The majority of the works are for piano, but the collection also includes chamber music for strings, large ensemble works, vocal works, and sketches. Praeger was born in Leipzig on January 22, 1815, to a Dutch father and an English mother. As a child, he studied cello, piano, and violin. His father, Heinrich Aloys Praeger (1783-1854) worked as a musician, composer, and conductor. In 1831, at the age of 16, Praeger became a music teacher at The Hague and continued to study piano, violin, and composition. He moved to London in 1834, working as a teacher and traveling to give piano recitals, many of which included his own works. Praeger became the London correspondent for Robert Schumann's music journal, &lt;em&gt;Neue Zeitschrift für Musik&lt;/em&gt;, in 1842. His contributions included highlights of London musical events, reviews of performances, and general discussions about current musical topics.&lt;/p&gt;
Praeger's compositions were performed in cities across Europe, including Paris, Leipzig, Berlin, Hamburg, and Meiningen. Praeger is perhaps best known today for his connection with Richard Wagner. Following Wagner's death, Praeger wrote the book &lt;em&gt;Wagner, as I Knew Him&lt;/em&gt;, which quickly became controversial and was pulled from publication. Wagner followers disputed the book, claiming that Praeger exaggerated his role in Wagner's life and portrayed Wagner in a negative way. &lt;br /&gt;&lt;br /&gt;The collection has been described in a finding aid available at &lt;a href="http://purl.org/net/findingaids/view?docId=ead/music/ubmu0046.xml"&gt;http://purl.org/net/findingaids/view?docId=ead/music/ubmu0046.xml&lt;/a&gt;</text>
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Ferdinand Praeger Collection of Scores, circa 1829-1891
Mus. Arc. 46

�State University of New York at Buffalo. Music Library
Ferdinand Praeger Collection of Scores, circa 1829-1891
Mus. Arc. 46

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                  <text>&lt;p&gt;The Ferdinand Praeger Collection of Scores, circa 1829-1891, consists of 484 items, all but a few of which are manuscript scores. Due to the fragile condition of some of the scores, not every score was digitized. As a result, there are only 472 digitized scores in this digital collection. Two of the additional documents received with the collection were also digitized and the digital collection includes digital copies of documents, portraits, and correspondence about the Praeger family generously provided by the great, great grandson of Ferdinand Praeger, Andrew Leach.&lt;/p&gt;
&lt;p&gt;This is the largest collection of Praeger's musical manuscripts in the world. Nearly all the scores are in Praeger's own hand. The majority of the works are for piano, but the collection also includes chamber music for strings, large ensemble works, vocal works, and sketches. Praeger was born in Leipzig on January 22, 1815, to a Dutch father and an English mother. As a child, he studied cello, piano, and violin. His father, Heinrich Aloys Praeger (1783-1854) worked as a musician, composer, and conductor. In 1831, at the age of 16, Praeger became a music teacher at The Hague and continued to study piano, violin, and composition. He moved to London in 1834, working as a teacher and traveling to give piano recitals, many of which included his own works. Praeger became the London correspondent for Robert Schumann's music journal, &lt;em&gt;Neue Zeitschrift für Musik&lt;/em&gt;, in 1842. His contributions included highlights of London musical events, reviews of performances, and general discussions about current musical topics.&lt;/p&gt;
Praeger's compositions were performed in cities across Europe, including Paris, Leipzig, Berlin, Hamburg, and Meiningen. Praeger is perhaps best known today for his connection with Richard Wagner. Following Wagner's death, Praeger wrote the book &lt;em&gt;Wagner, as I Knew Him&lt;/em&gt;, which quickly became controversial and was pulled from publication. Wagner followers disputed the book, claiming that Praeger exaggerated his role in Wagner's life and portrayed Wagner in a negative way. &lt;br /&gt;&lt;br /&gt;The collection has been described in a finding aid available at &lt;a href="http://purl.org/net/findingaids/view?docId=ead/music/ubmu0046.xml"&gt;http://purl.org/net/findingaids/view?docId=ead/music/ubmu0046.xml&lt;/a&gt;</text>
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                    <text>Dr. Rodgers was invited to speak and give workshops at many
conferences including the ones listed below. Following are
cover pages, syllabi and agendas for these workshops.
•
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ACSM
American Occupational Health Conference Meetings
American Society of Biomechanics
AOMA National Convention
AOTA Can AM
Applied Ergonomic Conference
ASSE
Back Pain
Bristol Myers Squibb Health and Safety Conference
Brouha Work Physiology Symposium
CAIRE
CANAM
Delaware Occupational Medical Association
ErgoCon
Ergonomics to Enhance the Bottom Line
Genesee Valley Chapter Arthritis Informational Meeting
Genesee Valley Safety Conference
Greater Rochester Area Rehabilitation Group
How To Ergonomics
IAPA
IBM US Safety Industrial and Technical Conference
Industrial Rehabilitation Symposium
International Symposium on Global Rehabilitation Trends
Lifting and Low Back Pain Seminar
Making Your Workplace Safer
Meeting Planners Conference
NE Safety Health and Environmental Conference
NIOSH Ergonomic Conference
Orthopedic Therapy Clinic
Physical Medicine Institute
Reducing Work Injuries and Illness Through Ergonomics
Repetitive Motion Injuries Seminar
Rochester Area Rehabilitation Professionals Meeting
Rochester Safety Council and OSHA
SAE-ASSE

�•
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Safety Environmental and Health Communications
Seminar for Professional Physical Therapy - Wash U
Society of Behavioral Medicine
Solid Waste Recycling Conference and Tradeshow
Strategies to Reduce Employee Medical Costs
Symposium on standards for occupational exposures to hot environments
Wisconsin PT Association
Wisconsin Safety Council
Work Physiology Industrial and Occupational Applications

�Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics

169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

1997 ACSM Annual Meeting, Denver, CO, May 28-31
Occupational Physiology Interest Group Colloquim: A Template
for Occupational Workplace Analysis for the Exercise Scientist
Return to Work and Placement and Other Avenues to Effect Work-Related
Issues in the Occupational Setting - Suzanne H. Rodgers, PhD, Consultant
in Ergonomics, Rochester, NY
A. Work Fitness and Work Tolerance
1. Fitness - Short Duration, Heavy Effort
2. Tolerance - Sustained Effort Over Hours, Days, Weeks
B. Factors Determining Successful Return to Work or Job Placement
1. Autonomy - Control of Work Pattern
2. Worker Knowledge of Limits - Can Detect Early Signs of Fatigue
3. Administrative Understanding - Risk Factor Knowledge, Flexibility
in Providing Temporary Placements to Reduce Injury Exacerbation
4. Medical Understanding - Knowledge of Preventive and Restorative
Roles of Exercise in Injury/Illness Management
C. Value to Employer of Effective Exercise and Ergonomics Processes
1. Ergonomics Problems are Process Problems
2. Eliminate Excessively-Demanding Jobs
3. Reduce Workers' Compensation Costs and Absenteeism - Decreased
Lost Time, Earlier Return to Work
4. Reduce Fatigue - Improved, Sustained Performance, Focus on
Quality Not Discomfort
Flexibility in Multi-Skilling the Workforce
More
5.

3/26/97 SHR

L

�: Suzanne H. Rodgers, PhD.

Consultant In Ergonomics/Human Factors
169 Huntington Hills
ROCHESTER, NEW YORK 14622

Job and Work Capacity Evaluation as a Preventive Tool
Talk to the American Occupational Health Conference Meetings,
Houston, TX, May 3, 1990, Afternoon Session by Sue Rodgers, Ph.D.,
Consultant in Ergonomics, Rochester, NY
A. Overexertion Injuries and Physiological Fatigue
.L The Four Components of Physiological Muscle Fatigue
a. Force or Effort Intensity- Fiber Recruitment, Circulatory
Effects
b. Continuous Duration of Effort Before Relaxation - Circulatory
Effects, Substrate Depletion, Oxygen Debt
c. Frequency ofActivation of Muscle - Recovery Time, Circulatory
Responses to Increased Acid in Environment
d. Tota/Work or Effort Time per Shift- Metabolic and Cardiovascular
Demands, Recovery Time Between Shifts, Cumulative Effects/Aggravation
2. Factors That Determine Effort Intensity for Major Muscle Groups
a. Neck/Shoulders
b. Back
c. Arms/Elbows
d. Hands/Wrists/Fingers
e. Legs/Knees
f. Ankles/Feet/foes

.1.

Interactions of Force. Frequency, and Duration - Ergonomic Job
Analysis Technique
a. Rating Scheme
b. Problem Example - Overhead Handling

4. Work Time Effects - Aerobic Demands
a. Whole and Upper Body Work Capacities
b. Metabolic and Heart Rate Responses to Overhead Handling
c. Acceptable Load as a Function of Work Time
5. Designing Jobs Ergonomically to Accommodate the Capacities of
Most Workers
a. % Strength vs Duration and Frequency- Grip, Other Muscle
Groups
b. Weight Lifted in Manual Handling Tasks
c. Metabolic Guidelines

�,.

0

Occupational Applications of Biomechanics
Keynote address to the American Society of Biomechanics·
13th Annual Meeting at the University of Vermont,
Burlington, Vermont, August 23-25, 1989

Outline
A. Videotape Review_ of 8 Industrial or Service Sector Jobs
B. Ergonomic Job Analysis Technique - Fatigue Model Basis
C. Application to Repetitive Tasks - Muscle vs Tendon/Joint Basis
D. Determining Effort Intensity - Importance of Biomechanics
E. Need for Further Biomechanics Research in Applied Ergonomics

Suzanne H. Rodgers, Ph.D

C ONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544.3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Occupational Ergonomics
Matching Job Demands and Worker Capabilities

6-Hour Seminar for the April, 1986 AOMA National
Convention in Denver, Colorado

Faculty: Suzanne H. Rodgers, Ph.D. , Consultant
in Ergonomics/Human Factors, Rochester,
New York
David M. Kiser, Ph.D. , Group Leader of the
Ergonomics Section, Health and Environment
Laboratories, Eastman Kodak Company, Rochester,
New York
Donald Day, Exercise Physiologist and Ergonomist,
Safety Services, Eastman Kodak, Windsor, Colorado·

April 29, 1986

'\

�Acknowledgements

· The anthropometric and reach/height interaction data on pages 13, 15,
17, 19, and 20 are token from the Eastmon Kodak Human Factors Section's
Ergonomic Design for People at �vork, Volume 1 published by Lifetime
Learning (now part of Van Nostrand Reinhold) in 1983. The material on
pages 37, 38, 49, and 50-52 is from S.H. Rodgers, Working with Backoche,
published by Perinton Press in 1985. Other material is either referenced or
prepared by Dr. Rodgers. Permission to reproduce unreferenced material
should be obtained from her.
1/31/86 SHR

�Occupational Ergonomics Seminar

•

Table of Contents
Topic

Page

Acknowledgements
Table of Contents
Goals of the Seminar - Ergonomics
and Occupational t'ledicine
Postural Dernands an,j Job Performance
Static t'luscle vv'ork - Intensity/Duration
vv'ork/Recovery Needs for Static Work
Human Variab1lity
Anthropometric Data
Height and Reach Interaction
, General Guidelines for Using Anthropometric
Data
Case Study - Assembly Line Workplaces
Work Restrictions and Workplace Design

#

1
2

3
5
6
8
12
14 '
19
21

23
26

Repetitive Work and Risk Factors for
Repetitive Motions DisordersFactors Affecting Grip Strength
Case Study: Tool Use
Work Restrictions and Repetitive Work

27
28
31
34

�-1anual Handling Task Design and Evaluation
Forces - Design Guidelines
Acceptable Lifts - NI0SH Guidelines
Frequent Lifts
Case Study: Manual Handling
'w'ork Restrictions and Manual Handling

. 35
40
42
49
50
53

Paced V1ork/Time Pressure
Case Study: Paced Work - Food Service
Wcirk .Restrictions and Mental/Perceptual Work

54
57
59

Ergonomics Bit,Hography
/
Faculty Resurnes

64
66

'�.

�AOMA Occupational Ergonomics Seminar

Goals:
To increase awareness of iob demands that contribute to occupational
illness, injury and stress.

To learn ergonomics principles can be applied to workplace,
environment, tool, and job design in order to reduce occupational
illness and disability.

To examine common medical restrictions from work . To evaluate
their appropriateness as well as other approaches to help
return peopl e to work after illness or injury.

1/15/86 SHR

��Ergonomics
Job Sati sf action
Productivity
Quality
... - . �
Safety

Work Programs SIS Program: A Practical Problem-Solving
Approach to Ergonomics, AOTA Can/Am Conference, 2:30 to
5:00 PM, July 10, 1994, Boston, MA

Outline

A.
B.
C.
D.

The Fatigue Model for Injury Prevention
Ergonomic Job Analysis Technique
Manual Handling Analyses
Problem Solving for Cost-Effective Risk Reduction

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY TllROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. lRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT ANO .PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Lessons Learned: Ergonomics in the Trenches

Keynote Presentation to the 3rd Annual Applied Ergonomics Conference
on March 15th, 2000, Los Angeles, CA

A. 32 Years in a Nutshell
1. I learn something new every day. I have probably made every
mistake in the book, but have done that in a supportive atmosphere.
2. The experts are the people doing the jobs. One cannot understand a
job without going into the workplace and gathering information
from the people who do it.
3. My job as a consultant/trainer is to teach the workers and support
staff to help themselves and to teach the designers to think like
ergonomists
4. The best solutions are found when workers and support staff
analyze jobs together. They approachjobs more globally.
5. Keep asking ''Why?'' respectfully, until the entire surround of the
job is clear (psychosocial and physical environment).
6. There are many ways to improve problem jobs. My job is to keep
options open until someone else identifies an effective solution that
they can live with. They must take ownership if the program is to
thrive.
7. I have tremendous respect for the people who work in
manufacturing and service jobs, construction and skilled trades, and
in offices across North America. They do high quality work,
sometimes in difficult settings, and they often do not mention their
discomfort or fatigue because they take pride in their work. Our
job should be to make it easy for them to do their best work with a
low risk for injuries and illnesses to occur. Ergonomics is the way
that goal can be accomplished.

�B. Lessons Learned in the T�enches
. .. ·"'
1. Workplace Evaluations - Job Analyses
a. Always make sure that someone is with you who really knows
the job and the people doing it.
b. Always introduce yourself and explain why you are there. Meet
with the team leader or supervisor ahead of time so they know
why you are there and that you will be talking with the workers.
c. Make yourself the student of the person who does the job. Have
them show you what they do and ask respectful questions to
learn more.
d. Observe what happens when things are going well, and what
happens when problems occur on the job. If no problems occur,
ask what could go wrong and how frequently it happens.
e. Learn what the quality requirements are, and review the quality
data posted in the workplace to see if ergonomics problems may
contribute to errors.
f. If videotapes are needed for further job analysis or for
presentations of problems and solutions at later sessions, give the
plant a simple, but thorough, set of instructions for how to take
them and let them keep control of them. If necessary, stay after
hours to do your own analysis of them if there is a reluctance to
have the tapes leave the plant. Always show the whole body on
the videos; only zero in on a specific body part for short periods.
g. When in a plant, observe the ceiling and roof support, HVAC,
cranes, and other facility designs before making suggestions to
change the location or orientation of a workplace. Ask people
on the floor, engineers, and mechanics about the design
constraints in the workplace area.
h. Remember that there is always a reason why people do what
they do. If they are not wearing protective equipment or
following a standard operating procedure, there is usually a good
reason why. We need to identify that reason and fix it rather
than focusing on worker behavior modification and punishment.

�1.

J.

After evaluating a job or doing a risk assessment, always share
your ideas for improvements with the workers in order to be sure
you had all of the relevant information. But, do not suggest that
there is only one way to improve the situation or that they can
expect a specific piece of equipment in a short time. Emphasize
the strategy rather than a piece of equipment: e.g., making lifts
above knee height rather than putting in a lift table. Stimulate
their creativity to;find 3 ways they could lift above their knee
height with a budget of $ 200 apiece for the improvements.
Never write a report without first sitting down with the people
who will be funding the changes and reviewing the risks, the
strategies for reducing the risk for injury, and why you have
chosen the solution that will be in the final report. Leave room
for additional suggestions from the managers and supervisors.

2. Office Ergonomics
a. People cannot see themselves when they are working at a desk or
computer. Teach them to watch each other and write down what
they see or use a checklist to describe the postures.
b. Instead of telling people to sit up straight and not do what they
are doing (like sitting on a foot), try to figure out why ? they are
doing that, or what benefit they get from doing it. Observe
carefully and then look for the driving factors.
c. Remember that many of the postural variations ones sees in the
office setting are driven by visual comfort needs. Evaluate the
person's preferred reading distance using hard copy at their
workplace, and then compare that distance to the distance their
eyes are from the hard copy if they sit in an upright posture.
d. Avoid the fallacy that every backache needs a chair, every wrist
problem needs a wrist rest or keyboard tray, and every neck and
shoulder pain needs a monitor stand. Define what is causing the
postural or visual discomfort and fix that, often with a
rearrangement of items in the workplace.

3,

�e. Avoid the situation where the only way a person can get a decent
chair is to have back pain. Phase in ergonomically-designed
chairs and equipment on an announced schedule; doing this over
3 years has been found to be acceptable in some companies once
the reasons for who got first attention were made clear.
f. Initiate a Lending Library for other workplace assist devices,
such as document holders, monitor stands, footrests, etc. Have
people evaluate their workplace before borrowing an item from
the Library so the appropriate type of assist is found. If, after
using a particular assist for a week, the worker is able to work
more comfortably, the department can buy the assist from the
Library or from an office supplies store with whom the company
has a contract.
g. Simplicity in the design of the office workplace is preferable to
having 6 degrees of adjustability in every chair, keyboard
support, worksurface, and monitor support. People rarely
change much except the height of the chair once they are in their
workplace, and even that is not changed often if they share the
workplace with another person on a second shift.
h. It is difficult to design an office unless you know what people
are doing. The need for certain features will be best determined
by the tasks being done, yet the choice of furniture and space is
usually made on the basis of the office hierarchy.
3. Ergonomics in Workplace, Equipment, Environment, and Job
Design
a. The goal is to design so that the largest majority of the potential
workforce is accommodated. If one has to compromise, one
compromises towards the existing workforce's capabilities.
b. Workers don't get angry if you make it easier for them to reach
their production goals and to be able to do quality work. Pay
systems and accounting practices may make these improvements

Lj,

�c.

d.

e.

f.

g.

undesirable, however, so solutions have to be worked out with all
interested parties involved.
The largest satisfier in most jobs is when the worker has control
over the way he or she performs the job. If the desired
productivity is known, the quality needs are clear, and the safety
requirements are defined, most people can accomplish their tasks
in a way that minimizes their fatigue over the shift. If they are
forced into a non-optimal work pattern by line speed, semi­
automation, or enforcement of a particular work pattern that
someone else had determined to be optimal, they often
experience more stress and fatigue on the job.
A designer should understand the potential jobs that will be done
before designing a piece of equipment or a workplace.
Simulations of workplaces or equipment that are made without
identifying the tasks to be performed in them are likely to have
problems when they are installed in the plant.
The instruction booklets for equipment and for training people on
production machines are a gold mine for identifying ergonomics
problems before one even goes to the floor.
Ergonomics is not very effective if it becomes part of a sign-off
function in a design process. Designers should learn to think like
ergonomists and learn the value of soliciting input from the
people who will operate the equipment once it is on the floor.
This should be done in the very early stages of design; a post­
mortem on the previous equipment or layout should also be done.
Ergonomics guidelines should be incorporated into the whole
design, not patched in after the equipment has been prototyped.
Materials flow is often considered separate from ergonomics
when a work area is being laid out, yet they are inextricably
linked. Minimizing non-value-added handling tasks along a
production line is desirable, but it also has ergonomic
consequences for the workers if things go wrong on the line.
There must be design contingencies to allow the workers to

C

�,.

..
,

I
J

Practical Ergonomics in the Workplace
ASSE Triad Chapter Professional Development Conference
April 13th, 1989, Ramada Inn Airport, Greensboro, NC

_j

Morning Session Syllabus
_J

A. Introduction and Overview
B. Posture and Productivity

___j

C. Back Anatomy and Related Risk Factors
.. _j

D. Ergonomic Approach to Job Design/Materials Handling
_j

E. Overview of Repetitive Motions Problems

7
_j

Specializing In Ergonomics and
Musculoskelelal Managemenl Programs

__J

• .J

I

O,ulu1hio.l !Bwmul'ut11Uli,

£1,ui.

P.O. Box 526
Oak Ridge, N.C. 27310

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

Carole Hunter, M.S./L.P.T.
President

919-643-7706
FAX:919-643-9646

t. AWARENESS SEMINARS
Z. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

Cynthia L. Lewis, M.S./L.P.T.

FAX: 919,643,9646

C7111 sc.t�7 • 189 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�GENESEE VALLEY CHAPTER NEWSLETTER
December, 2001

____!..-._________

"PRACTICAL ERGONOMI

Green Lantern Inn
At the intersection of
NYRoute31F
(East Church Street)
and NY Route 250
(South Main Street)

AMERICAN SO
OF SAFETY ENG
GENESEE VALLEY

FAIRPORT,
01

MONDAY, DECE

Am ·can Society of Safety Engineers
ne ee Valley Chapter
kbriar Drive
esfer, NY 14616-2350

,J

·•.

�BACK PAIN - '84
September 6-7, 1984
Sheraton-Atlanta Hotel
Atlanta, GA
Conference Agenda

Wednesday, Septembers, 1984

OPTIONAL SESSION I 1 (2:00 PM - 5:00 PM)
PIEDHORT ROOK

Management strategies for the severely disabled
• pain clinics • counseling• rehabilitation
Gary W. Jay, MD

Thursday, September 6, 1984

GENERAL SESSIONS (8:30 AM - 12:00 PM)
ATLARTA BALLROOM ORE
8:30 - 8:45

• Welcome and announcements

8:45 - 9:15

• Marketing: increasing revenue by effec­
tively sel ling your services
Ron Porter, RPT

9: 15 - 9:45

• How to recognize and manage psychogenic
back pain
Floyd P. Garrett, MD

9:45 - 10:15

••Coffee Break••
ATLDTA BALLROON FOIBR

10:15 - 10:45

• The Back School approach - how to organize
and implement a successful program
Nancy Selby

10:45 - 12:00

• Making sense or controversies in diagnosis
and treatment
• Diagnostic procedures
• Inversion therapy
•· Chymopapain
• Common drugs
Henry L. Feffer, MD - Moderator
Richard E. Hester, D C
Gary W. Jay, MD
Ron Porter, RPT

12:00 -

1:00

••Lunch**
ATLARTA B.ALLROOHS TRUE &amp; FOUR

�• Controversies in treatment (continued)
o Manipulation
o TENS and acupuncture
o Case discussions by a panel of
experts

1:00 - 2:30

••Coffee Break••
ATLARTl BALLROOM FOID

2:30 - 3:00
3:00 - 3:30

• Widening the scope or your services: a
multidisciplinary approach
Gary W. Jay, MD

3:30 - 4:00

• Legal perils: strategies to help you
avoid common back pain liabilities
Richard Galiher, Jr., JD

4:00 - 5:00

• Back pain in court: mock trial helps
protect you and your patients
Richard Galiher, Jr., JD

WINE &amp; CHEESE RECEPTION (6:00 PM - 7:00 PM)
ATLJIITA BALLROOMS TBBBI &amp; FOUR

Friday, September 1, 1984

GENERAL SESSIONS (8:30 AM - 10:45 AM)
ATLAIITl BALLROOM ORE
• The legalities of psychiatric claims:
planning your strategy
Merton Marks, JD

8:30 - 9:45

••Coffee Break••
.ITLARTl BALLROOM FOIBR

9:45 - 10:15
10:15 - 10:45

• Workers' compensation: practical tips to
guide you through the disability evaluation
process
Merton Marks, JD

CONCURRENT WORKSHOPS (10:45 AM - 12:15 AM)
COAST.IL ROOM
• WS# 1 Reimbursement: ensuring you get
every penny you're entitled to
from third party payers
Kenneth Roberge, BS, MBA
CUHBBILABD ROOM

•

WS# 2

Workplace back pain: practical
strategies to help cut the cost
to employers
Helen Abrahams, RN

�PIBDMOIT ROOM

• ws,

BLUE RIDGE A

• WS# 4

3

Hospital back clinics: how to
start one and successfully market
it to your community
Nancy Selby
Educational materials that work :
creating aids for your back
school or industrial setting
Ron Porter, · RPT

**Lunch**
lTLARTl BALLROOMS THREE &amp; FOUR

12: 15 - 1: 45

CONCURRENT WORKSHOPS (1:45 PM - 3:15 PM)
COMBERLDD ROOM

• WS# 6

Practical ergonom ics: applications
that correct workplace hazards
Suzanne Rodgers, PhD

PIEDMONT ROOM

• WS# 8

Creating and implementing effec­
tive exercise programs for pa­
tients and employees
Ron Porter, RPT

COASTAL BOOM

• WSI 9

Industrial clinics: practical
tips from a successful Midwestern
hospital
Jan R. Douglas, MPH, OTR

• WS# 10

Psychological testing: what do
the MMPI and other tests really
tell us?
Floyd P. Garrett, MD

BLUE RIDGE A

••coffee Break••
ATLARTA BALLROOM FOYER

3:15 - 3:30

GENERAL SESSION (3:30
ATLARTA BALLROOM ORE
3:30 -

4:15

4:15 - 4:45

PM -

4:30

PM)

• Simple strategies for incorporating
effective patient education into your
practice·
Nancy Selby
• Wrap-up and adjourn

�"'Suzanne H. Rodgers, PhD.

Consultant In Ergonomics/Human Factors
169 Huntington Hills
ROCHESTER, NEW YORK 14622

Bristol-Myers Squibb Health and Safety
Conference, Saddlebrook, FL, November 13-15, 1991
Ergonomics
Table of Contents
Topic

Page

Ergonomic Goals
The Costs of Poor Design
General Industry Ergonomics Guideline
Thoughts on Ergonomics Programs and Processes
Anthropometric Data
Standing Height and Reach Interaction
Work/Recovery Curves
Ergonomic Job Analysis Form
Table 2: Examples of Muscle Effort Levels
Risk Factors for Repetitive Tasks/Grip Strength
Risk Factor Analysis Form
Occasional Lift Guidelines
S.H. Rodgers' Bibliography

1
2
4
5
8
9
1O
11
14
15
16
17
18

Acknowletlgements
The illustrations on pages 9 and 17 are used with permission from Eastman Kodak's Ergonomic
Design for People at Work, Volumes 1 and 2 published by Van Nostrand Reinhold. The
illustration on page 8 is from Working ,With Backache by S. H. Rodgers. Information on page
11 has been developed in conjunction with Dr. Inger Williams. Work/recovery curves based on
those on page 10 have been published by Thieme Publishers in Seminars in Occupational
Medicine in March 1987. The analytical technique on page 11 has been published by Hanley
and Belfuss in a 1988 Occupational Medicine: State of the Art Review edition on Worker
Fitness Evaluations. The outline on page 4 is adapted from a draft copy of a proposed
ergonomics guideline for general industry by OSHA written in September, 1990. All other
material in this syllabus is by Dr. S.H. Rodgers and permission to reproduce it must be obtained
from her.
(716) 544-3587

�Brouha Work Physiology Symposium
State College, PA - September 9-12, 1985
Hospital Patient Tray Assembly - Paced Work and Low Back Pain
I.

A.
B.

The Job - Film
Perceived Problem/Union Grievance
Duration/Volume/Turnover

II. Conveyor Pacing
.A. Conveyor Rate - Setting vs Actual
B. Error Rates - Quality Control
c. Other Ways to Stop the Line

III. Analysis of Job Factors Contributing to Back Discomfort
A. Postures
B. Pacing - Time in Station
C. Visibility of Menu
D. Workplace Orientation
IV.

A.
B.
C.
D.

Problem Resolution
Conveyor Pacing
Use of Stools
Menu Design
Work Distribution

9/5/85 S.H. Rodgers

�Tray Loading and Unloading Rates
I.

Existing Job
A.

Conveyor Speed
Maximum

=

B.

Loading Rate

8 trays/minute average
Range = 1 to 15/minute

C.

Unloading Rate
Range
Errors

=

=

=

=
=

0.4 feet/second
20 trays per minute

7 to 8/minute average
3 to 12/minute

15% of trays
Other errors detected on patient floors

Time in Station:

5 seconds on average

Time to Put Items on Tray:

2 to 11 seconds

Time from Menu 3 feet Away to Tray Past Worker: 7.5 seconds
at 8 travs/minute
II.

Recommended Changes
A. Reduce Conveyor Speed by 20-25%
1. 15 trays per minute maximum rate
2. Time in Station: about 6 seconds on average
3. Time from Menu 3 Feet Away to Past Worker = 9 seconds at
8 trays/minute
4. Probable Decreased Error Rate
5. Decreased Twisting - Probable Reduced Back Discomfort
6. Anticipated 15-20% Improvement in Productivity
B.

C.
D.
III.

1.
2.

Provide Chairs for Checkers and Try Them at Some Other Stations
Balance Chair Use with Required Reaches, Need to Turn
Let Employees Find Best Use for Chairs on the Line
Form�t Changes and Type Size Changes on Menu
Rebalancing of Some Line Assignments

Follow Up
A.
B.
C.

Reduced Low Back Discomfort
Improved Quality of Trays - Fewer Errors
Job Reputation Improved - Improved Job Satisfaction

9/5/85 S.H. Rodqers

�JUICES

Cranberry

Grape

REGULAR

Tomato

Soup of the Day Served with Crackers

* Manhattan Clam Chowder

* Chicken a la King Over Rice

Apple

Appetizer- Gouda Cheese and Crackers
DINNER ENTREES

Prune

Fruit Select ion- Citrus Sections
DAILY SPECIALS

* Eggs Scrambled with Mushrooms
Home Fried Potatoes

Vegetable- * Seasoned Broccoli Cuts

TODAY'S SALADS

CHOICE OF POTATO/STARCH

Whipped Potatoes

VEGETABLES

Ital Ian
1000 Island
French
Low Calorie

Red Cabbage Slaw
with Pineapple

DESSERT CHOICES

* Individual Vanilla Tart
w Vanilla Wafer
Applesauce
BEVERAGES

Coffee
* Tea
Decaf. Coffee
Iced Tea
Whole Milk
* 2%Milk
Skim Milk

Ice Cream
Water Ice
Gelatin
ACCOMPANIMENTS

Cream
Lemon
Sugar
Salt
Pepper
Ketchup
Mustard
Mayonnaise

NAME

Rm ____

DIET

NAME _____________ Rm ____

Hi .�ro Drink
Skim Milk
AFTERNOON NOURISHMENT

Cinnamon Danish

* Beans O'Brien -Snaps/
Peppers/Lima Beans

DRESSINGS

Tossed

Fruit Juice
�ilk

JUICES

* Orange

Baked Fish Creole

Quiche Lorraine

BREADS

Pineapple

* Baked Lasagna

LUNCHEON ENTREES

White
* Wheat
Soft Roll
* Margarine
Butter

JUICES

Lemonade

._,, tr.-r,,1'\.I r,.U I

REGULAR

Hot Cereal- * Oat Bran
DINNER SALAD

DRESSINGS

* Tossed

Italian
1000 Island
French
Low Calorie

DESSERT CHOICES

Ice Cream
Water Ice
Gelatin

* Fruit Cocktail
Pineapple Whip
BRE.IIDS

White
* Wheat
Soft Rol 1
* Margarine
Butter

BEVERAGES

ACCOMPANIMENTS

Coffee
* Tea
Decaf. Coffee
Iced Tea
Whole Ml lk
2% Milk
Skim Milk

Cream
Lemon
Sugar
Salt
Pepper
Ketchup
Mustard
Mayonnaise

COLO CEREALS

Cornflakes
Rice Krlspies
40% Bran Flakes
Puffed Rice
Raisin Bran
Cheerios
Special K
Al 1 Bran
Shredded Wheat
Puffed Wheat

BEVERAGES

* Coffee
Tea
Decaf. Coffee
Whole Milk
* 2% Milk
Skim Milk
Cocoa

BREADS

* Toasted White
Toasted Wheat
English Muffin
Toasted Bagel
Croissant
* Margarine
Butter
Cream Cheese
Preserves

ACCOMPANIMENTS

Cream
Lemon
Sugar
Salt
Pepper
Ketchup

Rm ____

NAME

Rm ____

NAME _____________ Rm ____

NAME

Rm ____

. NAME

DIET

Fruit Juice
Milk
Skim Ml lk
Ht Pro Drink

Ginger Ale
Diet Soda
Cola
Crackers

DIET

Fruit Juice

HI Pro Drink

�Carefully Circle Choices By 12:00 Noon

Carefully Circle Choices By 12:00 Noon

CHILLED FRUIT AND JUICES
)range
�pple

Grape
Prune

Tomato
Grapefruit

,tewed
Prunes

Grapefruit
Sections

Fresh
Fruit

:ornflakes
lice Krispies
[0% Bran

Cheerios
Special K
All Bran

Cream of Wheat
TO START YOUR DAY

Scrambled Egg
made from
modified
egg fat
substitute

Pancakes
or
French Toast
Syrup

READS

BEVERAGES

CONDIMENTS

oasted White
oasted Wheat

Coffee
Decaf Coffee
Tea
Decaf Tea

Margarine
Jelly

nglish Muffin ·
oasted Bagel

Skim Milk
Creamer

�AME.._. ________
)IET

Mashed Potato
Baked Potato
Rice

Italian
1000 Island
French
Zero

Tossed

LF VEGETABLE CHOICES
Wax Beans
Mixed Vegetable
Broccoli

LF DRESSINGS

LF DINNER SALAD
Tossed

Fruited Cherry
Gelatin
DESSERT CHOICES
Fruit Cocktail
BREADS

BEVERAGES

CONDIMENTS

Salt
Pepper
Sugar

White
Wheat
Soft Roll

lemon Juice
Ketchup

Margarine

Coffee
Decaf Coffee
Tea
Decaf Tea

Cream
lemon
Sugar
Salt
Pepper
Ketchup
Mustard
Mayonnaise

---

RM

LF POTATO OR STARCH

Shepard's Pie

Corn
Spinach
Green Beans
TODAYS LF SALADS

Iced Tea
Skin-t Milk

FAT CONTROLLED

--------------

NAME
DIET

---

RM

Baked Ham

Spaghetti With
Meat Sauce

LF VEGETABLE CHOICES

FAT CONTROLLED

------

LF DINNER ENTREES

Onion

Sliced Turkey

Pineapple

lemonade

Grape

LF LUNCHEON ENTREES

Puffed Rice
Puffed Wheat
Raisin Bran

Oatmeal

JUICES

SOUP OF THE DAY
(With Crackers)

CEREAL

•

Carefully Circle Choices By 12:00 Noon •

JUICES
Cranberry

,,

UINNt:H

....u1\llvn

LF DRESSINGS

Italian
1000 Island
French
Zero
DESSERT CHOICES
Pear Halves

BREADS.

BEVERAGES

CONDIMENTS

White
Wheat
Soft Roll

Coffee
Decaf Coffee
Tea
Decaf Tea

Cream
Lemon
Sugar
Salt
Pepper
Ketchup
Mustard
Mayonnaise

Margarine

Iced Tea
Skim Milk

FAT CONTROLLED
NAME________
DIET

-------

---

RM

�Suzanne H. Rodgers, PhD.

Consultant In Ergonomics/Human Factors
169 Huntington Hills
ROCHESTER, NEW YORK 14622

"Doing It Right the First Time" -Teaching Ergonomics Design
Principles to Company Engineers
Brouha Conference, Spring Hill, TN, September 2-4, 1992
A. Reactive vs. Proactive Approaches
1. Drivers for Retrofitting
2. Drivers for New Design
3. Using Reactive Projects to Illustrate Need for Proactive Approaches
B. Building a Design Team
1. Sources of Designs
2. Site Visits - Gathering Information - Questions
3. Myths That Must Be Addressed
4. Establishing Communication Links
C. Approaches to New Design
1. Review of Existing Designs
2. Design Guidelines - Where to Be, How Serious if Not in that "Space"
3. Ergonomics from the Ground Up - Conceptual Level
4. When to Automate
5. Review Processes
8/27/92 SHR/bl

(716) 544-3587

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�2003 Lucien Brouha
Work Physiology Symposium

Research and Practice
Williamsville, NY
September 10th -September 12th , 2003

�Chronology of the Lucien Brouha Work Physiology Symposiums
Year

Location

Hosts

1961

Washington, D.C.

Initial Organizers (Davis, Miller, Pierce,
P.Smith, etc)
H.Davis, C.I. Miller
P. Smith
A. Henschel
H.Davis and C. Miller
T. Yoder, R. Lucas
S.Snook
J. Brown·

1962
1963
1964
1965
1966
1967
1968

(

Rochester, NY
Haskell Laboratories, DuPont, Wilmington, DE
NIOSH, Cincinnati, OH
Kodak, Rochester, NY
Eli Lilly &amp; Co., Indianapolis, IN
Boston, MA, Liberty Mutual
Toronto, Ontario, Canada, Ontario Ministry of
Labour
Kansas City, Western Electric/AT&amp;T
1969*
Washington, DC, St Louis Univ Medical School
1970
in St Louis, MO
1971** Quebec, Canada, Ontario Ministry of Labour,
Alcan
Ann Arbor, Ml, Center for Occupational
1972
Ergonomics
Fairborn, OH, Webb Associates
1973
Cincinnati, OH, NIOSH
1974
University Park, PA, Penn State
1975
Atlanta, GA, Georgia Tech
1976
Indianapolis, IN, Eli Lilly
1977
Kodak, Rochester, NY
1978
Estes Park, CO, IBM
1979
Cambridge, MA, Liberty Mutual
1980
NIOSH, Cincinnati, OH
1981
Texas Tech, Lubbock, TX
1982
Western Electric, Hopewell, NJ
1983
1984
Kodak, Rochester, NY
1985
Penn State Univ., University Park, PA
Deere &amp; Co., Moline, IL
1986
1987
Virginia Tech, Blacksburg, VA
Jackson, TN, Jackson Clinic
1988
1989
Estes Park, CO, Kodak Colorado
General Motors, Oklahoma City, OK
1990
Ohio State University, Columbus, OH
1991
1992
Spring Hill, TN, Saturn Corporation
University of Iowa, Iowa City, IA
1993
Yellow Springs, OH, Anthropology Research
1994
Associates
Toyota, Georgetown, KY
1995
Auburn Engineers, Auburn University, AL
1996
NIOSH, Morgantown, WV
1997
Seattle Center, Seattle, WA - 3 consultants
1998
University of Windsor, Windsor, Ontario,
1999
Canada
Univ. of Kentucky, Lexington, KY
2000
Hewlett Packard InkJet Plant, Corvalis, Oregon,
2001
Oregon State
State Compensation Insurance Fund, Clayton
2002
Group, and University of
California, San Francisco, CA
Univ. at Buffalo; SUNY, Amherst, NY
2003

F.Damon
A. Lind
J. Brown
D. Chaffin, G. Herrin
P. Webb
F. Dul&lt;es-Dobos
E. Kaman
T. Sadowsky
T. Yoder &amp; H. Fouchee
S. Rodgers and P. Champney
J. Morrison
S. Snook
H. Buescher, D. Badger
J. Smith
H. Foushee
D. Kiser and P. Champney
J.L. Pytel &amp; A. Freivalds
G. Lovested &amp; H. Hohensee
K.H.E. Kroemer
B. Erb
D.Day
W. Young
B. Marras
M. Gladde.n
T. Cook
J. Annis
M. Gladden
M. Seay &amp; D. Alexander, R. Thomas
T. Pizatella &amp; J. McGlothlin
--�:
W. Brough; I. Chong, P. Champney
S. Dutta
J.W. Yates
J. Buresh, S. Middleton, and J.
Woldstad
R.J. Banks, C.Shulenberger, and I.
Janowitz
V. Paquet and S. Rodgers

*At this meeting, participants adopted Dr. Brouha's name for identification of the conferences.
** Winter meeting

�Registered Attendees
2003 Lucien Brouha Work Physiology Symposium
Shona Anderson
President
Anderson Ergonomics Consulting Inc.
279 Hampstead Way NW
Calgary, Alberta T3A6E6 Canada
ph: (403) 241-7887
fax; (403) 547.-6174
shona@andersoi1 °ergo.ca

Anthony D. Banks
Ergonomist
Eastman Kodak Company
1669 Lake Avenue
Rochester, NY 14652-4387
Office (585) 477 - 5328
Fax: (585) 477-4304

Marty Barnes
Motorola, Inc.
Jamison Road
Elma, NY
martha.barnes@motorola.com

Isaac Barsky
Department of. Industrial and Manufacturing
Systems Engineering
University of Windsor
230 Essex Hall
401 Sunset Avenue
Windsor,. Ontario Canada
N9B 3P4
Phone: (519) 253-3000 x. 2607
barsky@uwindsor.ca

Valerie Beecher
Duke University
Occupational and Environmental Safety Office
Ergonomics Division
2200 W. Main Street
Wachovia Bldg.
Box 3834, Durham, NC 27710
Telephone 919-286-1722 X272
Fax (919) 286-6763
valerie.beecher@duke.edu

Ann Bisantz
342 Bell Hall
Department of Industrial Engineering
University at Buffalo, State University of New
York
Buffalo, NY 14260
Phone: (716) 645-2357 x 2474
bisantz@eng.buffalo.edu

Lisa Brooks
Group Leader - H&amp;S Regulatory Affairs
International Paper
(901) 419-3943
Lisa.Brooks@ipaper.com

Colin Drury
342 Bell Hall
Department of Industrial Engineering
University at Buffalo, State University of New
York
Buffalo, NY 14260
Phone: (716) 645-2357 x 2474
drury@buffalo.edu

;-.

David Feathers
RERC UD
Department of Industrial Engineering
University at Buffalo, State University of New
York
feathers@eng.buffalo.edu

Ken Glass
HSE Coordinator,
Global Manufacturing &amp; Technology Shops
Division
Eastman Kodak Company
2400 Mt. Read Blvd.
Rochester, NY 14650-3053
Office 585 - 726 -2643
Fax 585 - 726 -6793
email: kenneth.glass@kodak.com

�Katie Marshall
Center for Integrated Manufacturing Studies·
133 Lomb Memorial Drive
Rochester, NY 14623
Phone (585) 475-5390
Fax (585) 475-5455
marshall@reman.rit.edu

Matt Marshall
Department Industrial &amp; Systems Engineering
Rochester Institute of Technology
(585)475-7260
mmmeie@rit.edu

Vic Paquet
342 Bell Hall
Department of Industrial Engineering
University at Buffalo, State University of New
York
Buffalo, NY 14260
Phone: 716-645-2357 x 2474
vpaquet@eng.buffalo.edu

Hemant Prabhu
Department of Industrial Engineering
University at Buffalo, State University of New
York
Buffalo, NY 14260
Phone: 716-645-2857 x 2474
hemantp@yahoo.com

Randy Raybourn
The University of Michigan
Center for Ergonomics
1205 Beal Avenue, IOE Building
Ann Arbor, Ml 48109-2117
Phone: (734) 763-0567
Fax: (734) 764-3451
E-mail:rrabourn@umich.edu

Sue Rodgers
Ergonomics Consultant
160 Huntington Hills, Center
Rochester, NY 14622
SHRODGERS@aol.com

John Rosecrance
Environmental &amp; Radiological Health Sciences
1681 Campus Delivery
Colorado State University
Fort Collins, CO 80523
Phone: 970-491-1405
Fax: 970-491-2940
john.rosecrance@colostate.edu

Diane Stinson
HealthWorks
Ergonomics and Injury Prevention Consultants
220 1010-8th Avenue SW
Calgary, AB Candada, T2P 1J2
Phone: (403) 234-8222
Fax: (403) 234-8268
Email:dstinson@healthworks.ca

Robert (Rob) Thomas
Department of Industrial and Systems
Engineering
Auburn University, Auburn, AL 36849-5346
(334) 844-1420
rthomas@ehg.auburn.edu

�Agenda
-�

, )
____ _

Note: DL - Discussion Leader
Tuesday, September 9th
6:00-9:00 PM

Welcome Reception (Eagle House Restaurant, a brief walk
from the Hampton Inn)

Wednesday, September 10th
7:30-8:15 AM
Morning Welcome, Sign in, and Breakfast

8:15-8:30 AM

Opening Remarks (Victor Paquet)

8:30-10:00 AM

Round Robin Introduction of Attendees

10:00-10:15 AM

Break

10,15 - 12:00 PM

Discussions and Presentations
• Proactive Ergonomics (DL - Isaac Barsky and Sue Rodgers)

12:00-1_:00 PM

Lunch (at the Hampton Inn)

1:00-3:00 PM

Discussions
• Endpoints in Fatigue (DL -.Sue Rodgers)
• Video-based Job Analysis Strategies for Ergonomics
Practice (DL - Victor Paquet)
• Fatigue Modeling for Rest Allowance Requirements (DL Hemant Prabhu)

3:00-3:15 PM

Break

3:15-5:00 PM

Discussions
• Effectiveness of Train the Assessor Courses (DL - Shona
Anderson)
• Productivity in Offices (DL - Diane Stinson)

Thursday, September 11th
8:15-9:15 AM

Future of "Brouha" and Plans for 2004

9:15-10:00 AM

Presentation
.
Pre-placement Use of Nerve Conduction Tests in
Manufacturing (DL- Johrt Rosecrance)

10:00-1 O: 15 AM

Break

10:15-12:00 AM

Discussion
Job Rotation: Research Findings and Current Practices

12:00-1 :00 PM

Lunch

1:15-2:00 PM

Use of New Athropometric Data (DL � Ann Bisantz)

2:00-4:00

Tours of Industry or UB Research Labs

4:00-9:00 PM

Trip to.Niagara Falls and Dinner

�Friday, September 12th
8:30-10:00 AM

•
•

10:00-i 0:15
10:15-12:00

i

\ '-)

Discussions
Academic Programs in Ergonomics (DL � Rob Thomas)
Future of Work (DL·- Colin Drury)

Break
Discussions
Ergonomics Legislation, what works for whom and when
· (Conference Call with Lisa Brooks)
• A variety of topics brought by attendees to share with the
group such as ergonomics in poultry processing,
environmental issues that impact health and wellbeing, and
more.
•

12:00-2:00 PM

Lunch, Tour of UB IE Department, Student Poster Session of
Research Projects

2:00-2:30 PM

Closing Remarks

�Applied Ergonomics : Elements of Successful
Occupational Programs, su:zanne H. Rodgers, Ph.D.

a CAIRE Confere,nce PreConference, February 28, 1996
at the Hyatt Regency in Dallas, TX
Schedule

8:30 Intrcxluctions - Overview of Course
9:00 Securing Management Commitment and Employee Involvement
10:00 Job Analysis Techniques - Fatigue Analysis, Checklists, Accident Analysis, ADA
Analyses, Survey Techniques, Problem Solving - Driving Factor and Root Cause
Analyses
10:30 Break
10:45 Continue Job Analysis Techniques
11:45 Lunch
1:00 Problem Solving: Case Studies
2:00 Return to Work and Medical Management Approaches - Ergonomics1 ,Role
2:45 Break
3:00 Assessing the Effectiveness of an Ergonomics Process
3:30 Discussion, Questions, Case Studies As Requested by Attendees
4:30 Adjourn
Synopsis

The goal of this seminar is to share experiences in the setting up of effective ergonomics
programs and processes in companies, the service sector, municipalities, etc.. The topics
covered will include: approaches to secure management commitment and employee
involvement and ownership of the ergonomics improvements; a variety of approaches for
assessing job demands and relating them to appropriate capacity data to determine the risk
for overexertion injuries or overload; where ergonomics can help in medical management
and return-to-work issues; and how the effectiveness of ergonomics programs and
processes can be assessed. Attendees are encouraged to share examples from their own
practices, and several job analyses will be done to illustrate the evaluation techniques.

"'° '�
L�.II��

Suzanne H. Rodgers, Ph.D
Consultant in Ergonomics
f

HIGHER PRODUCTIVITY THROUGH JOB DESIGN
lfi!l IltJNTlNr.TnN !111.LS U ROCHF.STF.R, NF.W YORK 14622
1'/im11•: (7Hl) 544-35R7 O Fax: (716) 26fi-1174!l

�Applied Ergonomics:

Elements of Successful Occupational Programs
Table of Contents

Topic
Table of Contents
Acknowledgements
Securing Management Commhment
A Functional Job Analysis Technique
Work/Recovery Curves
Ergonomic Job Analysis - Fatigue
Table 2: Examples of Muscle Effort Levels
Table 1: Risk Factor Analysis
ANSI Z365 Draft Checklist
OSHA March 95 Checklist
Risk Factors for Upper Extremity Discomfort
Figure 1: Risk Factors for Low Back Pain
Computer Workplace Posture Checklist
Self-Help to Increase Seated Comfort
Risk Factors for Discomfort
Accident Analysis - Ergonomic Approach
Standing Arm Reach Envelopes
Lifting Guidelines - Eastman Kodak
Job Analysis Techniques and Solution Strategies
Return-to-Work and Medical Management
Assessing the Effectiveness of an Ergonomics Process
Summary of Job Analysis Techniques
Resource Materials - S. H. Rodgers
Extra Forms

Startin� Paee #
1
1

1
6
25
26
27
28
29
32
44
45
47
49
51
52
56
57
58
60
64
70
74
75ff

Acknowledgements
The article on pages 6�24 was published by Hanley and Belfuss in Philadelphia in a
monograph on Ergonomics edited by J.S.Moore and A. Garg and part of the series
Occupational Medicine: State of theArt Reviews, Volume 7(4), Oct-Nov, 1992. The
work/recovery curves on page 25 are based on muscle fatigue studies by W. Rohmert
summarized in Applied Ergonomics in 1973 with some limits set by more recent research.
The ANSI draft ergonomics checklist is from the January 1, 1996 draft of the proposed
standard on the control of cumulative trauma disorders. The OSHA ergonomics checklist
is from the March, 1995 draft of a proposed ergonomics standard for general industry.
The computer workplace ergonomics material on pages 47-49 has been developed in
conjunction with Dr. Inger M. Williams of Fairport, NY. The standing arm reach curves
are from Volume 1 of Ergonomic Design for People at Work by Eastman Kodak Company
(1983), New York: Van Nostrand Reinhold, and the lifting guidelines are from Volume 2
( 1986) of the same work. All other material in this syllabus is the property of Dr. Rodgers,
and permission to reproduce it must be obtained from her at 169 Huntington Hills,
Rochester, NY 14622; (716) 544-3587.

�Ergonomics: Work, Rest, Leisure An Occupational Therapy Perspective
Institute #1 O

CANAM Conference Boston,· MA
July 8, 1994

Sue Rodgers, PhD
169 Huntington Hills - Center
Rochester, N.Y. 14622
Offi.ce:(716) 544-3587

Melanie Ellexson, MBA, OTR, FAOTA
16246 Prince Drive
South Holland, IL 60473
Office: (708) 596-2111

Barbara L. Komblau, JD, OTR, DAAPM
__ 10350 Old Cutler Road
Miami, FL 33156
Office: (305) 949-4000 X 1201

�Schedule for a 1-Day Institute (#10) on Ergonomics: Work,
Rest, Leisure - An Occupational Therapy Perspective,
AOTA Can/Am Conference, July 8,1994, Boston, MA, with
Melanie T. Ellexson, MBA,OTR, FAOTA, Barbara J. Kornblau, JD,
OTR and Suzanne H. Rodgers, Ph.D.
9:00 - 10:00

Regulations - B. Kornblau

10:00 - 10:45

Risk Factors - S. Rodgers

11:00 - 12:30

Ergonomic Worksite Evaluations M. Ellexson and S. Rodgers

1:30 - 2:30

Hazard Prevention and Control - Panel

2:30 - 3:00

Medical Management/ Return to Work 8. Kornblau and M. Ellexson

3:15 - 3:45

Training and Education - Panel

3:45 - 4:30

Checklists/ Screening Tests - M. Ellexson
and B. Kornblau

4:30 - 5:00

Summary of Program Elements

�Ergonomics and Rehabilitation To Work
Talk to the Delaware Occupational Medical Association
on May 16, 1985, Wilmington, DE
Outline
I. Ergonomics and Occupational Health
A. Definition of Ergonomics
a. How Ergonomics Can Help the Occupational Physician or Nurse
II. Ergonomics and
A. Types of Jobs
B. Grip Strength
C. Techniques to
III.
A.
a.
C.

Repetitive Motions Disorders
Where These Problems Are Seen
and Factors Affecting It
Reduce Stress in Repetitive Tasks

Ergonomics and Low Back Pain
Occupational Low Back Pain
Factors That Aggravate Low Back Pain Symptoms
Techniques to Reduce Stress in Lifting, Handling, and
Postural ·rasks

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�.l

•··

�llzanne H. Rodgers, �h.D.

·. \' .--lfmsultant In Ergonomics

.�9 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Workshop 5: An Ergonomic Approach to Accident Analysis
ErgoCon '98, Wednesday May 6, 1998, 1:30 to 5:00 PM

A. Why Should We Look at Injury and Illnesses Accidents from an
Ergonomics Perspective ?
1. Multiple Factors Contribute - Rarely Domino Effect
2. Opportunities Missed to Improve Job If Only Treat Behaviors
3. Get Away From Blame and Focus on Continuous Improvement
B. Gathering Data at the Site of the Accident/Injury
1. Non-Threatening Approach - Assume There is a Reason for Errors
2. 4 Areas for Investigation - Person, Task, Environment,
Organizational Situation
3. Practice Questions Using Case Studies
4. Measurements Needed
C. Job/fask Demands Analyses
1. Defining Tasks That Should Be Improved
2. Upper Limits versus Job Design Issues (Interactions)
3. What Is "Heavy"?
D. Finding Feasible and Cost-Effective Solutions to Reduce Risk
1. Using Measurement Data and Interview Data to Establish Root Causes
2. Job Design and Workplace Design Issues
3. Defining the Seriousness of the Problem and the Probable Risk
Reduction With the Proposed Change
4/14/98 SHR

0
0
0

�i�
,..

---- ---

-f

�Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Avoiding Exposure in Manufacturing: Update on
Ergonomics for Materials Handling
Talk for the Conference on Ergonomics to Enhance the
Bottom Line, sponsored by STEPS Industrial Rehabilitation

Clinics, July 8th, 1993, Oakbrook, IL

Outline
A. R�_view of the 1981 and 1991 NIOSH Guidelines for Manual
Lifting
· B. Defining How Much of a Proble,n
a Lift May Be .
.
i..

C. Defining How to Improve th.e Lifting Situation Cost Eff�ctively
D. Materials Handling Situations NofCovered in the NIOSH Guides

�Chapter Arthritis Informational Meeting

'

depetitive Movement/Carpal Tunnel Syndrome
Brighton Presbyteri en Church, November 3, 1990

Ergonomics
Designing for People

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Ergonomics and Loss Control
Talk to the Genesee Valley Safety Conference 11/16/83
(716) 544-3587

I.

Signage
A.

Suzanne H. Rodgers, Ph.D.
Factors in Sign Design
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
1. Size
"'HIGHER PRODUCTIVITY THROUGH JOB DESIGN" . _
2. Shape - Stereotypes
3. Letter Size
169 HUNTINGTON HILLS
4. Space Around Letters
ROCHESTER, NEW YORK 14622
5. Contrast
6. Color
7. Information
8. Coding - International Signs

B.

Factors in Sign Placement
1. Lighting
2. Deterioration
3. Other Signs in Area - Information
4. Correspondence of Arrows with Turns

II.

Hand Characteristics and Manual Handling
A.

Importance of Handgrip in Manual Handling
1.
2.
3.
4.

B.

III.

Types of Handholds
Pinch vs Grip - Distributions of Grip Strength
Grip Strength and Span
Effects of Wrist Angle on Grip Strength

Effect of Gloves on Grip Strength
1. Reduction of Strength
2. Importance in the Design of Handling Tasks
Manual Handling Capability

A.

Lifting
1. NIOSH Guidelines
2. Frequency Effects
3. Design vs Compliance
4. General Guidelines for the Design of Lifting Tasks

B.

Pushing and Pulling
1. Whole Body
2. Arms
3. Intensity and Duration Relationship

�A

Ergonomics
Talk by Suzanne H. Rodgers, PhD, Consultant in Ergonomics,
to the Greater Rochester Area Rehabilitation Group
Monday, November 20, 1989 at the Gateway Inn Conference Center, Henrietta, NY

Outline
I.
II.
Ill.
IV.
V.
VI.

What is Ergonomics ? - National Trends
Work Capacities - Designing for Most People
Job Demands - Fatigue Potential
Analyzing Repetitive Tasks
Analyzing Lifting Tasks
Examples of Ergonomics Improvements to Difficult Jobs

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEAL TH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Ergonomics in the Management of
Upper Extremity Disorders
Keynote Address to the Conference on How To
Ergonomics: Ergonomic Assessment and Equipment

at the Gateway Conference Center, Rochester, NY, April 15, 1999
Outline of Talk
A. The "Epidemic" in Work-Related Upper Extremity Disorders
1. Why are there so many more cases reported ?
2. How has work changed over the last 2 decades ?
3. What is the role of ergonomics in abating the problem ?
B. Ergonomics and Better Job and Workplace Design
1. Defining good designs by understanding human capabilities
2. Quantifying poor designs and their impacts before changing them
3. The importance of the problem solving process in finding
solutions to ergonomics problems
C. Ergonomic Equipment - The Educated Consumer
1. Not every symptom requires an equipment "fix" - Offices
2. Define job requirements before deciding on a piece of equipment - Offices,
Manufacturing
3. The value of a good mechanic in solving a workplace problem
4. Choosing equipment for purchase - Manufacturing, Offices
D. Managing Upper Extremity Disorders
1. Involvement of employees and education about risk factors
2. Early detection of problems through "continuous improvement"
approach to job and workplace designs
3. Provision of control by the employee over the way the job is done; latitude in
technique used as long as productivity, quality, and safety goals are met

i

•,,.,

�iuzanne H. Rodgers, Ph.D.
:onsultant In Ergonomics

t 69

Huntington Hills - Center
lochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Workshop on An Ergonomic Approach to Analyzing Workplace
Accidents IAPA Conference in Toronto, Canada on April 12,
2000, 9:00 AM to 12:15 PM

A. Why Shoul4 We Look at Injury and Illnesses Accidents from an
Ergonomics. Perspective ?
1. Multiple Factors Contribute - Rarely Domino Effect
2. Opportunities Missed to Improve Job If Only Treat Behaviors
3. Get Away From Blame and Focus on Continuous Improvement
B. Gathering Data at the Site of the Accident/Injury
1. Non-Threatening Approach - Assume There is a Reason for Errors .
2. 4 Areas for Investigation - Person, Task, Environment,
Organizational Situation
3. · Practice Questions Using Case Studies
4. Measurement� Needed
C. Jobffask Demands Analyses
1. Defining Tasks That Should Be Improved
2. Upper Limits versus Job Design Issues (Interactions)
3. What Is "Heavy" ?
D. Finding Feasible and Gast-Effective Solutions to Reduce Risk
1. Using Measurement Data and lnterview Data to Establish Root Causes
2. Job Design and Workplace Design Issues
·
3. Defining the Seriousness of the Problem and the Probable Risk
Reduction With the Proposed Change

�1zanne H. Rodgers, Ph.D.

Consultant In Ergonomics
·i9 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

An Ergonomic Approach to Analyzing Workplace Accidents
The field of ergonomics and industrial safety complement each other in
trying to find ways to reduce injury and illness risk in the workplace.
While industrial safety has focused on identification of hazards, education,
protective equipment, and guarding against hazards, ergonomics
emphasizes job, workplace, equipment, and environmental design fo reduce
overload, simplicity rather than complexity in equipment and information
design, and assists to aid people at work (such as manual handling assists,
special tools, automation or semi-automation, and computer-aided
processes).
In evaluating accident reports on-site, however, one often sees a large
number of strain and sprain events that follow this pattern:
Accident type:
Injury type:
Body part:
Unsafe act:
Hazardous condition:
Recommended action:

Lift, lower, push, pull
Strain/sprain
Low back
Didn't lift properly
Heavy weight
Lift properly

A similar pattern is found for repetitive tasks where upper extremity
problems have been found:
Accident type:
Injury type:
Body part:
Unsafe act:
Hazardous condition:
Recommended action:

Repetitive motions
Inflammation
Hand and wrist
Rushed
High repetition rate
Rotate with less hand-intensive task

Even some laceration and contusion injuries follow somewhat predictable
patterns in accident reporting, such as:
Accident type:
Body part:
Unsafe act:

Stfl!ck against
Elbow
Not paying proper attention

�2

Hazardous condition: Congested work area
Recommended action: Pay proper attention
Some accident analysis methods try to dig deeper for root causes, but they
often stop once responsibility has been assigned for the hazardous condition
or unsafe act. Often an action is identified that will reduce the risk for
future accidents, but too often the outcome may be to reinforce or give
training, tell the injured person to follow the standard operating procedure
(SOP), or to tell them to wear protective equipment to protect against a cut
or bum.

·,

\

,'.

The field of human reliability is part of human factors and ergonomics and
has mostly been developed by psychologists and engineers working in
military and in space (and other unusual environments) programs. It
focuses on, and has developed ways of defining, error-free performance
for critical systems where an error could result in a castastrophic situation.
A very simplified way of looking at human reliability concepts is to
acknowledge that a person's risk of making an error depends on individual
factors (including knowledge, skill, and capabilities), on task demands
(what the job or equipment requires the person to do), on the environment
_ in wlµch the work is �one (this would be the physical environment, such as
- · � . temperature, lighting, workplace layout); and on the organizational factors
. :_ present (such as policies for training, production pressures, shift schedttle,
communications; etc.)� - An: error iri safety and ergonomics would be an
accident or incident.
·
·
A.

Ergonomics and Accident Prevention

The ergonomics goal is to design the workplace so that, even if a
person makes an error, an injury (accident) will not occur. One way to
accomplish that goal for strain and sprain injuries, for example, is to
keep the required forces exerted or �eights handled light enough to
accommodate the strengths of 75 - 90% of the female workforce. The
actual acceptable weights would have to be determined by the location
of the force application or lift. To meet this goal, the weights of objects
'handled in the workplace would have to be in the range of 4 pounds for
frequent lifts (10 times per minute) from a floor pallet to a workbench
and up to 51 pounds for a compact object handled infrequently (&lt; 1
time per 5 minutes), with good handholds, and held next to the thighs.
In most instances, acceptable weights for lifting or forces for pushing
or pulling will be under 35 pounds. This may be difficult to comply
with in some workplaces. For very repetitive tasks, ergonomic ways to

�.

/ ::,.

Municipal Ergonomics

A Workshop for IAPA 2001, Toronto, Ontario
April 3, 2001, Room 714A, 9:30 AM- 12:30 PM

Workshop Leaders

City of Toronto: Christine Hardy
Linda Mcllwain
Karen Raybould
Jane Byers

HR Ergonomics
Consultants

City of Rochester, NY:
Tassie Demps, City Safety/WComp Specialist
Suzanne Rodgers, Ergonomics Consultant

�List of Ergonomics Projects Done in the City of Rochester, N.Y.
(1987-2001)
Solid Waste Operations
1. Interviews, workload estimates, weights handled
in trash collection
2. Heart rate on recycling/trash collection routes Recycling box weights
Physical
capacity test for SWO's monitored heart
3.
rate on simulation
4. Toters, Boom Trucks, etc - Review of some jobs
and job elements
5. Looked at Snow Emergency Center Space analysis

Police Department
1. Record Room rearrangement - Flow patterns/space
analysis for better finger-printing, serving customers.
2. Property Room - Evaluation of space, heights of shelves
3. Assorted office ergonomics consults - Requested from
individuals.
4.· Awareness training for employees.

911-OEC
1. Evaluation of 5t11 floor of Public Safety Building Suggestions to improve current, and for future, designs.
Characterization of workload.
2. Training/consultation for employees in old center
3. Evaluation of comfort, response to DOL citation
4. Participation in the design of the new 911 Center Guidelines, simulations, data collection, team member.
5. On-going training and consulting, Medical management.

Parks Department
1.
2.
3.
4.
5.

Trailer gates - Evaluation and recommendations
Spring clean up - Leaves in school yard.
Cemetery - Head stone setting
Tree trimming
Wellness day ergonomics training, back program

�Water Distribution /Treatment/Bureau
1. Water treatment plant - Shift schedule - Workload
assessment.
2. Water main repairs - Pictures only
3. Water shed maintenance - Observed tree trimming
and harvesting.
4. Water Bureau Office ergonomics - Also working on
accident data base with them.

Library
1. Design of check-out desk
2. Office ergonomics consults
3. Shipping Dock book handling - job evaluation
and recommendations.
4. Consults on job accommodations - ADA.
5. Awareness training

Equipment Maintenance
1. Eidos visited garage and demonstrated creeper/scoot
stooV positioner to assist in low work
2. Maintenance shop for small equipment (mowers,
snow blowers, etc)- reviewed space and recommended
some improvements.

Fire Department
1. Office ergonomics in main offices - responding to
individual requests.

Central Safety
1. Ergonomics training and awareness for Supervisors,
Employees, and Temporary or Seasonal Employees.
2. Improving accident/incident-reporting system
3. Analyzing accident/incident and WC data to determine
city priorities in ergonomics /safety
4. Developing ergonomics process/program for the City.
S. Developing Website material.
6. Publishing papers and giving presentations on City ·
ergonomics projects.
7. Writing up grant proposals for new program
development

�Suzanne ff, Rodgers, Ph,D

�ONSUI,.TANT ,N. ERGONOMIC$/ HUMAN FACTORS
· HIGHER PROPUCTIVITY THROUGH JOB DESIGN"
(716) 544-3587, Fax (716) 266-8749
Email SHAODGER&amp;@aol.com
169 HuntinQton Hills • Rochester, NY 14622

Workshop on The Impact of Extended Overtime on
Acceptable Daily Workloads
For the IAPA 2002 Conference in Toronto, Ontario
Monday, April 22, 2002, I :45 to 4:45 PM Session
Supplemental Syllabus
4-Factor fatigue Risk Profile
Aerobic Capacities of Men and Women
Maximum Aerobic Workload Guidelines
Upper Body Aerobic Capacities
Aerobic Demands and NIOSH Lifting Guidelines
Heart Rate Response to Heavy Work Example
Some Oxygen Demands of Heavy Work
Analysis of the Suitability of a Lifting Job Workload
Heart Rate Responses to Work
Effect of Temperature on Time for Work at Diff Effort Levels
Effect of Extended Hours of Work on Leisure Time
Workload Limits as a Function of Continuous Hours
Overtime Guidelines/Shift Schedule Example
References - SHR

Page(s)
1
2- 4
5- 6
7- 8
9
10

11 - 12
13
14-18
19- 20
21
22
23
24-25

Acknowledgements
Most of the material included in this syllabus was published in Volume 2 of Ergonomic Design for
People at Work (1986) by Eastman Kodak's Ergonomics Group, now available through John
Wiley and Sons, and has been reproduced with their permission. The NIOSH Lifting equation
material is from a handout at a talk by A. Garg and T.Waters in Denver, CO in 1991. The
remaining material is by S. Rodgers.

�I

f

_ Suzanne H. Rodgers, PhD.
Consultant In Ergonomics/Human Factors
169 Huntington Hills
- ROCHESTER, NEW YORK 14622

I

I
I
I

Why Ergonomics ? Benefits and Applications in Industry
Talk to the IBM US Safety and Industrial Technical Conference in
Poughkeepsie, NY, May 12, 1989 at 9:50 to 10:50 AM

A. Ergonomics to Reduce Overexertion Injuries
1. Work Capacities and Job Design
2. Factors Contributing to Low Back and Repetitive Work
Disorders
3. Ergonomic Techniques to Reduce the Risk for Overexertion
Injuries
B. Ergonomics to Enhance Quality Performance
1. Reducing Fatigue and Discomfort Through Ergonomic Design
2. Reducing Complexity Through Ergonomic Design
C. Integrating Ergonomics Into the Corporation
1·. Where Ergonomics Fits With Quality Circles, Excellence,
Continuous Improvement, Natural Work Groups, and
Sociotechnical Systems
2. Ergonomics in the Manufacturing Plants
3. Ergonomics in the Initial Design of Facilities, Equipment,
Environments, Jobs, and Workplaces

3/26/89 SHR
(716) 544-3587

��·····

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2-Day Ergonomics Awareness and Problem Solving
Course for the Oneida Silversmiths' Plant,
. Oneida, NY, May 17-18, 1990
Outline
A. Overview of Ergonomics Principles and Value to Manufacturing
B. Designing Jobs To Prevent Unnecessary Fatigue
C. Preventing Overexertion Injuries
1. Repetitive Motions Problems
2. Low Back Pain
D. Identifying Cost Effective Approaches for Improving Jobs
E. Ergonomics Problem Solving Using Videotaped Oneida Jobs
Syllabus Table of Contents *
National Trends in Ergonomics
Plant Erionomics Programs and Organization
Identifymg Ergonomics Problems
Work/Recovery Curves
Designing Jobs to Minimize Unnecessary Effort
Findmg Best Solutions to Ergonomics Problems
Problem Solving Form
Risk Factors for C�al Tunnel Syndrome
Factors Affecting Gnp Strength
.Ergonomic Job Analysis
Risk Factors for Low Back Pain
Height and Reach Interaction
Maximum Forces in Design
Kodak Lifting Guidelines
Overexertion Injury Risk Factors
Cost-Benefit Analyses of Ergonomic Solutions
Cost Justification Problem Solving Form
References - SHR
Extra Problem Solving Forms

1
2
8
14
15
16
17
20
22
23
26
28
29
30
31
32
36
39
40

* Permission to reproduce original.material in this syllabus must be obtained from S.H.
Rodgers, PhD., 169 Huntington Hills, Rochester, NY 14622, (716) 544-3587.

�,·

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\

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Matching Job Demands and Worker Capabilities

Talk to the conference "Forging a Future", the 1992 Industrial
Rehabilitation Symposium, Nashville, TN, October 16, 1992

Outline
A. Work Capacity Over Time
B. Relating Job Demands to Work Capacities
C. Case Studies
1. Low Back Problem
2. Carpal Tunnel Syndrome Problem
D. Reasonable Accommodations

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Ergonomics: Opportunities for Health Professionals
Talk to the conference "Forging a Future", the 1992 Industrial
Rehabilitation Symposium, Nashville, TN, October 15, 1992

Outline
A.

What the Employer Is Asked To Do - ADA and Ergonomics

B.

How the Health Professional Can Help to Define Job Demands
1. Questions to Establish Job Demands, Worker Comfort, Possible
Accommodations
2. Fatigue Model to Predict Potential Risk Factors and Success of
Returning a Person to Work
3. Cumulative Trauma Disorders and Low Back Pain - Job Site
Analysis Techniques
4. Evaluating the Office Workplace

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�1

Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics

169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

A Multidisciplinary Approach to the Management of RSI

A talk to the Ontario Physiotherapy Association's First International
Symposium on Global Rehabilitation,Trends, January 17, 1997,
Toronto, Ontario, Canada.
A.

Background - Why Are There So Many Occupational
RSis Today ?

A good and often difficult question that managers ask of most
ergonomics consultants is "Why are there suddenly so many
musculoskeletal problems among people who are doing substantially
the same work that their parents' generation did ?" In my 28 years
of chasing down these problems in manufacturing, office, and public
service jobs, I have determined that four issues may explain the
different incidence rates: an increased rate of reporting
discomfort and injuries; substantial changes in the jobs associated
with automation, pacing, volume, and variety of tasks; more
awareness in the general public, medical community, and safety
profession; and social changes that determine worker behavior and
expectations. Table 1 includes listings of factors that have changed
in jobs over the past 20 years;
Some people think that RSis are not work-related because not all
workers on the same "high risk" jobs develop the symptoms. If the
jobs causes the problem, they say, then everyone doing it should
experience injury or illness, not just 10 to 20% of the workforce.
Their conclusion is that RSis are more prevalent in some people
than in others, and that a good selection test will reduce the
occupational cases by keeping the RSI-susceptible people out of the
repetitive jobs.
A not-yet-published epidemiology review of repetitive tasks and
RSis (NIOSH, 1996) suggests that there are significant effects of

�...
6

6

Problem Solving: Using Ergonomics and Physiology for Lifting Tasks
Lifting and Low Back Pdin Seminar, Richland, WA, April 4-5, 1991

Outline
A. Occasional Lifts -Two-Handed
B. Frequent Lifts -Two-Handed
C. One-Handed Lifts
D. Carrying
E. Postural Factors Contributing to Low Back Pain

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

Sixth
Annual
Medicine
in the
Workplace
Sentinar

OCCUPATl0NAl- l-JEAJ..TH N0RTHWES°T

�Occupational Health Northwest's Seminar on Lifting and the Low Back,
Shilo Inn, Richland, WA, April 4-5, 1991
The Science of Lifting: A Working Physiologist's Guide to the
Lift Task, S.H. Rodgers, PhD, April 4, 8:30 - 9:45 AM
A. Defining the Questions About Safe Lifting
1.
2.
3.
4.
5.

How much can a person lift safely?
How much is too much?
What is the safe lifting zone?
What are safe lifting weights?
How many lifts per shift are safe?

B. Capacities for Manual Lifting or Force Exertion
1.
2.
3.
4.
5.

Strengths at Different Locations
Local Muscle Endurance
Whole Body Endurance
One- vs. Two-Handed Lifting
Carrying

C. The Lift Task Demands in Relation to Lifting Capacities
1 . Percent of Functional Capacity Used
2. Postural Effects
3. Behavioral Factors

�
&amp;:
-=�,
�=
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---=
=
Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Ergonomics/Human Factors in Safety and Health
Luncheon address by Suzanne H. Rodgers, Ph.D. to the conference on
Making Your Workplace Safer, sponsored by the New York State AFL CIO, the Central New York Labor Council, and the Central New York
· Labor Agency, June 13, 1987, SUNY College of Technology, Utica, N.Y.

Outline
A. Today's Jobs and Work Environment
1.
2.
3.
4.

World Class Competition in Manufacturing
Increased Service Jobs
Changing Workforce/Market
How Do We Increase Productivity Without Increased Risk for
Safety and Health Problems?
5. Traditional Approaches - Safety and Health (Return to Work)
6. Disability Management

B. Ergonomics/Human Factors - Designing for People
1.
2.
3.
4.

More Work for Less Effort
Population Work Capacities
Acceptable Loads
Factors That Reduce Productivity
a. Static Work - Postures - Workplace and Equipment Design
b. Poor Working Environments
c. Heavy Effort Requirements
d. Complex Tasks
5. Techniques to Improve Jobs
a. Teamwork Required - Workers, Designers, Supervisors
b. Examples from Cost/Benefit Analysis Handout.

C. Gaining Commitment for Change - The Costs of Poor
Design

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 141i22

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�lpansion of the Therapist's Role in Industry
. .

.

Rodgers, Ph.D., Consultant in Ergonomics, Rochester, N.Y.,

. . rited at the Meeting Planners' Conference, Industrial Medicine: An
Introductory Course for Therapists, January 18th and October 12th, 1989

I. Characterization of Industrial and Occupational Needs
A. Productivity, Quality, Safety and Health
B. Practical Approaches - Prioritization of Needs
C. Flexibility to Respond to Production Needs
D. Ability to Respond to Changing Workforce Situations
II. Physical Therapy and Ergonomics
A. Focus on Job Demands as Well as Individual Capabilities
8. Functional Job Demands Evaluations
C. Defining the Capacities Required for Jobs That Are Difficult
to Redesign
D. Body Mechanics - Training and Job Design
Ill. Examples of Industrial Questions Which Physical

_Therapists Should Be Able to Answer

A. Capacity Required to Perform a Materials Handling Task
B. Impact of Increasing Hours of Work (12-hour Schedule or
Overtime) for a Heavy Job
C. Expected Benefits from Making a Change in a Repetitive Task
D. How to Reduce Injury Risk on Specific Problem Jobs

1/3/89 SHR

(

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�Postural Considerations in the Workplace
S.H. Rodgers, Ph.D., Consultant in Ergonomics, Rochester, N.Y.,
presented at the Meeting Planners' Conference, Industrial Medicine: An
Introductory Course for Therapists, January 18th and October 12th, 1989

I. Contributions of Work Posture to Low Back Pain
A. Static Muscle Work
B. Manual Handling and Postural Stress
C. Recovery Time Needs in Postural Work

II.

Contributions of Work Posture to Repetitive Motions
Disorders

A. Factors Affecting Grip Strength
B. Ergonomic Job Analysis Technique

Ill.

Workplace and Job Interventions to Reduce Postural
Stress

A. Workplace Design - Heights, Reaches, Orientation, Visibility
B. Tools and Equipment Design
C. Work Pattern and Job Design

1/3/89 SHR

i.

�Suzanne H. Rodgers, PhD.

Consultant In Ergonomics/Human Factors
169 Huntington Hills
ROCHESTER, NEW YORK 14622

Applied Ergonomics: Controlling Overexertion Injuries at
Work, A Meeting Planners Course Given on March 10-14, 1993
at the Twin Towers Hotel, Orlando, FL
Schedule
Wednesday, March 10th

10:35
10:55
11:20

Registration and Continental Breakfast
Welcome, Announcements, Introductions, Areas of Interest
The Scope of Industrial Ergonomics - Rodgers
Break
Ergonomics in Illness/Injury Prevention - OSHA Activity
OSHA General Duty Clause, Red Meat Cutting Guidelines,
Proposed General Industry Guideline, OSHA Reform Act of
1991 - Stuart-Buttle
ANSI Z-365 Guideline Development - Day
NIOSH Manual Lifting Guidelines - Rodgers
Other Guidelines - Heat, Vibration, VDT Workplaces -

11:30

Lunch

1:00 PM
1:05

Ergonomics and the Americans with Disabilities Act (ADA)
ADA Provisions and Definitions, Implications for Initial
Hires and Return to Work, Job Placement Issues - Kornblau
An Industrial Physician's Perspective on ADA, Return to
Work, Light Duty, and Ergonomics - Parrotte
Break
Case Studies: ADA, Return to Work, Medical Restrictions,
etc. - Kornblau, Parrotte, Golden, Other Faculty Members
Adjourn
Reception

7:00 AM
8:00
9:00
9:30
10:00
10:05

2:05
3:05
3:35
5:00
5:30 - 7:00

Rodgers

Thursday, March 11th
8:00 AM
8:05

Qualitative and Quantitative Descriptions of Job Demands
Functional Job Descriptions - Essential and Non-Essential
Tasks - Kornblau
(716) 544-3587

�) )

CHAIRPERSON:

SUZANNE H. RODGERS, PhD

TOPICS:
Ergonomics and Legislation - OSHA,
'.''
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Controlling OvereHertion Injuries at rnor�

�Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Workshop on An Ergonomic Approach to Accident Analysis,

1Vebraska Safety, Health, and Environmental Conference,
Lincoln, NE, April 27, 2000, 1 :45 to 3:45 PM

A. Why Should We Look at Injury and Illnesses Accidents from an
Ergonomics Perspective?
1. Multiple Factors Contribute - Rarely Domino Effect
2. Opportunities Missed to Improve Job If Only Treat Behaviors
3. Get Away From Blame and Focus on Continuous Improvement
B. Gathering Data at the Site of the Accident/Injury
1. Non-Threatening Approach - Assume There is a Reason for Errors
2. 4 Areas for Investigation - Person, Task, Environment,
Organizational Situation
3. Practice Questions Using Case Studies
4. Measurements Needed
C. Job/Task Demands Analyses
1. Defining Tasks That Should Be Improved
2. Upper Limits versus Job Design Issues (Interactions)
3. What Is "Heavy"?
D. Finding Feasible and Cost-Effective Solutions to Reduce Risk
1. Using Measurement Data and Interview Data to Establish Root Causes
2. Job Design and Workplace Design Issues
3. Defining the Seriousness of the Problem and the Probable Risk
Reduction With the Proposed Change

�1zanne H .. Rodgers, Ph.D.

:_onsultant In Ergonomics

;9 Huntington Hills - Center
.ochester, New York 14622

(716) 544-3587

(716) 266-8749 (FAX)

An Ergonomic Approach to Analyzing Workplace Accidents

The field of ergonomics and industrial safety complement each other in
trying to find ways to reduce injury and illness risk in the workplace.
While industrial safety has focused on identification of hazards, education,
protective equipment, and guarding against hazards, ergonomics
emphasizes job, workplace, equipment, and environmental design fo reduce
overload, simplicity rather than complexity in equipment and information
design, and assists to aid people at work (such as manual handling assists,
special tools, automation or semi-automation, and computer-aided
processes).
In evaluating accident reports on-site, however, one often sees a large
number of strain and sprain events that follow this pattern:
Accident type:
Injury type:
Body part:
Unsafe act:
Hazardous condition:
Recommended action:

Lift, lower, push, pull.
Strain/sprain
··
Low back
Didn't lift properly
Heavy weight
Lift properly

A similar pattern is found for repetitive tasks where upper extremity
problems have been found:
Accident type:
Injury type:
Body part:
Unsafe act:
Hazardous condition:
Recommended action:

Repetitive motions
Inflammation
Hand and wrist
Rushed
High repetition rate
Rotate with less hand-intensive task

Even some laceration and contusion injuries follow somewhat predictable
patterns in accident reporting, such as:

'

.·;

Accident type:
Body part:
Unsafe act:

· Struck against
Elbow
Not paying proper attention

�nio�h/ergo conf/Plenary Session II/Welcome
.

1/10/12 12:57 AM

NOTE: This page is archived for historical purposes and is no longer being maintained or
updated.

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Plenary Session II
Suzanne H. Rodgers, Ergonomic Consultant

DR. RODGERS: I'd like to start the Plenary Session, Focus on Effective Programs in Small Business.
I'm Sue Rodgers, and I'll be speaking first on a general basis.
Carol Stuart-Buttle is a consultant in ergonomics out of Philadelphia, and she is going to be our last speaker.
David Carroll from WoodPro is going to be our middle speaker. David is a small businessman who is going
to be talking about his program. Carol is going to be discussing three projects that she's worked on in small
businesses as well.
I have a handout for my comments that is copied on two pieces of paper with eight pages of text. This means
that you wouldn't be able to read it in this room, anyway, and, therefore, I set it around the sides of the room.
There are 300 copies, so I'll watch the stampede at the end to get the material. It's also, of course, going to be
included in the proceedings when those are available.
("-�'tle of you may look at me and say, "Well, why is she talking about small businesses?", because I mostly
�-,,fk with large corporations. But what I've found in my own practice of ergonomics is that the large
corporation is made up of a lot of small plants. Each of them has to deal with budgets. Each has to deal with
resources. The difference, perhaps, is that the large corporation can provide corporate resources, and the
small plant doesn't always have that luxury. What we decided to do is to make sure that we covered the things
that are common to small plants and large corporations and to small businesses, generally.
I had asked Carole Hunter if she could speak on the program because she has a unique approach, I think, to
small business ergonomics. She was kind enough to say yes, and then, when we thought we had too many
speakers, she was kind enough to pull out. And now she's here, but she said go ahead. So I want you to
realize that she is not missing from the panel because she's not willing to speak but because she's giving us
some more time for questions and answers. We want to leave about a half hour at the end of our comments so
you can ask questions and share your own experiences with us, particularly the small business people.
If you look at the handouts you got with the program, one of them is the Meat Packers Guideline, the original
Guidelines for Ergonomics in the Meat Packing Industry. I know this isn't new to any of you. What I'd like to
do is to go back to this and take a look, particularly at Parts I and II. As you know, the first one is
management commitment and employee involvement with some subsets. The second one is program
elements, which includes worksite analysis, hazard prevention control, medical management and training
education.
· Rc:&gt;ger Stevens and the OSHA group put out their straw man (I call it) back in July of '92. It was a general
bnomics guideline and Roger very intelligently put on the top "Not for Circulation, Do Not Distribute,"
\vnich meant that within a week every company in the country had a copy of it. I would like to go back to that
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particular document because I think it has the ingredients that all of us agree ought to be in a good
ergonomics program.
/.-.,,

�--. )at I thought I'd do this morning is just take the two that I find the most challenging -- well, actually, one I
find most challenging -- and this is, getting management commitment; and, two is: getting real employee
involvement. I'll share with you some of the things I've learned over 28 years of trying to get people to buy
into ergonomics in small as well as large plants.
Let's·Start with management commitment. We had some good comments yesterday about how to get that. I'd
like to share with you an approach that has worked very well for me. It takes no money, is done in a meeting
or session where you may be able to get the management team together, such as in a morning meeting. It
works very well in large groups, so I'm going to make you do it, too.
If you could all stand up, please. Thank you.
The best way to get commitment is to feel it, to feel what it feels like. Now, if you could take your left leg,
please, and raise it 45 degrees. Quality performance is keeping this leg at 45 degrees and not holding on to
anything to do it. Okay?
Now, while you're doing that, I'd like to talk a little bit about management commitment and things we can do.
Keep it up.Your quality is falling there. Get it up. Get it up. Right.
Essentially, what I did in this particular situation was a spur of the moment idea. There was a speaker before
me who was from the corporation and was telling a group of managers in a large subdivision why they should
1
------doing ergonomics. He had all the statistics, and he was going through them.

l

)

The trouble was that it was 1:00 in the afternoon. We were in Europe, and they happen to have nice big
lunches in Europe, and everybody was sort of, you know, looking as if they'd never quite make it through any
talk, not to mention the one with statistics. He finished his talk, and turned the audience over to me, and here
I am now supposed to be talking about ergonomics.

Larry, get that foot up again, there. Thanks. Come on, front row. Get those legs up.
I said to myself, let's get them up because they've been sitting for a half hour. So I got them up and asked
them, to raise a leg like you are doing now.
I had five benefits written on a transparency that I was showing, talking about "Why Ergonomics?". I spent a
lot of time on the first two points on accident and illness-injury prevention, and on peoples' improved ability
to perform. Then, I had three more points, which I finished up quickly about things related to reducing errors,
increased flexibility, and better utilization of peoples' skills.
I finished my five points. Then I said, "Okay, You can put your foot down." So you can put your foot down.
And then I said, "Can you tell me the last three points I made?" Absolute silence in the room. I said, "Well,
why can't you tell me? Weren't you listening?" They said, "No, we were concentrating so much on the
discomfort of holding that foot up, that we weren't listening.
\

'--,._lid, "Well, you're telling your people to do quality work, right? You say, do good, quality work; and you've
got them sitting around with one foot up in the air all day. How can they do quality work?"
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And all of a sudden I could see the lights go on. It's the same thing that was mentioned in yesterday's session
by Eric: Quality and ergonomics are directly related. If you hurt, if you're uncomfortable, there is no way you
(\put all of your attention to quality work; and that hit the chord. That was the thing that they needed to
(,__,A-. From then on, we had clear sailing.
You can sit now.
The point is that they knew they were weaving and bobbing; it wasn't me telling them they were
uncomfortable, it was them feeling it, and they understood what was going on.
Another time, I was talking to a plant manager who had just been berated by the corporate safety director
because he had a lot of injuries in his plant. When I say "a lot," this happened to be a good safety program,
and a lot to them was three.
Again, after being told that he really hadn't done a good job on safety, and he had to get busy, he was getting
madder and madder. You could see him holding his anger in because his job was get the product out and to
do it as safely as possible. He was not happy with being raked over the coals by the corporate safety director
in front of other people. This had gone on for 15 minutes and he was really quite angry, which I could tell
because his ears got very red -- he was sort of a fair complexion, and his ears just got totally deep red.
The safety director turned the meeting over to me. It's sort of like having a bad warm-up act, you know.
You're sitting there saying, "Gee, how am I going to get his attention?"
So I changed the discussion over to quality, and I said, "You know, one thing that ergonomics really does for
(-�s to make it easier to do quality work.", and I talked a little bit about examples that we had seen in the
\_-lit of things that made it hard to do quality work.
The ears got whiter and whiter. Not white, white, but they became less and less red, I should say, again
showing me that we had hit a point. He could understand how ergonomics interacted with what he was being
asked to do, which was to get a good product out the door.
So, again, management commitment to a large degree comes from understanding how ergonomics can
positively influence all of the goals of the company; not just the health and safety goals, but the performance
goals of the company as well.
I haven't met a manager yet who wants people to get hurt. It's just that they've got to understand why some
people get hurt and some don't. It comes back to the word "cause", the job causing the injury. If the job
causes the injury, then why doesn't everybody get it? And that's in the back of their heads when they're trying
to understand why suddenly, after doing the same jobs for years, we've got a lot of people getting into
trouble.
They really don't understand that if the job causes injuries why there aren't more of them around. As you
know, even when you have a problem, the injuries/illnesses are seen in just slightly over 10 percent of the
workers.
So that's my basic message on management commitment. Get them to feel it, get them to understand. I like to
r .· · ,id about an hour with them the first day I get there and just ask them questions about what they have to
\-domplish that year, and what are their goals. What are the things that get in the way of meeting their
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goals?, and how can ergonomics help them get there. It's very much a partnership when you start getting into
the ergonomics program. It's not all injury and illness. A lot of it is performance related.
(�the same reason, I talk about fatigue rather than causing injury. The reason I talk about fatigue is that's
performance related. Everybody knows that you can be tired on some jobs, that you have to stop and break in
order to get recovery on some jobs. Those are the ones that they can very often do something about through a
management policy or a management process that makes sure that we don't have jobs out there that create a
quick fatigue, a muscular or a mental fatigue that may lead to an injury, or error.
What we see there, too, is that they can identify this themselves, particularly with the meaner, leaner things
going on with downsizing and not adding staff but rather trying to find other ways of getting the job done.
They feel this themselves, and they'll talk about it. Once they take ownership of the fact that those are
problems that need to be addressed, they're very good about supporting the process.
I'll have to say that OSHA citations have always been an effective way of getting management commitment. I
guess I'd rather not get to the point where they have to get a citation because I'd like to think that they were
good enough before that, but it certainly is a form of clout.
One thing I noticed, and maybe you noticed, too, was that after the failure in March of '95, of the proposed
standard, there were some people who said, "Let's coast for a while now." Fortunately, the ones who had been
doing some ergonomics, generally realize that it has benefits that make it something that we want to
continually do. But, there was a pulling back by some people who thought of this as a necessary evil. I'd
rather do it because it's the right thing to do, rather than because you're going to be punished if you don't.
T1 main thing I've learned also, and this is both management and employee involvement, is to be teach
\__Jple to ask a lot of questions. I know somebody could probably argue that a consultant's job is to provide
information. I find that my major effort is to ask the questions, to have them find their own information, to
help them structure what they need to do and to help them structure the information, or find the information
that will help them know how much they need to do.
These are things we were talking about yesterday, how big a problem is it? what are the problems you need to
address first? and things of that sort. I think it's sort of neat to be able to go in, just ask questions, and get paid
for it.
I was told, by the way, also, by the engineering teams that I've worked with (and it was mentioned again
yesterday in some of the sessions)that the hardest thing is getting into proactive ergonomics. It's the most
effective way to go, but it's very hard to do. Now, if you're a small company and you're getting some
engineering done, often that's by contract. In some of the areas I've worked in we've actually had the
contractors come in for the ergonomics training so they get that training, the same training that the teams are
getting on the floor; they are wonderful, especially in the class, because they have ideas on how to solve
some of these problems that may involve more mechanical skills or more technical skills.
You definitely need to involve the contractors in the ergonomics program or else you're going to spend all of
your time reviewing what they are doing and telling him not to do that.
When we had trouble getting engineering commitment inside a company where we were building the
( )nomics teams in the plants, we wrote a policy that the engineer had to go talk to the inside team about
)tuything that was going to appear in their area. This was whether it was a workplace rework or a line rework,
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or a choice of major equipment they'd have to work on, and that would include the maintenance group as well
as the operators. That has been very effective where it has been implemented. Again, it's still a matter of
(1ng the process set up to be sure it happens.
Number 2 of the Ergonomic Process Needs: Employee Involvement.

·,.,. ___,�-✓

What I am going to show you here is the importance of the employee's input. Mark Johnson used this in his
presentation in the worksite analysis session yesterday, and because I didn't bring any transparencies, I'll put
it up for you. The basic steps in the problem solving part of the work analysis that we do are simply to
identify where the risk factors are by body part, and then the second column is what's called Causes on this
form, is the "Why?" column. If I see that somebody's bending over, and I've identified that that's more than
just a short duration bend, in other words, it takes maybe fifteen to twenty seconds or even more, then the
question is "Why are they bending?".
The first thing that I do when I have a lot of people looking at and analyzing jobs is, "What do you see?".
And they say, "Well, the workbench is too short or it's not tall enough." That's not what you see, right? That's
what you're inferring from what you see. What you see is somebody is bending over. It's very hard to get that
process going where they describe what they see first, and therefore, define the risk factors for the body parts
at risk. The risk is continuous or sustained bending. Now, Why do they do it?
It's not just because the bench is too short. It may be because they can't see what they need to see, and
therefore they have to bend over to get within the right distance to be able to see it. It may be because they
can't reach what they need to reach or can't use a tool properly without bending over. They all may have a
relationship to the higher workbench, but they aren't necessarily only related to the workbench height.

�"

�:..--/bu can define the posture and the risk, and then you look for all the possible reasons why they might be
bending, you begin to open up a very global way of approaching these problems.
In the final column are strategies or methods to reduce the stress of the risk factor. Those are our strategies
for making it better. How do we make it better?
In a generic sense, the risk reduction strategies for physical effort are: reduce the effort intensity; reduce the
time of the effort before I get a rest break from it (i.e., a muscle rest break); reduce the frequency of doing it;
or reduce the total time I do it before I move to some other activity that does not use the same muscles in the
same way. So there are several generic ways of reducing the risk.
This is where we begin to generate our solutions. As we are analyzing our job, we are also identifying
strategies that will begin to reduce the stress. What you will find is that when you do this for the body parts,
even the ones you don't think are affected, you often emerge with some generic ideas for directions to go that
will fix the problem in many parts of the body, not just one place at a time.
I'll walk you through the video that Don showed yesterday using those basic concepts.
This is a gas stove manufacturing line. What do you see as you watch people working on this line. What
strikes you as you see it? I need some of you to volunteer here. The thing you notice the most as you watch
this.?
\�IENCE: She has her head in the oven.
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DR. RODGERS: Yes. It's been a long day. Yes. She has her head in the oven. Fortunately, the oven's not
connected.
()ow would you describe that in terms of risk factors?
AUDIENCE: Bending over, bad light.
DR. RODGERS: Bending, poor lighting is a potential problem. Why is there poor lighting, by the way?
AUDIENCE: No light in the oven.
DR. RODGERS: Y6u're right. Okay. And they're not even hooked up electrically. This is a gas stove so we
don't need to have electricity, right?
The point is that she is having to reach in. It's really the reach, isn't it? What she's installing is the coil on the
back side of that oven. And she has to reach in because she's doing it at this point on the line, for one thing.
When we first showed this, I asked, "What do you see?"; and what do you suppose they said?
AUDIENCE: The conveyor is too low.
DR. RODGERS: The conveyor is too low, right? Yes. Why is the conveyor too low, because she's having to
bend over. Right? If she isn't bending over because the conveyor's too low, why is she bending over? Because
the reach in is so far that she has to bend over to be able to reach the back side. That's one issue. The reach in.

(�.)l you can say, "Well, why does she have to bend so far?" Did you notice the cardboard in the front of the
Mnveyor? That projects another four inches out from the conveyor side. It's moving, as you may be able to
tell. That's part of what keeps her away, too.
But the other thing that keeps her away is the fact that she has to reach so far and she has to be able to see
what she's doing. She can't do this blind.
We use these tapes in training courses so that when we finish the training course the teams have five projects
that they can proceed with. We expect to have their solutions implemented within about one to three months.
In this case, it was implemented in about a day.
We identified this as a bending risk, and there is repetitive motion, too. There is vibration and there are
several other things, too.
Give me another part of the body that you might be concerned about here.
AUDIENCE: Wrist and hands.
DR. RODGERS: Okay. What's the risk?
AUDIENCE: Strong wrist angles.
.

';. RODGERS: Okay. Awkward wrist angles. There's vibration, too. So you would like to find something

\rdt would help resolve those issues. As you can see, she has a slight twist in her back as well in order to

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reach that point with the air gun.
��t, we went through the "Whys", and we came up with the fact that the basic problem is the reach to the
� ), which is what is driving a lot of the postural elements, so we said, "How can you avoid reaching so
far?" Some people looked at the cardboard and said, "Let's not have the cardboard stick up; bend it up, and
put clips on the edge, so that won't be a problem." What would you have to evaluate that against? Is it really
better? We evaluated that against standing forward reach capability at that location, and it turned out that we
really had to get the reach within 12 inches to avoid bending. So it wasn't going to work just to bring it four
inches closer. We had a 28-inch reach on that job.
We could look at it in terms of the time of bending. What would you do there? What strategy could you use
to reduce the time of bending? It takes 17 seconds of bending out of every 30 second cycle now.
There is more than what determines how long you have to stay bent over? Just think generically now. Type of
fasteners, right? How long does it take to shoot a screw? Only a few seconds; but she has to be there longer.
It has to do with locating and finding things. So anything you can do to take time off that would reduce the
bending time and risk. A lot of people wanted to tilt the conveyor to fix this job; but there is other work going
on that would be impossible to do with a tilted line.
The final result of this was when the team whose job this was -- and, believe me, I didn't suggest this -- came
in with their solution. They said, "There's no reason why we can't put that coil on before we assemble the
oven. So they moved the operation up the line about five places, set up a fixture, put the part on the fixture,
and put the coil on at a perfect working height. The oven was assembled down the line, and none of this
awkward posture was required in this assembly. The fix cost them $47, if I remember correctly, the cost to
the fixture. That was it.

a

So for small companies, without big budgets, that's not really going to wipe you out, is it? That's something
you can put into your regular operating budget. It's the need to identify why there is a problem that I'd like to
have you think about. If you don't really analyze why that problem is there, and you simply look at it and say
you need to raise the conveyor, you are going to miss the inexpensive and very effective fixes.
I use anthropometric data and reach guidelines to compare what the job requires to what I'd like to have. I use
the NIOSH lifting guidelines and the version I made of those for the Kodak books that goes into the percent
of people who would find a lift acceptable for my assessment of how serious a problem the job is for a lifting
task. I use force guidelines, from Keyserling's studies and others that are published in the literature and again
in the Kodak books. I use those to evaluate the job forces I measure and to determine the degree of risk for
given muscle groups.You can identify how much of a problem it is and how much you need to change it
from the comparisons. Once you've done that, it's very easy for the team to come up with very creative ways
of fixing the problems.
Believe me, you have no trouble with employee involvement when you are asking them to use their expertise
to help in problem solving. My final point on that is, that if the employees are working together with the
engineers, and with the mechanics to solve these problems, there is a wonderful interaction that can't be beat.
It's much better than having a consultant come in, frankly.
.,A.�a full-time consultant, let me say that your use of a consultant, to my mind, should be to help you
( 'erstand what the problems are and to help give your team some basic knowledge about ergonomics and
hst factors for overexertion injuries. A consultant should facilitate your own talent or work with your
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contractors to be sure that they build these things into their designs as well.

JJ'- going to stop here, because I don't want to cut the others short. Just a final observation: empowerment

\___ es from both having knowledge and from having support from the support part of the staff, if you're a
person who works on a job like this. What I call it is control; that I feel that I have control of my ability to
work safely. That's what I shoot for when I'm trying to explain to management the importance of having the
teams be the primary people who do the job analyses; the support personnel are needed to help them to
achieve the best solutions.
It's wonderful to see the teams take ownership. I had an opportunity to teach a class where one person had an
M.D. degree and a few others had third grade educations and were functionally illiterate. The functionally
illiterate ones were actually better at problem solving. They didn't have all this clutter in the way of all the
things they knew!
So group problem solving of ergonomic issues really equalizes and builds respect for each other that is
needed to solve these problems that are both production problems, business problems, and health and safety
problems.
Thank you very much for listening to that.
My handout, by the way, includes -- I'll just tell you in case you don't get one right away -- two lists I made
up. One is the components of successful programs and the other is things that retard the ergonomic programs
and processes. I want to thank OSHA and NIOSH and the other sponsors for letting me get up here and
explain that I have made all of the mistakes that are under the second category.
C"11y, Carol pointed out to me when she looked at the handout that I had a human factors problem here. If
you get one of these, this is the first page. And then what you have to do is open it up and turn it over to get
the second page, okay? And then you have to tum it back this way to get the third page, and then you have to
turn it this way to get the last page, and this is a test.
The other material relates to securing management commitment and employee involvement; it was part of a
talk that I gave at Pat Devlin's CARE conference last year in Dallas.
And the final one is just a one-page thing I sometimes give to clients who are saying "It's all so confusing;
just give me one page." And I put that on the last page.
Thanks very much.
THIS PAGE WAS LAST UPDATED ON July 21, 1997

Return to
. CONFERENCE AGENDA

,:;

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ttp://www.cdc.gov/niosh/topics/ ergonomics/EWconf97 /ec4rodge.html

Page 8 of9

�Occupational
Ergonomics

.

'

Applied Ergonomics
A 1-Day Seminar for the Orthopaedic Therapy Clinic in Toronto,
April 8 j 1993
Syllabus

\

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH ANO SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Table of Contents

Topic

Starting Page

Capacity and Workload Detenninants .
Stress Sensitizers
Ergonomic Approaches to Reduce Injuries
Recovery Time Needs for Repetitive Work
How to Do An Ergonomics Survey ·
Examples of Questions to Ask About Jobs
Ergonomics Problem Solving Fonn
· Finding the Best Solutions
Job Evaluation in Worker Fitness Determination
Risk Factors for Carpal Tunnel Syndrome
Overexertion Injury Risk Factors
Risk Factors for Low Back Pain
Lifting Guidelines Problem Solving Graphs
1991 NIOSH Guidelines for Manual Lifting
Maximum Force Guidelines
A Functional Job Analysis Technique
Job Analysis Fonns
Computer Workplace Postures Checklist
Work Demands Survey Fonn
Postural Comfort Rating Fonn .
Visual Comfort Rating Fonn
Anthropometric and Workplace Measurements
Chair Evaluation Fonn/Ergonomic Needs
Self-Help to Increase Seated Work Comfort
Examples of Workplace Assists
Risk Factor Analysis Form
Ergonomic Reasonable Accommodations
Resources and Vendors for Applications in Ergonomics
Problem Solving Fonns
Cost Benefit Analyses of Ergonomic Problem Solutions
Costs of Poor Design
Cost Benefit - New and Old Designs
Cost Benefit Problem Solving Form
References - S.H.Rodgers

1
3
4
6
12
14
16
17
19
30
33
34
36
38
40
41
58
60
61
62
63
64
67
69
71
72
73
74
80
86
90
92
93
96

Acknowledgements
The illustrations and tables on pages 36-37 are used with permission from Eastman Kodak's
Ergonomic Design/or People at Work, Volumes 1 and2 published by Van Nostrand Reinhold in
1983 and 1986. The tables, text, and illustrations on pages 40 and 68 are from Working With
Backache by S. H. Rodgers published by Perinton Press in 1985. The VDT workplace
evaluation techniques on pages 60 to 71 and the stress sensitizers on page 3 have been developed in
conjunction with Dr. Inger Williams. The article on pages 6 -11 was published by Thieme
Pub lishers in Seminars in Occupational Medicine in March 1987. The articles on pages 19-29 and
41 - 57 hav been published by Hanley and Belfuss in 1988 and 1992 issues of Occupational
Medicine: State of the Art Review . The material on the 1991 NIOSH Manual Lifting Guidelines is
from a talk by A. Garg and T. Waters given in Denver, CO in June, 1992. All other unreferenced
material in this syllabus is by Dr. S.H. Rodgers and permission to reproduce it must be obtained
from her.

�-- '

0
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Workshop : Ergonomic Job Analysis Techniques
A problem solving workshop on Sunday, September 29, 1991
at the Physical Medicine lnstitute's 4th International Symposium,
The Worker in the Workplace - Rehabilitating Musculoskeletal
Injuries, University of Toronto by Suzanne H. Rodgers, Ph.D.

Table of Contents
Job Evaluation for Worker Fitness Determination
Page 1
Ergonomic Job Analysis Forms
12
Table 2: Examples of Muscle Effort Levels
15
16
Table 3: Heavy Effort in Manual Handling Tasks
17
Table 1: Factors Affecting Grip Strength
18
Kodak Manual Lifting Guidelines
20
Ergonomic Problem Solving Forms
26
Finding the Best Solution to an Ergonomics Problem
Cost/Benefit Analysis Problem Solving Forms
27

r

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Occupetione 1
Ergonomics

Fourth Annual Conference on Reducing Work Injuries and
Illness Through Ergonomics, April 23-24, 1992, Iowa City, IA

G

Friday, April 24th Schedule
8:15
9:00
10:00

Implementing Ergonomics: Program vs Process
Ergonomic Job Analysis Techniques
Break

10:15
12:00

Job Analysis (continued)
Lunch (on your own)

1 :00
2:00
2:45

Generating Cost-Effective Solutions and Selling Them
Case Studies - Return to Work
Break

3:00
4:15
5:00

Designing With Ergonomics in Mind
Questions and Discussion
Adjourn

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS'.
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

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Accident

Analysis

Concurrent Session F from 1:30 to 2:45 PM; at
the Repetitive Motions Injuries Seminar, Thursday,
October 31, 1996 at the Radisson Inn, Rochester, NY

Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT ANO. PRODUCT DESIGN
3. HEALTH ANO SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Suzanne H. R_odgers, Ph.D.

' , ,

.

. Consultant In Ergonomics

.r �
"'.

}9 Huntington Hills - Center
· Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

An Ergonomic Approach to Analyzing Workplace Accidents

The field of ergonomics and industrial safety complement each other in
trying to find ways to reduce injury and illness risk in the workplace.
While industrial safety has focused on identification of hazards, education,
protective equipment, and guarding against hazards, ergonomics
emphasizes job, workplace, equipment, and environmental design to reduce
overload, simplicity rather than complexity in equipment and information
design, and assists to aid people at work (such as manual handling assists,
special tools, automation or semi-automation, and computer-aided
processes).
In evaluating accident reports on-site, however, one often sees a large
number of strain and sprain events that follow this pattern:
Accident type;
Injury type:
· · Body part:
Unsafe act-:
Hazardous condition:
Recommended action:

Lift� lower, push; pun·
Strain/sprain · /
Low back
Didn't lift properly
Heavy weight
Lift properly

A similar pattern is found for repetitive tasks where upper extremity
problems have been found:
Accident type:
Injury type:
Body part:
Unsafe act:
Hazardous condition:
Recommended action:

Repetitive motions
Inflammation
Hand and wrist
Rushed
High repetition rate
Rotate with less hand-intensive task

Even some laceration and contusion injuries follow somewhat predictable
patterns in accident reporting, such as:
Accident type:
Body part:
Unsafe act:

Struck against
Elbow
Not paying proper attention

�Suzanne H. Rodgers, Ph.D.

Consultant In Ergonomics
169 Huntingtrin Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Defining Injury/Illness Risk in Very Repetitive Jobs
Talk to the Rochester Area Rehabilitation Professionals Meeting, June 17,
1998, at the Gateway Center, Rochester, NY
Analysis Process
1. Observe job from far enough away to be able to see the whole body.
2. Ask questions to gather data about the job demands, production
expectations, amount of control the worker has over job activities,
and the provisions made for responding to increased stress because of
emergency orders, absenteeism, or vacations.
3. Identify risk factors by body part. Rate effort level for each body
part, based on the risk factors.
4. Determine duration and frequency of effort for each muscle group
for each effort intensity observed. Determine the priority for change
based on the 3 number rating. High and Very High Priorities for
Change are tasks that must be - improved.
5. If the effort duration exceeds 30 seconds, use the fatigue-curves to
assess the fatigue levels (Time before repeating). If the frequency
exceeds 15 per minute, go to the curves describing effort at different
holding times and compare the maximum recommended frequency
against the frequency on the job.
6. From the Priority for Change ratings, determine how much the task
needs to be changed to get it to a moderate or low rate of fatigue.
Generate several options.
7. Re-analyze the chosen improvement to be sure a new problem has not
been created.

�-I
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Ergonomics in the Workplace
A Seminar Sponsored by the Rochester Safety Council &amp; OSHA
November 19, 1990, Logan's Party House 8:00AM-4:30 PM
Robert Szmanski, Safety Supervisor, OSHA, Buffalo Area
Suzanne H. Rodgers, Ph.D., Ergonomics Consultant

Outline
8:00- 8:30AM
8:30- 9:30
9:30-10:00
10:00- 10:15
10:15-11:15
11:15- 12:00
12:00-1:00PM
1:00- 1:30
1:30- 2:00
2:00- 2:30
2:30- 2:45
2:45 - 3:15
3:15 - 4:00
4:00- 4:30

Registration/Introductions
What OSHA Is Looking For in Compliance Reviews
Risk Factors for Hand, Wrist, Arm, and Shoulder
Overexertion Injuries
Break
Ergonomic Job Analysis Technique for Identifying
Cost Effective Solutions to Overexertion Problems
Problem Solving Example
Lunch Break
Review of Jobs with Overexertion Injuries- Defining
the Problems- Group Discussion
Risk Factors for Low Back Pain
Guidelines for Reducing Overexertion Risk in Manual
Handling Tasks
Break
Problem Solving- Manual Handling Problems
Developing an Ergonomics Process in Your Company
Why ? Who ? What? How?
General Discussion/Questions/Summary

�Table of Contents
Topic

Page

Table of Contents
Risk Factors for Carpal Tunnel Syndrome
Work/Recovery Graphs
Ergonomic Job Analysis Technique
Table 1: Examples of Muscle Effort Levels
Finding the Best Solutions
Ergonomics Case Study Problem Solving Form
Risk Factors for Low Back Pain
Force and Location Relationship - Static Pull
Maximum Forces for Design
Kodak Guidelines for Occasional Lifts
OSHA Proposed General Industry Guidelines
Thoughts on Ergonomics Programs and Processes
Table 1: Ergonomics Program Elements
Overexertion Injury Risk Factors
Extra Problem Solving Forms
References - SH R

1
2
5
6
9
· 1O
11
12
14
15
16
17
18
21
22
23
25

Acknowledgements
The illustration on page16 is used with permission from Eastman
Kodak's Ergonomic Design for People at Work, Volume 2 published by Van
Nostrand Reinhold in 1986. The table and illustration on pages 14 and 15
are from Working With Backache by S. H. Rodgers. The table on page 5 was
published by Thieme Publishers in Seminars in Occupational Medicine in
March 1987. The analytical technique on pages 6 and 23 has been published
by Hanley and Belfuss in a 1988 Occupational Medicine: State of the Art
Review edition on Worker Fitness Evaluations. All other material in this
syllabus is by Dr. S.H. Rodgers and permission to reproduce it must be
obtained from her.

}.

�A Self-HelP';_Approach to
Improving Office Safety

Suzanne H. R:odgers, Ph.D.
Consultant ii:' Ergonomics
and
Inger M. Wil:liams, Ph.D.
Consultant in Computer Ergonomics

Rochester Safety Council
Ergonomics: Series 2000
November 13, 2000

/

'\

���It:
Rochester Safety
Council

Suzanne H. Rodgers; Ph.D

CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
(716) 544-3587 • Fax (716) 266-8749
Email SHAODGEAS@aol.com
169 Huntington Hills • Rochester, NY 14622

ERGONOMICS SERIES 2000

Reduci11g Strai11s and Sprains by Improving Ma11ual Handling Tasks
Greater Rochester Chamber of Commerce, I 0/2/2000 morning
Presenter: Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics
Outline
I.

Injuries and Illnesses Associated With Manual Handling Tasks
A. Muscle Strains and Sprains
B. Repetitive Motions Disorders
C. Low Back Pain and Injuries
D. Contusions, Abrasions, 'Lacerations, Crushes
E. Dislocations, Fractures

II

Risk Factors For Musculoskeletal Injuries in Manual Handling Tasks
A. Horizontal Factor
B. Vertical Factor
C. Vertical Distance Factor
D. Asymmetry Factor
E. Coupling Factor
F. Frequency Factor
G. Total Workload Issues

III.

The Design of Handling Tasks - Containers
A. Design/Selection of Trays and Containers
B. Handles and Gripping Surfaces

_.J,�':

'·

�C. Design and Handling of Bags
D. Handling Special Containers - Carboys, Drums, Sheet Materials
IV.

Defining Safe Lifting Guidelines
A. NIOSH Lifting Guidelines -1991
B. Lifting Guidelines - Rodgers/Kodak
C. One-Handed Lifting Guidelines

V.

Guidelines for Carrying
A. Short Carrying Tasks
B. Long Carrying Tasks

VI.

Guidelines for Pushing and Pulling Tasks
A. Whole Body Push/Pull
B. Upper Body Push/Pull
C. Push and Pull in Different Postures

VII. Problem Solving Case Studies
A. Single Lifts - % Finding a Lift Acceptable
B. Frequent Lifting-Total Workload
C. Warehouse and Storage Shelf Designs
D. Push/Pull of Hand Trucks and Carts
VI.

Techniques/Assist Devices for Improving Handling Tasks
A. Materials Flow Analysis
B. Slide Instead of Lift - Conyeyors, Slides, Air Tables
C. Assist Devices to Position the Handling Tasks Optimally Levelators, Lowerators, Adjustable-Height Tables
D. Assist Devices to Handle Materials - Hoists, Arms, Counter­
Balanced Devices
E. Assist Devices to Push/Pull Materials and Hand Carts/frucks

�-'-�"y
.. _:J,

,·

Ergonomics Series 2000, Rochester Safety Council
Reducing Work-Related 1\4.usculoskeletal Disorders

October 1011, Rochester Chamber of Commerce, Conf Rm D, 8AM to Noon

I.

A.

B.

C.

D.
E.
F.

Risk Factors/or MSDs
A. Postural Risk Factors
B. Effort Risk Factors
C. Other Risk Factors

II.

Ill.

A Functional Job Evaluation Technique
A. Effort Estimations
B. Holding Times for Muscle Effort
C. Frequency of Muscle Efforts
D. Total Time of Task
E. Priority for Change

IV.

A.
B.
C.

D.
V.

',\

\:,�
i

Outline
Work-Related Musculoskeletal Disorders (MSDs) - What Are They ?
Muscle Fatigue
Muscle Soreness and Inflammation
Tendonitis, Tenosynovitis, Epicondylitis, Bursitis
Carpal Tunnel Syndrome and Other Nerve Entrapments
Muscle Strains, Tears, Joint Dislocations
Back Strains and Disc Problems

��•�
"
-=
-====
==

.

=-==

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 • Fax (716) 266-87 49
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

Problem Solving and Solution Generation
Why Are the Risk Factors Present ?
How Much Does the Risk Have To Be Reduced?
How Can That Be Accomplished (reduce effort, holding time, frequency, total
time of effort ?)
How Will the Chosen Solution Reduce Risk (re-evaluate)

Prioritizing Jobs for Ergonomics Improvements
A. Cost/Benefit Information
B. Must Change vs Should Change vs Okay (Re.ct, Yellow, Green)
C. Pro-Active vs Reactive Ergonomics

�October 16, 2000

Reducing Work-Related Musculoskeletal Disorders
Table of Contents
Starting Page#

Topic

�;

Table of Contents
Acknowledgements

I

Work/Recovery Times for Static Muscle Work
Risk Factors for Upper Extremity Discomfort/Illness/Injury
Basis for Supervisory and Employee Awareness Training....
Table 1: Risk Factors for Discomfort
Table 2: A Self-Help Approach to Reducing Risk....
Table 1: Factors Affecting Grip Strength
Functional Job Fatigue Analysis
Table 2: Examples of Muscle Effort Levels
Discomfort Survey for Operators Working on Difficult Jobs ...
Table 3: Definitions of Heavy Effort
Ergonomic Problem SolvingAnalysis Form
Hand Tool Selection and Design
A Functional Job Analysis Technique
Extra Forms and Lists
Measuring and Setting Ergonomics Standards...

la
lb
3
10

I

13

20
21
22
23
25
26
27
29
46
end

Acknowledgements

The articles included in this syllabus are referenced on the front page of each. The remaining material has
been developed by S.H Rodgers, and permission to reproduce it must be obtained from her.

�SAE/ AS;SE �ALK
I
'1/k in Human Factors talk about the systems approach and
wonder why those in the safety field aren't using the tech­
ni.ques we talk about.

Why don't they? · Why aren't System

Safety techniques used?

S

1.

Lack of training?

Perhaps.

2.

Lack of motivation?

3.

Lack of usable data base?

Generally not.
Generally yes.

Whi lack.of data base�
A.

What you need isn't there.

A.

. Form used doesn't suggest proper investigation .

g Why isn't it there?

S

. Lack of proper theoretical con6ept�
Whj n� proper ·theoretical concept?
A.

Never thought about it.

As H. W. Heinrich stated in the 4th edition of his
book, Industrial Accident Preventibn (1959), w�i£h dates
back to 1931, the basic working theory of accident causation
since ·the mid 1920's has been what is frequently called the
"Domino Se-quence".

The "Domino Sequence" or "Doinino_Theory"

briefly stated, holds that�
1.

Injuries are caused by accidents.

2. · Accident are causeci·by:
a)

unsafe acts of persons
or

b)
3.

.

.

ex_posure to unsafe. mechanical conditions.

Unsafe acts and conditions are _caused by faults_
of persons.·

�..

:

4.

Faults .of persons are· qreated by environment or
acquired by inheritance.
pg; 4, Inq.:ustrial Accident Prevention
Heinrich, 1959} ·

As you �an tee, it is .person centered.
.

.

·. ·Heinrich goes further to state that 88%· of the causes
of failures Which-cause or permit accidents are due to

of

"U�safe Acts
.·

persoriall and only 10% are due tQ "Unsafe
..

.

Mechaniqal ·or Physical Conditions''.

The other 2%,. presumably

t.he.se are acci.dents. that rekult from i'Ac '.ts of God" or other
.

. ..

unassignable such· ca.uses other than the operator or the
physical conditions.
(Trilevel
.

Study

coriclusion;·

.

A recent study by Indiana University

of Auto Accidents, 1972) came to the same

.

�6% due to Human Error.

-As a theory of Accident Causation, this position has
.·

.

..

some serious deficiencies.

· As Dan Petersen remarked in his
.

.

book, Techniques· of. Safety Management,. ,iPerhaps ou.r inter.

.

pr�tatfon of this do·mino the.cry has been toonarrow'i.
The 16g!cal consequence 6i this ·theorf'is to 6rame the·
indi vidua.1 who was injured or was in charge, to the.· machine
that had the accident� -· This comes from· the fac-t tha·t our
attention is directed firs-t to the "Fault of the person",.
.

.

then. to the "Unsafe Act" o:f' that person_ (88% of the time)
and rareJy to the "Unsafe Condition" (10% of the time).
Since

Using this. approach, let.�s �xamine our 6ptions.
we·are blaming people :; then we must somehow modify ·the
person.

Modification
of people i's· a· difficult business.
.

can select,. t-raih,. fire or reas&gt;sign people.

.

Beyond that .,

We

�there isn 1 t much one can do.· People forget, they revert to
previously learned behavior.

Workers get tired, bored and

fatigued; they seek stimulation.
·risk seekers.

Some people are active

Accident investigations based on this theory

typically find the cause of the accident to be operator
error.
In contrast to �his essentially unidimensional approach
to accident �ausation, let us look at a multi-dimensional
approach,

This approach has been advocated by many people.

Gordon ( 1950) first advocated. the use of Epidemiological·
approach for accident analysis.

It is the cornerstone of

the System Safety Engineering technique.

The man-machine­

environment and all its possible interactions is the pro­
venance of this theory and what is known as ergonomics or
Human Factors Engineering.

Basically, ttie belief is that it

is more effe.ctive to fit the. task to the person rather than
th� other way around.
Perhaps some examples will better illustrate what is
meant.
In WW II it is said, .a number of student pilots trained
on a particulaF trainer.

They then transitioned to a fighter

aircraft .. About 400 of them c�ashed.
vestigated.

Each crash was in­

In each case the pilots has retracted the flaps

rather than the landing gear immedi-ately upon take off.
This was attributed to pilot-error, as it most .assuredly
was.

The basic problem was not really the unsafe act of' the

pilot so much as it was the basic design· of the controls of

�the airplane.

The relatiyepositionof the controls for the

landing gear_arid flaPs were s�;itched in-the fighter as
compared to. the. traine:ri.. This meant 'that. the previously
acquired behavior of reaching over and grabbing the lever: On
the left which used to retract the wheels now retract::3 the

.

.
This&lt;is s,ufficient to ruir:i yo.'i.ir whole d·ay:.. ·• This is

. flaps.

-

.

.. ·

. .

.'

·,

.

.

.

.

the Classic l!negativ� transfer of training;" itoI'y.
· · - _ There are · many examples, one· might exaririne a,t thiS
point, but. the point I want
.

-...

-·

to

.

.·

'

.

-:

.

make is· that no Ina.tter how

·:

much: training; and selection you do' a ·poorly designed work"'.""
place .or Job ig just
to happen.

art

a_cciderit wa.iting for a. place .or. tirne
'

Alan. Swain refers to the desired ·end point a.s a
'

''Safety Prone· Sit�ationll (SPS} making .situ.ations ''safety
.

.

prone" and

..

11

.

faiT;...safe11 rather thari the oth:er waY shbul¢i

·_._ always be .our' goal. ·
I doubt that anyone here will quarrel with what·r·have
said_ thus far.·

Many.of you are very possibly saying at this

· point ,, "I've heard all· this before".

This is true, but what

have· we 'done .aboUt it?
Whether we realize it or not, our th.inking has been
unconsciously ·shaped lJy the• DorninO Theory rather than the
· mu.I ti�dimensiona1 .. theory.
.

I sugge:st that there are four

.

.

reasons w:hy we are thu� inf1uenced.
1st

..;

it is just human natur,e to blame what appears

to

be the-active operator when something goes

wrong.

All of our wester_n cultur-al heritage says

t.hat we are the masters or· Our destiny,. there,..;
fore, if something.goes amiss, it must be our

�fault.
2nd

Our legal system is geared towards the deter­
mi�ation of r�sponsibility, fault and blame.

When the police investigate an accident, they are

not trying·to find out what ciused the accident

so much as they are trying to determine the

individual who.will be held responsible for the
accident.
When a lawyer starts a case, they generally want
to know who is at.fault, who was negligent, etc.

Workman'S compensation is geared towards compen -­

sating the worker and penalizing the company and
only incidentally in removing the causes_of the

accidents.

3rd - For manage�ent, it is easier to blame the worker
than to accept the fact that the-workplace,

procedure or environment might need improving.
4th-- The very forms that we use when we investigate
accidents are modeled after the domino theory.
The major thrust is to identify the person that
did the unsafe a.et, ·rather than find the aspect
of.the job that contributed to the accident-or

the environment that disposed the individual to
-have the accident.

�Let us now examine in somewhat more detail what.the
implications are.for these two approaches as they pertain.to
accident and injury intervention strategies.

1) The domino

theory would have us fire, retrain or otherwise modify
operator behavior, 2) Most of tis are familiar with the

concept of "System Safety Engin.eering 11 , the application of a·
logical, step�by�step approach that systematically examines
, the whole system.

In this approach, the· human (as an operator,

mechanic or whatever) is merely a subsystem �ithin the t6tal
system that includes' the machine/tool or job subsystem as
well as the environment subsystem.

Classic Domino Theory

can be seen then to be subsummed within system safety engi..,.
rieering as the human subsystem.
paper,

11

John K. Gordon'simportant

The Epidemiology of Accidents 11 (American.Journal of

Public Health, 39:504-514, 1949) was the first detailed

analysis of the notion that accidents involved more than
just a person doing an unsafe act.

Accident Research (Harper

Haddon in his book,

&amp; Row, 1964) expanded this concept

and in subSequent writings has developed a 3xJ matrix·

(morphology) which can be very useful in a systems approach.

Each box has its·own appropriate intervention strategy.

Haddon's approach is a very broad one that has as tts ob­
jective to reduce losses due to injuries rather than .merely
preventing injuries. Haddon has evolved a set of 10 counter­
measure strategies that encompass the system safety concept
rather well..

We need to think along the
. se lines if we want to use
.

'

.

.

other HA1AYwAnalysis Techniques such as F.T.A., P.H.A., etc.

�T·his. 3x3 morphological approach lends itself to total
system analysis by subsystem and phase of the accident.·
Haddon implic.itly

takes Swain's concept that it is better

to analyze hazards than to.investigate accidents.

Hazards

are accidents waiting to happen-'-cari we afford another 747
or Titanic or Turkish Airlines DC-10?
This brings me to a major point -- why and how we in­
vestigate accidents and what do we use
form 101)

to do it?

·. We investigate accidents because we have to.

(OSHA,
OSHA

requires it, various state laws require it, the insurance
.

.

.

,carrier requires it, company regulations require it.
investigate accidents to find out what happened.
want to know what happened?

We

Why do we

In order to fix blame and

· •· ·responsibility--was anyone negligent?

Who is going to pay

for this, is the company liable for anything--is anyone due
compensation, and perhaps-:...what can we learn from this so
that future occurrences can be prevented.

It was not by

mistake that I put.that last, because all too often that is
just whe:re it comes in the real world.
How dOwe investigate accidents?

Take a look at your

�typi�al accident; report -- form.

Here is ah ·improved format

}

qh_e that has- check-off' spaces rather than reqt{iring narrative,
but is still bc1sed. OJI Domino rather&lt; ttiah· Systems.'

Wl1.at is

on it? . HowmJJch SI)a�e is ·a.evote_d to J:}erson data .:.. -i. e. , who
..

.

.

was hurt,' Whgt ·sorts bf in-juries' who was gt. fa_ult,. etc.,
.

.
•,

. .

hOW much ls Used to d.esc,r:lbe the Job; the j.ob aids, the
.

.

.

..

.. '

.

.

enviro'nment, the wodcp1ace ,.• the qualit; Of

environment?-

.

working

trie

Let tis go ,back to' the, Haddon: 3x3 matrix and see vthat -

_a typical

part of Jt· is covered' by

No.

ae:cident fo'rm.-

101, Which ·is basically the AN�T �-17

mended form is :probably_the most widely
country·.

or· the

used

The _OSHA,

NSC re com-.

form in this

What iS on it?: _There are· 19 questions Or sets of
.

blanks, divided into 5 sections:
.

· Section
I

·Questions
.·
1 ..,. 3 -

II

IlI.
IV

10-13

Sections.III

··-•19

&amp;

'

.

..

, Content

identify the employer __

relate to the injury

is the ··name of the physician

,

is the name of the hospital

IVare the only sections where real

infor_matioh might be generated---a total _of 8 items.

. ..

examine. each:,
10.

11.

·..

relate to·the accident

··· 14..:.17

18

.

.

identify the eciploy�e

4-9

V

;

·'

place of accid�nt (street a�dresS)

was - employee

..

.·

on premises

.

(yes

or
.

n6)

Let us

.

�12.· .Wh�t was employee. doing whE!n it1Jured (narrative)
13.

How. did ._· acc:i..dent . occut ·{narrative).

14; · . de�cribe_ injury &amp; indicate· part of body affected·

· 15.. Name obJect o.r su,bstance that injured employe.e

i6.

17.

pate

did employe_e ;die? (yeS or ·no)

12, 13,. 14 and: 15 are ,;eally the only questions that

generate any potentia'lly useful data. '·Withou� �ny real: help.

froni the :r6rrri, w� &gt;see that' our atteriticm is• dtr.ected _. to what
th� employee wa,s doing .. And most likely,
wiil only h�ar

we

about whattookplac� during the accident •. Thia.only covers

. . one of the nine areas identified by Haddon. . The. object_ or
substance is idE;?n�ified but without special. attention,· we

.

will

. .

.

.. .

..

..

: .

_nbt find b,tlt how i_t is related to anything else..

Nothing in the form directs our attention di!'eCtly to

any.

:fcl.cet · of· the envfronmerit or job or tbol or machine that may

have"en:abled 11 the �ccident in the first place.

Nothing

suggests that we. should iook at the ppa�es of the sequence.
-

.

·.

_ l'J&gt;Othing. makes us aslc not orily • i'what was. the worker doing?!'�
but a.lso !'why did the worke,r dc)what he/she did?" This is

-. really the crux of the problem.

The current form channels

. our thinking fl.long rather narrow paths. . Let us·. look at an
improved form that does look beyoricl just the worker.

Pope's Dept. of: Interior Torm).

(Will

Let us furthe� �xamitie··the·:�eijponses that can be made

to the unSare act and hazardous · condition categories, corner""" _·.
stones of Domj,no · Theofy �

In our recent analysis of these -

�types of qu,estions' we fotfnd the following&gt;distribution of
'

responses.,
.·

'

As you cah see, the categories of ''None.", ·"NEC",

•.

&gt;arid "inherently hazard;ous" • are the . categories of choice ..
This �bviously is not much help to those of us· t�ying to

determine what·· can .be done to pre;ent future occurrenc.es ..
It was in an eff·ort to correct
this that we started our
.
. .

.

.

.

effort to redesign the form.

.

.

, .

.

.

.

.

.

we·hoped to identi':fy aspects

of the opera.tor beha�ior, •· the job/machine br accident·. agent .·

and the environment that contributed to the occurrence of
'

the accident; ·. · From this we·· discovered ultimately that we
..

.

.

-

,··

:

·..

.

:

' heeded to readjust. our· entire
framework 6:t accid,erit causati6n
�
'

.

conceptj_bn;

: This turned out
.

:

to
.

'

'

'

be much more diff: ,cu];t than
i

we· had anti_cipai;;ed�-: We discovered many, rq�chanical problems,
for' example, that. the directions,' on tilllng

· .of

extrelJle importance-.

out' the. form

are

The instructions must.be as unambiguoµ.s

. and. clear as possible ..
.

.

.

In' an effort to dete'rmi:ne 'the . reliability of the. raters'
'
we. co�clu,cted inter..:.rater reliability studies. The results .
'

were eye ... opening�
analysi,s.
'

_There was noneed to do any.statistical

We sent out six acc:t dent scenarios, to. 9ver 100
'

'people who·. a.-r.e resporisib!e for' filling out accident reports.
We 'found :a lack of agreement ori almo.st everything.

The

degree ·of disagreement was not too bad with regard to.ob-'jective thinis such as ·agent of accident, but ev�nhere., we
found cause for conc.ern.

.It Was clear that not eve]?yone

·. understood the, . difference hetween .agent of injury . and agent
.
of.accident.
Our d:irectioris explicitly state that we only

�..
.· wa�ted. accident agertt,'. not injury agent., y�t in some qases,
:

.

·.

· ..

we got injury. not' accident.

Ac,V'

-:with_ regard to i'Unsafe

More sEi'.r'ious, was the pro.bl em
He-re

and "Hazardous Condition 11.

we·. f'.ound litt:le agreement and mµ,ch use of the "none'!, "NEc i ,.
and "Inherently. Hazardous" type response which.gives us very .
.

little to work with.·

..

. .

.·

.

.

.

Current: :forms :force you to think._t:ri.e

w.orker is at: fault, but the investigator i.s .not anx:ious. to
blame ;the worker.
.

Another problem .. Tn our· attempt to list· a.11 poSsJble ·
. . .

_

.

.

.'..

'

agents of accident and/or lnjury, we listed. ove·r JOO.. We
•. discovered that the closer an item-was

th�� beginning
.

to
.

.

.

.

.

.

of.
. .

.

People ·were

the list, the more lik�ly it was �o be chosen.

unwilling' to .tais:e the &lt;time to search the: .entire. list� they
.

.

.

••,,•·

.

··.

.

,

'

.

.

. ,,•

.

.

.

.. w.er� simply taking the: .tirst thing· th.at remotely carrie c1o-se.
So·, we had

to

"human-factorize" our list by g:i.Ving the major

categories&gt; in an·qrgaUizatiohchart format so_ that the
. .

:

.. ··.·

•,

••'

.·

.

perso_n fillihg :_out . thl form would first locate the general
category

and

..

.

.

.·

then search for the Specific�

We must cons:i.d'er/how the environment affects the operator/ ·
In·· much the same way, we a tteinpted to identify the

human.

ope;ator behavior characteristics.

Here we ask,ed not-only

what .did the;y do, butaTso why, in a two"'.""way matrix of what

and

why.

·....

:we are trying to tap the machine and environment yari.

ables by asking questi.ons about the nature of the.environment

as

,

·

it might relate to the accident.

We are trying to find

out to what d.egree the design of .the J&lt;?b, work�aids and.

�tools,,

etb.

relate to the accide�t.
.

.

.·

..

·.

···.;

_ ... _

.

.

.··

:·

.

·•

This is an dn�going effort. : We feel progres,s if3 b'eing

.,

. .

.'

made.

.

.

.

.

.

.

Our: finding.s· tO ·dat.� suggest that much attention.
.

.

needs .. to ·be directE=d in each. of the :following areas:

·
L ·. Design 'of a. form that forces·· the person fill_ing
.. oµt the form·to .•....t_hink•ih·. a systems.context ..
2.
... ·.

Directions for filling out. the · form must pe :-crystal·
clear 'and designed so that it helpS rather. than ·... '
·. hinders _locatii1g the . correct resp-onses to ·qµestio:ns
··
·
·
·
· on the form.
· ··
·
:

3.

_:

"

· .

·..

.

·,.:

.

.

.

.·The people fil�iilg. oy.t the forrns need to be moti,..
vated, .t.rained and knowledgeaole of the wbrk ahd
work area.
procedures rieed to be pre�tested and de;;.;,bugged
to. b,e sure you 'are getting what. you think· You are
getting. . ...

4.

All

5,

Meani11gful clata analysis starts with �a good
accid·ent report form •. The wrong form will pre,...·
dispose/prejudice the data base totally.

In clos·ing, let me share with you cornments frorn 2,000
Accidents,
· Risk inherent ·
Ac:c:tderit Rate - f ( work rate)
.

-�:xperience . •
·
'

.

.The Clear answer:

. Don't· blame the human until the

machirie and env'iro.11inent is cleaned up ,;:__.can't
. .

.

.

you cpange your theory of Accident Causation. •

..

.

do

this until

��SEHCOM '88

Safety, Environmental &amp; Health Communications Conference
Society Hill Sheraton, Philadelphia, PA
June 29 .. July 1, 1988
Agenda

Wednesday, June 29, 1988
11:00 a.m.-1:30 p.m.

Registration

1:45 p.m.-2:00 p.m.

Welcome -John M. Evans, President ITS Corp.

2:00-3:00

Keynote Address
Dr. Arthur Miller.Professor of Law, Harvard University

Law School, Legal Expert for ABC News - Current Trends
of Legal Exposure to Health Safety and Environmental
Professionals

3:05- 5:30

Focus Groups (concurrent)
Group #1 - Ted Trump, Manager of Training, ITS Corp.
-

How to Solve The Biggest Problems in Health
and Safety Training
- Effective Uses of AV in Training

Group#2

New Technologies in Training (Lecture/ Demonstration)

Group#3
Dialogue - A "one-on-one" opportunity to converse

with our producers, directors, market researchers and top
management personnel.

6:00 · 7:30

Opening Ni_ght Reception

Thursday, June 30 ,1988
7:30 a.m.- 8:00 a.m.

8:00-9:30

Coffee and Danish

Legal Perspective of Hazard Communication

William Ament, Esquire, Organizational Resource Coun­
selors, Inc.

9:35-10:40

Worker Notification - Lori Ramonas, Ph.D., Associate
Director of Health, Safety and Chemical Regulations,
Chemical Manufacturers Association

10:40-11:00

Break

11:00 a.m. -12:30 p.m.

Hazard Communication Update - . Louis S. Beliczky,
M.S., M.P.H., United Rubber, Cork, Linoleum and Plastic
Workers, AFL-CIO
Luncheon

*12:35 -2:00

�Guest Speaker- Film Recovery Inc. Trial - Jay C.
Magnuson, Deputy Chief, Cook County States Attorney
Office
2:05-4:05

OSHA 's Wall to Wall Inspection System (Work­
shop) - Raymond J. Colvin, President, Safety Training
Dynamics, Inc.

4:05-4:15

Break

4:15-5:15

Health, Safety and Ergonomics- Suzanne H.
Rodgers, Ph.D., Ergonomics/Human Factors Consul­
tant, SHR

7:00-10:30

Dinner Cruise on the Delaware

Friday, July 1, 1988
7:30 a.m. -8:00 a.m.

Coffee and Danish

8:00-9:00

The One World Concept: International Aspects
of Safety Health and Security - Dr. Glenn E.
Hudson, CSS, CSM, CSE, President, Director General,
World Safety Organization

9:05-11:05

Applications of Behavior Modification for Occu­
pational Safety - E. Scott Geller,Ph.D., Professor of
Psychology, Virginia Tech.

11:10-12:10

Environmental Issues and Trends From An In­
dustrial Perspective- Thomas J. Tuffey, Ph.D., Vice
PresidenVDivision Manager, econoENVIRONomics Divi­
sion, Roy F. WESTON, Inc.

*12:15 p.m. -1:45 p.m.

Luncheon
Congressman Joseph M. Gaydos, U.S. House of Repre­
sentatives, Author of the Worker Notification Bill

1 :50 -2:50

3:00-4:30

The UA w GM Team Concept &amp; Interactive Video
Training - James Howe and Kenneth A. Hulik, UAW-GM
Joint Health and Safety Subcommittee for Skilled Trades
Safety Training
Focus Groups
Repeat or follow-up-to Wednesday's Focus Group Topics

Spouses Program (Thurs.)
... Agenda items and speakers are subject to change up to the time of the Conference...

�Ergonomics, Return To Work, and Injury
Prevention in the Workplace
A 1-Day Seminar for Professional Physical Therapy,
Washington University, St. Louis, Mo,
Saturday, April 29, 1989
Outline of Seminar
A.- Defining Job Demands
1. Postures - Biomechanics
2. Intensity, Duration, Frequency, Energy Demands
3. Environmental Factors
4. Work Pace, Hours of Work, Accountability
B. Defining Worker Capabilities
1. Size - Clearance, Reach
2. Strength/Endurance, Joint Stress Tolerance
3. Aerobic Capacities - Whole Body/Upper Body
4. Visual Capabilities
5. Tolerance of Heat Exposure
6. Shiftwork Tolerance
C. Initiating and Performing a Job Review
1. Defining "Problem" Jobs
2. Surveying a Department
3. Collecting Data in the Workplace
D. Using Job Data To Recommend Change
1. Relating Job Data to Individual Work Capacities
2. Determrning When to Recommend Job Changes
3. Examples of Practical Job and Workplace Changes/Accommodations
(Repetitive Work, Manual Handling)
E. Case Studies

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�Ergonomics, Return to Work, and Injury Prevention in the Workplace
Table of Contents

r�\

\__j

Ergonomics and Return to Work
Industry's Needs/fherapists' Roles
Job Evaluation in Worker Fitness Determination

1
3
5

Capacity and Workload Determinants
Recovery Time Needs for Repetitive Work
Ratings of Perceived Exertion
Standing Arm Reach
Seated Arm Reach
Visibility and Quality Performance
Lifting Guideline - Occasional Lifts

16
19
27
30
31
32
33

How to Do an Ergonomics Survey
Equipment for Ergonomics Work
Ergonomic Job Analysis

34
36
38

Finding the Best Solution to Ergonomics Problems
Designing Jobs to Minimize Unnecessary Effort
Cost-Benefit Analyses of Ergonomic Problem Solutions
The Costs of Poor Design
Industrial Ergonomics Resource Materials - SHR.odgers

41
42
43

Problem Solving Form
Office Ergonomics Self-Help
Low Back Pain and Repetitive Motions Injuries
Risk Factors for Carpal Tunnel Syndrome
Risk Factors for Low Back Pain
Total Work Load Problem Solving Form
Carpal Tunnel Problem Solving Form

50
53

47

49

54

56
60
62
64

Acknowledgements
The material on pages 30, 31, and 34 is reproduced with permission of Eastman Kodak
Company from Ergonomic Design for People at Work; Volumes 1 and 2, published by Van
Nostrand l_leinhold in 1983 and 1986. The articles include references and are available through
their publishers. All other material belongs to Dr. Rodgers, and permission to reproduce it
must be obtained from her.

\,"-__;
.

\

�Occupational
Ergonomics

Institute VII: A Multidisciplinary Approach to
Occupational Rehabilitation, Society of Behavioral
Medicine, April 18, 1990, Chicago
A.
1.
2.
3.
4.
5.

Principles of Ergonomics
Ergonomics and Occupational Health
Work Capacities - Effort, Duration, Frequency, Total Time
Risk Factors for Low Back Pain
Risk Factors for Repetitive Motions Disorders
Ergonomic Job Analysis

B. Evaluation of Job Demands
1. Review of Job
2. Application of Ergonomic Job Analysis and Problem Solving Techniques
C. Work Re-Entry- Ergonomics Interventions
1. . Techniques to Reduce Low Back Risk
2. Techniques to Reduce Repetitive Motions Risk
3. Job Design Approaches

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�FEDERATION of NEW YORK SOLID WASTE ASSOCIATION
Solid Waste/Recycling Conference &amp; Trade Show

City of Rochester
Municipal Ergonomics
Solid Waste Collection
1987-2001
May 9, 2001

City of Rochester
Bureau of
Human Resource Management
Tassie R. Demps
Safety Coordinator
City Hall, Room 103A
30 Church Street
Rochester, New York 14614
(716) 428-6916
FAX (716) 428-6902
tdemps@mcls. rochester .lib.ny .us

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 • Fax (716) 266-8749
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

�The Ergonom1c Approach to Low Back Pain 1n the Workplace
by Suzanne H. Rodgers, Ph.D., Consu1tant in Ergonomics
A ta1k to attendees of a conference, Strateg1es to Reduce
Employee Med1ca1 Costs, presented by Eastwood Hosp1ta1,
Memph1s, Tennessee, June 17, 1986

out11ne
A What Is Ergonomics and How Can It Help Us Reduce Medical
Costs at Work?
B. Low Back Pa1n at Work
l. The Kodak Exper1ence - Dr. M.L. Rowe's Studies
2. Factors That Increase the Risk of Aggravating Low
Back Pain Symptoms
a. Workplace Design - Postures
b. Manual Mater1als Handling
c. Job Destgn - Work Patterns
d. Other Factors
C. Ergonomic Approaches to Reduce Low Back Pain D1sab1lity
1. Postures - Heights, Reaches, Vistbll I ty, Clearances
2. Manual Materials Handling Guidelines and Aids
3. Providing Worker Control Over Work Pattern
D. Case Studies
l. Work Height and Reach Requirements
2. Manua 1 Mater! a Is Hand I Ing
3. Work Pace
6/16/86 SHR
Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

�Ergonomics and Injury Prevention

Cumulative Trauma and Repetitive Strain Injury
Wisconsin Physical Therapy Association, Milwaukee, April 14-16, 1988
Ergonomics Support Materials for Sue Rodgers' Presentations
Topic

Pa2e#

A. Work Capacities and Factors Affecting Them

2

B. Individual Susceptibility For Repetitive Motions
Disorders

5

C. Factors Affecting Handgrip Strength

6

D. Evaluating Static Work Recovery Time Needs

9

E. Techniques to Reduce Job Risk Factors

14

F. Risk Factors for Low Back Pain

15

G. Height and Reach Interaction

17

H. Maximum Force Guidelines for Design

18

I.

Strength vs Location of Load

19

J.

Lifting Guidelines

20

K. Ergonomics Problem Solving Form

22

L. Technique for Ergonomic Analysis of
Repetitive Jobs

24

M. Industrial Ergonomics Resource Materials By or
Edited by S.H. Rodgers

30

3/13/88 SHR
Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Building Ergonomics Into Your Business
Talk to the Wisconsin Safety Council Annual Meeting, April 10, 1991
by Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics, Rochester, NY
A. Ergonomics and Safety Interactions
1. Human Error Prevention - Human Reliability
2. Reduction of Musculoskeletal Illness and Injury - Work
Capacities
B. Building Ergonomic Analyses into Job Safety Analyses
1. Asking the Right Questions
2. Defining the Situation, Job Demands, Environment
3. Assessing the Risk of an Injury or an Incident
C. Reducing Upper Extremity Stress on the Job
1. Risk Factors for Injury/Illness
2. Defining the Job Demands and Muscle/Joint Stresses
3. Techniques to Minimize the Stresses
D. Reducing Overexertion Injuries/Illnesses in Manual Handling Tasks
1 . Risk Factors for Low Back Problems
2. Design Criteria for Ergonomic Lifting and Force Exertion Tasks
3. Techniques to Reduce the Risk for Low Back Problems

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�OVERVIEW OF PHYSIOLOGICAL RESEARCH
APPLICATIONS IN AN INDUSTRIAL SETTING
Suzanne H. Rodgers, Ph.D.
Health, Safety, and Human Factors Laboratory
Eastman Kodak Company
Rochester, NY 14650

20 minute paper for presentation at a symposium: "Work
Physiology: Industrial and Occupational Applications",
American College of Sports Medicine, Chicago, Illinois,
May 25-28, 1977.

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6

Iridustrial Ergonomics Resource Materials
Written or Edited by S.H. Rodgers, Ph.D.
Eastman Kodak Company Human Factors and Ergonomics Groups, Ergonomic Design for
People at Work. Volume 1 (ISBN#442-23972-6) Workplace, Equipment, Information
Handling and Environment Design, 1983, $74.95; Volume 2 (ISBN#442-23939-4) Job
Design, Methods to Measure Job Demands, Human Capacities, Work Patterns, Shift
Work, and Manual Materials Handling, 1986, about $74.95. Available from Wiley &amp;
Sons, Phone Orders 1-800-225-5945.
Rodgers, S.H. Working With Backache (ISBN#931157-01-3), 1985, published by
Perinton Press. $18.95 plus handling. Review of occupational low back pain problems
and techniques to manage and prevent disability from them using ergonomics
approaches. Sections on what the worker can do, what workplace and equipment
designers can do, and what management can do to reduce low back pain problems at
work. Available through S.H. Rodgers, Ph.D., P.O. Box 23446, Rochester, N.Y.
14692. Phone= (716) 544-3587.
Rodgers, S.H. (Editor). Repetitive Motions Injuries, March, 1987 issue of Seminars in
Occupational Medicine. published by Thieme Medical Publishers, Inc., Suite 1501,
381 Park Avenue South, New York, N.Y. 10016. Phone= (212) 683-5088. Series
was discontinued in 1988.
Rodgers, S.H. "Job Evaluation in Worker Fitness Determination", a chapter in Worker
Fitness and Risk Evaluations edited by Jay Himmelstein, MD and Glenn Pransky, MD,
Occupational Medicine: State of the Art Reviews, March, 1988, published by Hanley
and Belfus, Inc., 210 S. 13th Street, Philadelphia, PA 19107, (215) 546-4995.
Rodgers, S.H. "Matching Worker and Work Site - Ergonomic Principles", a chapter in
Work Injury: Management and Prevention by Susan J. Isemhagen, PT, published in
1988 by Aspen Publishers, Inc., 1606 Research Boulevard, Rockville, MD 20850,
(301) 251-8500.
Rodgers, S.H. "Metabolic Indices in Materials Handling Tasks", in Safety in Manual
Materials Handling, edited by C.G. Drury, DHEW/NIOSH Publ.#78-185, 1976,
Cincinnati, OH, pages 52-56.
Rodgers, S.H. and I.M.Williams "Improving Worker Comfort and Performance in
Computer Workplaces", in Modern Job Safety and Health Guidelines, September 16,
1987. NY City: Prentice Hall, 1987.
Geras, D.T., C.D. Pepper, and S.H. Rodgers, "An Integrated Ergonomics Program at the
Goodyear Tire &amp; Rubber Company", in Advances in Industrial Ergonomics and Safety I
edited by A. Mital, Bristol, PA: Taylor &amp; Francis, 1989, pp. 21-28.
Rodgers, S.H. and J.W. Yates, "The Physiological Basis of the Manual Lifting Guidelines",
in Scientific Documentation for the Revised 1991 NIOSH Lifting Equation, NIOSH,
Washington, DC: NTIS, Dept of Commerce, Document# PB91-226274, May,1991,
pages 1-55.
Rodgers, S.H., "A Functional Job Evaluation Technique", Chapter in Ergonomics, edited
by S.J.Moore, M.D. and A. Garg, Ph.D., Occupational Medicine: State of the Art
Reviews Vol 7. No. 4, October-December,1992, Philadelphia,PA: Hanley &amp; Belfus,
Inc., pages 679 - 711.

�.

'

.

"

2.
Rodgers, S.H., "Measuring and Setting Ergonomics Standards - Issues and Perspectives",
in Advances in Occupational Ergonomics and Safety I (2 Vol) edited by A. Mital,
Bristol, PA: Taylor &amp; Francis, 1996, pp 884-890.
Rodgers, S.H., Chapter II-10: Work Physiology - Fatigue and Recovery in Handbook of
Human Factors and Ergonomics. 2nd Edition. edited by G. Salvendy, New York, NY:
J. Wiley &amp; Sons, 1997, p. 268-297.
Rodgers, S.H., "Predicting Ergonomically-Acceptable Highly Repetitive Tasks", in
Proceedings of the Silicon Valley Ergonomics Conference and Exposition. ErgoCon
'98, San Jose, CA, May 3-6, 1998, pages 3�11.
Williams, I.M. and S.H. Rodgers (1997), "Workstation and VDT User Mismatch and
Working Discomfort ", Proceedings of ErgoCon '97 Conference, Silicon Valley
Ergonomics Institute, San Jose State College, San Jose, CA, May, 1997, p. 85.
Williams, I.M. and S.H. Rodgers (1997), "An Ergonomics Program at an
Emergency Communications Center", Proceedings of the 1997 International
Ergonomics Association Meetings, in Tampere, Finland, June/July, 1997, p. 483�
4/99 SHR

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
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j / (7

'

1

Vo !f9-&lt;v' '5'�
Expert Witness Testimony for the Proposed Ergonomicf Rulemaking
Hearing at DOL, Washington, DC in February, 2000
My name is Suzanne Rodgers and I have been working in the field of
industrial ergonomics for the past 32 years. My doctorate is in Physiology,
and my area of special interest in ergonomics has been to understand what
are safe and reasonable job demands for the industrial workforce. The goals
of my on-site studies have been to define physical work capabilities of the
potential workforce and to identify ways to design jobs, workplaces,
equipment, and environments to reduce unnecessary fatigue on the job. In
my 13 years at Eastman Kodak Company, I learned the applications of
ergonomics by being out on the production floor or in the field and by f&lt;• biJy,,)
measu�ip.� the metabolic, muscular, and cardiovascular demands of the)obs
_JY, c@� employee volunteers� I was fortunate to be inside a company
where I could study people at work and also learn about production needs.
In those 13 years, I was taught by the workers, their supervisors, the
engineers, the medical specialists, the skilled trades people, human resources
professionals, and my colleagues in the Human Factors/Ergonomics Section
of the Health and Safety Laboratory that jobs have to be looked at globally
to reach production goals without putting
in order to find th� J
M ;�
people at risk of g�fietmt occupational injuries and illnesses. From
our work with production employees and with engineers, we were often able
to find better ways to design the workplace, production equipment,
environme� an�tasks so more o� �chieved with less stress on
the worke�. � �o-v���e book, "Ei-�ic �esign for People
at Work" msl.ude.s_maP¥-,OLL�&amp;ncs--f0f--the design of Jobs and workiltg
�s tha� aeeemmo.date a large majority of the potential
iRdustriaLworkfo1ce. Much of my work at Kodak was spent developing
guidelines for safe workloads so that women and older workers would be
accommodated on some of the heavier jobs and so people with disabilities or

�,..

short-term work restrictions could get back to their jobs in a safe and
efficient manner. It should be noted that none of the stronger men
complained when we found better ways to help them get their work done.
Good ergonomics benefits everyone.
Since 1982, I have been a full-time, self-employed ergonomics consultant
and have had the opportunity to develop ergonomics programs and processes
with clients in large, middle-sized, and small companies and service
or�a�o� :Jld in a municipality. I did not start a consulting firm because��
1 ttiafthe best ergonomics programs I have been associated
Idlave ol1s:ewed
�s'7 � �
I with are those where the production workers are the primary problem
��
identifiers, analyzers, and solution generators. They must be supported by ''J..c '&lt;t:r ,·
the service providers in the company (i.e., the engineers, medical specialists,
supervisors or team leaders, maintenance staff, materials handling
specialists, and managers), but the ownership for ergonomics is with each
person doing her or his job. In smaller businesses, where the support staff is
thinner, thineed to solve ergonomics-related problems on the floor is even
greater. I found that I could train production workers and the support staff to
I think like ergonomists, and could facilitate them through a fairly simple
fatigue analysis or lifting guideline to a problem solving process that
generates several ways of addressing the root cause of the problem.. Taking
a page from Kenneth Blanchard, I moved from the educational model of
trying to stuff a lot of information into the heads of my course attendees to
the industrial training model of asking the attendees to dump their brain
contents out on the table and let me rearrange them � to incorporate the
ergonomics principles. By doing this, I found I could tap into the wealth of
knowledge that is present in the workforce for ways to improve jobs. By
assuring that the support groups respect and assist the production teams in
finding solutions for these problems, we also improve communications and
�operation in projects where health and safety issues are not paramount.

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In addressin the P osed Erg
start with my
ition fer ononu s:

like to

�"Ergonomics is the science of making it easy for people to do high quality
work".
To do high quality work, one cannot be asked to work in a way that will
generate large amounts of muscular or whole body fatigue or to do tasks that
are very heavy or are less heavy and are sustained for a long time. Even if
the damage does not show up right away, one cannot expect people to
perform at a high quality level if they are performing difficult tasks at high
repetition rates or over long work shifts without adequate time to repair
microtraumas to the joints or muscles between shifts. People's desire to do
quality work may put them at additional risk of injury or illness in these job
situations because they neglect the signs coming from the body that indicate
an over-exertion i�jury is developing. The long term costs of
musculoskeletal disorders combined with the increased longevity of the
population and increased health care costs add to the reasons why we should
take steps now to prevent unnecessary stress on the job.
It has been apparent to me over the past 2 years, especially, that most
companies are trying to keep ahead of the global competition by keeping
their workforce small and using overtime to cope with production variations.
The "downsizing" of many companies has resulted in many employees
holding more than one position and feeling unable to do quality work in any
of them. The use of overtime in production has made it harder to keep
ergonomic teams active on the floor because they are too tired to take on
another ("unpaid") responsibility. They still have to get their work done. I
think this situation is coming to a head, and we need to find better ways to
get high individual productivity without putting the workers at risk of injury
because of accumulated physical and mental/perceptual fatigue. I believe
that the implementation of a flexible, work practices, ergonomics standard
can be a positive step in the prevention of occupational injuries and in
optimizing the design of problem jobs. It is not difficult to get the priorities
for health and safety overwhelmed by the business's need to keep market

�share in today's economy. By allowing companies to develop their own
ways of incorporating ergonomics into their operations and measuring their
effectiveness in decreasing the occupational injuries and illnesses, the
proposed ergonomics standard can help to underline the importance of
health and safety priorities in parallel with production demands.

Scope of This Testimony
In the remainder of this testimony, I would like to address the importance of
several of the basic program elements, including management commitment,
employee participation, job hazard analysis techniques, training needs,
implementing changes, and program evaluation. My testimony is based,
primarily, on my experience of building ergonomics programs with
companies and working within a company. I have been in a position to
learn about almost every mistake I have made over the past 32 years because
I often work with a client for several years as we build the program and
change the culture about ergonomics and teamwork on the production floor.
However, I think that there are many ways to do ergonomics in a company,
and each company has to find the way that best !its their re��urces, staffing,
and health and safety problems. The �roposed e;.gonomic�tfodard and
several OSHA and NIOSH documents provide guidance for those who want
more information. The basic components of a successful intervention
program that are spelled out in this document are fairly widely accepted in
the field, even if specific details may be problematic to some businesses.

A. Management Commitmcn.�
The Proposed Ergonomici§tlindard includes a basic requirement for
/\
evidence of management commitment to having an ergonomics process in
•
OCG�a'.U�
•
place m a company whereAmm;culoskeletal disorders asd oth@r oscupat1oeal
�es are seen. This commitment is usually shown through the
establishment of an Ergonomics Team, the provision of time for the team to�
meet, and provision of a budget to implement changes to reduce the risk of
injury on jobs where high risks are found. The commitment of management
i

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to the ergonomics program/process is critical beQause high risk tasks must be
q.,.j...(J.-j�
addressed and need priority when other peopl� such as maintenanc�Ji-1:
specialists and engineers, are needed to implement changes. With � the
production pressures already present in many companies, it is management
that can set the tone for when health and safety issues are addressed.
Without their commitment to ergonomics improvements to reduce
workplace risk, the best work done by the team(s) witi--eftefl fall short of the
implementation stage. Budgets should be adequate to allow simple
improvements to be done at the departmental level. Major improvements
with larger budgets, such as the purchase of a new production machine or
vehicle, should be reviewed from an ergonomics perspective and be handled
through the customary channels.
If the company has a union, it is critical to get union support for the
ergonomics process, too. There is some concern that ergonomics
improvements result in a loss of jobs, and this perception is not altogether
unjustified. Removing jobs that put people at high risk of injury and cannot
be easily modified may be appropriate, but the goal of ergonomics
interventions to reduce the risk of musculoskeletal injuries and illnesses
. should not be to remove the people, but rather to improve the tasks for
people. The union leadership should support the involvement of the
production workers in the risk identification, analysis, and ergonomic
solution generation process since the people who do the work are the experts ,,
�- Cooperation is needed to find the best, most effective, and least
expensive improve�ts instead of throwing equipment at a problem11 .am1iiat is the challenge 'ff- a production-based ergonomics program. When
everyone is focus;ed on how to solve the problem, there is little difficulty in
finding good and practical solutions for it.
B. Employee Involvement
\
rd'.:s kaid ia-my in-troda� I have tried a number of formats for getting
ergonomics programs started in companies. They have ranged from
programs that taught p¢;1 process and industrial engineers how to fix

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ergonomics problems, to programs that focu¥ed on following up onafis�
the internal medical clinic for musculoskeletal complaints, to training hourly
employees to be the ergonomics coordinators in each department, to training
hourly workers to be the primary ergonomics team members with a
secondary Ergonomics Steering Committee that is made up of the support
group managers or supervisors and that assures that the teams get the
appropriate support as risks are identified. In observing programs that have
not had much staying power, the primary problem that I have identified has
been that the steps between identification of a problem and implement�!
solution have not involved the people who work in those jobs. Thi�hrowi.'!
it over the wall" to the engineers or maintenance people to solve the problem
usually results in a solution being generated that cannot be implemented
w.
because of som� factors tha� not known to them when they ec,mo out &amp;e:d
observ�he job-:t9Por example, a problem of getting a oro�r 2:asket assembly
wiJ:.ti �,t -fL..! tf&gt;«'�lw.s
and seal on a refrigerator door in one companyAwas associated with
increased reports of forearm and wrist/hand discomfort from repetitive
screwdriver use. Several activities had been tried to reduce the hand stress
including a partial automation of the gasket assembly with a small robot, but
there were still many quality problems that the line workers had to fix. Two
engineers watched the hand assembly work and decided that they could
make a fixture to assist the operators in holding down the gasket on the
frame so the screwing down task would be easier to perform. The fixture
was fabricated and presented to the operators about a month later. Although
the concept was okay, the engineers had not tried it out with the operators
and did not note that they were seated at the line. The fixture could only be
used if one stood up, and this was not a popular idea for people working an
8-hour shift. The operators appreciated the trouble that the engineers had
taken to help them work better, but they saw the fixture as creating new
problems for them, and admitted that they would probably use it as a door
stop. When the operators were involved in analyzing the risk factors and
defining the highest risk activities with the engineers and production
supervision in a subsequent training course, they were a� identify the
semi-automation as the area that needed attention so Iesu-ework of the

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�gasket assemblies would have to be done � llaatJ.. The operators could then
dedicate themselves to fixing the exceptions rather than having to fix every
assembly on the line.
The most effective programs I have been involved with in terms of
employee involvement have been ones where each department has a Safety
Team or an Ergonomics Team made up of 5 to 7 people, at least 60% of
whom are hourly workers. A maintenance mechanic and a process engineer
from the area are either on the tea� O!..f�����11a!������)o it, and
at least one team leader or superv1so�also sert�ontlle tearl'i. �
d@partm@Dtal safety specialist set ves on the tearn as� Leadership of the
team is jointly held by an hourly and a salaried member,_ aatl-1Iiis has been
effective in helping the committee to perform job analyses together and
documenting the results for further action. No recommendation for a
workplace modification is made without sharing the ideas with the people
who work on that job on all shifts and getting their ideas and/or buy-in. This
process takes more time than many quick fi�s .w,ested by consultants or
wi.lf •
·
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company service prov1·ders, but the�pgfitantfte™
the workers � reJect
the solution are much hl/h�ban when thei ar art of the solution
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.
generation process. In one companywr:4.h
11. w ere mac 1 mg JObs W8i=€
was invited to look at some hand grinding tasks that had been associated
with forearm, hand, and wrist discomfort and tendonitis. This work is very
hand-intensive and involves very repetitive pinch grips with some awkward
wrist angles over most of the 8-hour shifts. As a consultant responding to a
call for help from the Safety Specialist, I came up with 5 ipiprovements to
the workplace that would allow people to sit more comfortably, see the work
better, and improve their wrist and hand postures. These were explored over
the next year and some were implemented, but there was some resistance
from operators who had been doing the jobs for a long time and did not like
to have their workplaces "messed with". In a meeting with the Ergonomics
Committee of the plant (made up of support personnel and 2 production
supervisors) the next year, it was agreed that we should train teams in the
areas where this type of work was done so they could do the evaluations and
�ff)

,

•

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�generate more approaches to reduce the stress on the operators' upper
extremities. After training upper and middle management in short courses
during the summer, the teams were chosen and trained in September. By the
end of the year they had developed 14 improvements for their workplaces
and jobs that cost $ 200. per workplace to implement. After implementing
the improvements, they calculated a savings of$ 150,000. associated with
just one of those changes. Because they had placed a mock-up of the new
changes on one of the workplaces on the floor, the other people working in
the area could come over and try it out and make additional_�'!:��.���ons for
improvements. Only 2 or 3 people refused to try the new �and they
were permitted to use a few unmodified stations as long as they did not have
musculoskeletal discomfort or symptoms. It is important to point out that
one of the outcomes of the improvements in the workplaces was that there
was less rework needed on the parts so they could increase their productivity
per person with less stress on the upper extremities. As their consultant, I
was not aware of how chatter in the grinder's drive shaft{ron,i �ty
. p�oblems. in (or_m the�afirould create quality problems when_g�
��Prneant th� had to be reworked fairly extensively. By reducing
the chatter through better quality control on the shaft dimensions, they
reduced the effort to hold the part and reduced the amount of rework .,6oth o...-r-L,
• 1iag effective ways to reduce the risk of developing musculoskeletal
disorders on those jobs. It is worth mentioning that this model for
ergonomics integration into the plant was a joint effort of the plant EHS
personnel, the consultant, and the management. It was a dynamic model that
changed as changes occurred in the plant, and it survived a major downsizing and the loss of some key personnel because the ergonomics was
understood and done on the production floor and management was
committed to support the teams. The current program is oriented more to
engineering improvements and continues to implement changes to reduce
injury risk, but the lower level of involvement of the hourly members has
probably contributed to the higher cost of improvements.

�C. Job Hazard Analysis
Job hazard analysis is a critical component of any ergonomics process or
program because it allo�the company to define the problem before solving
it. The approach that I use has similarities with approaches used by many
other ergonomics consultants in that I do define the risk for injury in terms
of the weights �andled, forces exerted, frequency of efforts, presence of
sustained awkward postures, and reaches and work heights required. There
are many checklists with these factors listed and others have defined why the
risk factors are included on them. Where my approach differs from some of
the others is in my focus on muscle fatigue as a way to predict the risk of
developing a musculoskeletal disorder on a production task. I watch people
work and note that they do many things in response to local muscle fatigue
or to whole body fatigue if the work is heavy. I think we monitor fatigue
more than we monitor force or postures, so the functional job analysis
technique that I developed to teach people on plant fu-gonomics1eams to
evaluate jobs is based on a 3-factor rating: effort intensity (which is
determined by the forces generated to do the work and the postures they are
performed in); effort duration before the muscle goes to a lower level of
effort (which measures the work/recovery pattern of the muscle and
estimates the amount of anaerobic work done on a task); and effort
frequency for the level of effort indicated in the first factor, that is, how
often the same level of effort is initiated in a minute The first three factors
combine to determine the amount of fatigue that accumulates in 5 minutes of
work. The higher the accumulated fatigue, the more the risk for developing
musculoskeletal problems on the job. A fourth factor is total task duration,
and it is used to determine the accumulation of fatigue over the whole task if
it lasts more than 5 �Jiutes. I use it to help decide how much has to be done
to address the fatigue. For example, if a person is doing an assembly task
that requires the joining o:ftwo parts with bolts and nuts, and the task
involves tightening 6 bolts per minute with a moderately heavy force for 10
minutes every 15 minutes over four hours a shift, the need to intervene is
greater than if the same task is done for 5 minutes every 30 minutes with
little hand-intensive work during the rest of the half-hour.

�The value of the fatigue rating approach, I have found, is that it is not
difficult to teach people to do (usually under 1 hour of instruction along with
the discussion of risk factors), and it gets people thinking about what the
problem is instead of how they are going to solve it. If the problem is
defined as "The table is too low", then the natural response is to solve the
problem by raising the table. If the problem is defined by noting that the
person is bending down and this puts a moderate stress on the back, but the
effort duration is less than 6 seconds and the frequency is 3 times a minute,
the fatigue rating is low because recovery time is adequate on the·task. If
one uses the problem solving approach next and asks .why the operator has to
bend over, it may be that the reach or orientation of the tool is the reason, or
it may be that the assembly cannot be seen without bending over because of
the way it is placed on the line or bench. The fatigue rating leads the team
into finding multiple ways to solve ergonomic problems.,.besausefCJme may be
able to change the effort level, the effort duration, the effort frequency, or
the total time on the task. Although attention to the forces required or
weights handled may be the best way to address some of the problem jobs,
one is not limited to these engineering solutions to reduce injury risk on
many production jobs.
Although the fatigue analysis referred to is based on physiological data and
information from the literature, there are no specific studies that prove a
linkage between fati�ue�d musculoskeletal disorders of the sort that the
�roposed b-gonomics �ndard is trying to prevent. I continue to use this
approach because I find that the problem jobs identified in plants through
their injury and illness data and through employee surveys also tend to be
those that have a high priority for change on the fatigue ratin�providing
they are not simply short duration, excessive weight handling or force
generation. In the process of discussing how to rate the effort, effort
duration, and frequency factors, the team members have to look at the jobs
and talk to the operators who do them. By the time they have gathered this
information, they can define how much the factors need to be changed to

j (]'

�reduce fatigue, aMI1h.is usually leads to several improvements that can be
implemented quickly and are of low cosf.fFor example, people packing
plastic liners into boxes were experiencing hand discomfort when working
on the 2 fastest machines. In analyzing the job, it was noted that they were
gripping the plastic liners with a 4.5 inch wide grip and using high forces to
keep them under control before they were stuffed in the box. Every 5.5
seconds, 2 new stacks of liners indexed forward at the end of a conveyoi;,ftiffl'
-{hey had to be picked up before the next stacks were indexed or they would
fall on the floor. It took 6 seconds to load each group of liners into its box,
so there was little recovery time for the hands during the task. The operators
and their supervisors recognized the problem and had dealt with it initially
by rotating people through the job every 30 minutes to curtail the fatigue
accumulation. The job analysis defined the problem as being a need to
reduce the time of holding the stack of liners with the wide grip and high
force. It was observed that 1 second of holding time was used when an
insert was pick
ross from the boxing station and placed on top of the
1:=�
into the box. By moving the inserts next to the
stack as it was
boxing location, holding time was reduced to 5 seconds, and the fatigue
rating dropped from very high priority for change to a high priority for
change. Engineering changes in the workplace were in process to improve
the stacking of the liners and make them easier to pack, so the risk was
eventually reduced to a low to moderate level which could be easily
accommodated by rotating people every 2 hours to less rapid machines.
D. Implementing Ergonomic Changes
As mentioned above, the implementation of ergonomic solutions in a
company should improve operations genera).l� as well as reduce the risk for
)
health and safety proble�
�Erg;nomic solutions can be found at all cost levels. It has been my
experience that the simpler solutions are not likely to emerge unless you
have strong involvement of production and maintenance personnel. And
they will not be found unless there is an analytical approach to problem
solving rather than simple brainstorming. It is essential to define the risk in

){

�terms of which factors contribute the most to it and how much they need to
be changed. Without this specification and a root cause analysis of other
factors that determine }:Yhy the risk factors are there, one can fix the wrong
thing and incur unnecessary expense. This is the hardest part of the team
training because everyone has ideas on how to solve the problem and few
people see the need to do an analysis of it when the problem seems so clear.
"\. For example, people on a car assembly line were experiencing arm,
shoulder, and back discomfort when handling doors off of an incoming
conveyor and on to a carousel storage uni� from which the assemblers put
them on the cars on the line. The group being asked to suggest ways to
solve this problem jumped into the fray without analyzing the jobs and came
up with very elegant ways of linking the line to the carousel so no manual
handling of the doors would have to be done. The cost of this improvement
would have been several hundred thousand dollars. What they did not hear
was that the person presenting the problem stated clearly that the incoming
line and the carousel line could not be linked because they had different flow
rates. When we eventually asked enough questions to establish what the
task demands were in terms of weights handled, heights and reaches used,
lifting frequency, and carrying distances, it became clear that there were two
major risk factors that could account for the arm, shoulder, and back
discomfort: the force needed to remove the incoming doors from the
conveyor (they stood upright and one had to break them out of the track by
applying a high force above mid-chest height on most people); and the need
to hold the door about 28 inches away from the body when setting it in the
carousel lengthwise. This breakdown of the risk factors resulted in a
suggestion to use air cylinders to push the door up out of the conveyor track
where it could be handled comfortably for the transfer to the carousel. At
the carousel, the door could be placed on a platform with a soft cover prior
to sliding it into position in the next carousel slot. The total cost for these
two workplace improvements was estimated to be less than $ 200..
Administrative interventions do not need to decrease productivity. When
inadequate recovery time is provided on a difficult task, people have to find

�ways to reduce the fatigue accumulation, so they tend to do more secondary
work, that is, work that relates to the job but doesn't directly help move the
product out of the door. This may be additional quality checks, parts
inspection, or discussions with colleagues or supervisors about production
issues. When adequate recovery time for fatiguing muscles is provided
within the work cycle (designed into the task or made unnecessary), people
can stay on the job longer and productivity usually improves. Rotating
people between difficult jobs or tasks and less difficult ones is only effective
if the fatigue rate is in the ni�oderate range. High and very high priority for
change tasks are difficult to rotate between people because they are likely to
find the people who are more susceptible to musculoskeletal disordersfven
when rotation times are short. Slowing down lines is often thought to be a
sure way to decrease productivity, and it is not a sure way to reduce the risk
of injury or illness unless the problem is related to inadequate recovery time
between exertions. I have been involved in 4 job studies where slowing
down the line actually increased productivity (measured as good units out
the door) because it reduced the amount of poor quality assemblies and
repair work. Other administrative interventions relate to policies or ordering
strategies that affect the availability of parts or tools and supplies in the
production area. In onepfa;[tl¥e%�e
increased complaints about hand
cf-uv«t(IOf)�
and wrist discomfort on a disc sanding job after a new inventory control
program was introduced. Analysis of the operations showed that 2 types of
sandpaper were used by the operators, one with a paper backing and one
with a canvas backing. It was taking 2 times longer to do the parts sanding
when the paper backing sand paper was used, and1iiis was the probable
cause of the discomfort problems that had recently appeared on the job.
Someone had set a reorder time of 90 days on the canvas-backed sand paper
and 60 days on the paper-backed discs. Since both were specified for the
operation, and since another department was also using the canvas-backed
discs, there were only paper discs available for most of the sanding
operations over a 3 month period. Respecifying the canvas discs and putting
a 30 day reorder time on it cleared up the problem. Training operators to
know when to change grinding discs or cutting tools on machining tasks

�represent other approaches that are administrative and can reduce injury risk
on the job. Most of these become clear when the £.gonomicsteam members
keep asking "Why ?" until they get to the root cause of a problem.
Administrative changes are often very low cost and easy to implement if
management commitment and employee involvement are present.
The ultimate goal of an ergonomics process or program is to design jobs,
workplaces, environments, and equipment within the capabilities of most
workers and to do this proactively instead of reactively. In the best
programs I have been involved with, the designers and process engineers
work with the ergonomics team to assure that improvements and new
technologies incorporate ergonomics principles before they get to the
workplace. This takes more time, but it reaps tremendous benefits.

�,\A./-� �':""'-/
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E. Training Needs
,,..._ 'i�,,T
Many employers are concerned that education about ergonomics and the risk
factors that may contribute to musculoskeletal disorders will open a
Pandora's box and leave them with unhappy and dissatisfied employees if
changes are not made quickly. In my experience this is only likely to
happen if there has been no attempt to provide for a response team before
the education or comfort surveys are done. The presentation of the
educational material should emphasize what the employees can and should
do if they experience significant discomfort or musculoskeletal symptoms
on the job and who should be informed. Techniques for improving the
workplace or better methods for doing the task should also be shown, and a
simple method for asking for a further evaluation from the Ergonomics
Team or a departmental representative should be provided. In general, I
think that it is important to train the first line supervisors or team leaders
first so they understand what their colleagues will be taught and so they can
tell when they need to call in additional expertise. Management needs to be
trained about the capabilities of the team members and the general benefits
of ergonomics in helping them reach both health and safety and performance
goals. Tuam tmtning has been discussed eadier ua.der employee ..
LAJ )

�involvement. It is important to train the teams when they need to get
additional ergonomics expertise, too. If not, there may be a tendency to take
on some design projects where a much deeper understanding of human
capabilities is needed. The process and design engineering staff need
ergonomics training of a more technical nature so they can know where to
find resources, how to ask the right questions to establish the human
interface needs in the workplace, and what trade-offs are appropriate when
specifying a new system. It should be their responsibility to be sure that
non-ergonomic tools, equipment, or workplaces are not brought into the
plant in the future.

F. Program Evaluation

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�eople find�interesting� the
· ·.
..
"common sense" ways they can identify better ways to do things, and�n
see no need to document the befores and afters in a quantitative way. The
usual comment I hear is, "Why bother with that stuff? We know it works
and the paperwork is unnecessary !". That is part of the reason that many
good programs have remained undocumented in the way that regulators like
to see them done despite much cajoling from the consultants and managers.
Most of my clients use their OSHA logs to define their ergonomic injury risk
and combine that with their Workers' Compensation data to define the
seriousness of the problem. Although these are important measures, they are
not the whole picture, and they only indicate about one fifth of the probable
costs of having ergonomically-poor designs at work. There is always a
delay in measuring the impact of ergonomic improvements in the workplace
because of two factors:
1. When work is done in a production area and more awareness of
ergonomics issues is encouraged, people who have chosen not to
report discomfort or moderate symptoms in the past usually report
them. This is especially true if it appears that people are listening
and acting on the information that the production workers give
them. Thus, one often has increased reporting of musculoskeletal
illnesses and injuries after an ergonomics evaluation is done in a

�department. This is ��en for 6 months after the change and
then falls to levels below the initial number. The severity of these
reported illnesses and injuries is often quite low.
2. Musculoskeletal disorders that have become chronic because of
repeated aggravation do not go away as soon as the ergonomics of
the workplace or job is improved. They are likely to be less
frequent and show less lost time, but they will not disappear
overnight. On the other hand, first visits to the medical clinic for
-fl--.
musculoskeletal problems will probably decrease and more�f�st
time �as es, will be seen.
It is important to measure other medical factors, such as the number of
people who have job restrictions from tasks that are considered difficult, the
number of people who are not successful on those jobs or tasks, the
absenteeism on those jobs, and the characteristics of the people who are
successful on them. Job satisfaction ratings can also identify the acceptance
or rejection of the new designs or job improvements.
Since the goal of ergonomics is to design for most workers, it is important to
integrate it into the day to day operations of the business rather than keeping
it in a safety pigeonhole. Mature ergonomics programs are harder to
document because enough people have been trained about the concepts and
given the guidelines to use in their own work that it is no longer easy to
isolate what is ergonomics and what is the engineer's or worker's original
concept.

m.

Benefits of Having an Ergonomics Standard

Why do we need an ergonomics standard today ? I have not been a fan of
ergonomics regulation because I find that more time and money is spent in
arguing why we should or shouldn't regulate this health and safety area than
is spent in fixing the real problems in the workplace. Regulation has the

�.

,.,,_

advantage that it provides a priority for ergonomics improvements in an
industrial atmosphere that continues to try to do more with fewer people.
Ergonomics should not be an adversarial area between management and
labor - both benefit from good ergonomics applications. People are able to
work better and with less fatigue, leaving them some reserve to take home
and enjoy their families at the end of the shift. Occupational injuries and
illness should be reduced, and people who are injured outside of work are
able to return to the job earlier • ;; etr'because their jobs are less likely to
aggravate their symptoms. In my review of many hundreds of jobs in a
variety of industries, I have frequently found that ergonomics problems are
also process problems in the plant. They should be fixed in order to improve
the production process as well as to protect workers' health and safety. With
jobs designed for the majority of workers rather than for a small fraction of
the potential workforce, many of the hassles that make first level supervisors
and team leaders tear their hair out are alleviated because more people are
able to fill in as needed. More ability to concentrate on quality work instead
of being distracted by discomfort from awkward postures or fatiguing
muscles means less reliance on overtime and its impact on workers' whole
body and mental fatigue in these days of global competition. In short,
having an ergonomics standard to address the most serious risk factors in the
workplace should give industries a priority to implement improvements that
will make them better able to compete in the global economy in the future.

1/17/00 S.H. Rodgers, Ph.D.

�'.
�.,. ··---·◄

·•

f.

Expert Witness Testimony for the Proposed Ergonomics
Program Standard Rulemaking Hearing at DOL,
Washington, DC in February/March, ·2000

I.

My Qualifications:

My name is Suzanne Rodgers and I have been working in the field of
industrial ergonomi�s f�r���2 yea!.s��octorate is in Physiology,
-:
and my area of special m:te,est 1nferg6ii�een to understand what
are safe and reasonable job demands for the industrial workforce. The goals
of my on-site studies have been to define the physical work c�pabilities of
the potential workforce and to identify ways to design jobs, workplaces,
quipment, 8f�iron ent ��duce unl}�e"Y fatigue on the job. ffl-,ef�
.
:_my_13 year�¥Eastma odak tompany, !learned the applications of
ergonomics by being out on the productioJ floor or in the field and by
measuring the metabolic, muscular, and cardiovascular demands of the
"problem" jobs using em�loy��j&lt;&gt;lunteers. I was fortunate�e insias a
_
-�-where I c�studfpoople
at work andy.so lea��out
production needs. In those 13 years, I was taught by the workers, their
supervisors, engineers, medical specialists, skilled trades people, human
resources professionals, an�leagues in the Human Factors/
_
Ergonomics Section of th� Health and Safety Laboratory. I learned that
jobs have to be looked at globally in order to find the best ways to reach
production goals without putting people at risk of developing significant
occupational injuries and illnesses. From our work with production
employees and with engineers, we were often able to find better ways to
design the workplace, production equipment, environment, and job tasks so
more output was achieved with less stress on the worker. I included many of )i Ld-­
these guidelines in -our two-volume reference book, "Ergonomic Design for I Jt,Jt�
People at Work." Much of my work at Kodak was spent developing
/ ,�; /

J,

�guidelines for safe workloads so that women and older workers would be
accommodated on some of the heavier jobs and so people with disabilities or
short-term work restric1T s �oul���k to their jobs in a safe and
� /.}
efficient manner. -It sh� a��none of the stronger men
complained when we found better ways to help them get their work done.
Good ergonomics benefits everyon�/'� /,I� �
Since 1982, I have been a full-time, self-employed ergonomics consultant
and have had the opportunity to develop ergonomics programs and processes
with clients in large, middle-sized, and small comp�es, in service
organizations, and in a municipality. I cfi-d-ftet start a consulting firm
because I wanted my clients to take ownership of1he ergonomics rather than
have me "do" it.
Lihavew,
discussions, the development of a propos
early 1970s. I have, until recently,....'l+l���
u
ndard. If you see
able to sell itself to com
2� �5JI�
ergonomics as a science
·
· design systems, jobs, and products with
the worker and consumer in mind so unndessary effort and overload is
avoided, it is hard to understand why everyone wouldn't embrace it. I define
occupational ergonomics very simply: "Ergonomics is the science of
making it easy for people to do quality work." Rather than a burden to
industry, I think ergonomics can be its salvation. Making jobs better and
better utilizing the skills of our human resources can only result in better
products, safer work, and higher job satisfaction. Ergo (in 2 senses of the
word), higher productivity and quality performance.
/41�

'L.,U!�
ft.

II.

Why do I now feel that an OSHA Ergonomics Standard
is needed?

You have already heard testimony about the increased numbers of

�musculoskeletal injuries and illnesses seen in companies over the past
several years. Some refer to it a� an epidemic. I personally think that it
represents something else, the need to report discomfort and symptoms in
today's work environment. In the earlier days of my ergonomics career,
when I was asked to look at a job where someone had sustained an injury or
developed tendonitis, I would find 5 more people in that job who hadn't
reported their discomfort or symptoms because they "didn't want to bother
anyone about it." The ratio of 1:6 for reporting these types of symptoms or
r
....-..... .�..�..
discomfort was quite common at that, time. Today, that ratio has changed to
about 1:3. There were many more options for workers to control their work
patterns and get relief from musculoskeletal discomfort before the
J/;
"leaner/meaner" management philosophy for remaining competitive came
�
tJr1,�
, !?
into vogue. Now, the workers must report problems to get relief, and they
often wait until they can no longer sustain their work, making recovery times
longer.
�The musculoskeletal injuries and illnesses seen in the workplace are real,
and they can be managed and reduced through better design of workplaces,
�
tll/"ii J_,1
equipment, environments and jobs. f would not have been able to support
-my�sP'lefH=f'"'3are-s..ga-,-CisH'le,Ulf==.-e�m'i'i'Kp17oreyrJS
l end"i5ei'Frgmomnmo�m1fflT·c"l:!'s.,.,c.,.,ornn�sui...11�ta:rrnrt-t-f:fu"'r.,...tfl=l'iuie�pv:a�srt �18�y;;;:e;;;ar�s:-;i'ff______ � �.
,- these statements "c1e not trae ! -Then why not just let nature take its course
and let the more progressive employers show the others the benefits of
ergonomic design ? This was my posture for many years. But, I have noted
a very disturbing trend in business that has made me think that an
ergonomics standard is needed in order to put a priority on the need to
address musculoskeletal injuries and illnesses in the workforce.

/I f#�
......

-�f-·_: ·

p- f�

To do high quality work, one cannot be asked to work in a way that will
generate large amounts of muscular or whole body fatigue or to do tasks that
are very heavy or are less heavy and are sustained for a long time. Even if
the damage does not show up right away, one cannot expect people to
perform at a high quality level if they are performing difficult tasks at high
repetition rates or over long work shifts without adequate time to repair

3,

�microtraumas to the joints or muscles between shifts. People's desire to do
quality work may put them at additional risk of injury or illness in these job
situations because they neglect the signs coming from the body that indicate
an over-exertion injury is developing. The long term costs of
musculoskeletal disorders combined with the increased longevity of the
population and increased health care costs add to the reasons why we should
take steps now to prevent unnecessary stress on the job.

_

It has been apparent to me, especially over the past 2 years, that most
companies are trying to keep ahead of the global competition by keeping
their workforce small and using overtime to cope with production variations.
The "downsizing" of many companies has resulted in many employees
holding more than one position and feeling unable to do quality work in any
of them. The use of overtime in production has made it harder to keep
Ergonomic Teams active on the floor because they are too tired to take on
another ("unpaid") responsibility. They still have to get their work done. I
think this situation is coming to a head, and we need to find better ways to
get high individual productivity without putting the workers at risk of injury
because of accumulated physical and mental/perceptual fatigue. I believe
that the in,iPl&lt;tWentation of a flexible, work practices-driven, ergonomics
standard e�e a positive step in the prevention of o��es and
in optimizing the design of problem jobs. It is not � the
--­
�
priorities for health and safety overwhelmed by the business's need to keep
market share1n today's economy. By allowing companies to develop their
own ways incorporating ergonomics into their operations and measuring
their effectiveness in decreasing the occupational injuries and illnesses, the
proposed ergonomics standard can help to underline the importance of
health and safety priorities in parallel with production demands.

J

Although there may be details contested in the new Proposed Ergonomics
Program Standard, I think that it bends over backwards to try to
accommodate businesses' needs while still assuring that worker safety and
health needs will be protected. It is more flexible than previous proposals,

�does not limit the ways that ergonomics can be integrated into operations,
and recognizes the importance of teamwork in resolving problems.

III. Scope of This Testimony
In the remainder of this testimony, I WOmtEl-1-Hre-tEe address the importance of
several of the basic program elemeni , including management commitment,
employee participation, job hazard analysis techniques, training needs,
implementing changes, and program evaluation. My testimony is based,
primarily, on my experience of building ergonomics programs with
I often work with a client for several years as we build the program and
change the culture about ergonomics and teamwork on the production floor.
However, I think that there are many ways to do ergonomics in a company,
and each company has to find the way that best fits their resources, staffing,
and health and safety problems. The proposed ergonomics standard and
several OSHA and NIOSH documents provide guidance for those who want
more information. The basic components of a successful intervention
program that are spelled out in this document are fairly widely accepted in
the field, even if s� details may be proble�atic to some businesses.

A. Management Commitment
The P�d Ergonomics P��d�d includes a basic requirement'
for evi� e,f managemen� commitment to having an ergonomics process
in place 111 a contpa9¥ where occupational musculoskeletal disorders are
seen. This commitm �lly show�e establishment of an
e
Ergonomics Team, th�9=0f tim,.,for the team to meet, and provision
of a budget to implement changes to reduce the risk of injury on jobs where
high risks are found. The commitment of management to the ergonomics
program/process is critical because high risk tasks must be addressed, and
�� peed priotily whea other people and resources, such as maintenance

��if.-��

specialists and engineers, ate ncedetl to implement changes. With all of the
, ., _ production pressures already present in many companies, it is management
sets the tone for when health and safety issues are addressed. Without
�f commitment to ergonomics improvements t�uce workplace risk,
the best work done by the team(s) can fall shortpfthe implementation stage.
Budgets should be adequate to allow simple improvements to be done at the
departmental level. Major improvements with larger budgets, such as the
purchase of a new production machine or vehicle, should be reviewed from
an ergonomics perspective and be handled through the customary channels.

J�

..-

V

If the company has a union, it is critical to get union support for the
ergonomics process, too. There is some concern that ergonomics
improvements �ifl�of jobs, and this perception is not altogether
unjustified. Removing jobs that put people at high risk of injury and cannot
be easily modified may be appropriate, but the goal of ergonomics
interventions to reduce the risk of musculoskeletal injuries and illnesses
should not be to remove the people, but rather to improve the tasks for
people. The union leadership should support the involvement of the
production workers in the risk identification, analysis, and ergonomic
/,:1-4solution generation process since the people who do the work are the �
experts. Cooperation is needed to find the best, most effective, and least
expensive improvements instead of throwing equipment at a problem. That
is the challenge for a production-based ergonomics program. When
everyone is focused on how to solve the problem, there is little difficulty in
finding good and practical solutions for it7 .-&lt;L-- -�- � ,

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B. Employee Involvement
I have tried a number of formats for getting ergonomics programs started in
companies. They have ranged from programs that taught process and
industrial engineers how � ergonomics problems, to programs that
focused on following up _9f1 all people who had visited the internal medical
clinic for musculoskeletal complaints, to training hourly employees to be the
ergonomics coordinators in each department, to training hourly workers to
-

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�be the primary Ergonomics Team members with a secondary Ergonomics
Steering Committee, made up of the support group managers or supervisors,
that assured that the teams got the appropriate support as risks were
identified. In observing programs that have not had much staying power, the
primary pi:oblem that I have identified has been that the steps between
identifi� a problem and implementing a solution have not involved
the people who work in those jobs. This approach of "throwing it over the
wall" to the engineers or maintenance people to solve the problem usually
results in a solution beiBg genentletl that cannot be implemented be caUSe of.
_
some facttm that were not known to them when they observed the Job.

r

For example, a problem of getting a proper gasket assembly and seal on a
refrigerator door in one company (with over 1000 workers) was associated with
increased reports of forearm and wrist/hand discomfort from repetitive
screwdriver use. Several activities had been tried to reduce the hand stress
including a partial automation of the gasket assembly with a small robot, but there
were still many quality problems that the line workers had to fix. Two engineers
watched the hand assembly work and decided that they could make a fixture to
assist the operators in holding down the gasket on the frame so the screwing down
task would be easier to perform. The fixture was fabricated and presented to the
operators about a month later. Although the concept was okay, the engineers had
not tried it out with the operators and did not note that they were seated at the line.
The fixture could only be used if one stood up, and this was not a popular idea for
people working an 8-hour shift. The operators appreciated the trouble that the
engineers had taken to help them work better, but they saw the fixture as creating
new problems for them, and admitted that they would probably use it as a door
stop. The operators were involved in analyzing the risk factors and defining the
highest risk activities with the engineers and production supervision in a
subsequent training course. Together, they were able to identify the semi­
automation as the area that needed attention so less manual rework of the gasket
assemblies would have to be done. The operators could then dedicate themselves
to fixing the exceptions rather than having to fix every assembly on the line.

The most effective programs I have participated in, in terms of employee
involvement, have been ones where each department has a Safety Team or
an Ergonomics Team made up of 5 to 7 people, at least 60% of whom are
"......,
/,

�hourly workers. A maintenance mechanic and a process engineer from the
area are either on the team or are designated as a resource to it, and at least
one team leader or supervisor and the departmental safety specialist also
serve on the team. Leadership of the team is jointly held by an hourly and a
salaried member. This has been �tive in helping the committee to
perform job analyses together anfoocumenQ the results for further action.
No recommendation for a workplace modification is made without sharing
the ideas with the people who work on that job on all shifts and getting their
ideas and/or buy-in. This process takes more time than many quick ����s
.. _"':"
suggested by consultants or company service providers, but the
that the workers will reject the solution �ower when they are part of the
solution generation process.

A �

�\.,P'"�

In one company with over 1000 employees where machining jobs are dominant, I
was invited to look at some hand grinding tasks that had been associated with
forearm, hand, and wrist discomfort and tendonitis. This work is very hand­
intensive and involves very repetitive pinch grips with some awkward wrist
angles over most of the 8-hour shift. As a consultant responding to a call for help
from the Safety Specialist, I came up with 5 improvements to the workplace that
would allow people to sit more comfortably, see the work better, and improve
their wrist and hand postures. These were explored over the next year and some
were igiplemented, but there was some resistance from operators who had been
doing the jobs for a long time and did not like to have their workplaces "messed
with". In a meeting with the Ergonomics Committee of the plant (made up of
support personnel and 2 production supervisors) the next year, it was agreed that
we should train teams in the areas where this type of work was done. The goal
was to train the team members to evaluate the jobs and to generate more
approaches to reduce stress on the operators' upper extremities. After training
upper and middle management in short courses during the summer, the teams
were chosen and trained in a 4-day session in September. By the end of the year
they had developed 14 improvements for their workplaces and jobs that cost
$ 200. per workplace to implement. After implementing the improvements, they
calculated a savings of$ 150,000. associated with just one of those changes.
Because they had placed a mock-up of the new changes on one of the workplaces
on the floor, all of the people working in the area could come over and try it out
and make additional suggestions for improvements. Only 2 or 3 people refused to

�try the modified workplaces, and they were permitted to use a few unmodified
stations as long as they did not have musculoskeletal discomfort or symptoms. It
is important to point out that one of the outcomes of the improvements in the
workplaces was that there was less rework needed on the parts so they could
increase their productivity per person with less stress on the upper extremities. As
their consultant, I was not aware of how chatter in the grinder's drive shaft from
quality problems in forming the shaft could create quality problems when
grinding the parts. That meant they had to be reworked fairly extensively. By
reducing the chatter through better quality control on the shaft dimensions, they
reduced the effort to hold the part and reduced the amount of rework. Both are
effective ways to reduce the risk of developing musculoskeletal disorders on those
jobs. It is worth mentioning that this model for ergonomics integration into the
plant was a joint effort of the plant EHS personnel, the consultant, and the
management. It was a dynamic model that changed as changes occurred in the
plant. And, it survived a major down-sizing and the loss of some key personnel
because the ergonomics was understood and done on the production floor, and
because management was committed to support the teams. The current program
is oriented more to engineering improvements and continues to implement
changes to reduce injury risk; but the lower level of involvement of the hourly
members has probably contributed to the higher cost of improvements.

C. Job Hazard Analysis
Job hazard analysis is a critical component of any ergonomics process or
program because it allows the company to define the problem before solving
it. The approach that I use has similarities with approaches used by many
other ergonomics consultants in that I do define the risk for injury in terms
of the weights handled, forces exerted, frequency of efforts, presence of
sustained awkward postures, and reaches and work heig�red. There
are many checklists with these factors listed, a_nd othe� liave defined why
the risk factors are i�n the12;_�)r{y appr6ach differs from
some of the others i,s...m..my focu�n muscle fatigue as a way to predict the
risk of �V.f,�ng a mu�c��etal disorder on a production task. I watch
peopl9t workati'd note�they do mtuty things in response to local muscle
fatigue or to whole body fatigu�if the work is he�·thiak we monittw-­
fatigue more than we monitor force or posturesJUle functiom{joh::analy�i,s
&lt;tet:lmiqtte that I developed tf) teach people on plant Ergonomics Teams to

��

evaluate jobs is based on a/3-factor rating: effort intensity (which is
determined by the forces generated to do the work and the postures they are
performed in); effort duration before the muscle goes to a lower level of
effort (which measures the work/recovery pattern of the muscle and
estimates the amount of anaerobic work done on a task); and effort
frequency for the level of effort indicated in the first factor that is, how
often thej'ame level of effort is initiated in a minute ::i:�three factors a,,.JL­
combin)lto determine the amount of fatigue that accumulates in 5 minutes of
developing
work. The higher the accumulated fati ue t
musculoskeletal problems on the joo �fourth factoys otal task duration,
� is sed to determine the accumulation of fatigue,0"1'et tire w�
1t lasts
e than 5 minut . I use it to help decide how much ha;-�t� edone
to address the fatigue. For example, a person who is doing an assembly task
that requires the joining of two parts with bolts and nuts, and is tightening 6
bolts per minute with a moderately heavy force for 10 minutes every 15
minutes over four hours of the shift, needs more recovery time than one who
is doing the same task for 5 minutes every 30 minutes with little other hand­
intensive work.
The value of the fatigue rating approach, I have found, is that it is noJ
difficult t,?�h people to do. They become reasonably proficient'doing the
ratings�our of training that includes a discussion of risk factors.
Doing the ratings gets people thinking about what the problem is instead of
how they are going to solve it. If the problem is defined as "The table is too
low", then the natural response is to solve the problem by raising the table:
By rating the person's posture when they are bending down, which puts a
moderate stress on the back, with a� , d
· on of less than 6 seconds,
and a frequency of 3 times a minute,,\ t fatigue rating is low because
recovery time is ade�eNe task. If the duration of bending over or -Af..
frequency of doin!J)t increases because of quality problems or increased
production rates, the fatigue rating could increase to a. moderate or high
priority for change. Using the problem solving approach next, one asks why
the operator has to bend over. It may be that the reach or orientation of the

�tool is the reason, or it may be that the assembly cannot be seen without
bending over because of the way it is placed on the line or bench. The
fatigue rating leads the team into finding multiple ways to solve ergonomic
problems. One may be able to change the effort level, the effort duration,
the effort frequency, or the total tim� on the task. Although attention to the
forces required or weights handled may be the best way to address some of
the problem jobs, one is not limited to these engineering solutions to reduce
injury risk on many production jobs.
Although the fatigue analysis referred to is based on physiological data and
information from the literature, there are no specific studies that prove a
linkage between fatigue and musculoskeletal disorders of the sort that the
Proposed Ergonomics Program Standard is trying to prevent. I continue to
use this approach because I find that the problem jobs identified in plants
through their injury and illness data and through employee surveys also tend
to be th"o..1 that haveNigh p�or change on the fatigue rating, 'Fhisis-proviru-� that they -&amp;re not -simply short duration, excessive weight handling
or force generation. In the process of discussing how to rate th�t,,..�f�� ;J/ _
duration, and frequency factors, the team members have to loo�at the jobsr-o­
and talk to the operators who do them. By the time they have gathered this
information, they can define how much the factors need to be changed to
reduce fatigue. This usually leads to several improvements that can be
implemented quickly and are of low cost.
For example, people packing plastic liners into boxes (in a plant with less than
200 people) were experiencing hand discomfort when working on the 2 fastest
machines. In analyzing the job, it was noted that they were gripping the plastic
liners with a 4.5 inch wide grip and using high forces to keep them under control
· before they were stuffed in the box. Every 5.5 seconds, 2 new stacks of liners
indexed forward at the end of a conveyor. They had to be picked up before the
next stacks were indexed or they would fall on the floor. It took 6 seconds to stuff
each group of liners into its box, leaving little recovery time for the hands during
the task. The operators and their supervisors recognized the problem and had
dealt with it initially by rotating people through the job every 30 minutes to curtail
fatigue accumulation. The job anal_ysis defined the problem as being a need to
!

I{ I

�reduce the time of holding the stack of liners with the wide grip and high force. It
was observed that 1 second of holding time was used when an insert was picked
up across from the boxing station and placed on top of the stack as it was stuffed
into the box. By moving the inserts next to the boxing location, holding time was
reduced to 5 seconds and the fatigue rating dropped from very high priority for
change to a high priority for change. Engineering changes in the workplace were
in process to improve the stacking of the liners and make them easier to pack, so
the risk was eventually reduced to a low to moderate level which could be easily
accommodated by rotating people every 2 hours to less rapid machines.

D. Implementing Ergonomic Changes
As mentioned above, the implementation of ergonomic solutions in a
company should improve operationo/generally, as well as reduce the risk for
health and safety problems. Ergonomic solutions can be found at all cost
levels. It has b
- y experience that the simpler solutions are not likely to
. . : ¥ } volvement of production and maintenance
�emerge unless �
.9P.� n
personnel. And� wilfofte�ot be found unless there is an analytical
approach to problem solving rather than simple brainstorming. It is essential
to define the risk in terms of which factors contribute the most to it and how
much they need to be changed. Without this specification and a root cause
analysis of other factors that determine why the risk factors are there, one
can fix the wrong thing and incur unnecessary expense. This is the hardest
part of the team training because everyone has ideas on how to solve the
problem, and few people see the need to ds-ttH-anal�/4 it when the
problem seems so clear.
For example, people on a car assembly line (in a plant with over 1000 people)
were experiencing arm, shoulder, and back discomfort when handling doors off of
an incoming conveyor and on to a carousel storage unit, from which the
assemblers put them on the cars on the line. The group being asked to suggest
ways to solve this problem jumped into the fray without analyzing the jobs and
came up with very elegant ways of linking the line to the carousel so no manual
handling of the doors would have to be done. The cost of this improvement
would have been several hundred thousand dollars. What they did not hear was
that the person presenting the problem stated clearly that the incoming line and
the carousel line could not be linked because they had different flow rates. We

/ 2-,

�eventually asked enough questions to establish what the task demands were in
terms of weights handled, heights and reaches used, lifting frequency, and
carrying distances. With that information, it became clear that there were two
major risk factors that could account for the arm, shoulder, and b�ck discomfort.
The first was the force needed to remove the incoming doors from the conveyor.
They stood upright, and one had to break them out of the track by applying a high
force that was above mid-chest height on most people. The second risk factor
was the need to hold the door about 28 inches away from the body when setting it
in the carousel lengthwise. This breakdown of the risk factors resulted in a
suggestion to use air cylinders to push the door up out of the conveyor track
where it could be handled comfortably for the transfer to the carousel. At the
carousel, the door could be placed on a platform with a soft cover prior to sliding
it into position in the next carousel slot. The total cost for these two workplace
improvements was estimated to be less than $ 200.

Administrative interventions do not need to decrease productivity. When
inadequate recovery time is provided on a difficult task, people have to find
ways to reduce the fatigue accumulation, so they tend to do more secondary
work, that is;,::work that relates to the job but doesn't directly help move the
product out of the door. This may be additional quality checks, parts
inspection, or discussions with colleagues or supervisors about production
issues. When adequate recovery time for fatiguing muscles is provided
within the work cycle (designed into the task or made unnecessary), people
can stay on the job longer and productivity usually improves. Rotating
people between difficult jobs or tasks and less difficult ones is only effective
if the fatigue rate is in the moderate range. High and very high priority�
change tasks are difficult to rotate between people because they are likely to
find the people who are more susceptible to musculoskeletal disorders even
when rotation times are short. Slowing down lines is often thought to be a
sure way to decrease productivity, and it is not a sure way to reduce the risk
of injury or illness unless the problem is related to inadequate recovery time
between exertions. I have been involved in$studies where slowing
down the line actually increased productivity (measured as good units out
the door) because it reduced the amount of poor quality assemblies and
repair work. Other administrative interventions relate to policies or ordering

�.
strategies that affect the availability of parts or tools and supplies in the
production area.
In one machining/assembly plant (with more than 1000 employees), there were
increased complaints about hand and wrist discomfort on a disc sanding job after
a new inventory control program was introduced. Analysis of the operations
r-

showed that 2 types of sandpaper w�re used by the operators, one with a paper
backing and one with a canvas backing. It was taking 2 times longer to do the
parts sanding when the paper backing sandpaper was used. This was the probable
cause of the discomfort problems that had recently appeared on the job. Someone
had set a reorder time of 90 days on the canvas-backed sandpaper and 60 days on
the paper-backed discs. Since both were specified for the operation, and since
another department was also using the canvas-backed discs, there were only paper
discs available for most of the sanding operations over a 3 month period. Re­
specifying the canvas discs and putting a 30 day reorder time on it cleared up the
problem. Training operators to know when to change grinding discs or cutting
tools on machining tasks represent other approaches that are administrative and
can reduce injury risk on the job. Most of these become clear when the
Ergonomics Team members keep asking "Why ?" until they get to the root cause
of a problem. Administrative changes are often very low cost and easy to
implement if management commitment and employee involvement are present in
an ergonomics program.

The ultimate goal of an ergonomics process or program is to design jobs,
workplaces, environments, and equipment within the capabilities of most
workers and to do this proactively instead of reactively. In the best
programs I have been involved with, the designers and process engineers
work with the Ergonomics Team to assure that improvements and new
technologies incorporate ergonomics principles before they get to the
workplace. This takes more time, but it reaps tremendous benefits.

E. Training Needs
As has been mentioned earlier, the best ergonomics programs I have been
associated with are those where the production workers are the primary
problem identifiers, analyzers, and solution generators. They must be
supported by the service providers in the company (i.e., the engineers,

Ji

�medical specialists, supervisors or team leaders, maintenance staff, materials
handling specialists, and managers), 'mt the ownership for ergonomics is
with each person doing her or his job. In smaller businesses, where the
support staffis thinner, this need to solve ergonomics-related problems on
the floor is even greater. I found that I could train production workers and
the support staff to think like ergonomists, and could facilitate them through
a fairly simple fatigu�lnalysis or lifting guideline to a problem solving
process that generate� ·several ways of addressing the root cause of the
problem. . Taking a page from Kenneth Blanchard, I moved from the
educational model of trying to stuff a lot of information into the heads of my
course attendees to the industrial training model of asking the attendees to
dump their brain contents out on the table and let me rearrange them to
incorporate the ergonomics principles. By doing this, I found I could tap
into the wealth of knowledge that is present in the workforce for ways to
improve jobs. By assuring that the support groups respect and assist the
production teams in finding solutions for these problems, we also improve
communications and cooperation in projects where health and safety issues
are not paramount.
Many employers are concerned that education about ergonomics and the risk
facto�s that may contribute to musculoskeletal disorders will open a
Pandora's box and leave them with unhappy and dissatisfied employees if
changes are not made quickly. In my experience, this is only likely to
happen if there has been no attempt to provide for a response team before
the education or comfort surveys are done. The presentation of the
educational material should emphasize what the employees can and should
do if they experience significant discomfort or musculoskeletal symptoms on
the job, and who should be informed. Techniques for improving the
workplace or better methods for doing the task should also be shown, and a
simple method for asking for a furtht;r evaluation from the Ergonomics
Team or a departmental representative should be provided. In general, I
think that it is important to train the first line supervisors or team leaders
first. Then they understand what their fellow employees will be taught, and
I

IS:

�they can tell when they need to call in additional expertise. Management
needs to be trained about the capabilities of the team members and the
general benefits of ergonomics in helping them reach both health and safety
and performance goals. Team training has been discussed earlier under
employee involvement. It is important to train the teams to know when they
need to get additional ergonomics expertise, too. If not, there may be a
tendency to take on some design projects where a much deeper
understanding of human capabilities is needed. The process and design
engineering staff need ergonomics training of a more technical nature so
they can know where to find resources, how to ask the right questions to
establish the human interface needs in the workplace, and what trade-offs
are appropriate when specifying a new system. It should be their
responsibility to be sure that non-ergonomic tools, equipment, or workplaces
are not brought into the plant in the future.

F. Program Evaluation
The-��-ic--js-4hat)eople find · very interesting, they like the
"common sense" ways they can identify better ways to do things, and, often,
they see no need to document the befores and afters in a quantitative way.
The usual comment I hear is, "Why bother with that stuff? We know it
works and the paperwork is unnecessary !". That is part of the reason that
many good programs have remained undocumented in a way that regulators
expect them to be done, despite much cajoling from consultants and
managers. Most of my clients use their OSHA logs to define their
ergonomic injury risk and combine that with their Workers' Compensation·
data to define the seriousness of the problem. Although these are important
measures, they are not the whole picture, and they only indicate about one
fifth of the probable costs of having ergonomically-poor designs at work.
There is always a delay in being able to see the impact of ergonomic
improvements in the workplace because of two factors:

/�,

�1. When work is done in a production area and more awareness of
ergonomics issues is encouraged,
, people who have chosen not to
report discomfort or moderate symptoms in the past usually report
them. This is especially true if it appears that people are listening and
acting on the information that the production workers give them.
Thus, one often has increased reporting of musculoskeletal illnesses
and injuries after an ergonomics evaluation is done in a department.
This is may be seen for 6 months after the change and then usually
falls to levels below the initial number. The severity of these reported
illnesses and injuries is often quite low.
2. Musculoskeletal disorders that have become chronic because of
repeated aggravation do not go away as soon as the ergonomics of the
workplace or job is improved. They are likely to be less frequent and
show less lost time, but they will not disappear overnight. On the
other hand, first visits to the medical clinic for musculoskeletal
problems will probably decrease and more cases �ith no lost time will
be seen.
It is important to measure other medical factors, such as the number of
people who have job restrictions from heavier tasks, the number of people
who are not successful on those jobs or tasks, absenteeism on those jobs, and
the characteristics of the people who are successful on them. Job
satisfaction ratings can also identify the acceptance or rejection of the new
designs or job improvements.
Since the goal of ergonomics is to ��-8-�_gn�!,or most workers, it is important to
integrate it into the day to day operations of the business rather than keeping
it in a safety pigeonhole. Mature ergonomics programs are harder to
document. People have been trained,about the concepts and given the
guidelines to use in their own work, so it is no longer easy to isolate what is
ergonomics and what is the engineer's or worker's original concept.

4 7,

�·--•- ·
IV. The Benefits of Having an Ergonomics Program Standard
I will conclude by returning to the ori�inal questiqn:�y1 �� ..:)jY-e need an
ergonomics program standard today ?' I have no�been a
ergonomics
regulation because I find that more time and money is spent in arguing why
we should or shouldn't regulate this heal� _anq��&lt;?tl 1rea than is spent in
fixing the real problems in the workpla�.JR-ef{Jft� has the advantage that
it provides a priority for ergonomics improvements in an industrial
atmosphere that continues to try to do more with fewer people. Ergonomics
should not be an adversarial area between management and labor - both
benefit from good ergonomics applications. People are able to work better
and with less fatigue, leaving them some reserve to take home and share
with their families at the end of the shift. Occupational injuries and illness�··
should be reduced, and people who are injured outside of work are able to
return to the job earlier because their jobs are less likely to aggravate their
symptoms. In my review of hundreds of jobs in a variety of industries, I
have frequently found that many ergonomics problems are also process
problems. They should be fixed in order to improve the production process
as well as to protect workers' health and safety. When jobs are designed for
the majority of workers rather than for a small fraction of the potential
workforce, many of the hassles are alleviated that otherwise make first level
supervisors and team leaders tear their hair out, because more people are
able to fill in as needed. More ability to concentrate on quality work instead
of being distracted by discomfort from awkward postures or fatiguing
muscles means less reliance on overtime and its impact on workers' whole
body and mental fatigue in these days of global competition. In short,
having an ergonomics standard to address the most serious risk factors in the
workplace should give industries a priority to implement improvements that
will make them better able to compete in the global economy of the future.

:funof

Respectfully submitted,

�.•

1.-··

r.

Hearing testimony of Suzanne H. Rodgers, Ph.D.
on
OSHA's Proposed Ergonomics Program Standard
Washington, DC
March 2, 2000

Suzanne H. Rodgers, Ph.D.
Consultant in Ergonomics
169 Huntington Hills
Rochester, NY 14622

I. My Qualifications

My name is Suzanne Rodgers and I have been working in the field of
industrial ergonomics for the past 32 years. My doctorate is in Physiology
from the University of Rochester School of Medicine and Dentistry.The
goals of my on-site studies have been to identify ways to design jobs,

�/'--\
\)

workplaces, equipment, and environments to reduce the risk of developing
musculoskeletal injuries and illnesses on the job.
For 13 years I was employed by the Eastman Kodak Company where I
learned the applications of ergonomics by being out _on the production floor
or in the field. I measured the metabolic, muscular, and cardiovascular
demands of the "problem" jobs using employee volunteers and also learned
about production needs. In those 13 years, I was taught by the workers,
their supervisors, engineers, medical specialists, skilled trades people,
human resources professionals, and my colleagues in the Human Factors/
Ergonomics Section of the Kodak Health and Safety Laboratory. I learned
that it is possible to reach production goals without putting people at risk of
developing significant occupational injuries and illnesses. From our work
with production employees and with engineers, we were able to find better
ways to design the workplace, production equipment, environment, and job
tasks so more output was achieved with less injury risk for the worker. I
included many of these guidelines in our two-volume reference book,
"Ergonomic Design, for People at Work" {Eastman Kodak. 1983, 1986 (26-1283)}, a
work that is considered one of the classical references in applied
ergonomics.

()
-.. . .,-

Since 1982, I have been a full-time, self-employed ergonomics consultant
and have had the opportunity to develop ergonomics programs and
processes with clients in 267 large, middle-sized, and small plants, in 12
hospitals and service organizations, and in a municipality. My consulting
work is done in conjunction with training in many of the programs
mentioned above. I have written 3 books, 8 papers in journals, monographs,
and conference proceedings, and 5 chapters for ergonomics and medical
books. In addition, I have spoken at 85 professional conferences throughout
North America, primarily on factors related to the control of injury and
illness risk through the application of ergonomics principles to the design of
jobs, workplaces, equipment, and working environments.
You have already heard testimony about the large numbers of
musculoskeletal injuries and illnesses seen in companies over the past
2

�several years. From 32 years of experience watching and measuring people
at work, I finnly believe that the musculoskeletal injuries and illnesses seen
in the workplace are real, and that they can be managed and reduced
through better design of workplaces, equipment, environments, and jobs.
Until recently, I believed that ergonomics should be able to sell itself to
companies without an OSHA standard. My posture for many years was to
let the more progressive employers show the others the benefits of
ergonomic design. But, now I think that an ergonomics standard is needed
in order to put a priority on the need to address musculoskeletal injuries and
illnesses in the workforce. The long term costs of musculoskeletal
disorders, combined with increased health care costs, add to the reasons
why we should take steps now to prevent these types of job-related injuries
and illnesses (Exs: 26-54, 26-33, BLS; 64 Federal�gister 65768,
65975-79).
The proposed ergonomics program standard is flexible and does not limit
the ways that ergonomics can be integrated into operations. It recognizes
that many problems can be addressed through _a "quick fix," and stresses the
importance of teamwork in resolving problems. The proposed rule's
" grandfather clause" acknowledges that many companies have already
implemented ergonomics programs in their plants, and these programs will
satisfy the rule providing that the injury and illness rates are being
addressed effectively. Most of the companies that I have worked with over
the past 18 years have ergonomics processes or pro grams that would more
than satisfyt,Cthe basic requirements of the proposed ergonomics program standard.

II. Scope of This Testimony

In my testimony I will address the importance of several of the basic
program elements of the proposed rule, including management leadership,
employee participation and involvement, job hazard analysis, hazard
controls, and training. I will also comment on the proposed OSHA triggers
3

�for job identification in the standard. My testimony is based on my 32-year
experience of building ergonomics programs in more than 250 plants, which
includes evaluating more than 4,000 jobs and finding improvements to
reduce injury risk on them.
In working with my clients to build successful ergonomics intervention
programs that result in injury and illness reduction, we have included the
same basic components that are spelled out in the proposed OSHA
ergonomic program standard, ones that are widely accepted in the field (cf,
Exs: 26-1370) .

. J. Management Leadership
�-

In my work with more than 50 different companies and businesses, in over
280 plants, I have found that management commitment and leadership are
essential to the success of an ergonomics program. Management
commitment to the ergonomics program/process is critical because high risk
tasks must be addressed, and people and resources (such as maintenance
specialists and engineers in larger plants) must be made available to
implement changes. Management sets the tone for how health and safety
issues are prioritized in the operations. It is common to see ergonomic
programs that specify content and structure, stating what is expected, who is
responsible and what resources are available. My clients know the
importance of communicating this information to assure the success of the
program so that ergonomic improvements are implemented to reduce
workplace risk factors.

/l,,.Employee Participation and Involvement
�Strong participation of hourly employees in every aspect of the ergonomics
program is essential because they know the most about the jobs.
Facilitating their participation in job analysis, problem solving, and in the
generation of solution strategies will help the plant to find cost-effective
interventions in both engineering and administrative categories.
In observing programs that have not had much staying power, the primary
4

�problem that I have identified has been that the steps between identifying a
problem and implementing a solution have not involved the people who
work in those jobs. This approach of"throwing it over the wall" to the
ergonomics expert, engineers or maintenance people to solve the problem
often results in a solution that cannot be implemented for reasons that were
not lmown to them when they observed the job.
Case Study 1:

A problem of getting a proper gasket assembly and seal on a refrigerator door in
one company (with over 1000 workers) was associated with increased reports of
forearm and wrist/hand discomfort from repetitive screwdriver use. Several
activities had been tried to reduce the hand stress including a partial automation of
the gasket assembly with a small robot, but there were still many quality problems
that the line workers had to fix. Two engineers watched the hand assembly work
and decided that they could make a fixture to assist the operators in holding down
the gasket on the frame so the screwing down task would be easier to perform.
The fixture was fabricated and presented to the operators about a month later.
Although the concept was okay, the engineers had not tried it out with the
operators and did not note that they were seated at the line. The fixture could only
be used if one stood up, and this was not a popular idea for people working an
8-hour shift. The operators appreciated the trouble that the engineers had taken to
help them work better, but they saw the fixture as creating new problems for
them, and admitted that they would probably use it as a door stop. The operators
were involved in analyzing the risk factors and defining the highest risk activities
with the engineers and production supervision in a subsequent training course.
_ Together, they were able to identify the semi-automation as the area that needed
attention so less manual rework of the gasket assemblies would have to be done.
The operators could then dedicate themselves to fixing the exceptions rather than
having to fix every assembly on the line.

The most effective programs I have participated in developing, in terms of
employee involvement, have been ones where no recommendation for a
workplace modification is made without sharing the ideas with the people
who work on that job on all shifts and getting their ideas and/or buy-in.
fl.Identifying Jobs

OSHA uses an OSHA 200 log recordable as a trigger for employers to use
'\

5

�(j

in identifying problem jobs. In manufacturing and materials handling jobs,
symptoms trigger the problem where the employer has knowledge from an
outside source that a risk for muculoskeletal injuries and illnesses exists and
the symptoms have persisted for at least 7 consecutive days after they have
been reported. In many of the programs that I have helped to initiate, my
clients have been interested in catching ergonomics problems before they
result in recordable injuries or illnesses. These programs focus on reducing
the risk factors before an injury is reported and use discomfort and early
symptoms to prioritize jobs for ergonomic improvements. High hazard jobs
get the first priority, but jobs without injuries that have known risk factors
are also addressed. Thus, my clients exceed the OSHA requirements for
triggering action in the proposed rule.
�Job Hazard Analysis
�Job hazard analysis is the method for defining the MSD risk in terms of
which factors contribute the most to it and determining why the risk factors
are there. It is a critical component of any ergonomics process or program
because it allows the company to define the problem before solving it. The
proposed rule requires that a job hazard analysis be done when a
musculoskeletal disorder has been recorded and a "quick fix" has not abated
the problem sufficiently to prevent additional injuries. The.importance of
using a job hazard analysis is to find the right and simplest solutions for the
probtemjobs. These solutions will be more likely to be found where there
is an analytical approach to the problem. The proposed rule's list of
physical work activities to look for when an injury/illness is detected on a
job are observable and practical. Employers/employees without extensive
ergonomics training should be able to find the factors on the list that are
most important to change in order to reduce musculoskeletal injuries and
illnesses.

Job hazard analysis must include the input of the workers on the jobs.
Without this input and analysis one can fix the wrong thing and incur
unnecessary expense.

/ \
\___�)

6

�Case Study 2:

People on a car assembly line (in a plant with over 1,000 employees) were
experiencing arm, shoulder, and back discomfort when handling doors off of an
incoming conveyor and on to a carousel storage unit, from which the assemblers
put them on the cars on the line. The group being asked to suggest ways to solve
this problem jumped into the fray without analyzing the jobs and came up with
very elegant ways of linking the line to the carousel so no manual handling of the
doors would have to be done. The cost of this improvement would have been
several hundred thousand dollars. What they did not hear was that the person
presenting the problem stated clearly that the incoming line and the carousel line
could not be linked because they had different flow rates. We eventually asked
enough questions to establish what the task demands were in terms of weights
handled, heights and reaches used, lifting frequency, and carrying distances. With
that information, it became clear that there were two major risk factors that could
account for the arm, shoulder, and back discomfort. The first was the force needed
to remove the incoming doors from the conveyor. They stood upright, and one
had to break them out of the track by applying a high force that was above
mid-chest height on most people. The second risk factor was the need to hold the
door about 28 inches away :from the body when setting it in the carousel
lengthwise. This breakdown of the risk factors resulted in a suggestion to use air
cylinders to push the door up out of the conveyor track where it could be handled
comfortably for the transfer to the carousel. At the carousel, the door could be
placed on a platform with a soft cover prior to sliding it into position in the next
carousel slot. The total cost for these two workplace improvements was estimated
to be less than $200.

tHazard Controls
I have had the opportunity to help companies identify ergonomics problems
and to work with them to control the risk factors that contribute to
musculoskeletal disorders in more than 4,000 jobs. I have found that
effective ergonomic interventions are identifiable and often simple-and
that employee participation in job analysis yields the best results. Solutions
are often a combination of engineering and administrative controls.
Case Study 3:

The operator of a die toggle press (to make a frame out of several metal parts) was
experiencing hand and wrist pain symptomatic of early tendonitis on the job. She
picked up 7 parts to place them in the die nest and made about 500 frames a shift

7

�on the press. She was rushing to keep the line supplied and had help from the
next operator to reduce some of the pace stress. In observing her work, we
noticed that one of the pieces she used was always set on the side of the press and
pushed on to realign it. She explained that the part did not fit in the die nest, so
she re-bent it by hand. This forceful push was identified as being very heavy and
quite frequent and contributed to the hand fatigue and pain mentioned by the
operator. Up to 5 seconds was spent re-bending the part, and this was the main
factor in getting her behind time on the line.
The operator'§ supervisor had checked with the Purchasing Department and was
told that the part met their specifications and could not be returned to the vendor
as an out-of-specification order. They agreed to tighten up the specification the
next time the part was ordered, but there was a 6-month supply of the "bad" parts
in stock, so the problem was not going to go away soon. The hazard analysis
indicated that most people would be at risk of upper extremity illness and injury
from doing 500 maximum effort hand exertions on this job each shift. The
decision was made to re-bend the "bad" parts off-line using a fixture and tooling
instead ofby hand in order to reduce the toggle press operator's injury risk until
the new part specifications were applied 5 to 6 months later. Reworking the die
nest to accommodate the parts was not really an option since re-engineering that
die would have taken several safety and client approvals and many months of
testing to implement.

Case Study 4:

Workers in a hospital Food Service department were experiencing low back pain
- �d upper extremity discomfort and symptoms that were associated with the
preparation of food trays for the patients. 12 people were lined up along 2 sides
of a 20-foot long conveyor belt with food items forming semicircles around them.
As each tray went by, the worker would read the menu and select the appropriate
items to put on it. Some people had been restricted from the tray line in order to
reduce their risk of getting more serious injuries or illnesses. I was asked to come
into the area in order to recommend an ergonomic chair for the lirte workers.
From the job analysis, we found that the workers were leaning and twisting
throughout the tray assembly process. Although they had thought their back pain
was associated with standing, it was more likely to be related to the leaning and
twisting. Chairs were only going to make the back discomfort worse because they
would have more twisting and pivoting and more extended reaches loading items
on trays from a chair. Using a problem solving approach, we identified 2
interventions that would reduce the leaning and twisting:

8

�I .Increasing the size of the type on the menus so they could be read from 3 feet away
(giving an additional 1 second for obtaining the items at each station). The menu was
redesigned by the department staff. and
2.Reducing the conveyor line speed a little bit each day until the workers were aware of it.
This would be the optimum speed that would balance the time needed to get the items
and put them on the tray when it was still in station and the need to move the trays
between stations in an efficient manner.
Both of these solutions were administrative. The combination of a 22% reduction
in tray line rate (from the vendor rate, not the actual rate being used on the job)
and a more readable menu resulted in a 7% decrease in the time to complete the
job. There was also a reduction in the error rate on the line from 15% to 1 %, and
a reduction in errors detected on the patient floors from 3% to 0.1 %. We saw a
reduction to almost nil of the medical restrictions and complaints of low back pain
and upper extremity discomfort formerly attributed to this job.

Case Study 5:

In one machining/assembly plant (with more than 1,000 employees), there were
increased complaints about hand and wrist discomfort on a disc sanding job after
a new inventory control program was introduced. Analysis of the operations
showed that the operators used 2 types of sandpaper, one with a paper backing
and one with a canvas backing. It was taking 2 times longer to do the parts
sanding when the paper-backing sandpaper was used. This was the probable
cause of the discomfort and symptoms that had recently appeared on the job.
Someone had set a reorder time of 90 days on the canvas-backed sandpaper and
60 days on the paper-backed discs. Since both were specified for the operation,
and since another department was also using the canvas-backed discs, there were
only paper discs available for most of the sanding operations over a 3-month
period. Re-specifying the canvas discs and putting a 30-day reorder time on the
item cleared up the problem.

Training operators to know when to change grinding discs or cutting tools
on machining tasks represent other approaches that are administrative and
can reduce injury risk on the job. Most of these become clear when the
workers or others doing the job analysis keep asking "Why?" until they get
to the root cause of a problem. Administrative changes are often very low
cost and easy to implement if management commitment and employee
involvement are present in an ergonomics program.
9

�F. Training
The proposed rule has a requirement for providing both training on
musculoskeletal disorders and ergonomics to employees and their
supervisors who are working on jobs where MSDs have been seen and for
training people who are responsible for the ergonomics program
development. Most of the programs I have been involved in have had
ergonomics awareness training for all managers and supervisors and for all
employees. The best ergonomics programs I have been associated with are
those where the production workers are the primary problem identifiers,
analyzers, and solution generators. In smaller businesses, where the support
staff is thinner, this need to solve ergonomics-related problems on the floor
is even greater. Thus, training is critical to assuring that the plant
management and employees can move the program forward. In addition to
my training and consulting for companies, I have participated in ergonomics
training and awareness programs for small businesses sponsored by the
Occupational Safety Section of my local Chamber of Commerce. Similar
programs that I have been part of have been sponsored by professional
organizations and by the State of New York.

(,)

In addition to the general awareness training mentioned abov�, my client's
ergonomic programs include special training for the persons involved in
setting-up and managing the program. In the plants I have worked with, this
job is often done by the members of an Ergonomics Team. I have trained
ergonomics teams in about 250 plants and businesses. More than 5,000
people have participated in these team training courses over the past 18
years.
I have found that I can train production workers and the support staff to
think like ergonomists, and can facilitate them through a fairly simple job
analysis or lifting guideline to a problem solving process that generates
several ways of addressing the root cause of the problem. The best
programs, I find, are those where the plant takes ownership of the
ergonomics program. One does not need an ergonomics expert to run them

CJ

10

�once they are trained.
III. The Benefits of Having an Ergonomics Program Standard
I will conclude by returning to the original question: Why do we need an
ergonomics program standard today? I have not in the past been a fan of
ergonomics regulation because I find that more time and money is spent in
arguing why we should or shouldn't regulate this health and safety area than
is spent in fixing the real problems in the workplace. This proposed
Ergonomics Program Standard has the advantage that it provides a priority
for ergonomics improvements in an industrial atmosphere that continues to
try to do more with fewer people.
I believe that the implementation of a flexible, performance-based,
ergonomics standard will be a positive step in the prevention of
occupational injuries and in optimizing the design of problem jobs. By
allowing companies to develop their own ways of incorporating ergonomics
into their operations and measuring their effectiveness in decreasing the
occupational injuries and illnesses, the proposed ergonomics standard can
help to underline the importance of health and safety priorities in parallel
with production demands. In short, having an ergonomics standard to
address the most serious risk factors in the workplace should give industries
and businesses a priority to implement improvements that will reduce
injuries and illnesses and make them better able to compete in the global
economy of the future.

11

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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l

QUESTIONS ON THE DEVELOPMENT OF A PROPOSED
ERGONOMICS PROGRAM STANDARD
FOR STAKEHOLDER MEETINGS
September 24 and 25, 1998

I. PUBLIC PROCESS
OSHA is meeting with stakeholders to draw upon their individual expertise as the agency
develops a draft proposed standard to protect workers from work-related musculoskeletal
disorders (MSDs). OSHA's ongoing efforts to foster public dialogue on this subject involve
many stakeholders, including workers, employers, trade associations, unions, State and local
governments, professional organizations, other Federal agencies, and our advisory committees.
In accordance with a prohibition included in OSHA's appropriation, the Agency will not publish
any proposed standard during fiscal year 1998. The prohibition prevents OSHA from
promulgating or issuing "any proposed or final standard regarding ergonomic protection before
September 30, 1998." The prohibition expressly allows OSHA to "develop a proposed standard
regarding ergonomic protection" in the meantime. Because of the many tasks associated with
drafting a proposed standard, OSHA does not anticipate publishing any proposed rule in the
Federal Register until, at the earliest, the summer of 1999.
In the meantime, OSHA is obligated to engage in a long list of pre-proposal actions:
(1) continue dialogue with stakeholders and the Agency's advisory committees;
(2) conduct economic and risk analyses;
(3) continue to review the extensive research on work-related MSDs;
(4) develop the regulatory text;
(5) develop the preamble and other supplementary analyses;
(6) assess the impact of a draft proposed rule on small businesses and, depending on that
impa_ct, convene a small business panel under the Small Business Regulatory
Enforcement Fairness Act (SBREFA);
(7) submit the draft proposed rule for Departmental review and clearance; and
(8) submit the draft proposed rule to the Office of Management and Budget for Executive
Order 12866 review.
Each of these activities takes time. OSHA will not begin the SBREF A process until it has
formulated its ideas for the regulatory text and evaluated potential impacts. The SBREFA
process takes a minimum of two months, after which OSHA must respond to the comments of
the SBREF A panel. After this is done, OSHA must submit the draft proposed rule to 0MB for
an additional review that lasts a minimum of three months. Only after each of these steps has
1

�been completed is a proposed rule ready for publication in the Federal Register.
Once a proposal has been published, OSHA will undertake another extensive effort to obtain
public input through public comment and the agency's informal hearing process. Informal public
hearings allow for extensive comment and questioning on relevant subjects by the scientists,
economists, safety and health professionals, representatives of potentially affected industries,
workers and other interested parties who participate. After the hearing ends, participants are
given additional time to submit comments and briefs.
OSHA is meeting with various stakeholders at this time to seek their input on key questions that
must be addressed in whatever proposed ergonomics standard OSHA publishes. These
discussions are occurring early in the standard development process, to give OSHA the benefit of
stakeholder experience as the agency drafts its proposal.

II. WHY A STANDARD IS NEEDED
The most recent Bureau of Labor Statistics data show that 34% of all lost-workday injuries and
illnesses are musculoskeletal disorders. Workers' compensation costs for these disorders account
for more than $20 billion annually. BLS data show that MSDs like carpal tunnel syndrome
cause, on average, more days away from work than is the case even for amputations, fractures, or
falls from heights.
Thousands of employers across the nation have addressed their MSD problems by implementing
ergonomics programs that prevent these disorders, save workers' compensation costs, and
improve worker morale and productivity. However, many employers remain unfamiliar with the
protective and financial benefit of implementing such programs. OSHA wishes to hear from
stakeholders on how a protective standard should be structured to reflect the effective practices
used by industry in such programs.

III. PRINCIPLES GUIDING OSHA'S EFFORT
OSHA believes that the development of a proposed standard should be guided by nine principles.
The proposed standard should:
•
•
•
•
•
•

be based on sound scientific principles;
focus on areas where the risk of MSDs is great and solutions are well understood;
maximize worker protection and minimize burden;
reflect practices shown to be effective;
call for efforts that are commensurate with the size of the MSD problem at that
establishment;
recognize the unique needs of small businesses;

2

�•
•
•

focus on performance and permit flexibility;
recognize employers who already have effective ergonomics programs; and
be written in plain language.

IV. ELEMENTS OF AN ERGONOMICS PROGRAM
There is widespread agreement that the following elements form the basis for successful safety
and health programs, as reflected in the voluntary Safety and Health Program Manag€ment
Guidelines issued by OSHA in 1989. These elements are the foundation of the ergonomics
program OSHA outlined in its Meat Packing Guidelines and of countless successful ergonomics
programs implemented·by employers across the country.
•
•
•
•
•
•
•

Management leadership and employee participation
Hazard awareness and identification
Training
Medical management
Job hazard analysis
Hazard prevention and control
Program evaluation

An ergonomics program standard would include these elements in some form. At this meeting,
OSHA is seeking input on how the elements of real-world programs can be embodied in a
proposed standard.
V. DISCUSSION OF KEY ISSUES
OSHA has held several meetings with stakeholders to discuss the Agency's ideas for a proposed
ergonomics standard. At those meetings, stakeholders expressed views ranging from opposition
to a standard to support for an OSHA ergonomics rule. Many stakeholders strongly favored a
program standard, i.e., a standard that includes the elements of safety and health programs that
have been shown to be effective in many different applications, as well as for a standard with a
narrow scope. A program standard with a narrow scope would differ in important ways from
OSHA's 1994-1995 efforts to develop an ergonomics standard. At the meetings with
stakeholders held earlier this year, OSHA discussed a standard that would cover manufacturing
operations, manual handling operations, and keyboarding operations. OSHA also discussed the
difficulty of obtaining data to identify those computer users at significant risk ofMSDs in order
to tailor the scope of the standard to these users. Various stakeholders urged the Agency to work
further on this problem, and OSHA has continued to do so. At the stakeholder meetings in
September, OSHA hopes to continue this discussion with stakeholders, and the following
material raises a question about this issue.

3

�OSHA has identified four key issues that the Agency would like to discuss with stakeholders:
A.

What should all employers covered by the scope of the standard do to protect their
employees from MSDs?

B.

What action levels should be used to trigger further employer action?

C.

How does an employer with an effective program determine when controls are
adequate for a problem job?

D.

Should OSHA limit the scope of a proposed ergonomics program standard?

4

�KEY ISSUE A: What should all employers covered by the scope of
the standard do to protect their employees from MSDs?
OSHA is working on a draft proposed ergonomics standard that would establish the basic
obligation of all employers covered by the standard but would then incorporate action levels that
would trigger action such as analyzing jobs for risk factors, developing solutions and
implementing controls; providing additional training; or applying medical manageme,nt
procedures. OSHA believes that hazard identification is an essential part of any effective
ergonomics program, and seeks input from stakeholders on how best to ensure that employees
are aware ofMSD hazards and that MSDs are reported promptly.
QUESTIONS:
1.

What minimum elements of an ergonomics program should all covered employers
be required to have in place? How do those elements protect employees from
MSDs?

2.

How do employers with ergonomics programs determine when it is necessary to do
more than monitor workplace conditions?

3.

Thinking beyond the minimum requirements for covered employers, how should
further requirements of the standard be tailored to correspond to the magnitude of
the MSD problem in a given workplace?

4.

What are some of the ways an employer with an effective ergonomics program can
demonstrate management leadership of that program?

5.

What steps should an employer take to encourage employee awareness of MSD
hazards?

6.

What steps should employers take to encourage early reporting of MSD hazards?

7.

What steps should an employer take to increase employee participation in an
ergonomics program?

8.

How can an employer be sure that the hazard identification phase of an ergonomics
program is working effectively?

5

�KEY ISSUE B: What action levels should be used to trigger further
employer action?
OSHA would like to discuss whether the recording of a job-related MSD is a useful "trigger" or
"action level" for requiring further action in an ergonomics program. Further actions might
include job analysis, implementation of controls, additional employee training, and medical
management. The purpose of an incident-based trigger of this type is to ensure that employers
act when real problems occur and to limit the number of jobs an employer is required to address
at one time.
Stakeholders at the July meetings suggested that the standard should incorporate a variety of
"triggers" which employers might use in their programs. For example, the triggering event for
"medical management" might be different from the trigger for implementing controls. Some
practitioners pointed out that they use different triggers for different workplaces, depending on
the conditions in or size of the workplace. For example, a single incident may be an appropriate
trigger in a small workplace or where only a few employees perform certain jobs or tasks; in
large workplaces, or where many employees perform nearly identical jobs and tasks, an incident
rate change may be a better trigger. Others analyze jobs when changes in work methods,
materials or processes are planned.
Some stakeholders also suggested that a prioritization system based on seriousness of hazards
could be incorporated into an ergonomics standard to "phase in" the abatement of hazards
identified through the program. Under such an approach, employers might be required to
analyze and fix some percentage of all covered jobs by a certain date, followed by phase-in dates
for fixing the remaining jobs.
QUESTIONS:
1.

What are the trigger events (e.g., observation, occurrence of an MSD, results of a
symptoms survey) that employers with effective programs rely on to indicate that
job analysis, job controls, medical management, and/or job specific training are
needed?

2.

Should the signs and symptoms of work-related MSDs, in addition to recordable
occurrences, trigger further action? If so, which signs and symptoms should trigger
such action? For example, should all signs or symptoms trigger further action, or
only those that persist for some period of time?

6

�3.

Would it be appropriate and useful for OSHA to develop a list of alternative
triggers and to offer employers flexibility to choose among a combination of those
action level events or conditions?

4.

Do certain high-risk jobs warrant further action even before an MSD occurs? If so,
how can such jobs be identified?

5.

What criteria would employers use to prioritize jobs for implementation of
controls?

7

�KEY ISSUE C: How do employers with effective programs
determine when controls are adequate for a problem job?
In earlier meetings, stakeholders said that a proposed ergonomics standard needs to tell
employers when they will be considered to have installed adequate controls (including training,
work practices, administrative controls, and engineering controls) on a problem job. OSHA is
seeking feedback on how best to translate effective industry practice into regulatory t�rms.
Some stakeholders suggested than an ergonomics program is an on-going effort, and therefore,
that OSHA should evaluate the process and not the intermediate results of the ergonomics
program. They felt that the occurrence of incidents of MSD by themselves is not a good measure
of the effectiveness of a program. Several employers suggested that an alternative means of
evaluation of the workplace program would be to measure the activity and progress of the
ergonomics process. Such measures could include steps taken to implement elements of the
program, actions taken in response to reports of MSD, jobs analyzed, controls evaluated, tested
and implemented, or changes of patterns of MSD incidence. These and similar measures could
become indicators of good faith efforts to implement a control process.
QUESTIONS:
1.

OSHA intends the proposed standard to recognize that employers who have
implemented a control process in good faith and are taking reasonable steps to
address their MSD problems should not be at risk of a citation. How can OSHA
best do this in a standard?

2.

How should OSHA determine compliance with an ergonomics program standard?
What measures clearly indicate that a program has been properly implemented?
How can employers, employees and OSHA decide whether a program is effectively
identifying problems,·generating solutions and following through on
implementation and evaluation of results?

3.

What processes do employers with effective programs use to set priorities for
controls for problem jobs?

4.

What processes do employers with effective programs use to select controls for a
job determined to be a problem?.

5.

How do employers with effective ergonomics programs determine that a particular
control is functioning adequately or inadequately?

8

�6.

How do effective programs incorporate training, employee participation, and/or
administrative controls into the control process?

9

�KEY ISSUE D: Should OSHA limit the scope of a proposed
ergonomics program standard?
At earlier meetings with stakeholders, OSHA discussed taking a phased regulatory approach to
the problem of work-related musculoskeietal disorders (MSDs). Since those meetings, OSHA
has focused on limiting the scope of the first phase to two operations: production work in
manufacturing and manual handling in general industry. These operations are of interest because
their reported rates of musculoskeletal disorders are 2.6 times the rate for all of private industry
and account for over 65% of all reported MSDs, but involve only 25% of all private industry
employees. OSHA is aware that this narrow scope excludes many operations that pose
significant risk and cause substantial disability among workers. For example, a standard that
addresses production work and manual handling might not address the problems that lead to
carpal tunnel syndrome in computer users or retail cashiers. OSHA is seeking input on effective
ways of addressing these and similar significant risks.

QUESTIONS:
1.

Should OSHA limit the scope of the first phase of this rulemaking to certain jobs,
risks, or operations?

2.

How should OSHA identify other high risk jobs, risks or operations for which
solutions are well understood?

3.

What data are available that would permit OSHA to identify those computer users,
cashiers and other workers whose jobs might not be included in "manufacturing
operations" and "material handling" but who are at significant risk of incurring
work-related MSDs?

10

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>1

Suzanne H. Rodgers, Ph.D.

Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

'

Comments on the Development of !l Proposed Ergonomics
Standard by OSHA/DOL, in connection with the Stakeholders
Meetings, September 24th and 25th, 1998

Key Issue A: What should all employers covered by the scope of the
standard do to protect their employees from MSDs ? .
1. What minimum elements of an ergonomics program should all covered
employers be required to have in place ?
At a minimum, an employer should have a program that educates
employees about MSDs and risk factors, encourages them to report
discomfort early, and has a process to assure that job analyses and problem
solving by the employees will lead to interventions to reduce the risk of
MSDs. A process for returning people to work after an MSD has occurred
should also be in place. Management commitment is best measured by the
number of job improvements made in response to employee reports of
discomfort or injury and by the amount of time employees are permitted to
work on ergonomic projects and receive training.
2. How do employers. with ergonomics programs determine when it is
necessary to do more than monitor workplace conditions ?
If the employer has a medical department or uses a nearby clinic, records
of visits for musculoskeletal discomfort give a late indication that
ergonomics issues may need to be addressed. A structured program of
reviewing all jobs in the plant over a 1 to 3 year period (depending on
plant size and frequency of changes of jobs), in addition to responding to
injuries and illnesses, can assure that problems are picked up earlier.
The usual problem is that people do not want to "bother" their supervision
about muscle soreness, .so they wait too late to report it. The most
successful companies make it acceptable to mention soreness by treating
suggestions for job improvements as positive contributions from the
employees, not as complaints.
Another time when it is necessary to do more than monitor the workplace.
is when a significant change is being made in the job, workplace,

�2

environment, or tooling. The ergonomics team can review the plans
before implementation and identify any added risk for MSDs instead of
waiting for them to appear after the changes are made.
3. Thinking beyond the minimum requirements for covered employers,
how should further requirements of the standard be tailored to corres­
pond to the magnitude of the MSD problem in a given workplace ?
More matQre ergonomics programs have sometimes been penalized because
they have reached the stage of integrating ergonomics into all phases of a
plant's operations. Consequently, they may no longer have the structure
that they once had because more people have been trained and there is less
need for a separate team to deal with ergonomics issues. If an outbreak of
MSDs occurs, these plants would be more likely to set up a corrective
action team (CAT) or to designate the health and safety team to set up an ad
hoc team to investigate the problem and recommend action. This qpproach
should not be considered inappropriate because it puts ergonomics where it
should be, on the floor and within the responsibilities of every work
center.
As in all health and safety issues, the way the goal is reached should not be
restricted so as to set up yet another structure that generates more
paperwork than action. Good safety and medical surveillance, carefully
done "comfort" (as opposed to symptom") surveys, and an open attitude by
the employer to respond to suggestions for ways to improve the jobs will
usually assure that major ergonomics issues are not missed. Prescriptive
solutions that do not emerge from a problem solving process involving
hourly workers, support staff, and supervision are less likely to be
effective and are more likely to run into funding limits.
More attention should be paid to the role of job design in resolving some of
the ergonomics issues. Administrative improvements are currently limited
primarily to job rotation, slowing down the speed of a line, and giving
additional rest breaks, all of which may affect productivity and quality
goals. Good job design can build the needed recovery time for active
muscles into the tasks and can cut the time needed for recovery by
focussing on the elements of tasks that require the heaviest efforts and
longest effort times (e.g., those that are most fatiguing). Without
prescribing how this is done, one can indicate that improving the job design
to minimize fatigue is an effective way to reduce overexertion injuries. I
have found that the hourly workers know exactly what needs to be
improved even though they may throw a common solution at it rather than

�3

looking at all of the ways the task/job can be improved. For example, not
every heavy lift needs a hoist; sometimes an adjustable-height cart is all
that is needed to move the item into position by sliding it.
4. What are some of the ways an employer with an effective ergonomics
program can demonstrate management leadership of that program ?
I have not yet met a manager who wants employees to be hurt on the job.
Most of them do not understand why the job is a problem if only 1 out of
6 or 3 out of 20 people have reported MSD problems. They do not
understand the reporting issues or the individual susceptibility that helps to
explain those figures. It is a similar problem to the one that results in
many back injury reports being attributed to "improper lifting", with the
recommended action being to either teach the person to lift better or tell
them to be tnore careful. There is still an underlying belief in many plants
that you find the people who can do the work safely (train them how and
enforce the training rules), and anyone who can't do it, can't have the job.
The notion that the job can be designed to accommodate most people is still
a new one to many managers. I can often sell them on the desirability of
improving the job by pointing out that jobs that can only be done by 20%
of the potential workforce create a hassle for supervision when the usual
people doing them go on vacation.
The usual problems I see with management leadership relate to the
problems of today's production world. There are too few people to do the
work, so making time available for an hourly worker to be part of an
ergonomics team, or to get ergonomics risk factor or problem solving
training, becomes an issue. Many of the hourly people involved on the
teams have found themselves doing some of the work outside of their
normal working hours and without pay. Even with their dedication to the
process, this is not an appropriate �xpectation. Although the numbers will
be hard to retrieve, it is useful to document how many hours are spent in a
plant on meetings, investigations, and implementation of ergonomics
solutions. The dollar amounts spent each year are useful, but can be
misleading. Good problem solving often results in low cost solutions that
are very effective. Throwing hoists and lift tables at problems is very
expensive and may not be effective. A count of the numbers of projects
addressed each year and the average time to resolution (i.e., completed
action), as well as the cost and time spent, will also give a reading of
management commitment.

�4

A measure of management commitment that has not been used very much,
but does appear to correlate With the more effective programs, is how
many times a year ergonomics is on the management's agenda in their
regular meetings. In general, if the topic is on the agenda on a regular
basis, the program/process is active and management is keeping informed.
If it never shows up on an agenda, ergonomics work may be active at a
lower level, but management is not actively involved. I usually suggest that
ergonomics be included on the agendae of quarterly or annual management
meetings across plants or within a company, often in association with the
EHS (Environmental Health and Safety) presentations.
Another management role is to be sure a budget is available for addressing
ergonomics issues that are not major cost items. Some plants have set up a
"checkbook" for items under $ 500. that can be used at the team's
discretion for tools, assist devices (e.g., adjustable keyboard supports),
small carts, etc.). Other plants have indicated when approvals are needed
from a higher level, usually based on cost. In some plants, the teams
report through their plant's operations committee and make presentations
for all but the least expensive items at regularly-scheduled production
meetings.
Management must also resolve conflicts that can occur in the Maintenance
Department if there are many projects in the hopper and the ergonomics
ones keep getting shoved down the list. We have solved this problem in
many plants by assuring that at least one maintenance person is on the
Ergonomics Team and by getting approval from management ap.d the
union for bringing in an outside vendor/contractor if there is little hope of
Maintenance being able to get to the projects in the next few weeks.
5. What steps should an employer take to encourage employee awareness
of MSD hazards ?
For smaller businesses, every employee should have a minimum of a 1hour introduction to ergonomics and risk factors for MSDs as part of their
initial training and on an annual basis. Someone who can answer questions
should be present at each of these sessions, either a health and safety
specialist in the plant or a qualified professional from outside the plant.
There are good videotapes available on a number of ergonomics topics, and
these can be used for the annual refresher sessions. The employees should
be given an opportunity to indicate if they have musculoskeletal discomfort
and would like to have their job evaluated both at the training session and
within their department.

�5

If the plant has an Ergonomics Team, I usually suggest that the team
members do this training so they are known to the other employees as
people they can ask for help in looking at their jobs. The team members
have proven to be very good at answering questions, too, and know when
to refer the person to a medical specialist or to their supervision.
6. What steps should employers take to encourage early reporting of MSD
hazards?
The success rate of getting people to report their symptoms early depends
very much on the over-all psychosocial working environment and the
consequences of reporting soreness versus some disability from an MSD.
The best plants encourage early reporting of symptoms by responding to
short term problems positively and by looking for ways to improve the
jobs on a continuous basis. If a person has done something outside of work
that has set them up for an MSD, there is little emphasis on the Workers'
Compensation issue because the goal is to keep the employee on the job and
injury-free. Very short (2 to 3 days) job alterations or restrictions can be
used to let the short term overexertion injuries heal and to reduce
aggravation of the problem by the job.
Unfortunately, short term restrictions like this go on the OSHA log and are
considered a negative situation for the plant. There needs to be a better
way to recognize the need for occasional short periods of respite on a job
with some risk factors that could further aggravate an outside of work
injury. I am attaching a "think piece" that I put together in 1996 to help
describe the patterns of MSDs seen in the workplace to further address this
issue.
7. What steps should an employer take to increase employee participation
in an ergonomics program ?
a. Acknowledge that the employee is the expert on his/her job and is
essential to good problem identification, analysis, and solution finding.
b. Provide time away from the production or office job for ergonomics
training and for meetings and problem analysis and solving.
c. Provide a process for implementing agreed-upon changes and provide a
budget and project priority system to assure that small changes are not
delayed unnecessarily.
d. Publish the activities in the company newsletter and praise good work !

�6

8. How can an employer be sure that the hazard identification phase of an
ergonomics program is working effectively ?
Since thete are usually only 2 reasons why the reporting is not good, the
employee's decision not to report or management's desire not to have them
report, this problem can usually be resolved through education of the
employees and managers and through management commitment to solving
problem� rather than hiding them.
We have found that some hazards are missed because the tasks occur very
irregularly or rarely, such as a seasonal cleaning task or a rare
combination of circumstances that leads to a work overload for a few days.
As usual, the best source of information about these types of tasks are the
people who do the work. They come to the surface when looking at jobs
together and asking respectful questions about how things are done (in
other words, being their student on the job). An on-going process of
providing a way someone can call attention to these issues when doing the
job or afterwards will move the plant forward in hazard identification.
Some people comment that because these things are not done regularly,
they cannot justify spending alot of money on them. That may be true, but
there is no reason to think that alot of money will be required. Using a
problem solving process will usually come up with a policy or an assist
device or a job process change that will reduce the risk substantially.
Hazard identification is needed before a process or piece of equipment goes
into the plant, too. So the ergonomics team or people trained in
ergonomics should be part of or consult with each new project team that is
designing or purchasing equipment or processes that people will be
working with. The people who install the equipment should also be
knowledgable about ergonomics or should be subjected to oversight by the
team so new problems are not created at this point in the project.
Key Issue B: What action levels should be used to trigger further
employer action ?
1. What are the trigger events (e.g., observation, occurrence of an MSD,
results of a symptoms survey) that employers with effective programs
rely on to indicate that job analysis, job controls, medical management,
and/or job specific training are needed?

�7

Everyone would like to know what the incidence of MSDs is in the general
population throughout the USA. Without a reliable number for general
incidence, it is difficult to decide what the trigger point should be on a
strictly epidemiological basis. The recent literature review from NIOSH
showed val�es all over the place, and I have learned from a local DOL
group that they use a trigger value of 10% of people self-reporting any
musculoskeletal discomfort for office jobs, based apparently on a Boston­
based DOL guideline.
For an ergonomics standard to reduce MSDs, I believe there should be at
least 2 levels of job "trigger": those risk factors that we all agree are
excessive for most people (handling very heavy weights, lifting more than
24 inches in front of the body, sustained work in very cramped or
awkward postures for a majority of the shift, and doing highly repetitive
hand work at muscle use frequencies exceeding 30/minute for a large
majority of the shift); and those risk factors where the risk is more related
to the combinations of effort intensity, effort duration, effort frequency .
and total time of the task per shift. A paper I wrote on this concept for a
meeting in Zurich in 1996 is attached. The decision that has to be made is
how many people can be protected in a standard without creating an
unreasonable burden on plant production needs ? We have already lost too
many manufacturing jobs to the rest of the world, and too strict a standard
would assure the flight of many of the rest of them. The quandry comes
from knowing that the best jobs are those where there is very little risk,
but, without a massive retooling of many plants, there are many job� that
can be done by a smaller percent of the workforce without risk but would
not meet the design standard. I have addressed this issue in my paper and
will only add that we need to keep clear when setting a standard for
ergonomics to reduce MSDs that we are defining hazard in terms of part,
not all, of the population in many repetitive motions tasks. I'd like to
protect everyone, but I'd also like to keep good jobs in the USA ! I think
we need to give employers some room to address the lower risk issues
differently than those that are a problem for most people.
2. Should the signs and symptoms of work-related MSDs, in addition to
recordable occurrences, trigger further action? If so, which signs and
symptoms should trigger such action ? For example, should all signs
and symptoms trigger further action, or only those that persist for some
period of time ?
My major problem with symptom surveys is that they are rarely done well
in the plant, and, often, they are not followed up on, so the employee who

�8

has identified a problem gets the feeling that no-one really cares. My own
suggestion is that plant areas should be selected based on health and safety
data and that discomfort surveys (10 point scale by body part) are
administered as part of a specific project to reduce MSDs in those areas.
All parts of the plant should be surveyed, but not all at once if one is to see
action in response to the survey. Like any good ergonomics process, the
surveys should be planned and progress in reducing risk through job
analysis and problem solving should be monitored on it. By targetting the
problems initially through the injury/illness data, it is not difficult to
explain why some areas get preferential treatment by the ergonomics team.
The use of a discomfort survey will let you know how accurate your
reporting system is and whether there is a need for further employee
education about early reporting or a need to educate a team leader or
supervisor about the importance of responding to employee discomfort.
The combined data will usually point to a few tasks where there are
significant opportunities for improvement, and the problem solving process
will usually lead to solutions that can be handled withing the department's
budget.
If one waits for a symptom or sign of an MSD to persist for a certain
period of time, one is not reinforcing the value of early detection in the
workplace. For a standard, I would suggest that symptom persistence is
significant if they last 3 days or more, basing this on the typical pattern of
short term overuse problems (see ""think piece" attachment on MSDs).
3. Would it be appropriate and useful for OSHA to develop a list of
alternative triggers and to offer employers flexibility to chose among a
combination of those action level events or conditions ?
Yes. Good luck!
4. Do certain high risk jobs warrant further action even before an MSD
occurs ? If so, how can such jobs be identified ?
I don't believe that having an injury is the best way to find high risk jobs,
although it is the most consistent way across plants because of the OSHA
reporting system. The tasks or jobs with the highest risks may not occur
very often, so, again, the best source for this information is the people who
do the job. They can be given a list of risk factors (see the Zurich paper
for details) and asked to identify tasks that may require those activities.

�9

Then, the next level of analysis can be done by the ergonomics team with
employee involvement.
5. What criteria would employers use to prioritize jobs for
implementation of controls ?
Where possible, the best priority schemes are those tied to the degree of
risk present or the percent of the potential workforce (men and women)
who would find the task acceptable (based on Liberty Mutual's lifting
studies). I use the accumulation of fatigue in 5 minutes of work as another
way of prioritizing the need to improve a job or task, adding caveats
according to the over-all work pattern during the shift.
Another factor comes into the picture in the field, however. Some
solutions developed in the problem solving process are easy to implement,
and others are more difficult or are affected by other projects in the plant.
Thus, I think that the prioritization approach should be tied to the high risk
jobs and that the less serious risks (where 50 to 75 % of the potential
workforce may not be at risk) should be handled in a work practices
mode, where progress against goals is tracked, but firm deadlines aren't
set.

Key Issue C: How do employers with effective programs determine when
controls are adequate for a problem job ?
1. OSHA intends the proposed standard to recognize that employers who
have implemented a control process in good faith and are taking
reasonable steps to address their MSD problems should not be at risk of
a citation. How can OSHA best do this in a standard ?
Avoid being too strict on the interpretation of what makes a good program
since there are many different effective models and mature programs or
processes look very different from start-up programs. My experience has
been that it is not difficult to tell who is doing a good faith effort and who
is not. In plants with a commitment to the ergonomics process or to health
and safety, there are people with the training and responsibility to respond
to ergonomics issues, and they can usually run through a number of
projects out on the floor where changes have been made in response to
employee discomfort or injury. The employees on those jobs, unless they
started working there after the improvements were made, will also

�10

comment on how much better the task/job is than it was before the
ergonomic improvement was made.
What should be avoided is heavy paperwork documentation of every phase
of the projects. I have struggled for years to find a way to make this easier
for the ergonomics teams, and it still doesn't get done, even by the best
plants. The usual comment is, "We know it is effective. Why do we have
to write it up ?". Because there is always plenty to do, active teams often
do not get to the paperwork and "just do it", so documentation can be a
problem. I try to get them to keep project lists and progress notes at their
regularly scheduled meetings and to do before and after videotapes to
illustrate their work. I also encourage them to make presentations to their
managers and to professional meetings so more documentation and follow­
up gets done, In some plants, I have seen so much emphasis on
documentation that very few job analyses and problem solving solutions get
done in the time allowed for ergonomics. So, some follow-up and
documentation is needed, but pay more attention to the over-all attitude
towards ergonomics on the floor and the numbers of completed projects.
2. How should OSHA determine compliance with an ergonomics program
standard ? What measures clearly indicate that a program has been
properly implemented ? How can employers,. employees, and OSHA
decide whether a program is effectively identifying problems.
generating solutions, and fallowing through on implementation and
evaluation of results ?
Set some process goals, such as having ergonomics knowledge in the plant,
a process for requesting job analyses, doing problem solving to generate
solutions, and implementing changes; there should be employee awareness
of risk factors and a medical management process for injured employees
and people returning to work. Set some outcome goals, such as reduction
of injuries/illnesses on jobs where high risk factors are present, numbers of
meetings per year, percent of employees trained in ergonomics awareness,
numbers of projects completed, etc ..
3. What processes do employers with effective programs use to set
priorities for controls for problem jobs ?
The priorities are often set by the perceived risk, which is often
determined by injury and illness data, specifically OSHA recordables.
With a good problem solving process for generating solutions, the cost of

�1 1

the solution is usually not too high, so priorities may often be given to
those projects with easy-to-implement solutions. Where there are serious
safety or ergonomic risks evident in an operation, priority is given without
regard to cost in many plants. For solutions that are costly but not
associated with a high risk for MSDs, I usually recommend that the costs be
planned over several years and that priorities be assigned according to job
demands. For example, if new chairs are needed in the production areas, I
recommend that the people who sit for 4 hours or more per shift be given
the first priority and that the others be phased in over a reasonable time
period. The same may be true for phasing in improved power tools or
new work benches.
4. What processes do employers with effective programs use to select
controls for a job determined to be a problem ?
Many processes are used, some more effective than others. Many plants
equate a type of injury with the lack of a piece of equipment or furniture
and spend a great deal of money "solving" the wrong problem, although
they have the best intentions. For example, not every backache in a
standing job is going to be improved with a fatigue mat on the floor. By
using a problem solving process that not only identifies the risk factors but
asks "Why are they present ? " , the ergonomics team can usually find
multiple ways to improve the job or task. For example, if a person is
bending over a floor pallet to inspect a part, the problem solving process
does not necessarily result in the common fix of placing the pallet on a lift
table. By asking why the person is bending over, one may learn that the
item being inspected has an identification mark placed on a label that is
very difficult to read or hard to see from the usual inspection location.
Although the pallet lift would be a nice piece of equipment to have,
addressing the location and.legibility of the label would reduce the time the
inspector has to be in an awkward posture and reduce the risk for back and
leg discomfort substantially. The cost of the lift would be likely to be
considerably higher than the cost of improving the labelling, and the side
benefit might be to reduce errors in transcribing the label information.
This would be more of an administrative solution than an engineering
solution, and those are less onerous financially for small plants to
implement.
5. How do employers with effective ergonomics. programs determine that
a particular control is functioning adequately or inadequately ?

�I2

If the plant is tracking injuries and illness by job or work center, is
encouraging employees to report discomfort early, has a medical
management process that assures that people with discomfort are followed
up in their return to work, has a team or people able to do ergonomic
analyses and to recommend and implement improvements to reduce risk
factors for MSDs, and has a process for making changes once they have
been approved, they will know if the program/process is effective. A
common outcome of a good ergonomics program is improved morale and
cooperation in finding and improving jobs or tasks that are production
problems as well.
They also ask their people to keep them informed about areas for
improvement on a regular basis, and they respect and act on their
suggestions or, better yet, give them the authority to resolve the problems.
6. How do effective programs incorporate training, employee
participation, and/or administrative controls· into the control process ?
The problem solving process requires that the hourly workers and support
staff and supervision sit· down together to find solutions for ergonomics
issues. The support staff will never know enough about thejob to solve the
problem in a way that is cost effective and will be accepted by the hourly
workers. The outside consultant will not be around to assure that the ideas
come to fruition in a job or workplace modification, and will never know
as much about the job or working atmosphere as the people who work in
the plant. The engineers will usually come up with an over-designed
solution, and they need to work with mechanics and the hourly people to
find the simpler solutions. Supervision has to fund the solutions and
explain them to the cost accountants, so they need to be involved in the ·
process as well.
When all of these people work together to determine how to reduce the
risk for.injuries (and.fatigue) on a job, there is a form of training going
on, especially if there are some analytical tools used (fatigue analysis,
lifting guidelines, postural analyses) and a videotape of the task. Very
often, administrative controls emerge from the problem solving process
where "Why ?" is asked until one runs into a dead end. These include
decisions to reduce the size of a load (chemical bag size when small
numbers are used) or change the way it is delivered (hoppers of chemicals
or Super Sacks instead of paper bags), production planning improvements
(when materials are delivered or decisions on when preventive maintenance
is scheduled), or staffing policy changes (adding labor temporarily when

�13

failures occur in automated equipment). I don't know how one reaches the
same point if the hourly workers are only asked to identify problems, the
engineers are charged with analyzing and fixing them, the maintenance
people have to implement those changes, and the supervision has to fork
out the money for it, all independent of each other. This "throwing it over
the wall" approach is fairly common when plants use an outside consultant
and do not develop ergonomics talent inside. It is subject to the power
structure in the plant (whether they think the consultant really knew
enough about the plant), to the degree of commitment of the hourly
workers to the solutions suggested, and to human relations issues that are
best resolved by sitting down to develop consensus.

Key Issue D: Should OSHA limit the scope of a proposed ergonomics
program standard ?
1. Should OSHA limit the scope of the first phase of this rulemaking to
certain jobs, risks, or operations ?
As discussed above and in the attached paper from the 1996 Zurich
meeting, I think that the standard should be set for high risk factors that we
can all agree on, because there are still many of those in plants. The risk
factors that begin to limit the numbers of people who can perform them
safely, but where at least 50% of a mixed (M/F) population would not be at
risk, would be better addressed through a work practices approach and not
be prescriptive in their approach.

2. How should OSHA identify other high risk jobs, risks, or operations for
which solutions are well understood ?

I worry about the phrase " ... for which solutions are well understood." here
because I find over and over that people throw equipment at problems
rather than doing root cause analysis to determine the real drivers of risk.
Two jobs that appear very similar on the surface may yield very different
solutions because of the circumstances prevailing in each situation.
I think that a panel of ergonomics experts could sit down and make a
preliminary list of high risk job requirements that could be used by plant
ergonomics teams to survey all jobs and set priorities for ergonomics
improvements. This would avoid the situation of waiting for a person to
have an injury to identify a problem job.

�14

3. What data are available that would permit OSHA to identify those
computer users, cashiers, and other workers whose jobs might not be
included in "manufacturing operations" and "materials handling" but
who are at significant risk of incurring work-related MSDs ?
They need to be treated under the second level of risk factors that I address
in my paper and above, because the risk is not inherent in the task itself,
but rather is in the way the task is done in time . In other words, it is a
multifactorial problem that cannot be treated by looking at one risk factor
at a time. I find that job design is the ultimate way to address the issues
once the person has been put in a reasonable workplace (one that meets
basic ergonomics guidelines for postural and visual comfort). Legislating
furniture, etc. is totally inappropriate, in my view, because it assumes the
problems are all related to equipment rather than recognizing that the way
the job is done (the employees control over the work) often determines
individual comfort and risk for MSDs. We lump these factors together
under "psychosocial stress factors" now, but some are really work design
issues that should be addressed through better job set-ups.

Respectfully submitted,
9/24/98 SHR

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                    <text>.·
Suzanne H.\Rodgers, Ph;D.
Consultant In Ergonomics

· · �1-69 Huntington Hills - Center
· · Rochester, New York 14622

Comments on the Draft Document 29 CFR Part 191 O Ergonomic Safety and Health Management Program

(716) 544-3587
(716) 266-8749 (FAX)

A. General Comments
Putting myself in the role of an industrial respondent to the questions
you are asking, I have the following reactions:
1. To answer all of the questions thoughtfully, I would need to spend
at least a month on the response. I don't have a month to spare.
2. I could cut out some of the time by not answering questions
that I don't have an immediate answer to (would require research or
calculations) and not answering questions the lawyers are going to
cut out anyways (what jobs are the injuries seen on?, how many
cases do I have?, etc).
3. What they should be asking is whether my company has tried

ergonomics and how successful have we been in reducing our
injuries. I'd save a lot of time if I could ignore most of these

questions and just send them a copy of our program - use the end of
year summary report we did last December.

4. It looks to me as if they have already decided that this standard will
be like the red meat guidelines; they are asking me to bless it with
my data. I would like to know how effective the standard has

been in reducing the incidence rates in the meat cutting
industry. (In one corporation with a worldwide ergonomics program,

we saw a 25% reduction in overexertion injuries in the first 2 years
of the program. Has a similar drop been seen across meat cutting
industries in the past 2 years?)

5. There are too many places where it is assumed that I know what an
unacceptable level of illness or injury is - where it can be identified
as job-related. The major diagnoses we are looking at (low back pain,
tendonitis, CTS, shoulder and arm strain and sprain, etc) can have risk
factors in recreational and home activities as well as in work
activities. Also, we know that some people are more susceptible than

�2.
others to some of these problems. I'd like to see more questions
that address the state of knowledge about job versus
non-occupational risk factors.
6. I don't feel comfortable about solutions being included in
any legislation since each problem may have a different solution
depending on the circumstances. I don't mind a performance
standard, but I don't want to be forced to do something that may not
be effective or may cost much more than needed to fix the problem.
7. This is a very reactive program - one responds to injuries with an
ergonomic redesign process. Many of the problems relate to
equipment and tooling that is not ergonomically designed in the first
place. Why isn't there some activity in the area of requiring
ergonomic involvement in the design process or a
performance standard that requires a machine or tool to
meet some basic ergonomic guidelines (usability, reaches,
clearances, maintainability, visibility, etc) ?
B. More Specific Suggestions
1. Use a much simpler form for gathering initial information from
industry about their experience with or concerns about ergonomics
programs. Put more emphasis on learning what has worked for them
and less on evaluating their thoughts about the meat cutters'
guidelines format. I have attached a suggested format that you are
welcome to play with. Anything much more than 1O pages long will
discourage many plants from responding, even if they have good
programs - just because everyone is carrying several responsibilities
now, and no-one has the time to write a treatise on their program.
2. Expand the section on how they are or are not using existing
ergonomics guidelines, including the meat cutters guidelines (or
the infamous draft document of the general guidelines from July,
1990 of which most companies have "pirated" copies), the Guidelines
for Manual Lifting, the Vibration Exposure guidleines, the Guidelines
for Exposure to Hot Environments, and the monograph by Verne
Putz-Anderson of NIOSH on Cumulative Trauma Disorders.
3. Ask more specific questions about how their programs are
organized and what record keeping (outside of OSHA logs)
they require. Find out their follow-up mechanisms and what data
they track to identify the effectiveness of their programs.

�3.
4. Find out more about how they developed ergonomic expertise in
the plant/workplace and whether they were satisfied with the quality
of that service if it was obtained outside of the company. Identify

the "expert's" qualifications and the specific projects or
work they did. You may be surprised by the outcome of this set of

questions. Ergonomics is a multidisciplinary field and a wide variety
of people can do parts of it very well, in many cases better than a
single "qualified" ergonomist can do them.

5. Most plants do not keep very good records of Before/After data on
ergonomics projects. I push this very heavily in my training and still
rarely get it except from a few industrial engineering coordinators.
The OSHA log will reflect some of the benefits, but this is the only
sure data you can count on. Attached is an example of a case study
report form I used to try to get some consistency in the reporting of
the first year's results of 3 pilot projects in a large corporation.
Despite the request for cost data, it was rarely given, even though
they all agreed that there were significant savings. It is just too
difficult to dig out the figures; and it does not seem necessary to do
so because people agree that the solution was effective and they want
to go on to the next one. Also, so many things change in a plant over 6
to 12 months, you cannot always identify how much the ergonomics
contributed to the response. In over 23 years of doing ergonomics,
I think I can count about 8 times when a really careful analysis
of cost/benefit on an ergonomic project has been done. In most
cases, the client felt that the time spent doing the documentation
was not worthwhile because the benefits were obvious.
Therefore, make the section of questions on the additional
benefits of ergonomics programs more qualitative - give
categories of improvement rather requesting specific amounts.
See the simplified format for an example.
6. Under management commitment and employee involvement
there are too many questions and most of them are getting at the
same thing. My guess is that the people who respond will have good
management commitment but will not necessarily have good employee
involvement. The usual model has the employees identify the "bad"
jobs and turn over the rest of the task to the engineers or to
maintenance to fix them. It is less common to see these groups work
together throughout the process to solve the problems and analyze the
job. Because the line workers are often not involved in the design of
the fix, the solution is often an engineering change that may not be
accepted by the workers because it may not work in practice (takes
too long, shifts the stress to another muscle group, makes it harder

�4.
to do a quality job, etc.). These are failures that discourage people
and make some managers think that ergonomics is an expensive way
to go. The failures may set up an adversarial situation between the
engineers and line workers instead of an appreciative relationship,
especially if someone tries to force the workers to use a tool that
really does not work for them. I think that what you need to know
is whether the line workers have really bought into the
ergonomics program and feel ownership for it or whether they
are on the sidelines and acting primarily as problem identifiers. This
can be identified by asking a few questions about the way a
project is handled. See the suggested form for an example.
7. Job site analysis can be very intensive or very casual, depending on
who is involved in it. For example, with a good problem solver, one
can do one-on-one training in a few hours on the floor. By providing a
fairly simple format for identifying problems and analyzing their root
causes (by using the question "Why ?" until you hit a dead end, then
going back and asking it again), one can often identify effective
strategies for resolving problems that contribute to poor postures,
excessive loads, or poor visual conditions. Although videotaping is
probably the best way to capture the mechanics of a job, it only
shows you what one or a few people are doing and should not be relied
upon totally. The best information will come from sitting down with
a number of people who know or have designed the job, workplace, or
equipment and using the videotape to ask questions and discuss the
factors that contribute to discomfort. Rather than lead the question
by suggesting specific job analysis techniques (such as
biomechanical models, the NIOSH Manual Lifting Guideline formula,
etc), the questions should be directed towards what they are
currently using and whether they are using such guidelines
to direct their designs or policies. I would personally deplore
any legislation for how one should analyze jobs. There are many ways
to look at them and no one way is adequate for all. Although I have
learned to use biomechanical models and understand their value for
comparing different lifting conditions, I have rarely used them to
either justify the need for a change or to design a better lift. I have
found it much more appropriate to use the NIOSH Lifting Guidelines
information (based largely on Dr. Snook's studies with an overlay of
the biomechanical model for single lifts) to predict the percent of the
population that might find a specific lift difficult. I am constantly
looking for better ways to do job site analysis and think that we are
very far from having a perfect system at this time. So, I do not think
one technique, or even a series of methods should be pushed, although
there should be a repository where interested people can go to learn

�about what is available. There probably should also be some attempt
to evaluate the results of some of these analyses and to see if they
can be validated based on epidemiological data. In the meantime,
however, I think that industry's experience with different methods
should be evaluated and fed back to the people who are developing
analytical techniques so further improvements can be made.
8. On the medical management issues, you should ask less about

the qualifications of plant medical people and more about
the policies and interaction with the local medical
community. There are a new set of considerations coming in with
ADA legislation, and even the meat cutters' standard will have to
revisit the issue of work restrictions in 1992. Therefore, I think
there should be more questions included about the impacts of

work restrictions and how they handle them, what concerns
they have about exposing people to additional risk, what
mechanisms are established for early detection of
overexertion or cumulative trauma problems, etc. I am
personally very negative about the symptom surveys

suggested in the meat cutters' guideline. I find that they create more
problems than they solve because at the time they are done there is
often no mechanism set up to respond to them. As a result, either
people are afraid to report because they think they may be taken off
their job, or they report their discomfort and nothing happens for a
long time. Both situations are a long way away from the desired
outcome of an ergonomics program - a close teamwork between
employees and supervision. Some questions about symptom
surveys should be included because it is a topic of great concern
to management. They do not wish to educate the workforce about risk
factors and health hazards before they are prepared to respond to
their employees' concerns.

9. Under education and training, I think the questions should relate

to content and timing of training as well as what level of
training is needed for different people. Providing checklists of

risk factors is some people's idea of training, but such an approach
may leave people without control over their exposures. In some
cases they may use the list to issue grievances or to bargain for
additional work privileges, whereas the outcome of the training
should be to provide them with the ability to identify and solve some
of the non-ergonomic aspects of their jobs. Training of the people
who design the equipment, select the tools or furniture, and build the
jobs is just as important as training the line workers, yet it has not
been focused on in these questions. Some commitment to

5.

�6.
incorporating ergonomics principles into the design and purchasing
processes should be included in the guidelines. Questions about
available training materials seem a bit out of place here, but perhaps
the question could be asked more generally about what materials
they have found most useful in their programs. Questions
about how the training was accomplished (who did it, what
topics were covered, what groups were involved, how much
time was spent, etc) could also help to identify how much is
effective versus how much is too much or too little.
10. Computer workplace legislation seems to be in vogue lately, and
there is justification for considering it as part of a general standard.
As before, however, I think it is entirely inappropriate to legislate
furniture or specific rest break strategies for office workers in a
standard. I have seen people throw money at these problems and buy
all new furniture and lighting for areas only to find that the effect on
the office workers' comfort has been marginal. Although good
furniture is desirable and should be provided in any workplace, there
are still driving factors for discomfort that will make more
difference if they are resolved than simply providing a new chair or
changing the height of the keyboard. The questions in this section
should be directed to the companies' concerns about
computer workplace issues. Are they seeing "ergonomic
problems" such as carpal tunnel syndrome, tendonitis, headaches,
visual symptoms, or low back pain ? What have they done to relieve
them ? What is their usual turnover of furniture ? What policies
have they initiated to build ergonomics considerations into their
choice of office furniture, lighting, and layout ?

It is always difficult to set a standard that will cover employers who are
already involved in ergonomics (because they are concerned about their
employees and wish to reduce their injury/illness rates) and, yet, will
still have teeth to assure that less enlightened employers will be held
accountable for non-ergonomic jobs that contribute to overexertion
injuries and illnesses. The fear of most companies who are already
actively involved in ergonomics is that the new standard will make them
abandon a proven model for one that may be less effective. This can be
avoided if the legislation is not too specific in determining how things are
analyzed and solved but rather focuses on the desired outcome.

8/11/91

Respectfully submitted,

�Suggested Questions for Review of ANPR of �9 CFR Part 1910,
Ergonomic Safety and Health Management Program
(Start with an introductory statement but please avoid the use of terms like "ergonomic hazards"
or "ergonomic risk factors". If anything they should be "non-ergonomic hazards" and
"injury/illness risk factors". Suggest that if a company has more than one program and they are
substantially different, they should submit information on each separately.)

A. General Information
1. What level of ergonomics activity is present in your company today ?
_
_
_
_
_

None, see no need for it
None, some in past, let drop
Some activity, not formal
Pilot projects in process now
Company-wide activity

_
_
_
_

None, but planning to start some
None, some in past, not effective
Activity in localized areas in company
Some activity related to citations
Other __________

2. IT you have had an unsuccessful experience with ergonomics, why do you
think it failed ?
_
_
_
_
_

Management commitment low _ Lack of employee participation/support
No depth - "one-man show" _ Lack of expertise in-house
Budget and personnel cuts
_ High costs relative to benefits seen
p
Im ractical solutions recommended by outside consultant
Inability to give ergonomics a priority
Other ________________________

3. Hyou do have some ergonomics activity or are about to start some, what
stimulated your interest in it ?

_ Low back problems
_ Repetitive work problems
_ Union grievances
_ Employee discomfort
Cost control measures
_ Union negotiations
_ Increased knowledge of field _ Discussions with other companies/plants
_ Anticipation of legislation
OSHA citation
_ Team approach philosophy
_ Continuous improvement philosophy
_ Design improvement process _ Competitivity issue
_ Corporate policy
_ Media attention to topic
_ Concern about long term health of employees
Other _______________________

4. What department/person is charged with the responsibility of overseeing the
ergonomic activity in your company/plant �· ____________
5. Please describe briefly the organization of vour ergonomics program/process
and attach any examples of documentation on the program that you can.
Problem Identification Approaches: ______________
Problem Analysis and Resolution Approaches: __________

�2.
Project Prioritization Techniques: _______________
Approval Requirements: ___________________
Funding Sources: _____________________
Implementation Processes: __________________
Follow-Up Procedures: ___________________
Program Evaluation Techniques: ________________
Communications Techniques:-----'-------------Education and Training Strategies: _______________
Use of Outside Consultants and Trainers: ------------6. Do you have an ergonomics process in place for your office workers ? _ Yes
_ No Describe any concerns you have about a general ergonomics standard
that includes office workers' jobs ? _______________
7. What have been some of the impacts of ergonomics approaches to reduce
overexertion injuries and discomfort in the workplace m your company? Please
mark the extent of the impact in the columns to the right for those measurement8
you have observed.
Impact
# of Injuries
Cost of injuries
Absenteeism Level
Job Turnover Level
# of Job Restrictions
Job Reputation
Training Time
Quality Performance Level

None

Little

Some

Sil,!nificant Very Laree

�Impact

None

L.iU.!e

Some

3.
Si�nificant Very Lari:e

Productivity
Amount of Rework
Scrap or Waste Levels
Employee Morale
Supervisory Stress Levels
Lost Time Days
Ability to Meet EEO Goals
Other _______
Other _______

B. W orksite Analysis
1. Which of the following guidelines/information have you used to develop
ergonomic policies or for analysis of problem jobs?:
_
_
_
_
_
_
_
_
_
_
_
_
_

OSHA Red Meat Cutters' Ergonomic Program Standard, 1990
NIOSH Guidelines for Manual Lifting (1981, 1991 ?)
NIOSH Guidelines on Vibration Exposure (198�n
NIOSH Guidelines on Exposure to Hot Environments (1972, 1978, 1986 ?)
NIOSH Monograph on Cumulative Trauma Problems - V. Putz-Anderson
Biomechanical Models (U of Michigan, etc)
Metabolic Models (Garg, U of Mich, etc)
Fatigue Models (Work/Recovery Needs)
Liberty-Mutual (Snook) Tables
Checklists
Methods Provided by Outside Consultants
Methods Developed Internally
Methods Learned at Conferences/Courses
Methods Taken from the Literature
Methods/Guidelines Developed by Other Plants/Companies
Other __________________________

Which 3 sources of information have you found to be most effective and useful
in your program? ________________________
2. Who performs the worksite analyses and develops the solutions? _____
Who is involved in looking at ergonomics issues in the design of new
workplaces, jobs, and layouts or in the reworking of an existing workplace or
machine? -------------------------3. How is a proposed solution introduced to the floor? _________

�4.
What control do the people affected by the change have during the
implementation penod? ___________________
I

4. Videotaping can be an important tool for analyzing jobs, particularly jobs that
are highly repetitive and ones that are done intermittently. Do you have any
concerns about suggesting videotaping as a recommended part of the worksite
evaluation process? _ Yes _ No Explain your concerns, if there are
any.
5. What qualifications have/will you look for wh�n having a worksite evaluation
performed by either an inside or outside "expert"? __________
How will/did you find an expert in ergonomics? __________
C. Hazard Prevention and Control
1. Which of the following hazard prevention and control strategies have you used
to improve jobs/workplaces/equipment/environments from an ergonomic
standpoint ?
Automation
Assist devices (hoists, lifts)
Outsourcing
Reduce speed of line/machine
Change specs on parts
Job rotation
_ Splints, belts, restraints
_ Employee education/awareness
_
_
_
_

_
_
_
_
_
_
_

_
_
_
_
_
_
_

Semi-automation
Height adjustability
Add labor to job
Modify production goals
Redesign product for better assembly
Job reassignment
Job redesign (changed content)
FitPess/wellness program

Team approach - self-directed workforce for problem solving
Environmental improvements (lighting, noise, vibration controls)
Workplace redesign (heights, reaches, clearances)
Improved processes to reduce more difficult tasks
Selection of employees for more difficult tasks (or Swot teams)
Set Purchasing guidelines to value ergonomic qualities of furniture/equipment
Build safety/ergonomics performance into personnel rating system
O ther _______________________

2. Which of the above strategies used have appeared to be the most cost-effective?
1. ---------------------2. ----------------

3. ----------------------

What are the average times for implementation of the above most effective
ergonomics intervention strategies?
1. ---------------2. ----------

3. ----------------

�5.
3. Have you documented before/after measurements of productivity, quality,
personnel issues, health, and safety statistics to determine the impact of your
ergonomics program? _ Yes _ No If not, why not ? ______

4. What size of budget do you think is needed to :initiate and to sustain an
ergonomics process/program in a plant/company ? __________
What level of expenditure requires a high level of approval in your company ?
How much can be commited by a department head without having to go to
higher levels (except in the initial budget process) ? _______

D. Medical Management

1. What processes have you used to detect early signs of potential ergonomics
problems in the workplace ?

_ OSHA 200 logs
_ Employee suggestions
Grievances
_ Productivity problems
_ Symptom surveys
Absenteeism data
Job turnover rates
_ High repair or rework
_ Long training times
Other ________

_ Medical or first aid logs
_ Safety meetings
Job restrictions
_ Qut'lity performance problems
_ Us� of outside expert to survey jobs
_ Use of internal audits to survey jobs
_ Difficulty staffing jobs
_ High scrap rate
_ Diniculty meeting EEO goals (women,
older workers)

Which three of th�se 1?rocesses have you found most effective for identifying
areas for ergonoffilcs nnprovements ?

1. -------------2. -------------3. ______________

2. What processes have you set up to encourage employees to report early signs of
sustained musculoskeletal discomfort ? ---------------

3. What approaches have you used to decrease discomfort after an employee has
reported symptoms ?

_ Sent to dispensary
Sent to clinic

_ Referred to own physician
_ Sent to specialist

_ Observed employee at work and recommended approaches to reduce the stress
on the affected muscle/joint
_ Initiated an ergonomics review of the job
_ Identified a job accommodation and implemented it
_ Provided assistance to employee for the tasks most difficult to perform

�_ Provided employee with a brace/splint/assist device
_ Educated empoyee about risk factors at job and at home

6.

_ Removed employee from her/his job for: _ a few hours
the shift
less than a week
a month
the forseeable future
_ until the symptoms abated
_ until the job was modified
Other _______________________

4. What are the most effective parts of your company's job restriction and return to
work policies? ________________________
What areas for improvement do you see ? ______________
5. Symptom surveys have been used in many meat cutting plants to identify the
magnitude of ergonomic problems. What are the positive and negative aspects
of doing employee symptom surveys in your company ?
Positive Impacts
1.

Negative Impacts
1.

2.

2.

3.

3.

How else can the magnitude of the symptoms in the workforce be determined?

6. Have you been successful in returning people to their original jobs (unmodified)
after an absence of more than 3 weeks for a musculoskeletal problem without
incurring a repeat problem? _ Yes _ No What approaches were used?
_ Employee awareness/education
_ Work hardening
_ Reduced job demands or help given

_ SpEnts/protective equipment
_ Fitress/wellness program
_ Changed tools/workplace intuitively (not
aware it was ergonomics)

7. Do you have a process for evaluating jobs when a person has been out for more
than 3 weeks with a musculoskeletal injury/illness that may be work-related?
_ Yes _ No If so, please describe the process and how the job
information is communicated to the medical people making the return-to-work
determination for the employee.

�7.
8. If a person enters a new job, is there a pol;icy of phasing her/him into that job
gradually so the skills and strengths can be developed without excessive stress
during the break-in period? _ Yes _ No
'

What concerns would your company have if a policy of work "acclimatization"
is suggested to reduce the risk for injuries in the initial stages of learning a new
job? _______________________

E. Training and Education

1. For the following people or groups in your company, please indicate the type of
ergonomic training or awareness you think is needed to provide the basis of an
effective program/process. N= None, A= Awareness, B = Basic training, I= Intensive Training
_
_
_
_
_
_
_
_
_

Top management
Line supervisors/Dept heads
Key operators
Medical specialists
Industrial engineers
Job Placement specialists
Process engineers
Skilled trades specialists
Facilities engineers
Trainers
Office workers
_ Purchasing specialists
_ Industrial hygienists
_ Product engineers
Other ________

_ Middle management
Foremen
Union stewards
_ Safety specialists
_ Labor Relations specialists
_ Production planners
_ Design engineers
_ Tool and Die specialists
_ Maintenance specialists
_ Materials Handling specialists
Production workers
Service workers
_ Wellness/Fitness specialists
_ Union leadership
Other _______

2. In what order were people made aware of ergonomics in your plant?
First:
Second:
Third:
Fourth:

--=--------------------------------------------------------------------

No
Would you change this order if you were starting again? _ Yes
What changes would you make and why? ____________

3. Who has done the employee awareness training in your company?
_
_
_
_
_
_

Outside consultant/trainer
Ergonomics team members
Internal company ergonomist
Industrial hygienist
Industrial engineer
Production supervisor
Other: -------

_
_
_
_
_
_

Internal company trainer
Ergonomics Coordinating Committee
Safety specialist
Medical or Fitness/Wellness specialist
Personnel specialist
Co-op student or summer employee

�4. Where have you obtained the materials for your awareness courses?
_
_
_
_

8.

Developed by the corporation _ Developed in-house
Purchased commercially
_ Obtained from seminars, courses
Taken from publications
_ Adapted from published programs
Purchased or taken from other companies with programs

5. What approaches have you used to obtain more intensive training for your staff
and employees?
_
_
_
_
_
_
_

Outside consultant on site
_ Outside training firm on site
Sent people to outside courses
_ Sent people to outside seminars
_ Hired ergonomist
Purchased training packages
Hired student with ergonomics training
Developed an ergonomics library
Brought in experts from other plants
Sent people to professional meetings
Visited other plants and studied their programs and approaches
Other ______________________

Which of the approaches has appeared to be the most cost effective? ___
5. How often do you provide ergonomics awareness or training programs or
schedule a discussion of ergonomics topics in a typical year (once the initial
phases of the program have been completed) ? __________
Is ergonomics included in employee orientation or new job training programs?
No
Yes
6. What means have you used to communicate ergonomics program successes inand outside of your company ?
_ Grapevine
_ Safi:!ty meetings
_ Production meetings
Conferences
_ Joint meetings of teams
_ Quarterly meetings
_ Company newsletter
Bulletin boards
Union newsletter
Plant newsletter
_ Suggestion System tie-in
_ Recognition ceremonies
_ Videotape on internal TV
_ Health and safety reports
_ Audit results reports
_ Ergonomics reports
_ Local community media
_ Presentations at professional meetings
_ Health fairs/Open houses
_ Management reports
_ Professional publications
_ Lobby displays
Other: __________

F. Other
1. Do you think there is a need for an OSHA regulation for the establishment
of an Ergonomic Safety and Health Management Program to reduce
No
musculoskeletal Injuries and illnesses in the workplace? _ Yes
Please explain why or why not. _________________

�9.
2. If you already have an ergonomics program, which three of its elements do you
think have contributed the most to its effectiveness ?
1. ----------------------2. -----------------------

3. -----------------'---------Thank you for your assistance in responding to this request for comments.
Please mail your responses to:
Hershal W. Hensley, Director
etc.

(8/12/91 S.H. Rodgers, Ph.D.)

(716) 544-3587

Suzanne H. Rodgers, Ph.D.

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

169 HUNTINGTON HILLS
ROCHESTER, NEW YORK 14622

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                    <text>Suzanne H. Rodgers, Ph.D.

Consultant In Ergonomics
169 Huntin¥ton Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Comments Regarding the Issuance of a General Industry OSHA
Standard on Ergonomic Safety and Health Management
1. Thanks to the good fortune of being invited to work in the Human Factors
Section at Eastman Kodak Company in 1968, I am now in my 25th year of
practiving ergonomics, 13+ years at Kodak and 11+ years as a consultant to
companies and municiJ?alities. At the time I joined the Kodak group, they had
already been studying Jobs and making improvements for 11 years. The
advantage of having many years of practical experience in this very challenging
and fascmating field is that one learns to look at each potential or real problem as
a set of unique circumstances. It is possible to develop cost-effective solutions
to almost all of these problems if the available talent in the business or plant is
tapped. Because we had to live with our mistakes as members of the same
company, we learned what worked and what didn't work in implementing
solutions in the workplace. We did extensive measurement of the physiological
responses of people during work, measured many work capacities to establish a
baseline for good job design, and did research on measurement techniques.
From this we learned that people doing the jobs could often tell us where the
problems or discomfort were before we could objectively measure them, and
that job design could contribute as much to problems as workplace or equipment
designs.
2. What has concerned me in watching the increased attention to ergonomics over
the past 5 years is that a very limited, mostly biomechanical, model is featured
that leads one to defming risk as a posture or a piece of equipment rather than to
how that posture or equipment is used in time. Many of the solutions that come
from the risk factor checklist type of evaluation of jobs or tasks involve
elimination of the person via automation of the process. This certainly reduces
the risk of injury to people (unless it is self-inflicted because of the lack of a
job), but it is often a very expensive and not very productive way to go. Such
solutions leave the management with the unpleasant task of having to choose
between an expensive solution to a safety problem or a loss in their competitive
edge in a global marketplace. In most instances, this is not the only ch01ce
available because very cost-effective solutions can be found to reduce the risk
for the workers if the problem is defined beyond the listing of risk factors. I am
concerned that a standard that perpetuates this model will result in companies
fighting ergonomics because of the apparent fiscal penalties to their businesses
when the field really can help to provide them with that very competitive edge
for which they are striving. To find the cost-effective solutions, what is needed
is a good facilitator and access to the people who design, work, supervise, and
service the workplaces and jobs of concern. An ergonomist who does not tap
into these talents short changes the client and employees because little happens if
they do not take ownership of the problem and solutions.
3. As a consultant, I have found it difficult to work with companies who want me
to give them the "ergonomic rules" so they can enforce them. Although there an

�some good design principles, I cannot think of many "rules" that wouldn't resul1
in an inappropriate solution at some point.. In manual materials handling tasks,
I can generate a few "rules", such as handling objects weighing more than 35
pounds or any object handled more than 6 times a minute below waist level for
more than 1 hour continuously by some other method than manual lifting
(sliding, for instance). However, other than "good ideas", like keeping the wris
in the neutral position, there are not too many other guidelines that are
"rule-like." One outcome of suggesting that there are such rules is that people
throw furniture and equipment at "ergonomic problems" and get mad at the
workers if they still complain of discomfort or symptoms.
4. The approach that I have found to be most successful in getting people to work
together to improve working comfort uses a problem solving technique (see
article attached to Section A comments later m this package). It complements
other improvement programs currently being used m companies, such as Total
Quality Management and Continuous Improvement. Ownership is given to the
people working on the jobs of concern, their supervisors, and service providers
(such as health and safety specialists, engineers, materials handling specialists,
and maintenance specialists), and things do happen. By teaching the team to
define the risk factors, why they are present (root cause analysis), and by using
a fatigue model to predict how much change is needed to improve the job and
reduce the risk, one can define several interventions and choose the one that gets
the most benefit for the least cost.
5. Despite active ergonomics programs to improve existing workplaces and jobs,
we still bring in new lines, jobs, equipment, etc., that does not meet good
ergonomic design criteria. There should be much more emphasis in any
ergonomics standard on the incorporation of ergonomics design guidelines into
the processess for purchasing or designing new plants, offices, equipment,
tools, and for setting up new jobs and defining new work schedules. There are
good design and evaluation guidelines for all of these (see, for example,
Ergonomic Design for People at Work, Volumes 1 and 2, from Eastman Kodak
Company), yet few companies have set up the processes to be sure the
ergonomics considerations are included.
6. There is value in setting an ergonomics standard if it is work practices and
results-oriented and does not specify how one has to get there. The general
sections on Management Commitment and Employee Involvement, Worksite
Evaluations and Analysis, Hazard Prevention and Control, and Medical
Management are fme {Jroviding they do not exclude effective ways of achieving
each goal. The inclusion of checklists and symptom survey forms is not
appropriate if it suggests that there is only one way to gather job and employee
discomfort information.
7. In the past 4 ye�s I have seen some very successful ergonomics programs hurt
badly by OSHNCompany citation resolution agreements that forced one procesE
on all plants. In 4 GM plants that were doing ground-breaking ergonomics
work (since the mid-1980's), the requirement to go to another process has all
but destroyed these programs that were far ahead of their times. People who
previously were empowered to make changes, call in vendors, requisition tools,
etc., have been told they cannot do that any more and must depend on engineers
to solve the problems. As a result, where there were several hundred changes
made in a year in the previous program to improve people's comfo� and ability
to work well, there have been only a handful of changes suggested m the past
year. They have more clout to enforce the changes, but far less is being

�accomI?lished. This should not be the result of the implementation of any
upcommg standard.
8. I suggest the following philosophy for an ergonomics standard, if there is to be
one:
a. If strains, sprains, overexertion, or cumulative injuries and illnesses are
present in the job, these will be investigated to determine how the jobs can be
rmproved and cost-effective changes will be implemented.
b. New plants, workplaces, jobs, equipment, and tools will be designed or
selected to meet ergonomic design guidelines.
c. Management will support the development of ergonomics problem solving
expertise in plant or business personnel, preferably at the work center or
departmental level. Every employee who may be exposed to non-ergonomic
job risk factors will be provided with awareness training and will be
encouraged to report their discomfort early to their supervision and the
ergonomics team so interventions can be initiated.
d. As part of the general process imJ?rovement goals of businesses, members of
the ergonomics teams should participate on production project teams doing
HazOp reviews and problem solving to be sure that the ergonomic concerns
are included in these evaluations.
Respectfully submitted,
�--. ,

1/30/93

�

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tl RI) iJf, ·�
£

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Attachments: Comments on specific parts of the Proposed Ergonomics Safety
and Health Management Rule
"A Functional Job Analysis Technique" reprint

�Suzanne H. Rodgers, Ph.D.

Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Comments on A. General - #1 a and b, p34196 of Federal Register
Vol 57 (149), Monday August 3, 1992 -#29 CFR Part 1910,
Ergonomic Safety and Health Managment; Proposed Rule
A. Working definitions for "ergonomics", "ergonomic hazards", and "ergonomics
disorders".
1.

As described in the comments on AJ?pendix A, I find the expressions
"ergonomic hazards" and "ergonomics disorders" oxymorons. If it is
ergonomic, it is not hazardous and does not result in a disorder.

2.

In doing my own consulting, training, and lecturing, I stress the multifactoria\
nature of repetitive motions disorders and low back pain and discuss what the
person can do to reduce personal risk factors (mostly related to body water
balance effects), what the engineers can do to reduce workplace, equipment,
and environmental risk factors, and what the "job designers" can do to reduce
job pattern, l?acing, and total hours of work risk factors. In my experience,
many repetitive motions disorders symptoms can be significantly reduced by
assuring that the shoulders are relaxed while working (or only tense for short
r,eriods during a work cycle). Thus, I do not talk about "hazards" but about
'contributors to discomfort", or "stressors". Few of the risk factors are
hazards in themselves. They appear to contribute to the problems through
synergism with other risk factors and through work patterns that do not build
in recovery periods after intense efforts (best done by varying the muscle
activity rather than stopping it).

3.

To get away from the oxymorons, I use the terms "ergonomic problems" with
jobs or "non-ergonomic stressors" and refer to jobs with these problems as
ones that will "benefit from ergonomics interventions". The use of the terms
"ergonomic disorders" and "ergonomic hazards" has created a negative
attitude towards ergonomics in some companies whose businesses would
benefit significantly from good applications of the design principles.

1/28/93 SHRodgers

�Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics

169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Comments on A. General - #2-4, p. 34196 Fed Reg. 57 (149),
Monday, August 3, 1992 - #29 CFR, Part 1910, Ergonomic Safety
and Health Management; Proposed Rule.
A. Program Components for an Ergonomics Standard
1. In my 24+ years of applying ergonomics principles in the field and
developing guidelines for use in industry, I have found that ergonomics
principles are most effective when they are integrated into every part of the
business. In my work with Goodyear and General Electric, we found that
teaching a process for evaluating jobs where employees were experiencing
discomfort and for anticipating the effectiveness of suggested improvements
would lead to very cost-effective interventions. The process of doing the
ergonomics problem solving builds teamwork, provides ownership to the
team for carrying through the changes, and most often results in production
improvements as well. The problem solving approach with teams made up oj
hourly employees, supervisors, maintenance specialists, materials handling
specialists, health and safety specialists and engineering specialists results in
strong employee involvement m not just the identification of problems but in
their effective resolution. The process is exciting to participate in and fits in
very nicely with Total Quality Management and Continuous Improvement
philosophies that are being implemented today in businesses of every kind.
2. In my work with some 25 companies, hospitals, and municipalities, I have
found that the weakest link in establishing an ergonomics process has been to
be able to determine where they are having overexertion or cumulative injuries
and illnesses, since many of them are not traumatic in nature. The OSHA
200 logs are the most useful data, but jobs are not indicated specifically and
one has to do a great deal of digging to identify which factors may be
contributing to problems that might be resolved by ergonomic interventions.
When I worked at Kodak, I had access to a data base with 39 variables per
report that I could cross tab with the personnel data file to get a person's job
stamped on each accident. Then, I could cluster accidents by building, job
family (handler, packer, assembler, etc.) across all buildings, agency of
injury, contributing agencies, length of service, time of day, etc. This very
powerful data base gave me the ability to prioritize the ergonomic needs of a
plant of 27,000 people and over 3,500 jobs. Most companies do not have
data bases anywhere near as sophisticated, but they could improve the OSHA
200 log's usefulness by including a more specific Job title on each report and
indicating the work center where the job is done. Similar information should
be included in first aid logs so early signs of potential ergonomics problems
can be identified.
3. The work site analysis is essential in defining ergonomic problems, but it is
my impression that far too much time is spent in analyzing every motion and
task systematically while the overall problems are lost in the detail. There are

�many different ways to analyze job demands, and I have found that
characterization of a job requires one to use several methods. However, if
people are experiencing discomfort or injuries/illness on a job, my first
mterest is to define how much we need to alter that job to make them
comfortable and able to work without the injuries and illnesses that may be
exacerbated by job demands. Identifying the risk factors has to be done in
conjunction with understanding how they come together in time to increase
the potential for overexertion or serious fatigue. In my experience, the fatigm
model best predicts problems because it looks at the effort, duration of effort,
frequency of that level of effort and total task time in one analysis. Many of
the risk factors included in the red meat cutting guidelines are components of
the effort part of the fatigue model. They describe postures and forces that
determine whether an effort is light, moderate, or heavy based on what
percent of capacity it takes for the involved muscle groups to exert that force.
What is usually missing from the industrial engineering and systems safety
analyses is an evaluation of what degree of control the mdividual employee
has over the pattern and methods of work. This determines what ability an
individual has to work within his or her comfortable range. When a person i5
constrained to work in a particular way that could overload a joint or muscle,
the opportunities for injury are greater than if he or she can modify the task to
make it fall on stronger muscles or can alternate the task with other tasks to
permit full recovery between exertions. In sum, then, a systematic evaluation
of the job in questions involves more than administering a risk factor
checklist. One must look at the demands of the work on the body and the
degree of control the employee has to alter them. With a risk factor evaluatior
only, one can overweight a very transient posture that is contributing very
little to joint or muscle stress while missing the more sustained but less
intense efforts to maintain posture.
4. The prevention and control measures usually focus on engineering changes
since these can eliminate the problems by automating the process. In today's
manufacturing climate, the investment of many millions of dollars in existing
plants to automate jobs currently performed by people is just not in the cards.
To maintain competitivity in the world market, most companies have to be
very cost effective, and most automation has not proved to be that. The good
news is that making it easier for people to work well through ergonomic
improvements is cost-effective and also reduces the opportunity for injuries
and illnesses. The "small engineering" approaches, that include relocation of
materials, improved flow of materials, some adjustability in working heights
(not just through workbench height adjustments), and improvements in
equipment design and tooling, are more likely to be inplemented effectively
than large capital projects. If they are evaluated appropriately beforehand,
these types of interventions have been shown to have very positive influences
on safety and health statistics, too.
5. Because I have had the opportunity to follow some ergonomics consultants
into plants where the risk factor a proach has been used and equipment has
been thrown at the problem, I fee fvery strongly that specific solutions should
not be included in an ergonomics standard. By using a problem solving
approach, one can always find a root cause for a repetitive motions or back
problem that can be addressed to reduce the risk for injury and illness. For
example, I have personally helped people improve their back comfort
substantially by removing a plastic mat under an office chair, increasing the
size of the type on a menu in a tray assembly line, and removing a section of,
machine panel that prevented a person from getting close to a pick-up point.

�Each of the solutions emerged from a careful look at back pain risk factors,
asking why? they were present, and defining the driving factor or root cause
for the risk factor's presence. All were implemented within a month, and all
resulted in effective reductions of discomfort for many workers. So, I think
it is very important to avoid an approach to the standard that suggests that
certain types of equipment or furniture will solve "ergonomic disorders"; the
root cause of the problem may still be there. In office ergonomics, for
instance, I have seen people surrounded by well-designed furniture who still
experience significant discomfort because proper supports for their feet or
arms are not available or their visual needs are not accommodated. In a study
of 21 people at one facility we found that improved workspace was a major
consideration, and this was far more important to address than the chair,
desk, or screen characteristics. The longer I work in this fascinating field, thf
more I learn that each situation has its own set of variables and a problem
solving approach is far more effective than buying all new ergonomic chairs,
desks, or changing the lighting. On the other hand, there is no doubt in my
mind that all people who work in seated workplaces should have
ergonomically-designed chairs and that adjustability is desirable. The
commitment to making the workers comfortable should come through a
phased-in program of updating equipment and furniture, however, not via a
case by case request based on low back pain or upper extremity disorders.
6. Under health management, I have found that early detection is the best way to
avoid the more serious repetitive motion and low back disorders. The best
form of early detection I have seen has been an active search for how people'�
comfort can be improved through the training of an ergonomics team in each
work center. The team is on site and can be called over to look at any job, so
they can look for cost-effective interventions before injuries and illnesses are
reported. They can also work with the medical practitioners to help define
potential risk factors for a person returning to work after an injury or illness,
whether this is work-related or not. Another role the team can play is in
assessing the job requirements for ADA (Americans with Disabilities Act)
compliance. The worksite evaluation techniques that I teach these teams
permit them to look at several parts of the body and assess the potential for
fatigue for each of them in the tasks performed. By knowing the location of
the musculoskeletal problem that an employee has experienced, the team can
identify whether that joint or muscle will be under particular strain and how
much it would take to reduce the strain to an acceptable level.
7. Training and education is essential to control overexertion risk factors, but it
should not be purely didactic. The model I have been developing over the
past 6 years has the following training needs:
a. Awareness and process discussions with top management and
supervisors. Subset of this group may make up the Steering Committee
for Ergonomics.
b. Content training and problem solving analyses with work center teams 3.5 to 4 days including 0.5 days of _projects that the teams use as their firs·
implementation example after trainmg. Teams are made up of hourly
workers, supervisors, maintenance, materials handling, engineering, and
health and safety specialists. They do most of the work, going to the
Steering Committee for funding approvals and assistance m implementing
changes. An example of a typicaf course outline is attached.

�c. The work center teams are expected to do the awareness training for the
rest of the plant using videotapes and in-plant examples from their own
training session and experiences. Before and after examples are used to
illustrate the successful resolution of problems.
d. The engineers who design or select equipment and environments, do
layouts, and select tooling should receive content training from a skilled
ergonomist. Actual design problems should be used to illustrate how to
incorporate ergonomics into their designs. They should be linked to the
plantErgonomics teams when they are working on a design that will be
used in that plant so the work center team can contribute to the design, in
the early stages, especially. This can be done via a corporate policx, "All
designs will incorporate ergonomics guidelines", or "No project will be
approved until it has been reviewed by the work center Ergonomics
Team", or "Each Engineering project will include the coordinator of its
work center Ergonomics team on the design team", etc.
B. Program Additions and Qualifications to Perform Ergonomics
Services
1. One place where I think a skilled and experienced ergonomist is needed is in
the training of engineers and related specialists to design with ergonomics
principles m mind. This is a complex business, and an inexperienced person
can make significant errors if he or she al?.proaches it too simplistically. It is
essential that engineers be given these skills early in their careers. There is a
recent heartening effort by ASME to define what is needed for their
professionals. As part of any ergonomics standard, I would hope to see a
statement that all new desf1s are expected to be ergonomically sound by a
certain date (1995 for ADlegislation, for instance). That is the best way to
improve the health and safety picture in the future.
2. There are two types of ergonomists currently working in industry and the
public sector: those who have studied ergonomics or a related field
(physiology, psychology, industrial engmeering, occupational medicine) and
have done research or developed ruidelines for the field; and those who have
learned ergonomics principles in seminars or training courses and are
a lying the principles in their jobs. The former fall into a category I called
"silled ergonomist" earlier in this commentary but so do some of the latter
group who have extensive experience in applying the principles and also have
often attended a large number of training courses. I have followed people
with PhD's (who would be called "skilled ergonomists") into plants and
found that they made serious errors in suggesting solutions to ergonomics
problems, mostly impractical solutions that would not have reduced the
over-all risk for the injuries or illnesses of concern or would have shifted the
problem to another joint (e.g., wrist was straight but shoulder was put under
a heavy strain by the solution). I have also been absolutely delighted by the
effectiveness of hourly workers (with no degrees beyond high school), using
problem solving techniques to defme the risk, in finding ele�ant but simple
solutions to problems tliat had stumped me. So, I do not think that it is
necessary to have a person with an ergonomics degree do the job evaluations
or develop the solutmns. One does need an experienced ergonomist available
to train the work cernter teams, however, and to be available for additional
help, as needed, as the teams develop their skills and proceed with the
process. The point is to have the work center teams take ownership of the
process and integrate it into their other activities rather than seeing 1t as an

18

�outsider's province.
3. I do not think that it is appropriate to require that people who develop and
implement the various elements of an ergonomics program have some
"nationally-reorganized qualifications or training". I encourage people
actively involved in ergonomics problem solving to attend as many
conferences and training courses as they can. The effectiveness of the best
programs I have been involved with has come not from how much
ergonomics the team members learned but from how well they learned to
evaluate the driving factors for the problems and how successfully they
developed solutions and sold them to management. We need the researchers
and people with degrees in ergonomics/human factors and related fields to
develop the best information on human capabilities and on the stresses on the
body from different types of work. They are not necessarily the best people
to implement the processes, however, because they often do not understand
the manufacturing environment and factors that may make their theory
impractical to implement. The most effective ergonomists to initiate and help
a com_pany develop an ergonomics process will be people who have
expenence in plants or other occupational settings and who also have kept up
their skills in ergonomics and related fields through attendance at conferences
courses, or trainin� programs. They will also be good facilitators of the team
members and willing to subject th.err egos to the process of making the teams
independent of them.
4. Attached is a recent article describing a job analysis technique that forms the
basis for my current approach to teaching teams to identify, analyze and
develop solutions for discomfort and injuries/illnesses in the workplace. My
approach is continuously evolving, so this is representative of my current
work with companies like General Electric, Srruth.Kline Beecham, Amoco
Chemical and Goodyear. I have also used part of it with a VA Hospital,
several small companies (plastics, food service) and municipalities (911,
Police, and Environmental Services) and its acceptance has been good.
Where we have good data, we have found significant improvements on health
and safety statistics.

1/28/93 SHRodgers

�Suzanne H. Rodgers, Ph.D.

Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Comments on B. Systematic Analysis: W orksite Analysis and
Surveillance, 1-3, P. 34197 of Fed Reg 57 (149), Monday August
3, 1992 - #29 CFR Part 1910, Ergonomic Safety and Health
Management; Proposed Rule
1.

See "A Functional Job Analysis Technique" attached to the comments on Section
A.

2.

An er�onomic analysis of a job or task should be triggered whenever a person
expenences discomfort over more than the first few days of starting the job and if
that discomfort persists into the non-working part of the day. Early reporting is
important, so encouraging a person to suggest improvements to reduce their
discomfort is another way to home in on possible ergonomic opportunities.

3.

\Vhen first inititiating a rocess, the OSHA, medical, and quality control logs all
give good indications ofwhere to start. However, in many instances the
ergonomic concerns have been addressed by staffing the jobs with people who
have well above average capacities, so a general screen to review all jobs is an
eventual goal for a work center team. To become proactive, not simply reactive,
one has to link the ergonomics approach to a Contmuous Improvement
philosophy. Then it becomes part of each process analysis, materials flow
analysis, accident investigation, root cause analysis, etc. that goes on in the work
center.

4.

As mentioned earlier in the comments on Section A, one wants to be assured that
all new designs, layouts, equipment, tools, and environmental changes
incorporate ergonomic principles. By setting a policy that a member of the
Ergonomics Team for the affected work center will be part of the project team,
one can go a long way towards assuring that the workers' needs will be
addressed. In addition, one could suggest that the project team receive some
ergonomics training early in the project to enhance their skills.

5.

Please avoid checklists except as a reminder to people of things they should look
for in the workplace. I have found over and over again that people who use
checklists tum off their thinking and do not see things that are not on the list.
Such lists of risk factors also lead them into solutions that may be limited and not
get to root causes. For example, a person is observed to be bending over to
work so the recommendation is to raise the height of the conveyor so they won't
bend over. In studying the job more carefully and asking why they are bending
over, one might identify the fact that what they are lookin� for (a defect, label,
etc.) is not visible from their upright posture, so they bena over to see it. Or it
might be a reach problem, inability to reach the far side of the part without
bending. Raising the conveyor height might be a very expensive solution, but
improvmg the lighting to better see the defect, diverting the part closer to the
worker so the reaches are reduced, or using a mirror to see a label on the back
side of the part are quite inexpensive to do and could have an equally positive
effect on back comfort. Ergonomics solutions are as cost effective as its

�practitioners are creative, and I find that checklists do not do a thing for the
creative process ! A form that shows how to go from risk factor identification to
driving factors for the risk would be far better than a simple checklist.

6. It would be inappropriate for OSHA to tell people how to do an ergonomic

analysis of a job and to suggest how the problems should be resolved. There are
many ways to improve jobs and reduce the risk for injuries and any system
included m a standard could become obsolete as we learn more about the causes
of these problems. To understand the factors that appear to increase the risk of
developing repetitive motions and low back problems, there needs to be more
research to define the levels at which the problems are more likely to appear. By
suggesting that there is one best method for evaluating jobs, we suggest that we
know more than we do about the synergism between the risk factors and job
design. To my mind the best approach 1s to make several options available in an
Appendix to the standard, but to indicate that other apJ?roaches are acceptable if
they permit identification of the tasks where overexert10n or cumulative injuries
and illnesses are seen, and if they lead to effective reduction in the OSHA 200 log
injury/illness rates.

7. If the readers of this material have not read Maurice Oxenburgh's book,

Increasing Productivity and Profit Through Health and Safety. I strongly
recommend it. It takes case studies from companies in four countries and shows
effective strategies to reduce injury and illness using many different analytical
approaches. A brochure is attached.

1/28/93 SHRodgers

�Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics

169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Comments on C. Hazard Prevention and Control, pp. 34197 and
34198, Fed Reg 57 (149), Monday August 3, 1992 - #29 CFR,
Part 1910, Ergonomic Safety and Health Management; Proposed
Rule
C. Hazard Prevention and Control
1. I have basic problems with the treatment of ergonomics "hazards" like
chemical hazards and safety concerns (like confined spaces, etc.) because in
most instances they are not "hazards" but combinations of factors that may
contribute to injury in susceptible people. A few things fit this approach,
such as handling very heavy loads, exerting very high forces, and working
with inadequate clearance so twisting is required and sustained. Most factors
that contribute to ergonomics problems, however, are not hazardous in
themselves, but they combine to increase the potential for injury. For
example, exerting a forty pound grip force is not inherently hazardous, but
doing it with a strongly flexed wrist increases the risk for wrist and elbow
discomfort. Repeating it 2,000 times a day may bring out repetitive motion
problems in susceptible people. If it is a true hazard, one would expect most
people to experience repetitive motions problems. Because they do not, in
most instances, it suggests that different methods of performing the task may
affect outcome, but that has not always proved to be the case. Some people
doing the task properly have symptoms and some people doing it
"improperly" (not the recommended technique) do not have symptoms. As
was mentioned earlier, repetitive motions and cumulative problems have
multifactorial contributors, and our job is to reduce the ones we have some
control over in order to make jobs better.
2. Many people without much experience in ergonomics are telling employers to
rotate employees between jobs in order to reduce their exposure to tasks that
appear to be contributing to repetitive or cumulative musculoskeletal
disorders. I have had the opportunity to follow up on what has happened in
several of these situations and have found that job rotation is of limited value.
If the task is inherently very fatiguing (evaluated using my job analysis
approach in the article attached to Section A comments), it does little good to
rotate people after 2 or 4 hours; the recovery time was needed much earlier to
reduce the potential for injury. By rotating people on a 2 to 4 hour schedule
in that type of job, one only exposes more people to the risk factors. The
incidence of repetitive mot10ns problems may go up because more susceptible
people are doing the job. Where job rotation does help is when the task is
mtense but not inherently very fatiguing (e.g., moderate fatigue) and where
the total exposure time will be reduced by rotating to a less intensive job (for
that muscle or joint). The other job condition where rotation is effective is
when the task requires a moderately heavy to heavy energy expenditure. By
rotating to a lighter activity, it is possible for a person to work an extended
hour shift, for mstance. Or, more people will be able to do the job if the total

�energy requirements are reduced over the eight hour shift by rotating between
the heavy and lighter tasks.
3. Prescribing rest breaks after a certain period of work is not appropriate for an
ergonomics standard since it assumes there is only one way of dealing with
potential overexertion or cumulative problems. I have found it much more
effective to educate supervisors about why they need to permit their workers
to get up from their desks or assembly lines now and then to get a visual and
postural break from the seated work. Most employers give their employees a
15 to 20 minute break after 2 and 6 hours of work and give a 30 minute lunch
break, so the suggestion that you need to add extra rest breaks becomes less
defensible. The better approach is to build jobs with more variable tasks so
the recovery time for one activity is built into the next one.
4. I have personally been involved in suggesting that 3 production lines be
slowed down in order to reduce the risk for repetitive motions or back
problems, but I was careful to collect data to show that the current line speed
was not optimal for meeting productivity or quality goals as well. As a
general rule, I do not consider the slowing down of a line as a feasible
solution to a problem unless there is no other way to control the risk. My
own approach is to say, "How can we run the line even faster and have less
stress on the people working on it?". Using that as a design or solution goal
pushes us to define the true risk and how we can work around it. If an
ergonomics standard includes a strong push for slowing down operations, it
will probably be fought by most manufacturing industries. They see machine
and line speed as measures of their productivity and slowing them means they
may lose their competitive edge.
5. For evaluating the risk of manual materials tasks, I use the Kodak guidelines
that I developed from Dr. Snook's original studies of acceptable lifting
weights based on 38 men and 18 women. I used the data to create a problem
solving form for occasional lifts that will allow the user to estimate what
percent of a mixed male and female workforce will find a given lift acceptable
An overlay of the graphs was made to be sure that the acceptable lifts would
not violate the NIOSH criteria for compressive forces on the lumbar discs. A
copy of this set of graphs is included in the article attached to the comments
on Section A. The graphs allow one to plot the horizontal and vertical axes oj
each of the lifts being made at the object weight and to determine
approximately what percent of a 50/50 mixed male/female population would
fmd the single lift acceptable. If more than 50% of the population would fmd
the lift acceptable, the frequency factor is included as a correction to the
design zone acceptable weight (75% of the mixed population would find this
lift acceptable). If, however, less than 50% of the potential workforce would
find the lift acceptable, no matter how frequently the lift is made, we try to
improve the lift by seeing what it would take to get it where more people
would find the weight acceptable. This might be a change in its horizontal or
vertical location; the % who would fmd it acceptable can be estimated again sc
the cost-effectiveness of the improvement can be assessed. With the problem
solving graphs one can also evaluate the effectiveness of reducing the item's
weight, 1f that is an option. Only when the lift is improved is the frequency
factor added to the evaluation. Lifts that exceed the acceptable weights for
95% of the population are considered hazardous and other methods of
transferring the item are required, such as sliding, bulk loads, and the use of
assist devices. The graphs can also be used in design to identify the priorities
for making materials handling equipment available.

�6. An IBM plant in Rochester, :MN implemented a lifting policy that said that an)
time theu product or parts/supplies weighed more than 35 pounds, it would
be moved by some other method than by manual lifting. This was done in an
existing plant and was very successful in reducing low back problems in a
large plant. By pushing the process to find other ways to transfer the product
and parts, they also improved the quality, reduced product damage, and
gained more flexibility in assigning people to jobs.
7. fu my work with several companies, I have worked with design, facility, and
process engineers to try to get them to think like ergonomists when they do
their designs and layouts. I have also worked with production planners and
placement people who build jobs to help them understand that what they do
has a strong impact on peol'le's ability to work safely and comfortably. It ha�
been difficult to get the designers to acknowledge their responsibility to
design with the operators in mind because they consider that to be
production's problem, something that can be resolved by finding the right
person for the job. After trying a number of approaches at Goodyear, we
found that the following traming and policy approaches were most effective:
a. Consultant visits the engineers' newest or most modernized plant and
reports back on ergonomics opportunities missed.
b. Consultant listens as engineers present their plans on a new plant design
(or a new machine) in an early stage of the project. Questions are asked to
determine what will happen if the automation fails, what the operators will
be doing, etc.
c. A training course for engineers in which some production people from one
of the plants participate. The first part of the course involves teaching the
engineers how to ask questions to determine how the current equipment is
working; the production people respond to their questions exactly as they
are asked (volunteering nothing). The rest of the course involves content
training on using information about body size and strengths for design,
layout issues, controls and displays, etc. and problem solving on project
designs to apply the ergonomics information.
d. fuclude the name of any machine associated with an accident or
overexertion injury in the workplace and make that data available by
machine type (across all plants) to the engineering design groups.
e. Improve the flow of information from the plants to the design engineers
and be sure the plant engineers are trained to be able to evaluate the
ergonomic concerns in equipment and plant design. With those skills,
they can assure that any designs coming into their plants will be
ergonomically sound. As the customer of central or contract engineers,
they can insist on appropriate designs for their workforce.
1/28/93 S.H. Rodgers

�Suzanne H. Rodgers, Ph.D.

Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Comments on Factors Associated With the Increased Incidence
of Musculoskeletal Disorders in Industry - 29 CFR Part 1910
Ergonomic Safety and Health Management; Proposed Rule, page
34196
In conducting training courses on ergonomics at about 50 locations over the past few
years, I have developed the following list of factors that contribute to the increased
reporting of repetitive motions disorders in the past 5 to 10 years:
A. Factors Related to Increased Awareness
1.

Public awareness - through the media's attention to red meat cutting
concerns.

2. Medical awareness - better understanding of risk factors and more specific

diagnostic testing (used to be called "sore hand", "sore arm", etc.) May also
be over-reporting of carpel tunnel syndrome since many of control studies of
peripheral nerve conduction delays have not been adequately done (e.g.,
Mayo Clinic data based on older population; they do not do Worker's
Compensation work so may have fewer actively employed people in their
data base).

3.

Employee awareness - through safety and health programs at work; also
through the media's attention to risk factors; union education programs.

B. Social Factors
1.

Older workforce - cumulative problems more apparent.

2.

More women in the workforce - risk for women is about 2.5 times the risk
for men in the same jobs (based on an unpublished Kodak study, 1978).

3.

Less acceptance of musculoskeletal discomfort by younger workers (as part
of the job).

4.

Increased stress in workplace and outside of work that synergizes with
musculoskeletal risk factors to increase discomfort.

5.

Pay systems and personel motivation to earn more income - incentive
systems, overtime work, extended hours schedules (12 hour days).

C. Changing Work Requirements
1.

More output with fewer people in order to improve productivity.

�2.

Automation for simpler tasks - humans for more complex motions
(orienting, etc.).

3.

Multiskilling requirements expose more people to the less ergonomic jobs.

4.

Shorter production runs associated with some just-in-time inventory
reduction programs result in increased numbers of changeovers on
production equipment. Puts more time pressure on the whole production
process.

5.

Lack of spare parts in inventory may result in a decision to "make parts
work" through working harder. For example, if one part is on the small side
of the acceptable size range and the other is on the large side, the two parts
may not fit together without the assembler exerting excessive forces. If no
other parts are available, the assemblers may go ahead with the task instead
of leaving work 4 hours early and not making their goal for the day.

6.

More 12-hour work days (more exposure/less recovery per day) especially
schedules with 4 continuous 12-hour shifts and where employees can
volunteer (with no limits) on rest days.

7.

Increased interaction of employees with hard and soft automation which is o1
fixed pace and highly repeatable (people are variable). Some loss of control
over work pattern by employees.

8.

Increased machine speeds without concomitant ergonomics designs.

D. Transient and Other Factors
1.

In recessions, lay-off periods, and other periods of uncertainty, employees
often do not report discomfort until it interferes with their ability to work or
do outside activities. Thus, the diagnoses tend toward the more significant
problems (carpel tunnel syndrome versus tendonitis).

2. Many people who like their current job do not report discomfort as the report
might lead to their being assigned to another, less favored, job; they may
only report problems when their ability to work is affected.

3. Occasionally, repetitive motions disorders may be reported when a person is
asked to learn several other jobs and this is perceived as stressful by him or
her . The presence of a medical problem might exempt the employee from
the multiskilling process.

1/28/93 SHRodgers

�Suzanne H. Rodgers, Ph.D.

Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Comments on OSHA Appendix A: Glossary of Terms; Ergonomic
Safety and Health Management; Proposed Rule - 29CFR Part 1910.
1. The definition of "Ergonomics" is appropriate. Using that definition, how can
one have an "ergonomic hazard"? Ifit is ergonomic, it should not be hazardous.
Please eliminate this expression ("ergonomic hazards") since it is incorrect and
tends to suggest that ergonomics causes 1?,roblems rather than solves them.
Suggested substitutes: just "hazards" or 'non-ergonomic hazards".
2. " ... combination of stressors or workplace conditions that may cause harm to the
worker." (from the definition of "Ergonomic Hazards" p. 34199). I have been
working in the field of ergonomics for 24+ years and still do not feel that I know
what causes repetitive motions disorders or low back pain. As a person with
diagnosed carpal tunnel syndrome in both wrists/hands, I have to admit that I
cannot clearly define why it is exacerbated at some times and not at others.
Therefore, I think we have to be very careful to state what we know, i.e.,that
some activities, postures, environmental exposures, patterns of work, etc. make it
more likely for repetitive motions problems to appear in a susceptible person.
"Causation" implies more than we know at this time. "Correlation" is there and
the problem is multifactorial.
3. "Ergonomic Disorders" and "Ergonomic Stressors" -- For the same reason that I
think "Ergonomic Hazards" is inappropriate, I feel these terms are inaccurate and
should be eliminated from any document. Possible substitutes: "Health disorders
associated with non-ergonormc jobs and equipment" (a mouthful, but much more
accurate), or "Overexertion Disorders"; just plain "Stressors" or "Excessive
Stress" to replace "Ergonomic Stressors".
4. Under "Systematic Analysis" (p. 34200) -- "The objective of this step-by-step
analysis is to determine if and where the limits of human capability have been
exceeded". This suggests that only peak loads are of concern in ergonomic
evaluations (e.g., forces that exceed a person's strength). In reality, many of the
risk factors may not exceed a human capability but, in conjunction with long
durations or high frequencies of effort, they contribute to overexertion or
cumulative disorders. Toe breaking up of the job into small parts may
overemphasize the relatively small contribution of an occasional biomechanical
risk factor and miss the large contribution of a lesser effort that is sustained for a
large part of the job cycle. Thus, the standard industrial engineering and safety ,
systematic analyses, while valuable, should not be required if other approaches
have been used to integrate the factors more holistically.
1/27/93 SHRodgers

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                    <text>NIOSH Work Practices Guide to Manual L1fting - Future Evaluations
Revisions, and Extensions - Proposed Contr1but1ons - SHR
I. Summary of April 18, 1986 Meeting Major Po1nts
A. Current Guide 1 ines
1. They have been received well by industry although
they may not be being used as intended or being
applied as widely as they have been disseminated.
2. The original publicat1on ts a source document
summarizing the state of the art through 1979/ 1980.
To assure that the guideltnes are used by more
Industries, a user's guide to the guidelines (with
some revisions) is needed, one that shows a less
sophisticated health and safety officer how to apply
the guide I Ines to reduce the risk for manual handllng
Injuries.
3. There are some problems with the existing guidelines,
most notably the underestimation of load for frequent
hand! Ing tasks (&gt;6 lifts/minute) and some
overestimation of MPLs for less frequent handling
tasks. These problems need to be rectified In the next
revision of the guide11nes.
B. Revising the Guide11nes
1. Because of some problems with the equation for
calculating the AL and MPL values., It w111 probably
be necessary to do a fairly complete revision of the
current Gulde.
2. The revtslon of the Gulde should Include an
Introductory chapter on why the revision has been
made, drawing on the experience of people who have
used the 11fting gulde11nes both for new design and for
evaluating existing designs. This Information should
be gathered In a controlled manner so that priorities
can be set for revisions of those parts of the Gulde
that w111 have the most 1mpact on accidents and
1nJurles.

I.

�..

3. Relevant injuries and industrial/occupational studies,
where they extst and can be made ava1Jable, should be
tncorporated tnto the Gutde In the next revision.
Parttcular attention should be patd to getting more
eptdemlologtcal studies tn order to evaluate rtsk
factors for tnjurtes and related 1Jlnesses associated
with manual materials handling tasks.
4. Current literature and data from relevant studtes that
may not yet be published should be reviewed for
Inclusion of gutdeJtnes for carrytng, pushtng, puJltng,
one-handed ltfttng, dynamtc ltfttng, and awkward
postures (bending, extended reach) or uneven loads.
Preferably thts Information should be presented In a
way that permits a person to "correct" an AL
calculated tn the manner stmttar to the current gutde.
5. The revtston should strtve for stmpJtctty so that tt ts ·
not necessary to have a computer to evaluate a Jtfttng
task but an analysts can be performed quickly by a
person only aware of the fteld of ergonomics.
Software atds for use by engineers, professional
safety, medtcal, tndustrtal hygtene, or unton health
and safety practtttoners should be "user friendly" and
requtre only short and stmple tnstructtons.
6. The revised gutde should form the basts for the User's
Gu Ide as the new source book and 1nc I ude the
derivation of the new calculations of AL and MPL as
wen as examples of how to apply the tnformatton In
the fteld.
C. Testing The New GuldeJlnes
l. In para11el with the lntttal phase of evaluating the
experience of practitioners In using the current
guldeJlnes for manual lifting, the revised guldeJtnes
should be tested before being flnaJtzed. This Involves
both testing the predictions against experimental
data from laboratory and occupational studies and
evaluating the relattonshlp between the presence of
Inappropriate design and Increased risk of MMH
.Injuries on the job.
.

::?. i

..

�2. Any new factors that are developed to descrtbe
the tmpacts of postures, force exertion, muscle
groups used, etc. on AL and MPL values should also
be tested before betng adopted. The testing procedure
must be lterattve and be subject to rev1s1ons unt111t
accurately reflects workforce handltng capacities
or acceptable loads.
3. Better definitions of the assumptions made In
predicting AL and MPL should be framed. Vartattons
for calculating them should be simulated In order to
determine the conftdence ltmtts of these values In
evaluating handling tasks In the workplace.

D. Developing a User's Gulde to the NIOSH Handling Guidelines
1. In a parallel process to the Gu1de revisions, a
User's Gulde should be prepared that focuses on how
to Interpret the AL and MPL values, pttfalls, and
Inappropriate use of the AL and MPL values, how to
handle task evaluations that do not meet all of the
handling assumptions, and how to use this
tnformatlon to justify changing existing workplaces
or to demonstrate the Importance of good Initial
ergonom Ic dest gn.
2. The user's guide should be simple, short, easy to
understand, and be dlfftcult to apply Incorrectly. It
should be In the nature of a "mint Alert" bulletin,
preferably with little explanation of how the
guldeltnes have been developed C which will be In the
sourcebook) but good visual atds to make 'It easy to
use for people who are not trained In ergonomics.
3. The User's Gutde should Include some case studies to
Illustrate not only how to calculate the AL and MPL,
but also how to go about ldentlfytng the most
effecttve ways to reduce the risk for Injuries.
Examples of multiple approaches to reducing rtsk,
tnstead of a stngle approach, should be tncluded as
well as a clear explanatton of how the handling task
evaluation can be used to define the problem.

�4. Information that shows the Impact on the workforce
of a given job design {percent of people excluded by
the design, for �xample) Is favored over too specific
a load weight, which might be used 1nappropr1ately
as a TLV. Work practices to counteract the problem
should be enumerated so the user Is not left without a
way to remedy a situation that represents a
restrictive design or high risk for many people.
5. The User's Gulde should Include a form for soltcltlng
feedback about the usefulness or difficulties In using
the handling guidelines.

E. Additional Aids for Users of the Revised Handling Guidelines
I. Videotape aids should be developed that illustrate
the major points In the User's Gulde and show
examples of how to use the handling guidelines to
reduce the risk of Injuries or overexertion Illness on
jobs. These should be targeted to specific audiences.
The management tape should focus less on how to use
the guldellnes than on explaining why proper design Is
good business. The engineers/health and safety
professionals tape should focus more on proper use
and cautions on using the guidelines and train them In
learning to Identify the problem before solving It.
The first-line supervisors and foremen's tape should
address the value of using the guidelines to Identify
why and In what direction an Intervention may be
useful to reduce Injuries and Illnesses. More
attention should be given to the Impacts of trying to
match the worker to the lifting tasks Instead
designing the task for more workers, especially In
terms of personnel hassles, flexibility 1n adapting to
change and quality performance on the job. A
worker's videotape should emphasize their role In
Identifying difficult handling tasks and In finding
ways to reduce the risk for Injuries through methods,
administrative, and engineering changes.

�'

'

2. The vtdeotapes shou1d present the baste concepts of
ustng the gutde1tnes but then 1eave room for
tndtvtdual p1ant vtdeotape examples so the
information can be tat1ored to the specific types of
hand11ng situations of Interest.
3. An instructor's manual should be written for the
videotape programs so that the person destgnated to
carry forward the hand11ng acctdent reduction
program knows the baste concepts to be emphasized
w1th each tape.
4. The videotape and instructor's manuals might be
deve1oped with the help of funds from the Nat1ona1
Safety Council. The assistance of a professional
communicator to help "market" the Gutde to the user
community should be considered.
F. General Comments
1. The importance of management committment to
implementing the NIOSH Hand11ng Guidelines
and the relative effectiveness of treating this
revision as a potent1a1 criteria document Instead of
design guidelines were discussed. Although a criteria
document might improve the lmp1ementation of the
gulde11nes tn tndustry, deve1oping one wou1d tnvolve
a major new developement effort. If done, It shou1d
emphastze work practices that gtve emp1oyers
f1extb1e, not overly expensive techntques to comply
wtth the regu1attons. Performance ranges rather
than dtscrete va1ues mtght be more appropriate.
2. BNA O� Reporter or National Safety News and other
pub11cations that reach the intended users of the
hand11ng gulde11nes might be used to so11cit tnput
from current users of the NIOSH Lifting Gulde.
Examples of ways that have been developed to make
them easter to use could also be so11c1ted.

....-

�.

.
11. Areas of Poss1ble Contr1but1ons to These Programs by SH Rodgers
A User's Gu1de to the NIOSH Hand11ng Gu1del1nes

Th1s ts the area 1n wh1ch I can contribute the most unique
material and expertise to the handling gu1de11nes rev1s1on
and expansion. Hav1ng worked tn industry and currently
hav1ng a large part of my work assoc1ated w1th try1ng to
commun1cate the baste pr1nc1ples of ergonomics to
untra1ned employees and managers, I have some 1deas of
how to reach these groups. I would also have the
opportun1ty of test1ng out the mater1al wh11e 1t 1s be1ng
developed, as I have tested several of my 1deas about
work/rest patterns, t1me pressure, and repet1t1ve mot1ons
problems. Th1s iterative approach helps 1dent1fy unclear or
confusing concepts and potential for misusing data as well
as providing opportun1ties to develop case stud1es that
demonstrate proper use of the gu1de11nes.
I could see my contr1but1on as being in four areas:
1) Work with the source document revision group to
f1nd simpler ways of integrat1ng the
biomechanical, psychophysical, physiolog1cal and
epidemiological data into an easy-to-use and
work-pract1ces-oriented gu1de11ne for var1ous
manual handling tasks.
2) Prepare a draft of a User's Gu1de for health,
safety, personnel, and engineering staff members
use.
3) Prepare drafts of v1deotape scripts and
Instructors manuals for the target groups:
managers, engineers, f1rst-11ne superv1sors, and
11ne employees.
4) Develop 1O case stud1es from a variety of
occupat1onal tasks to show how to apply the
gu1de11nes and to just1fy change to reduce the risk
of handl1ng accidents.

lo.

�B. Revise the Current NIOSH Manual Lifting Guidelines
This major project has three components:
1) Evaluating the experiences of users of the current
guide11nes and prtoritiztng areas of improvement;
2) Rev1ew1ng the literature and other data available
since 1979 to update the gutde. Developing
gutde I tnes from extsting data on pushing and
pulling tasks, one-handed carries and lifts,
carrying, dynamic ltfting, asymmetric ltfts, etc.
3) Testing the guideltnes developed against the data
already collected and wtth actual problems from
Industry or the service sector.
I will complete the proposed frequency factor revtston In a few
months, so we can work wtth that new material In the next revision.
I will also test that factor against the literature data and against
industrial and service sector experience.
I will complete a summary paper on the earlter evaluation I did
for NIOSH on how well the current guidelines predict the risk for
Injury on handling tasks in small parts manufacturing. This will be a
follow-up on the 2-part report prepared tn 1983 for NIOSH. The
emphasis wtll be on how to and how not to use the current
gulde1 Ines.
I would be able to help in testing the new guidelines by
providing a series of case studies from industry and the service
sector. These same cases could be used for the User's Gulde
examples and to 11lustrate the videotape instructor's manuals.

�;

J

111. Funding to Cover Work by S.H. Rodgers As Noted Above
A User's Gulde
See proposal relative to this from March, 1986

($ 6.9 K).

Videotape scripts and support materials (except
case studies); travel associated with taping
($ 4.5 K).
B. Revising and Expanding Guidelines
Evaluate existing use and areas for Improvement (Covered).
Improve frequency factor

(Covered)

Simplify Guidelines for End-User - Review,
development, and travel to work on final draft ($ 3.5 K).
C. Case Stud l es
Develop t O case studies to test guidelines (March proposal).

D. Budget Summary
User· s Gu I de
Videotape Materials
Guidelines Revision
Total

4/18/86 SHR

$ 6.9K
$ 4.SK
$ 2.SK
$ 13.9 K (Includes provision for
6 trips)

�IV. Timelines
June 1, 1986

.

�

August 15

Working draft of frequency factor revision out
ifor review and critique
frequency factor revisions completed and
tested

September 30 Paper completed on application of current guide­
Jines to industrial tasks ( 1983 work)
October 31

Develop 10 case studies to test new guidelines.

November 30

Draft of User's Guide for style critique.

December 31

Draft of videotape scripts and Instructor's
manuals for style critique.

March 31, '87 First draft of simplified guidelines for the
User's Gulde.
June 30

Complete the test Ing of the revised guide I ines.

September 1

Complete User's Guide with case studies.

December 3 t Complete videotapes and Instructor's manuals.
S.H. Rodgers 4/18/86

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                  <text>IN COPYRIGHT - EDUCATIONAL USE PERMITTED &#13;
&#13;
This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                <text>Summary of April 18, 1986 Meeting Major Points, Areas of Possible Contributions to These Programs by SH Rodgers, Funding to Cover Work by S.H. Rodgers As Noted Above and Timelines</text>
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                    <text>Suzanne H. Rodge�. PhD.

Consultant in Ergonomics/H¥man Factors
169 Huntington Hills
ROCHESTER. NEW YORK 14622

Proposal for Revisions to the Frequency Factor in
the NIOSH Guide for Manual Lifting
�- The Need for Frequency Factor Revisions:
When the NIOSH Guide for Manual Lifting was published in
July of 1981, it offered industry and scientists a way of
analyzing lifting tasks and defining their difficulty in terms
of people's strengths, pressures on their lumbar discs, and
acceptable lifting loads determined using psychophysical tech­
niques. For occasional lifts the Guide has been very useful to
define appropriate weights for lifting tasks. For lifting at
frequencies greater than 1 per minute, however, there have been
inconsistencies in relating the calculations of Action Limits
(AL) and Maximum Permissible Limits (MPL) to observed acceptable
workloads in industry. Specifically, the maximum frequency
(Fmax) factor of 12 for lifting below 30 inches and more than
1 hour per shift results in the finding that anyone lifting 12
times per minute for more than 1 hour at common pallet heights
can lift 0 weight per lift. Since 12 lifts per minute is not
an unusual frequency for loading and unloading pallets of product
in a shipping or warehousing operation, this suggestion that it
cannot be done without high risk of injury lacks credibility.
In analyzing the frequency factor developed for the NIOSH
Guide for Manual Lifting, it is apparent that the physiological
data collected by Petrofsky, Lind, and Webster of St. Louis
University Medical School was not fully utilized, perhaps because
they did not participate in the final guideline development
stage. Figure 5.8 on page 88 of the Guide suggests an approach
to improving the frequency factor calculation that should be
further explored.
A major difficulty in using the current frequency factor
is in defining the time base for calculating the lifting frequency.
If a person lifts 480 boxes a shift (about 480 minutes), that
could be called a lifting frequency of 1 per minute. If those
480 boxes are lifted in the first half of the shift only, the
frequency would be 480/240 or 2/minute. If the real work task
requires one to lift all 480 boxes in one hour, then the fre­
quency would be 480/60 or 8/minute. But if you watch the workers
you may find that they lift for 10 minutes, do something else for
5 minutes and alternate the work that way through the lifting
task period. So the actual frequency may be 480/40 or 12/minute.
From an industrial engineering standpoint, frequency is often
calculated by determining how many units have to be handled per
shift. From the physiological viewpoint, the stress of lifting
is defined by the pattern of lifting and the time of sustained
lifting, so peak frequencies would have to be considered as well
as average ones.
(716) 544-3587

�Proposal for Revisions to the Frequency Factor in
the NIOSH Guide for Manual Lifting
A. The Need for Frequency Factor Revisions:
When the NIOSH Guide for Manual Lifting was published in
July of 1981, it offered industry and scientists a way of
analyzing lifting tasks and defining their difficulty in terms
of people's strengths, pressures on their lumbar discs, and
acceptable lifting loads determined using psychophysical tech­
niques. For occasional lifts the Guide has been very useful to
define appropriate weights for lifting tasks. For lifting at
frequencies greater than 1 per minute, however, there have been
inconsistencies in relating the calculations of Action Limits
(AL) and Maximum Permissible Limits (MPL) to observed acceptable
workloads in industry. Specifically, the maximum frequency
(Fmax) factor of 12 for lifting below 30 inches and more than
1 hour per shift results in the finding that anyone lifting 12
times per minute for more than 1 hour at common pallet heights
can lift 0 weight per lift. Since 12 lifts per minute is not
an unusual frequency for loading and unloading pallets of product
in a shipping or warehousing operation, this suggestion that it
cannot be done without high risk of injury lacks credibility.
In analyzing the frequency factor developed for the NIOSH
Guide for Manual Lifting, it is apparent that the physiological
data collected by Petrofsky, Lind, and Webster of St. Louis
University Medical School was not fully utilized, perhaps because
they did not participate in the final guideline development
stage. Figure 5.8 on page 88 of the Guide suggests an approach
to improving the frequency factor calculation that should be
further explored.
A major difficulty in using the current frequency factor
is in defining the time base for calculating the lifting frequency.
If a person lifts 480 boxes a shift (about 480 minutes), that
could be called a lifting frequency of 1 per minute. If those
480 boxes are lifted in the first half of the shift only, the
frequency would be 480/240 or 2 /minute. If the real work task
requires one to lift all 480 boxes in one hour, then the fre­
quency would be 480/60 or 8/minute. But if you watch the workers
you may find that they lift for 10 minutes, do something else for
5 minutes and alternate the work that way through the lifting
task period. So the actual frequency may be 480/40 or 12/minute.
From an industrial engineering standpoint, frequency is often
calculated by determining how many units have to be handled per
shift. From the physiological viewpoint, the stress of lifting
is defined by the pattern of lifting and the time of sustained
lifting, so peak frequencies would have to be considered as well
as average ones.

�Another difficulty in using the current frequency factor is
in defining the one hour vs 8-hour duration categories in a way
that makes sense physiologically. If a person lifts at 2 lifts
per minute for five 15 minute periods throughout the shift, the
Fmax is the same as if he or she lifts 2 times per minute con­
tinuously for 8 hours. It appears that there needs to be consi­
deration of some other duration category that more accurately
reflects the way people perform lifting tasks. It has been my
observation that high frequency (greater than 6 per minute)
lifting is seldom sustained for more than 15 to 20 minutes con­
tinuously except when a person is at the end of a conveyor line
and is being paced by the machine speed. Even there, I have
observed that breaks from the line are often taken every 15 to 20
minutes either by rotating someone else in, by allowing a storage
conveyor to fill up, or by shutting down the line. During the
8-hour shift there may be many 15-20 minute segments of lifting,
but that physiological load is different from the load of doing
one to two hours of continuous lifting at the same rate. Loading
and unloading a pallet in shipping operations, for example, often
takes less than 3 minutes if 2 people are working together, and
then there is a "break" of 2 minutes or more when a new pallet is
procured. The frequency during the lifting task can often be 1012 boxes per minute, but the work pattern permits some recovery
between the lifting activities and effectively reduces the work­
load. The pattern has to be evaluated throughout the shift in
order to assess the whole body and local muscle fatigue potential
of the job.
B. Suggested Approach for Frequency Factor Revision
Two studies were recently reported at the Brouha Work
Physiology Symposium in Rochester, N.Y. where frequency of
lifting was varied and psychophysical (Ciriello) and physi­
ological (Yates) data weer collected to establish acceptable
loads. Other frequency studies, notably by Mital, have also been
reported in the past few years. The Ciriello and Yates studies
concluded that lifting frequencies greater than 6 per minute were
associated with whole body energy expenditure demands limitations
on the acceptable weights for lifting tasks. If one takes the
Lind and Snook data from Figure 5.8 on page 88 of the Guide and
alters it to reflect more of the female population's capabilities
(instead of the average male as is shown), a frequency of 6 lifts
per minute also emerges as the point at which total workload must
be factored into the calculation of acceptable load.
Building on those laboratory studies, it would be wise to
collect more data on typical lifting frequencies in occupational
tasks, paying particular attention to work patterns. Tasks that
are self-paced, as well as ones that are situation- or machine-

�paced, should be studied. The focus should be on jobs where
ting takes place for a majority of the shift, such as postal
package delivery services, warehousing, stockroom attending,
construction jobs, chemical workers, some agricultural jobs,
shipping dock workers, or handlers on production lines. The
to be collected would be:

lif­
or
some
data

1) Work pattern - this would be established by timing the
activities and tracking the continuous lifting times
as well as the time between them when other tasks are
done. It could also be gathered by monitoring ECG
continuously if the industry is willing to ask for
volunteers for a work physiology study.
2) Weights Handled - the workload would be characterized in
terms of the weights of the items handled and their
distribution in time. In many shipping operations it
may be difficult to get the exact weights for every item
handled, but ranges of weights could be identified and
classified into light, moderately heavy, and heavy cat­
egories.
3) Load Configuration - the sizes of the units handled and
how they are gripped would be noted. The same diffi­
culty of defining this per unit in shipping operations
could be addressed by defining 3 load size categories
and classifying the ease of gripping them as well.
4) Lift Location - the locations of the lifts would be des­
cribed in terms of the NIOSH guidelines for manual
lifting, using H, V, and D. Pallet patterns and shelf
heights would be measured for multiple tier lifting tasks.
5) Lifting Frequency - this would be measured in conjunction
with the work pattern data collection. The number of
lifts per minute and continuous minutes of lifting would
be recorded so that frequencies can be calculated
across multiple time bases.
6) Subjective Comfort or Fatigue - this would be quantified
using a psychophysical method such as a discomfort in­
dex and a rating of perceived exertion. It would be
used to identify local muscle fatigue limits to the
lifting tasks and to help define the potential whole
body fatigue limits.

c.

Use of This Data to Develop an Improved Frequency Factor

There are several ways in which the data on occupational
lifting patterns can be used to develop an improved frequency
factor. The energy requirements and heart rate responses of
people doing laboratory lifting studies can be used to identify
total workload demands for the patterns that emerge as most
representative of repetitive lifting tasks. Further laboratory
studies may also be needed to confirm these estimates, however.

�In addition, the discomfort and perceived exertion data can be
related to the workload, weights and locations of lifting at
given frequencies, and to the load configurations. This will
help to define the lifting limits in terms of ways that the tasks
could be modified to accomodate larger weight objects. It would
provide the Guide user with some options for workplace or packaging
design, for instance, that could reduce the stress in repetitive
handling tasks.
The goal in developing the new frequency factor would be to
make it as simple to use as it is now (or simpler), but to make
it more reflective of the real world situations where highly
repetitive lifting tasks are done. Ambiguity in the definition
of the time base for calculating frequency would also be reduced.
D. Time to Accomplish the Study
Study 4 people each in 6 occupations

=

250 hours

Analyze data

=

120 hours

Develop frequency factor

=

100 hours

Prepare Report

=

50 hours
520 hours

Suggested Time Lines:

Complete
Complete
Complete
Complete

data collection
data analysis
frequency factor
report

Respectfully Submitted,
10/18/84

June 30, 1985
August 31, 1985
October 31, 1985
December 1, 1985

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&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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A Practical Guide
To Adjusting Your
Computer Workstation

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Inger M. Williams, Ph.D.
Suzanne H. Rodgers, Ph.D.
© Febru�ry 1999

.•

�fl

�Welcome to your workstation. It is designed to fit all sizes of
employees. To assure the workstation meets your individual
needs, go through this self-help guide and make the necessary
adjustments. Be proactive, set up your workstation to fit you and
your tasks before you develop any discomfort.

E

rgonomics is a multidisciplinary science that studies how to best
design work environments and tools to fit all peo le. The
computer workstation is designed to fit all employees. �erefore,
to make your workstation ergonomically designed especially for
you, you must make the final adjushnents to ensure your postural and
visual needs are properly accommodated when you perform your specific
tasks.

R
G
0

ead this manual carefully. We want you to refer back to this
material in the future if you have any questions about further
adjustments of your workspace or if you start to experience any
discomfort.

o through all sections in the manual before you start working. It
should not take you more than 10 minutes to read and you will
find many important and practical ideas on how to make
adjushnents yourself. If you have any concerns or questions
after you have finished, talk to your supervisor who will refer your concerns
to the "Ergonomics Help Desk" 238 4652.
nee in a while you will find an article in the weekly newsletter
the "Bulletin" under the "Wellness" section. It will remind you
how to adjust your workspace so you are working comfortably.

�Your Chair and Desk

C

hairs made by Haworth come with a manual on how to use all of
the adjustable features. You can find it under the armrest. Take
time to try them all. Before you continue reading here, make
sure you know where and how to adjust seat height, seat and
backrest positions, and armrest height as well as position.

H

eight of your seat should allow you to rest your feet flat on the
floor and keep your upper legs level and parallel to the floor
when your lower back, also called the lumbar region, is properly
supported by the back rest. Make sure, as you first sit down and
use the back support that the edge of the seat pan does not cut into your
lower legs or push them out. If that is the case, you must move the seat pan
back to shorten its depth.

A

nnrest height should allow you to keep your forearms level and
parallel to the table top without pushing your shoulders
upwards when you type. On the Haworth chair, you can turn the
armrests to the side and behind you if you do not want to use
them or if they are preventing you from getting close enough to the
keyboard and desk top.

I

f you cannot keep your anns and hands level with the keyboard
and the desk top you can try one of two things to assure you can
use a comfortable arm and hand posture: raise the seat height
and add a footrest if needed to keep your feet supported or, add
a keyboard holder that lowers the keyboard. Make sure the surface of the
keyboard holder is large enough to accommodate your mouse and mouse
pad. If you are short, you might need both a keyboard holder and a footrest.
Talk to your supervisor if you are having difficulties getting into a
comfortable typing posture.

R

emember, no matter how comfortable you are in your chair, you
should not sit still for too long. Stand up and stretch now and
then and do tasks that take you away from your workstation
occasionally.

�Your Keyboard and Mouse

K

eyboard location depends on three things: your task, what
section of the keyboard you use, and your dependence on the
mouse. Your goal is to have your forearms level with the desktop
and straight ahead of you. Try to maintain your wrists straight
and the keyboard centered. If you are only using the alphabetic section and
the numbers on top, center the keyboard with yourself on the § key. If you
are using the whole keyboard with the number pad as well, center the
keyboard with yourself on the I or i key. If you are only using the number
pad keys for an extended time, center those to assure that your right hand is
comfortable straight ahead of you. If you are only using the mouse, move
the keyboard to the side and place the mouse straight ahead of you. When
you are using the whole keyboard as well as the mouse, make sure you do
not use a long reach for the mouse.

E

ven if you have a wrist rest, it is not always necessary to rest
your wrist on it while you are typing. Sometimes, when you
place your wrists on the rest, your hands will be held in an
awkward angle. Make sure, that if you are resting your forearms
on a hard surface that you are not resting them on a sharp edge. Talk to your
supervisor if you need to add a wristrest.

Y

ou might need to raise your chair and add a footrest in order to
hold your hands, wrists and feet in comfortable positions. This
might be an easier solution than lowering your keyboard with
the help of a keyboard-holder. If your keyboard is lowered with
the help of a keyboard holder, make sure you do not have to reach over the
keyboard to read and/ or write on your paper documents. In addition, you
must adjust your computer display height to assure you are not looking
upwards and tilting your head backwards. Talk to your supervisor to help
you find the best typing posture that will fit you and your task.

�Your Display and Glasses

D

istance to your display is very important for the comfort of your
eyes as well as of your neck and shoulders. If you cannot see the
text on the display clearly you are more likely to squint, stick
your neck out and lean your upper body forward to see better
rather than move the display itself to a closer viewing distance.

I
S
P
L

f you are using bifocals and if you are using the lower area of
your glasses to read, place the display as low as you can on the
desk top. To achieve that viewing angle, you can also raise your
chair to sit higher than you usually would. In that case, raise the
keyboard to maintain a comfortable arm position and maybe add a footrest.
eparate one inch-high platforms are available to raise the display
if you need to. Make sure you do not look upwards. When your
eye muscles get tired from elevating the eyes, you might start to
bend your head backwards which might result in neck and
shoulder discomfort over time.
rimary viewing area on the display is the area that you are
looking at most of the time. This area should be at or slightly
below eye level. If you cannot lower the display enough, move
the window you are working in down on the screen itself. This
might be especially important if you are using bifocals.
eave your paper documents as close to straight ahead as
possible if you need to look at both while you are typing. If you
are only looking at the documents and just glancing over at the
display occasionally, move your display to the side and place
the documents straight head.

A

y

sk your supervisor to help you move your computer display.
They can be very heavy and it is difficult to move the platforms
under the display by yourself.
ou should try to get an eye exam every two years. Your medical
insurance usually covers such exams. It is important to do when
you are over 40 years old and your eyes naturally start to change
due to aging.

�Your Books and Telephone

B
0
0

ooks, manuals, and reference material that you need for your
work,. should be placed as close to you as you can. This will
ensure that you can reach them comfortably without having to
lean over far to the side. Heavy manuals should be stored at the
desk height if they are used frequently.

K

verhead reaches that are long and to the side can be very
uncomfortable for your shoulders and back. H your material is
heavy, it is important that you stand up to get it rather than use a
long awkward reach from a seated position.
n the panel behind your computer is the telephone jack. The
telephone cord is long enough to allow you to locate your phone
where you prefer to have it on your desk.

eep the phone within an easy reach. Try not to cradle the
receiver between your head and shoulder. This could give you
neck and shoulder discomfort! There are head sets available for
employees who frequently use the phone. Talk to your
supervisor if you need one.

�Maintaining Good Postures
at
Your Computer Workstation
Once your workstation is properly adjusted to meet your postural and visual needs it is important to
maintain comfortable and good postures. However, remember, no matter how comfortable you are, you
should not sit still for too long. Stand up and stretch now and then and do a task away from your worksta­
tion occasionally.

Eyes level with text most worked
with on display
Viewing distance that is
preferred

Hands and wrists straight,
fingers slightly curved

Head straight or slightly turned to the
side

I

Neck straight or bent forward

I

houlders lowered and relaxed

. Upper back relaxed

Lower to middle back supported
Thighs parallel to the floor
Feet resting flat on the floor or
other foot support

No pressure on thighs and back of lower
legs
Lower legs stretched out unhindered

I

�..
'

�.,,

TM

© 1999 Inger M. Williams, Ph.D. and Suzanne H. Rodgers, Ph.D. All rights reserved
For more information e mail cergos@rochester.rr.com

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
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                <text>Susanne Rodgers Collection</text>
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                  <text>Suzanne Rodgers Collection</text>
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                  <text>Human engineering</text>
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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                  <text>Rodgers, Suzanne H.</text>
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                  <text>University at Buffalo. University Libraries.</text>
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436/536

The Physiological Basis of Human Factors

Monday Evenings, 6:30-9:30 PM; Fall Semester
Course Summary

0

The course will be run as a seminar/lecture with reading
assignments for 9 of the 15 sessions. There will be four
laboratory sessions and a midterm exam. The 15th session will be
used to work on a project to study a job from an ergonomics
standpoint, focusing on the physiological demands of the job.
Lab reports will be required for the four laboratory sessions and
a final report on the project is to be done in place of the final
exam. Several quizzes and problem sets will also be included in
the course. Topics include muscle, cardiopulmonary, and nervous
system physiology, work capacities, fatigue, stress responses,
circadian rhythms, and tolerance of heat exposure. These topics
will be discussed in the context of the design of jobs and work­
places to accommodate most workers.
Instructor:

Suzanne H. Rodgers, Ph.D.
169 Huntington Hills
Rochester, New York 14622
(716) 544-3587

Textbooks:

Textbook of Work Physiology by P.-O. Astrand and
K. R6dahl, McGraw-Hill, 1977. (Required)
Working With Backache by S.H. Rodgers, Perinton
Press, 1985. (Optional)

l)

�....
'

IE 436/536

'

0

0

The Physiological Basis of Human Factors
Schedule

Date

Topic

Type

_August 26

Overview of Course, General Review of
Physiology, Industrial Applications

Lecture

Sept. 9

Muscle Structure and Chemistry, Metabolism

Semi.nar

Sept. 16

Muscle Function, Strength, Endurance

Sept. 23

The Cardiopulmonary System: Blood Flow,
Breathing, and Blood Pressure

Seminar

Sept. 30

Temperature Regulation

Seminar

Oct. 7

Lab
Heart Rate, Blood Pressure and Metabolism
(due 10/21")
in Occupational Tasks

Oct. 14

The Nervous System - Coordination, Alert­
ness, Reactivity

Seminar

Oct. 21

Stress Response - Hormonal, Nervous System, Factors Influencing the Response

Seminar

Oct. 28

Midterm Exam - All Material To Date

Exam

Nov. 4

Biomechanics

Seminar

Nov. 11

Biomechanics and Work Capacity

Nov. 18

Projects - Observe Som�one at work
(Collect Data)

No Class

Nov. 25

Paced Work, Total Workload, Circadian
Rhythms and Shift Work

Seminar

Dec. 2

Paced work and Workplace Design

Dec. 9

Low Back Pain and Repetitive Motions
Disorders

Dec. 16

Projects Due

7/22/85

S.H. Rodgers

(Dr. David Kiser)

Lab
(due 9/30)

Lab
(due 11/25)

Lab
(due 12/9)
Seminar

�.,

II

IE 436/536

Physiological Basis of Human Factors

General Information
A.

Office Hours:

Mondays 4:30 to 6:30 PM Room 411
(knock on door at top of stairs)
Phone (Rochester):

B. Grading:
4 labs and reports
1 midterm exam
1 project
2 problem sets
Class work
Pop quizzes

0

1-544-3587

40% of grade
=. 15%
of grade
20% of grade
=

=
=
=
=

(10% each)

10% of grade (5% each)
10% of grade
5% of grade

More will be expected of you as the term progresses, so I
will be a little more lenient in my grading at the beginning
than I will be at the end. My primary interest is in how well
you think and solve problems, so I am less interested in the
answers than how you get them. If your lab experiments give
confusing results, for example, I expect you to analyze why
they are not the expected ones and also to indicate how you
would expect to remedy the situation if you were to . repeat
.
the lab.
C. Attendance:
Your attendance at each session is important since you will
be assigned specific reading to report on to the rest of the
class. If you are not there, that part of the material will
not be available to your colle�gues, but you will still be
responsible for it on any tests. If you miss a lab it is very
difficult to write the report's discussion section and to ana­
lyze the data. You are responsible for writing your own dis­
cussion section for each lab, and each lab represents 10% of
your grade. So, don't miss them.
D. Plagiarism:

C,

Most of my material is new each year, so it is not very
helpful to look to previous years' reports or exams to com­
plete your own. Thinking is faster and more effective! I
have a very good memory for things I've read before, whether
they're books or old reports. If such material appears without
·an appropriate reference, I will automatically deduct·l0 points.

t.

�E. Refer•nce Materials:
There will be articles �nd reference materials on reserve in
the Science and Engineering Library. Readintj assigned for the
· seminar sessions will be passed out in class the week before the
topic is discussed. Any extra class handouts will be placed in
a folder to· the right of the faculty mail boxes in Nancy Pilon's
office - marked 436/536.
· The Health Sciences Library should also be searched for
additional material for lab and project write-ups. It has a
better supply of physiological reference.materials than the
Science and Engineering Library does.
F. Laboratories:
The labs are extensions of the seminar materials and give you
an opportunity to test some of the theory. We will often collect
some standard data on ourselves in order to see where we fall
in relation to the sizes or strengths of an industrial popula-.
tion. You will work in groups of four in the lab. At least one
part of each lab will require you to design your own experimen�
to illustrate an ergonomic principle with a physiological basis.
Y6u will get instructions for each lab a week ahead of time
so that you will have time to •think about the principle you want
to test.. I .will review your ideas at the beginning of the lab
in order to identify any potential overexertion problem or to
help define a "do-able" task, if needed. You will need the
full 3 hours for each lab in order to collect the data and
understand how to analyze it.
A sample lab report will be given to you before the first
lab to show what is expected in the lab write-up.
G. Project:
The project is meant to be an opportunity for you to bring
together all of the material presented in the course by watch­
ing people working. You are expected to describe what they
are doing qu�litatively and quantitatively and to identify
environmental influences as well. A sheet describing the types
of observations and measurements that can be made will be given
to you lat�r in the course. The project report replaces a
final exam and accounts for 20% of your grade. Each person
does his or her own project.

�"'

tli

C

•

H. Problem Sets:
You will be given 2 sets·of 3 problems each to solve as
homework assii;Jrunents during the ·term. They will ask you to
analyze an industrial or occupational task or workplace and
to explain why a certain set of problems (e.g., low back pain,
sore shoulders, etc.) may be occuring on the job. You will
have to use body size 2'nd strength data or other information
from the course to solve the problems. You will have 2 weeks
to complete each set, and I will use them to work with you
individually on your job analysis skills. These are 10% of
your grade.
I. Pop Quizzes:
Short quizzes will be given occasionally (3 to 4 total) in
order.to identify how well the class is grasping the material
being presented in the seminars. All together they will make
up 5% of the grade for the course.
J.

c

Class Work:

Since the majority of the course will be run as a seminar
class work will be important and will account for 10% of the
grade. Class preparation ( familiarity with the topic) , presen­
tation of assigned material, and attendance at class will be
used to determine the score for class participation.
8/24/85

S.H. Rodgers

.

3

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
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                <text>Syllabus for IE 436/546 The Physiological Basis of Human Factors 1985</text>
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                    <text>summary of Grip Strength Laboratory - October, 1983
'··,·,,)

IE 436/536 - S.H. Rodgers, Ph.D., Instructor
Despite the lack of equipment and.the confusion surrounding
the first set of lab reports, you have done quite well on this
lab. A few points of confusion are summarized below, and a
synopsis of the projects is also given. Some of last year's
data is included to increase the 'n' and help identify where
data used in the class handouts may be questioned.
A. Presentation, Spelling, etc.
1 •. The problem words - this time are :
Breadth

not breath (that comes in the next
part of the course)
Clearance
not clearence
not dynometer (which must be an
Dynamometer
ancient scale for_measuring rep­
tiles)
Affect/Effect - confused over and over. The
easiest way to get these straight is to agree·
never to use affect as a noun unless you are -­
going into psychiatry. When you are using
_
them as verbs, test to see if you are trying
to say that something caused a thing to occur
(effected) or if it only influenced it (af­
fected).
2. Several of you had alot to say about tne experiments and
in answering the questions, but you put some of it in
the introduction, some in the discussion, and some in
the conclusions. Please try to.place the answers to the
questions in the Discussion section, and note that you
are doing so with a heading (like "Answers to Quest­
ions"). Save true conclusions from your experiments for
that section: any afterthoughts can be tacked on to the
discussion session with an.llinsert" signal. _ The best
waytq keep from rambling on too much and repeating
material bewteen sections is to make a good outline
before you start to write. This is critical in the
exam situation, so doing it for the lab reports is
good practice for you •
. 3. Some of you noted that I had given you some incorrect
instructions on how to handle the hand-length and

�.

.

breadth measurements from the class data. I had said
that you had to subtract 49 mm from the values in the
class data for these two measurements. That was be­
cause the anthropometer scale read 49 before the start
of the hand measurements. However, after you pointed
out the inconsistency of the corrected readings with ·
the population data from·the Kodak book, I realized
that the 49 mm represented the distance between the
arms of the anthropometer and should be included in
the readings •. Those of you who made the correction
were not penalized, those who caught the mistake were
given extra credit, and those who didn't seem to
notice the whole business were given the benefit of
the doubt that you saw the problem but were not given
extra credit. I lost 15 points.
•.

4. The handout you got in lab did have Kroemer's method
for static strength measurements on th.e top, but the
anthropometric data in it was from the Kodak book.
5. Because we measured them in kilograms of force, I.have
not marked anyone off for grip strength values in these
units. However, the standard unit (SI) is Newtons, which
can be· found by multiplying the kg values by 9.8.

B. Analysis of Lab II Data
1. Those who measured grip strength changes with wrist
angle changes and found less reduction in strength ·
than was suggested in the class handout. shou1d not
get overly zealous about finding the errors in their
experiments. It is always possible that your data
is closer to the Ultimate Ergonomic T�uth than mine
is. If you get consistent results and,do not know
of any reason why they should be disregarded, do
not be afraid to use them in answering questions.
The search for sources of error is always important,
but it should not be done solely to discredit a
value that does not agree with someone else's pub­
lished data. Published data can be, and often are,
wrong! See the discussion of radial and ulnar dev..;.. · ·
iations of the wrist and grip strength later in this
summary of Lab II.
·

�2. Several people confused percentiles and percent of the
population in discussing who was accommodated by a
given design. A percentile defines a value where 1 x 1
percent of the population has the same or less than
that reach, height, breadth, etc. You cannot find what
percent of the people with a 5th percentile measurement
are accommodated. Either the design accommodates people
with that level of the measure of interest or it does
not. The percent of the population accommodated would
be determined by looking at the design in terms of
both large and small values of the measurements of in­
terest. If the value of interest is a strength, then
the percent of the population accommodated would be
(1 - the percentile at value x 1 of the design). If
it is a reach and the design is not optimal for either
very short- or very long-armed people, then the percent
of the population accommodated would be the difference
between the percentiles marking the design limits.
1

3. In the discussion of grip span vs grip strength, several
people brought in the data on p •. · 310 of Konz' s work De­
sign. This is attributed to Greenburg and Chaffin, where
it does appear, but is actually a thesis project by
Fitzhugh from U • · of Mich. • It represents 50 men and 50
women whose grip strengths were measured using a leaf
spring dynamometer developed by Jim Foulkes of u .. of
Mich •• It is interesting to compare the class data to
Fitzhugh 1 s data, but be careful that you note the dif­
ferences in the way the span is measured. In ·the hand
dynamometer the entire grip-has a span of 2-inches (or
whatever value is chosen), whereas in Fitzhugh's leaf
spring dynamometer the span decreases near the top of
the hand. The value recorded is at the base of the
·spring. Dr. Lind of St. Louis University Medical School
would go one further and suggest that the hand dynamo­
meter we used is too compressible and should be replaced
with a stiffer set of bars (made by Petrofsky). So, the
discrepancies between· the Fitzhugh data and the data
from last year's class that was handed out in class are
rela.ted to differences in measurement techniques. I
purposely gave you the class data instead of the Fitz­
hugh data because I think it more accurately reflects
manual handling grip design needs. The Fitzhugh data
is most applicable .for tool design where the handl.es
resemble the leaf spring type of grip •
.3. A few of you also noted the discrepancy between some
recommendations for cylindrical handle design and the
grip span data from class. It is important that one.
look carefully at the item being gripped in determining

�the most appropriate grip span or circumference. If
the item can be handled with a power grip or cylindri­
cal grip, then the cylindrical handle should be con­
sidered, and the diameter should reflect the cone cir­
cumference measurements of the population, or 1.25 to
1.5 inches in diameter. If the gripping surface is
a block that cannot be encircled, then the grip span
of 1.75 to 2.5 should be used. If the handle is able
to be grasped with a power grasp but it is not cir­
ular, like a carving knife handle, the thickness of
the handle as well as its span must .be evaluated and
the best combination determined. The thicker the han­
dle, the less wide the grip span can be.
4. Only one person, so far, explored the biomechanics of
the hand and wrist when trying to explain why grip
span and grip strength are related in an inverted
U 1 -shaped curve. The main thing I was looking for was
the realization that the force measured on the dynamo­
meter is the resultant of the forces generated by
forearm and hand muscles. These forces are greatest
when the fingers and wrist line up so the pull on the
tendons from the forearm muscles is direct, and does
not have to go around bends (as with wrist deviations}
where resistance to movement is increased. The levers
of the system are most effective when all of the joints
can be stabilized to form one long lever. This is not
possible when too-small an object is gripped and the
fingers wrap around it. It is also not the case when
too wide an object is grapsed and the force is applied
at an angle instead of perpendicularly on the dynamo­
meter. See Figure I for an illustration of grip force
vectors with an appropriately sized object and in a
similar task on a too-wide object.
1

-,�

5. The discussion of anthropometric measures and grip
strength identified that hand length was quite well
(r = .8) correlated with strength. In a study last
year, one group looked at grip strength with 0.125
inch incren1ents in grip span from 1.12 to 2. 38 inches.
They found a fairly consistent relationship between
the span at which people reached their maximum grip
strength and their hand length, or:
Span at max grip strength, inches
Hand Length in Inches

=

0.27

From this data one can estimate what span would be best
for any percentage of the population based on hand len­
gth. It is not terribly precise, but it does seem to
predict a person's best grip span for some tasks.

�.

.
· 2. In discussing the implications and applications of the
lab results to industrial tasks, many of you focussed
on the design of hand tools. Although these are very
· important, you seldom get a chance to design them. So,
be sure you consider other grip interfaces that you
can do something about, such as tray handles,-handles
on machine components, etc •• Many product sizes are
chosen without attention to grip requirements as well.
Not only is the orientation of the handle important
because of its implications for wrist angles, but the
handle size :is very important. From your data in class,
and from last year's group data, you can.feel quite
secure in recommending gripping block tray handles that
are from 1.75 to 2.50 inches in width.
3. Do not get confused about.minimum handle sizes and re­
commended handle sizes when it comes to designs that
minimize pressure on the fingers (Rigby in Konz's .
book). The recommended diameters for handles on ob­
jects of different weights are minimum levels; they
are determined by calculating the force per unit area
that the handle exerts on the fingers.· Larger handles,
such as those developed from grip span considerations,
are more satisfactory than these minimal dimensions •.
D. Group Projects
Stapling activities led the list in the types of tasks
evaluated for the group projects. Radial and ulnar deviation
of the wrist during stapling was analyzed by two groups.
Another group looked at flexion and extension of the wrist
during procurement of library books, but did not get a dyn­
amometer to collect data with. One group did collect data.
on strength changes with flexion and extension and �l.so
looked at strength loss with time during a fatiguing hand. grip exertion. The results are sµ.mmarized in Tables 1 and 2
for radial and ulnar deviations and flexion/extension of
the wrist, respectively.

�6. Some people stated that people would get carpal tunnel
syndrome or a related problem if they don't have the
right grip span or wrist angle, ·etc. • In the interest.·
of accuracy, you should be aware that there is no evi­
dence yet that the awkward grip spans, high forces in
respect to maximum voluntary contraction capabilities,
or extreme wrist deviations actually cause overuse ·
syndrome problems. What we do know is that they aggra­
vate pre-existing problems, and if they are reduced,
fewer people have difficulties with these tasks.
7. Some of you confused a fatigue curve for muscle work
that is sustained over time (holding a grip and watching ·
the maximum force decrease with time) with Rohmert's
curve (actually first described by Scherrer and Monod)
which relates intensity of muscle effort and duration.
Rohmert's curve suggests that one can hold a 20% MVC
for over 10 minutes. This is not the same as saying
that if one does a maximum grip for 10 minutes, it
will be down to 20% of the original value at the
.end of that time. There is no way you would be able
to continue the maximum grip for 10 minutes unless
you needed it to keep from falling into a pit of alli­
gators with big appetites. We will get into muscle
fatigue next week, but suffice it to say that the shape
of the fatigue curve and of Rohmert's curve are not
the same, and they should not be used interchangeably.

c.

Implications for Industry
1. Several people· suggested that workers should be in­
structed to keep their wrists in the neutral position
during work and to select their tools to fit their hand
size. These are not terribly practical solutions to the
handgrip problem, as you can see if you try to keep
your wrist in the neutral position as you write your
midterm exam. Tool selection is not always an option
for the worker, although it can be controlled somewhat
by the purchasing agent. More recently, there have been
· attempts to design tools for the smaller hand and to
angle them to reduce the amount of ulnar and radial
deviation required in some tasks. The latter approach
has resulted in some ergonomically fine tools that are
seldom used in the workplace. The reasons for their
abandonment relate to the lack of versatility an angled··
tool often has, usually only being good for a specific
operation in a given orientation (vertical work witn
the angled Western Electric pliers, for instance). The
less ergonomically optimal tools are more versatile,
.· and are preferred by workers in tasks where multiple
tasks are performed in different orientations.

�'

"'

,,.,i

a)

.... ..

F
(tendon l ," - - , ,,
_,

Fy
ed
. ·:·. For a requir nap the lid.·
s
to
kg
5
•
F
y
5 . cosl5
· F • F : cosa •
_y
F • 5.2 kg_.
to the

llelgram solution
Figure l' , ·. A para
squeezing
the hand in : a)
forces exerted by
b) the
ortably closed and;
with the hand comf
ly wide op en .
hand uncomfortab

--·. ·•-····--:---------;_____- ..

-��- .... - -... -- ----- -- -··

Fx

{tendon)
For a required
the lid,
F • 5 kg to snap
y
. cos75
F • F � cosa s 5
y
F • 19 kg_; ·-

�Grip Strength and Wrist Deviation - Strength Changes
Expressed as a Percent of the Neutral Position Values
1982 and 1983 IE 436/536 Data
Table l :

Radial
25 Deg.

--------Maximum

Mean

+/- 1 SD
Range

50

Median
N

Radial and Ulnar Deviation

80

75

57

6

l

8

13

-

67

79

-

70

38

85

-

71

60

8

3

3

8

Table 2 :

Flexion and Extension

65 Deg.

Flexion
45 Deg.
25 Deg.

+/- 1 SD

10

13

29

-

80

60

N

81

61

47

Median

40 Deg.

59

Mean
Range

Ulnar
Maximum

--------- --------- --------- --------Neutral

-

67

43 - 85

J

Neutral

70

Extension
45 Deg.
25 Deg.

--------- ------ .--

82

· 88

76

8

9

9

73 - 93

78

-

100

64

-

86

48

60

81

86

72

9

9

4

4

9

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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Exam,- October 19, 1983
IE 436/536 - Mi\:lte:im
.
\
.

20 points

I.

Definitions - Write short definitions of five of the
following words or phrases. Explain what {s meant
and how it is important in human factors/ergonomics.

GD

1'

Ulnar deviatio.n.-Uf/- ·Hft- y
S~h perc7ntile ilfl-fttt- till &lt;!if) .
P~ncJ; gr~P--1/-(f~· \ @
Flex~on
ilq q
Length-tensi .· relationshipfttr±fH-

,
40 points II.

Ill

E)

Clearances -~~Iff Gi)
Static work ~fftt-ifft.·fflt@:.
Grip span fl// @
.·
Acromial height{fft~
Adjustable back
support ·+ftt-f\1/

(f)

(§)

Short Problems - Answer ~of the following problems.;
Follow the instructions for each carefully.
For each of the following situations you have been
asked to determine who should be considered in the
design.
Indicate what population data you would
use for your design. Be sure to include the specific anthropometric measurements that determine the
design.
a.
b.
c.
d.
e.

Drinking fountain height in a pediatrics office
Seat height in a movie theatre
Door height in the New York Knickerbocker's (a
basketball team) locker room
The force required to trigger a power drill
The weight of a portable T.v. set

The strength to lift a tray at full arms• extension
above 75 inches (above the floor) is only about 15%
of the strength available to lift an item close to
the body and 30 inches above the floor.
Explain
why.

1·-H-l+

3.

ill l 4.

Mrs. Jones is 50 years old and suffers from arthritis.
She is having difficulty opening screw-top soda pop
bottles and the peanut butter jar when her grandchildren come for lunch. Why do you think she has
trouble with these items, but has no trouble opening
the jelly jar? Be quantitative, where possible.
In the move from English units {pounds) to SI units

�£:· .

•

......

(kilograms) some bulk packaging standard sizes will .
be changed. At present, chemical and food comp-·
anies in the u.s. use a 50-lb bag. With metrification, a decision has to be made whether togo
to a 20 or a 25 kg standard bag size. What would.
your recommendation be, and why? Use information
from the lifting guidelines ahd be quantitative
where you can be.

40 points III.

-

Longer Problems - Answer one of the following problems•
You have been asked to desi~rn a lunch counter for a
local hot dog stand. The owner wants to use stools
and to make them just slightly uncomfortable so
people will not hang around too long after their
meal.
a.
b.
c.
d.

11 r1

2 •.

What anthropometric measures should you consider in designing the counter and stools?
What population will you consider in your design?
·
What approach will you use to produce just a
little discomfort, and why will this be uncomfortable?
Sketch the recommended lunch counter and include the relevant dimensions:

A construction worker handles 200 rectangular
concrete building blocks with one hand over a 4hour period while building the foundation for a
skating rink. The blocks are 16 x 10 x 4 inches
(1 x w x h, solid) and weigh 12 lbm each. At the
end of the day, he notices that his arm and hand
a,re quite sore.
a. If he has a 96 lbf grip strength (m'easured with
a 2-inch grip span and with the wrist in its
neutral position), can you explain his arm
and wrist soreness? Be as quantitative as
possible.
b. Would you anticipate that he would have any
d.ifficul ty carrying a block in one hand for
one minute continuously? Explain your answer.

�IE 436/536 - Midterm Exam - October 19, 1983

20.points

I.

Definitions- Write short definitions of five of the
following words or phrases. Explain what is meant
and how it is important in human factors/ergonomics.
Ulnar deviation ~
5th percentile ;l..
•Pinch grip $'
· Flexion 10 ·
Length-tension relationship 3

40 points II.

Clearances if
Static work
I
Grip span Cj
Acromial height . '
Adjustable back
support f.

Short Problems - Answer ~of the following
Follow the instructions for each carefully.
1.

/

problems~

For each of the following· si tuatioris you have been
asked to determine who should be considered in the
design. Indicate what population data you would.
use for your design. Be sure to include the specific_anthropometric measurements that determine the
design.
a. Drinking fountain height in a pediatrics office
b .. Seat height in a movie theatre
, c. Door height in the New York Knickerbocker's (a
·basketball team} locker room
. d. The force required to trigger a power drill
e. The weight of a portable T.V. set

2.

The strength to lift a tray at full arms• extension
above 75 inches {above the floor) is only about 15%
of the strength available to lift an item close to
the body and 30 inches above the floor. Explain
why.

3.

Mrs. Jones is 50 years old and suffers from arthritis.
She is having difficulty opening screw-top soda pop
bottles and the peanut butter jar when her grand~
children come for lunch. Why do you think she has
trouble with these·items, but has no trouble opening
the jelly jar? Be quantitative, where possible.

4.

In the move from English units (pounds).to SI units

(f)

�.

"'-·

····••i!_lol

-..

(kilograms) some bulk packaging standard sizes will
be changed. .At present, chemical and food companies in the u.s. use a 50-lb bag. With metrification, a decision has to be made whether to go
to a 20 or a 25 kg standard bag size. What would
your recommendation be, and why? Use information
from the lifting guidelines and be quantitative
where you can be.

40 points III.

-

Longer Problems - Answer one of the following problems.
1.

You have been asked to design a lunch counter for a
local hot dog stand. The owner wants to use stools
and to make them just slightly uncomfortable so
people will not hang around too long after their
meal.
a.
b.
c.
d.

2.

What anthropometric measures should you consider in designing the counter and stools?
What population will you consider in your design?
What approach will you use to produce just a
little discomfort, and why will this be uncomfortable?
Sketch the recommended lunch counter and include the relevant dimensions.

A construction worker handles 200 rectangular
concrete building blocks with one hand over a 4hour period while building the foundation for a
skating rink. The blocks are 16 x 10 x 4 inches
(1 x w x h, solid) and weigh 12 lbm each. At the
end of the day, he notices that his arm and hand
are quite sore.
a. If he has a 96 lbf grip strength (measured with
a 2-inch grip span and with the wrist in its
neutral position), can you explain his arm
and wrist soreness? Be as quantitative as
possible.
b. \'lould you anticipate that he would have any
difficulty carrying a block in one hand for
one minute continuously? Explain your ans\.,rer.

�IE 436/536

Physiological Basis of Human Factors

Midterm Examination - 75 minutes (25 points)

I. Definitions.

iD/Jo/fs~

Choose~..,..

Define ,2. of the following terms. In each definition say
what the term means and why it is of importance in ergonomics.
Action Limit - NIOSH Lifting Guidelines
Anaerobic Metabolism
Grip Strength
Percentiles - Muscle Strength
Radial Deviation of the Wrist
Motor Unit
Muscle Fatigue
L-5 Disc
Intensity-Duration Relationship for Muscle Work
Optimum Grip Span
Static Muscle work
Sarcomere
(40 points)

II. Short Problems.

Choose .:::;::::.
2.

1.

You have been called in to act as a consultant at
a local warehouse where electronic equipment, such as TV
sets, video players, radios, and computers, is stored.
The architect and engineer are convinced that the
shelves should be at 5, 40, and 75 inches above the floor,
while the warehouse foreman is pushing to put them at 15,
35, and 65 inches above the floor.
The usual inventory
could be accommodated in either design. Which shelf
height combination would you choose (of these two) and
why? Be quantitative where you can be, and state your
assumptions clearly.

2.

Dennis is a body repair auto mechanic and has a
hand-grip strength, as measured on a dynamometer with a
2-inch span, of 100 pounds. He is using a grinder with
a 1.5-inch diameter cylindrical handle to prepare the
surface of a car's door. The grinding is done in a vertical surface, so Dennis's wrists are extended at 45
degrees from the neutral position during the task. What
is probably the longest period of continuous grinding he
can perform before his grip muscles will start to fatigue
if the task requires a grip strength of 50 pounds?

3.

Metal ingots are delivered via a 30-inch high con-

�veyor to a work station where they are removed and placed
on a flat table that is 45 inches above the floor.
The
ingots are only one layer high on the table and are
12x6x4 inches in length, width, and height. They arrive
on the conveyor so that there is very little extended
reach to procure them and there is only room for 2 rows
(not stacked) on the table that they are lifted to. The
ingots weigh 50 pounds each. Estimate the percentages of
the male and female workforce that may find this lifting
task too difficult if an ingot arrives once every two
minutes and the job is done throughout the shift.
4.

Claudine is a ticket and baggage checker at the
Buffalo Airport for Air Chance. The airline is a low
budget organization and only flies by night. They have
made a deal with Agony Airlines to use Agony's luggage
conveyor after 9 PM, so Claudine has to carry each piece
of luggage about 80 feet after it has been checked in.
It takes her about 20 seconds to reach the conveyor.
Air Chance is considering setting a luggage (per bag)
weight limit in order to reduce the chances of Claudine
getting too fatigued or injuring herself on the job
(Claudine is Air Chance's President's daughter).
If the
main fatigue problem is for the grip muscles and Claudine has average grip strength for women (2-inch span),
what would you recommend as a weight limit for the
luggage? State your assumptions clearly.

(35 points)
1.

III. Long Problem.

Choose one.

-=

Several people in a job where steam irons are
packed into boxes have complained of back, shoulder, and
wrist pains. The workplace has the following dimensions:
Incoming iron line (conveyor)

= 50

inches above the
floor (packing table in
front of it)
Packing table = 30 X 30 X 30 inches (1 x w x h)
Iron box dimensions = 12x8x6 inches
Distance from front of table to middle of conveyor
line = 30 inches
Outgoing conveyor is behind worker as he or she stanqs
at the packing table and is 50 inches above the floor.
rEmpty boxes are stored there, too.
Irons when boxed weigh 10 pounds.
The irons are picked up by the handle which is 2.5
inches in circumference.
The irons arrive at each work station at a rate of 3 per
minute for boxing. The line runs all morning (about 4
hours). There is a 20 minute break after the first 2
hours of work.
a)

Using the above information, identify potential

�workplace and job factors that may be associated
with the workers• complaints of sore backs, wrists,
and shoulders. Use diagrams, graphs, and anthropometric data to clarify your answer.
b)

2.

What might be done to improve the workplace,
assuming that you have to keep the production rate
at 3/minute in order to meet the Christmas rush demands?

Workers in a ~oy factory are manufacturing several
sizes of Rubik 1 s cube for the mass market. The cubes
range from a key chain version that is 0.5 inches on a
side to a 6-inch coffee table model in 0.5 inches per
side increments. They are delivered to the packing station through a conveyor system that presents them to the
worker at 45 inches above the floor and 20 inches in from
the front side of the workplace at a rate of 10/minute.
They are placed in preformed boxes and put back on another
conveyor that is set 90 degrees to the supply conveyor
and has the same dimensions.
Some of the workers are having symptoms of hand
soreness with some of the Rubik 1 s cubes they pack. The
results are as follows:
Cube Side, Inches
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0

Difficulty?
Yes
Yes
No
No
,.~No

No
No

Yes
Yes
Yes
Yes
Yes

The largest cube weighs 2 pounds and the smallest
one weights an ounce.

10/5/84

a)

Indicate why some people are having hand soreness using anthropometric data and the information given above.

b)

What might you do at the workplace to reduce
the hand soreness without reducing the necessary
production rate? Explain why this approach
should improve the work situation.

SHR

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Data Sheet for Comprehensive Exam Question
I.

Anthropometric Data

I

Women

Inches, Means +/- ISD
Men
50/50 Mix

±

Forward Functional
Reach (from Abdominal Extension)

23.8 ]:.. 2.6

24 4

3 5

24.1 + 2.6

Waist Height,
Standing

40.0 + 2.0

41. 9 + 2 1

40 9 + 1 9

Elbow Height,
Standing

40 4 + 1. 4

43 5

±

1. 8

42.0

±

Eye Height,
Standing

59.6 ± 2.2

64.7

j:

2.4

62.1

±. 2.8

Shoulder Height,
Standing

51.9 ;±. 2.7

56.6 ± 2.4

54.4 + 2.6

9.1 + 1.2

9.5 .± 1.3

9.3 + 1.0

Elbow Rest Height
(height above seat
height)

~)

*

0

0

0

0

0

0

0

2.0

Upper Leg Length,
Seated

22.6 ± 1.0

23.4

± 1.1

23 0 ± 1. 0

Eye Height, Seated
(height above seat
height)

29 0 + 1. 2

31.0 :±: 1.4

29.9 ± 1.5

Popliteal Height,
Seated (back of
knee)

16.2 + 0.7

17.2

± 1.0

16.6 ± 21.9

Overhead Functional
Reach, Standing

78.4

3.4

82 5 t 3 3

80 5

Hand Length (wrist
crease to middle
finger tip)

7.2 + 0.4

7.5 + 0.4

7.4

Grip Breadth, Inside
Diameter

1.7:!:0.1

1.9 ± 0.2

1. 8 ± 0.15

Hand Spread - Digit
One (Thumb) to Two2nd Joint

3.2 ,.....
+- 0.7

4.1

*

0

j:

0

0

:t 0.7

From Kodak Human Factors, 1983 tables.

0

0

;:1:.

3 4
0

±. 0.4

3.6 ±. 0.7

�II.

Strength Data
A.

Grip Strength - maximum isometric force, at optimal hand
span, no wrist deviations; mean values+ l S.D.:
\vomen:
60 ..±. 14 pounds
Men:
101 ±. 24 pounds
50/53 Mix:
80 t 20 pounds
Span at Max Grip Strength, ln./Hand Length, In. = 0.27
Pinch

=

25% of Power Grip

Wrist Deviations and Power Grip (PG) Strength:

B.

Flexion:

25 degrees= 80% PG.; 45 degrees= 60% PG.;
65 degrees = 45% PG
Extension:
25 degrees = 90% PG; 45 degrees = 75% PG
Ulnar Deviation:
40 degrees = 75% PG; max = 55% PG
Radial Deviation:
25 degrees = 80% PG; max = 60% PG

c.

2-Handed Lifts - NIOSH Guidelines - Occasional Lifts
Pounds, Mean values
Women
Men

Floor to Knuckle
Height

------.±

-----

lS.D.
50/50 Mix

----------45 t. 7

5

54

±. 8

Knuckle to Shoulder
Height

34 ± 5

53

± 10

43 ± 8

Shoulder Height to
Arm Reach (above head)

29 + 3

49 + 10

-

39 + 7

III.

37

+I-

-

Work Capacity Data
A.

Aerobic Work Capacity
Kilocalories/min - Treadmill
Women
Men
50/50 Mix

(

9.5 .± 1.5
15.3 ± 2.5
12.0 + 3.0

Upper body aerobic capacity is about 70% of whole body
capacity (treadmill)

�B.

Endurance
Intensity vs Time - Aerobic Work and Strength Exertion

Average % of Aerobic
work Capacity

Time of Continuous Effort
Aerobic Work

100
85
70
50
40
33

-----------6 minutes

12
25
1
2

minutes
minutes
hour
hours
8 hours

Strength

--------

seconds
seconds
seconds
minute
minutes
2 minutes

6
12
25
1
1.5

SHR 10/25/93

(

\

\____)

3

(

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,

___

(lb.)

/

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(K~.)

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200

'!

80

150
0

w
t-

LL.
..J

t-

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Hazardous
Liflinq
Conditions

100

:z:
(.!)

Functional Reach
limit ~ 1

w
~

1 Maximum
1 Perr:nissob.le
Limit

-----J...-~

Act1on

~~~~~~~~~~Limit
0o

20

40

60

60

.I
;'
•
. ----~~·--~--~·~--~--~·~~--~-·--~

0

10

20

'

30

(em)

(in.)

HORIZONTAL LOCATION OF LOAD
~~~:&lt;imum tve1ght versus Horizontal Locat1on for

Infre-

quent Lifts from Floor to Knuckle Height

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200

/

0

80

150
0

w

....

Hazardous
Lifting
Conditions

LL.

-.J
....

100

:I:
C)

Functional Reach
limit ~ 1
1 Maximum
1 Permissob.le
Limit

w
~

50

---........._l_~

Ac t1o n

~~~~~~~~-'-!...Limit
0o

r.

0

20

40

60

80

----~-·~~----~·~--~--~·~~--~-·--~
10
'20
. 30
-

I

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'

(em)

(in.)

HORIZONTAL LOCATION OF LOAD
~~u:&lt;imurn tve1ght versus Horizontal Locatlon for

quent Lifts from Floor to Knuckle Height

Infre-

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                    <text>1

Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics

169 Huntington Hills - Center
Rochester, New York 14622

•
(716) 544-3587
(716) 266-8749 (FAX)

Chris Gjessing, Public Health Advisor
Division of Physical Sciences and Engineering
NIOSH/DHH/PHS - Mail Stop R-2
4676 Columbia Parkway
Cincinnati, OH 45226-1998
July 24, 1996
Dear Chris;
Thank you for asking me to comment on the NIOSH document "Elements
of Ergonomics Programs - A Primer Based on Workplace Evaluations of
Musculoskeletal Disorders". I have just returned from a nice vacation in
Europe and attacked the task with gusto, perhaps more gusto than was
intended when you sent the manuscript to me. As I warmed up to the task,
I got more prolific in my manuscript comments, so much of what I can
offer, in the way of specific suggestions for improvement, will be found
there. In this letter I will put some more general comments, some of
which address the questions you asked in your letter.
First, let me emphasize that I make a living as a consultant in ergonomics
helping plants set up ergonomic processes to control occupational injury
and illness and to integrate ergonomic principles into their plant operations
for better productivity and quality performance. I have been doing this on
my own for 14+ years after 13 years of doing similar work at Kodak, and I
have made probably every mistake there is to make in the process.
Fortunately, I have been able to learn from those mistakes (mostly created
by a lack of political astuteness or by trying to apply ergonomics theory
too rigidly in the field), and have thrown out quite a bit of the material I
learned from books in favor of what I have learned from being out on the
floor. I am also fortunate in having clients with plant sizes ranging from
44 to 27,000 people, and I have found that the only real difference between
a large and a small plant is in the number of resources they can tap into to
solve problems. The types of solutions they find to problems, providing
they really analyze the problem, range from simple rearrangements or
assists to full automation, the latter being less feasible unless it has a

�2

productivity improvement associated with it as well. Money has not really
been the issue when we've properly analyzed the risk and developed ways
to reduce it, because the solutions have not been expensive to implement.
Because of my opportunity to follow progress in the ergonomics programs
I have helped to start (over 6 years in many instances), I have learned what
"works" versus what should work based on ergonomics theory.
Consequently, I have rejected many of the "standard" ergonomics
guidelines and solutions that have only limited application in the field (bent
handle tools, tilt- or adjustable-height tables, etc.) and focussed on a
broader problem solving approach based on an analysis of the risk for
fatigue or overload on specific muscles groups. I have found the checklist
approach to ergonomic risk factor identification problematic because it
only defines the potential for problems if the job pattern is non-optit»J.al.
The risk factor checklist tends to describe postures or give force levels or
repetition rates independent of each other, and therefore, overestimates the
risk in some situations and badly underestimates it in others. I am
attaching a copy of a paper I gave in Zurich earlier this month that tries to
address the problem in terms of the need to evaluate the interactions of
effort intensity, frequency, and effort duration to assess the risk for
musculoskeletal injury and illness. That should give you a sense of where I
am coming from in evaluating the toolbox methods, for example.
I will address some general issues in the rest of this letter:

1. Intentions of the Document
There seem to be two intentions of the document:
a. To share what NIOSH has learned from doing workplace
evaluations and helping companies establish ergonomics
programs; and
b. To provide small and middle-sized companies with direction for
what they should do to start an ergonomics program or improve
an existing one.
My observation is that you have accomplished the first goal and have
not really addressed the second goal in a way that a company could
develop an effective program. I like the vignettes where specific
problems are discussed using the job studies you have done, and I like
the tables summarizing the studies except for missing an "Impact"
statement based on follow-up in the last column in many of them (see
comments in that section). But there is no "How To" section that relates

�3

to the essential elements in a program (c.f., 1992 General Ergonomics
Guideline outline or the Red Meat Cutter's Guideline that spells out the
essential elements for an injury/illness control program). The plant
with little in-house expertise and not much money for consultants wants
some direction in this way and, although most of the material is present
in the document, there is no place where it comes together. Perhaps
that is intended for an "Executive Summary" of the whole document.
2. Level of Document for Intended Audience
As you have said in the document, to be useful to small companies and
people without a lot of ergonomics training, the document has to be
presented in laymen's language and the content should be practical. I
find that the language and content range between academic and
practical and, thus, do not meet the needs for a "primer". As a
discussion of what NIOSH has learned, it is an appropriate style; but
for a company to use in starting up a program there is too much
information in some places and not enough in others. I have learned
the following "truisms" from working with a wide diversity of
businesses in the past 28 years:
a) Do not provide them with guidelines that have to be interpreted.
For instance, don't give 2 sets of design guidelines for working
heights or reach distances unless it is for different tasks (see
manuscript for specific comments). Especially, do not give
them male and female guidelines since those will encourage
them to design for one or the other sex and perpetuate a
design problem we've had for generations. Design for the
largest majority of both sexes.
b) In providing general guidelines for postures or forces, etc.,
use words like "minimize" instead of "avoid" when talking about
working with a bent wrist or bending over to reach something.
Working with a bent wrist or bending over is not a problem
unless a high force is exerted or a long time passes before the
wrist goes back to the neutral position or the person stands
upright. I do not like to see risk factors described in only
one dimension, anyways, because it mis-states the injury/illness
risk and results in people making many changes instead of
targeting the most effective interventions. Large companies
may be able to afford the new tooling, furniture, materials
handling devices, lift tables, etc., but smaller companies often
need to home in on less expensive ways to reduce risk. These

�4

are often simple changes in job pattern or production planning,
but they will not emerge as solutions from a checklist approach
to ergonomics.
c) A good checklist should lead the user to the next phase of
problem analysis, finding out why? the risk factor is present.
I find very few job analysis methods that include this step,
they rather go straight into the solutions from the risk factor
identification. Therefore, in a VDT workplace, for example,
every low back problem gets a chair, every wrist discomfort
gets an articulating keyboard, an adjustable height work
surface, or a wristrest, every leg discomfort gets a footrest,
and every neck discomfort gets a monitor stand. These
improvements are not bad, just often they are not necessary;
and in a smaller plant they may not happen because of lack
of a budget for equipment like this. In typical problem solving
approaches where the "why?" is identified, we have often
found that vision drives the posture, and the backache and neck
problem disappear when we improve the screen text contrast
or color combinations or rearrange the locations of hard copy
and screen to meet the visual needs of each task. Improving the
office workplace and furniture can then be done over time,
instead of on an emergency basis, and Purchasing can be assisted
in assuring that only ergonomic equipment, furniture,
workplaces, and tools are brought into the plant.
d) Don't bother the inexperienced ergonomics practitioner (for
whom this "primer" is intended) with technical information
that he or she cannot evaluate and that will just confuse them.
Leave that discussion for an Appendix or refer them to original
papers about it. Give them your best understanding of how to
do things, and qualify it accordingly as your opinion.
e) Continually emphasize that the people who do the jobs in the
plant are the experts on them, and they must be an integral part
of the job analysis and solution-generating process. The role
of an ergonomics consultant should be to help bring out all of
their knowledge and to help bridge the communications gaps
between the workers and their supervisors/managers and with the
plant engineers or maintenance specialists who will have to
implement any changes.
f) Analytical tools should be easy to use, not much more than one

�5

page in length, and should lead to root cause analysis and
solution-generation. It should not be possible for people who
have not done the jobs to fill out the forms without talking to
the people who do them, even if they have a videotaped sequence
to study. One cannot understand all of the elements of a job and
understand why it is done as it is done unless one talks to and
listens to the worker. Most failures in solutions come from not
getting enough information about the job from its practitioner.
I have attached a few additional articles and documents from my own
consulting practice to illustrate some of these issues. Since this is
primarily a document on what NIOSH has learned in doing its job
analysis, I do not expect that you will want to change anything, but I
include them to show what I am alluding to in my above comments.
3. Proactive Ergonomics
I am glad this has been included because it is the way to do ergonomics
in companies. However, I find the section very weak, on the whole.
The biggest problem is the ability to get ergonomics input into the
design or selection process. I have included one of my "outlines" on
this in the attached material. Some of the processes I've used to get the
designers to see their responsibilities to include ergonomics principles
in their work include:
a) Sitting on a design project committee and working as a team
member to identify and help resolve potential ergonomics
problems as they arise.
b) Providing a set of design guidelines for designers of equipment,
workplaces, etc. or for purchasers of tools, furniture, etc. that
define when they need to come to the ergonomics team for
additional help. This is like a "design space" within which they
are okay or outside of which they are creating a significant risk
for workers, with a gray area between these areas where risk
is defined by the interactions of risk factors and job pattern.
c) Reviewing an existing design before it is near finalization and
asking questions about how people will operate equipment, move,
be supplied, etc. It is the process of asking questions to
understand more about the new jobs that brings about an
increased awareness by the designers of their responsibility
in making the workplace, equipment, or tools safe and easy to

�6

use.
d) Training designers in ergonomics principles around potential
future projects. In this way one does not appear to be criticizing
a designer's work but can show the application of ergonomics
information to the solution of design problems. The training
has to be technical initially so they understand the data bases on
capabilities and understand their limitations. Then, the training
should leave at least one day for applications to real problems
or evaluation of existing designs (although this approach is
difficult for some designers to handle if it is their design).
Most designers will think that ergonomics is not one of their
responsibilities (except in product design), but rather is the
responsibility of production people who operate the machines ("just
have to find the right person to do it"). They see their responsibility
as getting the machine or tool to do the required job or the layout to
fit the space available, and they rarely think of maintenance or what
will happen when the system fails. They get quite interested in
people's capabilities and in applications of the data, however, and the
goal of training should be to raise that awareness. Since you can
rarely get more than 2 days of their time to train them (even on site),
one has to target the best use of that time and make it as relevant to
their needs as possible. Assuring that they spend time on the production
floor talking with operators of similar equipment will be almost as
effective as trying to teach them a lot of ergonomics !
The Toolbox Proactive Ergonomics section uses the checklist approach,
and, although, the design guidelines may be helpful in some cases, in
too many instances there is not enough guidance and too much is left to
the designer to figure out. See the paper on Ergo Standards attached
with these notes to see another way of helping the designers identify
potential ergonomics problems. I have written all over the checklist
to illustrate where I have difficulty with it. There are more helpful
tools available. The Kodak books are focussed totally on Proactive
Ergonomics, for example.

4. Other Issues
a) "Ergonomic hazards"
You mention in the introductory material that, although it is not
really appropriate, the term "ergonomic hazard" has become an

�7

acceptable way of describing risk factors. I have been trying to
kill the use of this term since the Red Meat Cutter's Guidelines
first inappropriately used it almost 10 years ago. Bad use of
language has effects on people's thinking, and I anticipated and have
seen that this oxymoronic term has cast the whole field of
ergonomics in a negative light for many industries. Note the
National Association of Manufacturer's comment when they
protested the OSHA Ergonomics Guidelines in 1995, saying that
they didn't want anything to do with ergonomics and that they did
not believe there were hazards to control.
I have accepted that some term is needed, and have used "ergonomic
problems" as a weak accession to the need to define ergonomic
risk factors. The use of "hazard" is fraught with many difficulties
because it assumes serious injury can result when it may be a
discomfort issue. I beg you to eliminate it from this document so
you do not perpetuate the damage and inaccuracies that the field is
having to overcome with industry. Sloppy language and sloppy
thinking go together, and we need much clearer thinking in how to
reduce the risk of non-ergonomic designs !
b) Guidelines for Men and Women - see comments in the text
I realize that this material came from Grandjean's book and the
male/female values are separated there. However, the Affirmative
Action Legislation of 1974 does not allow companies to build
workplaces for women and men alone - all workplaces have to fit
all people, in so far as that is possible. By putting in 2 sets of values
for work height, etc., one leaves it up to a designer to choose who to
design for, and most designers will not do it properly. The values
that should stand should be ones that accommodate the majority of
both the male and female populations, no matter who currently
works there. If one designs for the existing population, one only
perpetuates the situation that makes it difficult for men to work
in traditionally-female jobs or vice versa.
In practical applications of anthropometric data, I have found that
the general guidelines for heights and reaches are only slightly
useful because each job is different. The first thing that is needed is
to find out where the hands have to be in relation to the work surface
(the size of parts or product or packaging materials and the tools
used and how they are oriented are some needed data). The reach
data is not meaningful unless you identify the working height as well,

�I

•

8

since a 15-inch reach in front of the body at a height of 30 inches
above the floor requires everyone to bend over. Thus, some of the
simpler statements we like to use like "let the tall person fit and the
short person reach" are simply wrong if applied to standing reaches
below 40 inches ! Good design looks at male and female capabilities
together to develop a design value,or a small range of values that
does not inordinately affect either extreme of the population for that
measurement.
If you keep the two sets of data for workplace design, people will
choose the values based on who they think is most likely to do the
job. That is against the law, and we shouldn't push them in that
direction whether they understand the law or not. The Kodak books
give design guidelines based on accommodating the majority of both
populations. Sometimes the value is taken from the female data
(maximum forces) and sometimes from the male data (clearances),
but the ultimate outcome is to accommodate the largest majority of
both populations.
c) Transferability of Solutions to Similar Jobs
In the 28 years of job evaluations I have done in a wide variety of
industries, businesses, and service sector/municipality jobs, I have
rarely found two jobs that were identical, even when they carried
the same title. The Dictionary of Occupational Titles categorizes
job demands and responsibilities by title across industries which
can help define equivalent pay and assist in the rehabilitation-towork process; but actual measurement ot a job with the same title
often does not meet those estimates of job demands. More emphasis
should be put in the document to inform the less experienced
ergonomics practitioner that one really has to understand the job
before developing solutions to the ergonomics issues. Not every
frequent lifting task needs a lift table, for instance; often a
fixed-height platform will do the job if the pallet load height is under
40 inches and the primary problem is handling from the lower 2
tiers on the pallet. The best way to understand the necessary
improvements is to do a root cause analysis on why" the problem
exists (why the risk factors are there) and then work with the
workers and service groups to find several ways to address the
problem. Anytime someone says that there is only one way to solve
a problem, I know they haven't really analyzed the job or talked to
the worker.

�9

I think that is plenty of feedback for you to chew over, Chris, so I will stop
here. I think there is a need for this type of document, and my efforts to
show you where I think it needs improvement are offered in that light. If
it is to be a "primer", then I think it needs a fair amount of work. If it is
primarily a document showing what NIOSH has learned in studying jobs
and helping set up ergonomics programs, it needs less revision, but that
goal should be clearly stated up front. Despite a great deal of experience in
this field, I still find that each plant has its own set of needs. A good part
of my first contact with them is spent in trying to determine the most
effective approach for getting ergonomics built into their processes, so they
will see the positive results and reinforce them quickly. 'Lots of traps out
there, mostly political or managerial, and working through them takes
more time than does developing their enthusiasm for ergonomics
applications in the workplace ! I am currently developing a "Dilbert Meets
Godzilla the Ergonomist" approach to break down industry's negative
barriers set up by the proposed OSHA Ergonomics Guidelines of '95 ! I
hate to see a good thing killed for the wrong reasons.
Thanks again for letting me review this document, Chris.

Sincerely yours,

7/24/96 SHR/mes

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>The Visual Access Simulator for Standing and Seated Work
Constructed by S.H. Rodgers, Ph.D., Consultant in Ergonomics

A. Description of the Visual Simulator
The purpose of this simulator is to provide a way to predict the impact of
recommended workplace or equipment designs on the ability of a person to
see what he or she needs to see to do the job. It is made up of three parts. A
gri.Q_showing height above the floor versus distance in front of the eyes
makes up the bottom layer. Three eye height ranges are shown on this grid:
the first is for standing operations and the second and third are for seated
operations, the second for sitting on a 27-inch high stool and the third for
sitting on a 17-inch high office chair. The range of eye heights
accommodates 90% of the potential workforce (men and women) but does not
make allowances for bifocal or trifocal wearers. That adjustment should be
made after the other impacts have been evaluated because it will affect the
choice of height uniformly across most viewing conditions.

The second part of the simulator is a set of dotted lines that represent
visual angles and the line of sight from a worker's given position. This
should be positioned on the eye height range lines (at top and bottom to
evaluate the extremes of eye height) for the working posture of interest. It
is important to note that even if a person is scheduled to be standing while
monitoring a process or machine, he or she will probably sit down whenever
the machine or process is running properly, So, it is usually wise to test the
visual access in both standing and sitting postures.

1.

�The third part of the simulator is a set of vertical bars that represent
different height barriers (walls, supports, equipment, etc.) to vision. They
project down and rise from the floor or standing surface. This transparency
can be moved horizontally across the grid after the visual angle overlay has
been located at the appropriate point on the eye height range. The bars will
intersect the visual angle lines at different distances from the eye.

B. How to Use the Simulator to Determine the Visual Impact
of a Given Design
There are at least 2 ways in which the simulator can be used in designing
or retrofitting a given workplace or piece of equipment. One can use it to
determine how easy it will be to � a given part of the equipment from a
specific distance, using a given window location or a structural barrier. Ease
of seeing the part is equated with a comfortable working posture, that is,
not having to crane one's neck, lean forward for extended periods, or crouch
down to be able to visually access the location of interest. The simulator
can also be used to recommend the location of a window or access port to
allow a comfortable posture at the location where the job is being done.
For the situation where the design has been done and one wants to
measure the impact of that design on the operators' ability to see the
location of interest, the simulator is used as follows:
1) Determine which ranges of eye height are most appropriate to
use in the evaluation.

2.

�2) Move the visual angles overlay to the top or bottom of the eye
height range. Place the intersection point on the line
representing eye height.

3) Determine the distance from the eyes to the barrier or
window, for the design problem. This value may be the width
or depth of a control console or of a table, for example.

4) Place the vertical bar barrier overlay at the point determined by 3)
above and move the different length bars across this point until the
one closest to the existing design is simulated.

5) Note the visual angles that are intersected by the bar at this
point. Items placed in areas where the visual angle lines are
!J.Ilinterrupted should be easy for the worker to see in the
posture shown.

6) Note the impact of the upper barrier (window frame, for
example) on visibility of higher items using the appropriate
upper bar to represent the existing design.

7) Repeat 4) to 6) for the other extreme of the eye height range or
for the next posture in which the operator may be found.

8) Summarize the analysis by identifying the area in which visual
access is good for the job.

3.

�For the workplace or equipment design situation where one is trying to
determine the best location for a window or access port, one should follow
steps 1) to 3) as above, initially. Then, the following approach can be used:
1) Determine the visual distance from the operator's job site to
the most commonly viewed parts of the production system.
Measure the height of these items, too.
2) Determine which visual angle lines should be @interrupted in
order to see the desired areas at their height and distance
locations.
3) Move the vertical bars (barriers) over the g.d.d and visual angle lines to
the point where the desired visual angle lines are left
uninterrupted. Note the vertical heights that are compatible
with visibility using both the top and bottom vertical bars.
4) Use this information to help determine the best designs
for control rooms, etc.. Define the design by the working
posture (sit, stand) and always consider both extremes of the
population.

C. Assumptions:
The following assumptions have been used to develop this simulator:
1. A cross-section of the working population will be involved in
these tasks. Therefore, the design should consider men and
women and tall and short people. A 50/50 male and female
4.

�mix is assumed (see Kodak, Ergonomic Design for People­
at Work, Volume 1, Appendix A. Anthropometrics).
2. The vertical lines illustrating eye height include values where 95%
of the workforce is taller (5th percentile, at lower end of
the distribution) to where only 5% is taller (95th percentile,
at the upper end of the distribution.) The shorter workers
will have more difficulty seeing low objects and the tall
workers will have more difficulty seeing high
objects.
3. It is assumed that the operator can easily turn to face the area
of interest, so the visual access lines are always straight in
front of the body, not to one side.
4. Chair heights of 27 inches (stool) and 17 inches (office chair)

above the floor have been used for the seated eye height
range calculations. If the seating differs from these values,
just adjust the visual lines up or down by the amount the
chair height deviates from the given value. The range of
eye heights will remain constant, so this chair height
adjustment should be made at both ends of the distribution
of eye heights.
5. All heights are measured above the walking surface. If a false
floor is used, it is important to add the floor height to get
the actual window height above the slab floor.

5.

�D. Example:
Where should a control room window be located (height above the floor)
so that an operator standing 30 inches back from the window can see a liquid
level display that is 1 O inches above the floor and 12 feet away?
Analysis: Operator = 30 inches from window
Object to be seen = 144 inches away, 1O inches high
Using the grid for object distance and height and for the window location,
one can use the visual angles overlay to determine the needed visual angle
for short and tall people. For both the tall and the short persons, the needed
visual angle is between 20 and 30 degrees below the line of sight.
For the short operator, the view to the display is clear as long as the
lower part of the window does not exceed 45 inches. The tall operator would
still be able to see the display until the barrier height exceeded 50 inches.
Assuming that the operator may sit on a stool in the control room, one
might decided to test the 45- and 50- inch high barriers against that
posture, too. On the 27-inch high stool, the seated eye height of short and
tall people ranges from 54 to 60 inches above the floor or walking surface.
The visual angle of concern is now about 20 degrees below the horizontal,
and barriers in excess of 42 inches will block the view of the shorter
operator. The tall operator can still see the display if the barrier is less
than 45 inches high.
7/21/87 S.H. Rodgers, Ph.D.
6.

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�</text>
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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                    <text>\,

Matching Worker and Work Site - Ergonomic Principles
Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics
The major goal of ergonomics is to design jobs, equipment,
environments, and products within the capabilities of most

\_,,
\'.people.

If this is done, it is not very difficult to return people

to work after an illness or injury.

However, we are far from

realizing this goal, and there are many jobs that are too
difficult physically for many eligible workers to perform for a
full shift.

In most of these jobs we use either worker

self-selection or "natural selection" to find the people who can
do the work.

Those who can perform the tasks safely often

tend to be young, male, and physically fit.
Although one can find people to perform difficult jobs by
this trial and error method, a side effect is that there is often
high turnover in the job and strain and sprain injuries are
common.

The ergonomist can approach such jobs from two

directions.

One approach is by defining the job requirements

and the cababilities needed to perform them so that a person
can be selected for the job based on a measureable strength or
endurance capacity.
requirements,

Another approach is by defining the job

identifying

the

limiting

activities,

and

determining how to lessen those demands so that more people
can do the job.

Selection testing does not solve the job

problem and requires continuous screening of applicants for the
job.

Job redesign eliminates the problem and is probably the

�less expensive alternative over time, although it may require a
significant up-front expenditure.

For this reason, it is the

second approach that will be discussed in detail in this section.
1.

Characterizing the Job Demands
To determine the suitability of a job for a person who is

coming back to work after an illness or musculoskeletal injury,
there are three major requirements to characterize:
1.

the intensity of effort required

2. the amount of time the effort has to be sustained
continuously (duration)
3.

the pattern of effort exertion over the total working
period, or shift

Other

factors

such

as

environmental

conditions,

social

interactions, and psychological stresses are also important but
will not be discussed here.

A model of upper extremity

disorders, especially those of the hand and wrist, will be used
to illustrate an ergonomic approach to matching the job and
worker and to suggest ways of improving jobs that are outside
the capabilities of many people.
a.

Effort Intensity
The strength required to exert force or lift something will

depend upon the muscles used and their posture during the task.

�For work with hand tools, one should identify the amount of
force exerted on the tool and characterize the type of grip the
person can use for the task.

The force on the tool can be

measured directly using a torque meter.

If this is not

available, reasonably good estimates can be made by asking the
worker to recreate the force while pressing on a platform (e.g.,
bathroom) scale or pulling on a spring (e.g., fish) scale using
the same posture as is used in the task.
The type of grip used can be definXed as either a power grip
or a pinch grip.

Figure 1 illustrates these types of grip.

The

primary difference between them is that pinch grip strength is
only about 20 to 25% of power grip strength.

Consequently, a

required force of 15 pounds (or 150 Newtons) could be
perfectly acceptable for most people if they are using a power
grip (requiring about 25% of their strength or less) but would
be a maximum exertion if they have to use a pinch grip.
Other factors limit the amount of power grip strength
available, especially grip span and wrist postures.

Too large or

too small a grip span make it difficult to curl the fingers and
bring them together in a power grip.

The grip muscles in the

forearm have to exert high forces in order to get the required
force at the hand in these biomechanically inefficient postures.
Wrist posture also affects the biomechanics of grip exertion by
making the tendons from the muscles in the forearm pull around
corners instead of directly on the fingers and thumb.

This

�means that

larger forces have to be developed in the forearm

muscles to get the same strength output one gets when the
wrist is in the neutral position (no flexion, extension, or radial
or ulnar deviation).

Table 1 shows how grip span and wrist

angles influence power grip strength.
Another factor that influences the amount of power grip
strength available on a job is whether gloves are worn.

Thin

gloves without seams between the fingers have the least
interference with grip force development.

Thick gloves with

seams can reduce grip strength by up to 40%.

Table 1 also

summarizes the effects of wearing gloves on grip strength.
Having estimated the force exertion requirements of the job
and determined the type of grip, wrist postures, hand span, and
the characteristics of any gloves being worn, one can express
the job force requirements in terms of a percentage of
available strength for most people.
%MVC,

This is referred to as

or percentage of maximum voluntary contraction

strength, for the muscles most involved.

For example, about

75% of the potential workforce can be expected to have a
maximum power grip strength of at least 60 pounds (or 27
kilograms) if the grip span is from 2 to 2.5 inches (5 to 6.2
cm), the wrist is in the neutral position, and no gloves are
worn. So a force of 20 pounds exerted in a task would use 33%
of the capacity of a person with a 60 pound grip strength.

If

the task is designed so the worker has to flex his or her wrists

�45 degrees, the available strength would be 75% of the original
value, or 45 lbs (about 20.5 kg), so the same 20 pound force
would now be 44% of capacity. If the tool being used has
a 1-inch (2.5 cm.) grip span instead of a 2 to 2.5 (5 to 6.2 cm.)
span, power grip strength would be 40% of the initial value or
24 pounds (11 kg).

With a neutral wrist and no gloves; the

20-pound force is now 83% of capacity.

When awkward wrist

postures, gloves, and suboptimal grip spans are all present,
only those people with high grip MVC's will be able to perform
the tasks on a repetitive basis.

b.

Duration of Continuous Effort.
A most important concept for ergonomic design is the

relationship

between

continuous work.

effort

intensity

and

duration

for

It is not only how intense an effort is needed

to perform a task, but how long that effort must be sustained
before there is a break to allow the muscles to recover. As the
effort intensity increases, blood flow into the working muscle
is compromised.

At about 40% MVC blood flow reduction is

measurable, and at 70% MVC there is a very significant
reduction.

Since the blood carries oxygen which is vital for

supplying energy for muscle contraction, the higher the %MVC
used, the shorter the time it can be sustained continuously.
Figure 2 illustrates this relationship.
Without enough oxygen to supply the energy for muscle
contraction, anaerobic metabolism is used and lactic acid is

�formed.

This by-product of inadequate oxygenation has to be

sent to the liver to be reconverted into glucose or glycogen, so
it takes longer to recover from a period of oxygen debt in the
muscles than it does to develop the debt in the first place.
is

the

availability

of

recovery

time

between

It

intensive

exertions that determines the acceptability of some highly
repetitive tasks.

As the frequency of repetition increases,

there is less recovery time between exertions.

Even if the

effort is quite short (3 to 5 seconds), there may not be enough
time to recover if the intensity of the effort is high.

Figure 3

shows the needed recovery time for efforts of several different
intensities as a function of holding time.

By summing the

holding and recovery time for a given effort intensity and
dividing it into 60 seconds, one can determine the best
frequency for performing the task.
The duration information can be used to identify whether
the work will be suitable for most people to perform in a
repetitive manner.
periods

If the effort has to be sustained for long

(a minute or two),

the duration information will

determine whether most people can perform the task even on a
lowly repetitive basis (see Figure 2).

Ways to improve the

tasks to make them suitable for more people are discussed
later.
c.

Work Pattern
If the effort intensity and duration requirements of the

�job are appropriate, one still has to consider the overall job
demands for the shift.

It is possible that a person will be able

to sustain a task for 30 to 60 minutes but may reach limits
when trying to sustain it for 120 minutes before having a work
break.

It is important to observe the degree of control that the

worker has over his or her work pattern.

The more control, the

easier it is to get them back to the job, because they can
arrange the work to fit their need for recovery time.
Intermittent work, where short (1 to 2- minute) breaks are
alternated with intense efforts, is known to be more efficient
as a work pattern than is sustained intense work with a 15 to
20 minutes rest break afterwards.

If a machine or other

outside influence is determining the work pattern and requiring
the worker to match its pace, the worker with a lower capacity
will be disadvantaged.
Work patterns are best categorized by describing the
distribution of tasks in time and over the shift, then timing
within the major tasks to see if periods of lighter effort are
interspersed with the heavier ones.

In addition, it is useful to

observe specific muscle groups and to identify their work and
recovery cycles.

Videotaping the jobs permits these analyses

to be done more carefully.
the job

so

appreciated.

individual

Several people should be taped on
differences

in

technique

can

be

�2.

Characterizing the Individual's Capabilities for the Work
In the discussion of job characterization above, it was

mentioned that we can express physical job demands as
percents of capacity for given muscle groups.

There is data

available on the strengths of specific muscle groups in men and
women and on the strength available for pulling up or pushing
and pulling horizontally where several muscle groups are used.
Some of the relevant strength measurements are given in Table
2, which includes average values and values representing
weaker people (5th and 25th percentiles) and stronger people
(75th and 95th percentiles).
To determine whether an individual has adequate strength to
do a task, one should identify the active muscle groups and test
the patient's strength in the posture used on the job.

In the job

analysis discussed earlier, the job strength requirements were
measured, so one can then compare the job requirements to the
strength available, expressing the job demands as a percent of
the patient's capacity.

For example, if an upward pull of 35

pounds (16 kg) is needed and the patient has a pull capacity of
70 pounds (32 kg) at that location, the job requires 50% of his
or her capacity.
If the task is a repetitive one, the demands have to be
related

to the work/recovery cycle guidelines presented

earlier in Figures 2 and 3.

If one wants to test the patient's

endurance capability, it is possible to have the strength

�exertions repeated as they are in the job for a period of three
to five minutes in order to observe the patient's tolerance of
repetitive work.

If several different types of work are done, it

may be necessary to test the strength

of several muscle

groups in order to assess the patient's suitability for the work.
For most of the strength measures, a strain gauge or
dynamometer is adequate to assess the strengths of interest.
Use of a tray with calibrated weights added to it may be
appropriate to evaluate a person's capacity for repetitive
lifting tasks.

The primary concern is to make the test similar

to the job requirements by assuring that the same muscles and
similar postures are used.
If the job requires frequent lifting throug,hout the shift,
total workload limits may be of concern, so an aerobic capacity
determination may be needed.

Then the estimated or measured

energy requirements and the job pattern information can be
used to assess what percent of aerobic capacity is required in
the job.

Figure 4 illustrates the aerobic workload time limits

for different percentages of capacity.
3. Examples of Techniques to Reduce the Demands of Heavy
Jobs
If it is determined that the patient does not have adequate
capacity for the job, one should not simply set a restriction
against doing that work without looking for ways to modify the

�job effort requirements.

Ergonomists will look for ways to

reduce the strength requirements or to shift them to stronger
muscle groups, to reduce the overall effort levels, and to give
the worker control, in so far as it is possible, of the work
pattern.

Ergonomics

interventions in the workplace will be

illustrated using low back pain and carpal tunnel syndrome as
examples of common musculoskeletal problems for which a
person may need work modifications.
a. Low Back Pain
People with low back pain may have difficulty with jobs
that require frequent awkward postures and with repetitive or
awkward manual handling tasks.

The postural characteristics

of jobs that may produce problems include:
working over shoulder height
bending over
crouching down
constant standing
constant sitting, especially if the seating is poor
twisting of the trunk
extended forward reaches
These can be modified by adjusting working heights to
reduce bending over or crouching down.

One can often use

platforms to bring the person up so the work is not done above
shoulder height.
less likely to occur.

By orienting the workplace trunk twisting is
So there are 90-degree angles between

�work locations instead of 180-degrees (for supplying parts, for
example),
Activities in the job that allow the worker to get up and walk a
bit in a sitting job or to sit down for short periods in a
standing job will also provide relief for the person with low
back pain.

Handling aids such as reach extenders, back supports

for chairs, and foot supports are also useful aids.
Manual handling tasks may make it difficult for a person
with low back pain to return to work, but the ergonomist can
look for ways to reduce these problems using the following
techniques:
1)

eliminating barriers that prevent the person from getting
close to the load, such as inadequate foot and leg
clearances around items to be lifted.

2) raising items to be lifted to 20 inches above the floor or
more by using platforms or lift tables so less energy is
needed to lift repetitively and there is less strain
on the back.
3) looking for ways to handle some items in bulk in order to
reduce the amount of manual handling required.
4) providing less heavy tasks as part of the job in order to
assure adequate recovery time between lifting tasks.
An example of a theoretical return-to-work situation will
serve

to

illustrate

how

ergonomics

techniques

can

incorportated into the medical evaluation of the patient's

be

�ability to return to the job after an attack of low back pain.
The Job:

Packing boxes of product, labeling and sealing them,

and then placing them on pallets for shipping. Boxes are
12x12x12 inches (30x30x30 cm) and weigh 30 pounds
(14 kg) each. The packing line is 30 inches (75 cm) high;
the labeling and sealing line is 25 inches (62 cm) high, and
the pallets are 5.5 inches (11 cm) high as they sit on the
floor. The lifting rate is 9 per minute and is sustained for
2 to 3 minutes at a time.

In a full shift there are 540

boxes handled per shift on the job. The pallet is loaded 5
tiers high with 12 boxes on each tier.
The Patient's Status:

5th attack of low back pain in 8 years;

some chronic pain, radicular - R leg; found to have pain
when lifting 30 pounds (14 kg) at 15 inches (38 cm) above
the floor and 10 inches (25 cm) in front of the ankles
in a laboratory simulation of the job. No pain on handling up
to 55 pounds (25 kg) between 30 and 40 inches (76 and 102
cm) above the floor and close to the body. Additional
pain generated with lifts of 25 pounds (11 .5 kg) at 50
inches (127 cm) above the floor or higher.
Initial Evaluation:

At first look it would seem that the patient

could not go back to this job because it involves frequent
handling below 15 inches (38 cm), some sustained bending

�for the labellng and sealing activity, and some lifting
above 50 inches (127 cm) to stack the 4th and 5th tiers of
the pallet.
Ergonomics Interventions:

Among the approaches that could be

considered to reduce the load on the patient's back and to
make the job better for most people would be:
1. Raise the labeling and sealing conveyor so the labels
are applied between 35 and 45 inches (88 and 114 cm)
above the floor.
2.

Place the pallets on levelators so the low lifts are
avoided; and provide a platform for the workers to use
when loading the top tiers.

3.
4.

Consider eliminating the 5th tier of the pallet pattern.
Evaluate the feasibility of sending the boxes to a
central area where an automatic palletizer may be
cost-justified so that hand palletizing is eliminated
altogether (long term solution).

�b. Carpal Tunnel Syndrome and Tendonitis
People with cumulative trauma disorders of their hand,
wrist, and forearm may find it difficult to return to a job on
which the symptoms first appeared.

Several of the risk factors

for these problems have been discussed earlier under the
heading of characterizng the job.

These include:

high grip forces
awkward wrist angles
too large or too small a pinch grip span
use of gloves
In addition, cumulative trauma symptoms are more prevalent in
jobs where the following conditions apply:
time pressure
work with arms elevated, tension in shoulders
constant holding tasks
forceful rotations
cold temperatures
vibrating tools used
high frequency tasks (7 strong exertions per minute or
more)

To reduce the risk of aggravating the symptoms in people
with a susceptibilty to carpal tunnel syndrome or to tendonitis,
the ergonomist looks for ways to improve the wrist and hand
postures through workplace and tool design, to relieve neck and

�shoulder tension by adjusting workplace heights, to improve
the grip type and span, to chose appropriate gloves, to reduce
the forces required, to provide short recovery periods in
constant holding tasks or to provide aids to hold or support
parts or tools, to control cold and vibration exposures, and to
design the job to provide periods of less forceful exertions so
the arm and hands can recover and so the patient can regulate
his or her work pattern as needed to minimize the symptoms.
An example of how this information can be used to help
return a person to work after an episode of carpal tunnel
syndrome or tendonitis follows.
The Job:

Using a pistol grip power tool to attach nuts to bolts

on a product on an assembly line. The nut driver's
handle is 3 inches (8 cm) wide and the trigger is
another 0.5 inches (1.2 cm) from the front of the
handle (span = 3.5 inches (9 cm) ). There are eight
nuts to tighten on each part and there are 480 parts
done per shift in this job. The part is bulky and must
be held in place with one hand while the other hand
operates the tool.

The nut driver is air-driven with the

hose connected to an air outlet 30 inches (76 cm) from
the front of the work bench. When each nut is tight, there
is a "kick", which must be resisted to control the tool.
The assembly is done at a seated workplace with a 30

�inch (76 cm) high work surface and a stool that adjusts from
20 to 30 inches (51 to 76 cm) above the floor. Incentive
pay creates some time -pressure.
The Patient's Status:

Bilateral carpal tunnel syndrome

diagnosed using a nerve conduction velocity test. Night
pain and aggravation with flexed wrist posture
and with pinching tasks or high repetition rate. Grip
strength with 2.5-inch (6.2 cm) span is 55 pounds
(25 kg). Symptoms also aggravated when shoulders
are elevated.
Initial Evaluation:

The risk factors are high forces (the "kick"),

high repetition (about 8/minute throughout the shift),
shoulder tension (it is necessary to work with the elbows
elevated because of the work surface height and lack of leg
clearance), vibration from the tool, two wide a grip span for
triggering the tool and for holding the part down with the
other hand, and some pacing associated with the pay plan.
would not appear to be a good job for this patient.
Ergonomics Interventions: The following approaches would
reduce the risk factors for repetitive motions problems on
this job:
1 . Reduce continuous holding of the tool and the part by
supporting the tool from overhead and providing a

It

�fixture to hold the part in place.
2. Consider using an in-line (straight) tool to press
vertically down on the nuts from above so awkward
wrist angles can be avoided and so that less "kick"
is translated to the hand at the end of each nut
tightening cycle.
3.

Consider using a nut driver with multiple heads to speed
up the task and provide more recovery time between
parts.

4.

Use vibration damping material on the tool.

5.

Improve the workplace seating so the shoulder tension is
reduced.

Each of these changes would benefit all workers, not only
the patient.

Some will take longer to implement than others,

but often they can be phased in slowly as workplace and job
changes evolve.

4. Summary
At present, we usually deal with patients who have chronic
musculoskeletal problems by looking for a job that they can do
given their reduced functional capacities.

Trying to find the

right job creates new problems such as having to "bump" people
with less seniority from their jobs to accommodate the injured

�worker, having to train them to do the new job and train the
"bumped" worker on a new job as well, having to deal with
other psychosocial aspects of creating jobs for injured
workers, etc.. To avoid these disruptions and to improve
problem jobs for all workers, it is important to address the
risk factors that make it difficult for people with chronic
musculoskeletal problems to return to their job.

The probable

result of ergonomic redesign will be to reduce the amount of
time lost and restricted from the job, keep trained people
working productively, and reduce the number of poeple who
develop cumulative trauma or low back symptoms that
interfere with their ability to do their job.

8/3/86 S.H.Rodgers

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>Notes on the 7/14/87 Meeting at NIOSH Regarding the Manual
Materials Handling Guidelines - S.H. Rodgers

Revision of the Work Practices Guide for Manual Lifting and
development of a User's Guide were the subject of this meeting. Dr.
Ayoub has been designated as the person to pull together the
update/revision of the Work Practices Guide with assistance from
Ors. Drury, Garg and Rodgers. Ors. Rodgers and Drury, with assistance
'

from Christine Chi, are responsible for completing a User's Guide
which will be supplemented with a videotape to show users how to
use the manual lifting guide.
Dr. Badger opened the meeting with several questions relating to
the Work Practices Guide (WPG)

..

1) What should be done with the Guide?
Should it remain the same with the emplaasis on updating
the formula using on more recent research ?
Does it need a total rethinking with a new approach to
presenting the information ?
2) What needs to be changed ?
3) What should be added ?
The User's Guide was to be discussed in the afternoon once the
content and form of the WPG was established.

1.

�A. What Should be Done With the WPG ?
Because of the incorporation of the 1981 Manual Lifting Guide
formula for determining AL and MPL into many industrial and seNice
sector safety programs, and because an update rather than a "start
from scratch" approach is preferred by this committee, it was agreed
that the WPG revision should concentrate on the formula to improve
the AL and MPL values where they appear to be incorrect. Although
the MPL values often appear to be to conservative, the direction of the
deviations of the AL and MPL from empirical and experiential data is
not always consistent.

There was much discussion about the need to improve the
presentation of the guidelines so they will be easier to use and will
not require a computer at the workplace. I shared my experiences
with trying to teach the formula to a wide variety of industrial
,

employees, ranging from production workers to safety and design
• engineers. There has been resistance to using the formula from all
except industrial engineers, with the most common complaint being
that the formula is "too complicated". Dr. Drury indicated that he has
not had those problems, and that the people with whom he has worked
(using a simple portable computer program) love to play with the
formula in the computer. Dr. Garg indicated his concerns that many of
the people who are using the formula are using it inappropriately,
especially in calculating the horizontal distance factor (H).

2.

�It was agreed that many of these factors relating to how people
use the Guide should be addressed in the User's Guide instead of in
the WPG itself. The basic Guide revision should be done without
regard to how people are misusing the formula and should give the
best guidelines for design. The User's Guide will be built around the
formula from the revised WPG and will look for presentation modes
that will make it difficult for a user to misuse the information.

B. What Needs to Be Changed?
If one hypothesizes that maximum acceptable loads determined by
psychophysical studies reflect work conditions where the
biomechanical conditions (compressive forces on the spine) are also
within safe limits, then a stronger reliance on the empirical
psychophysical data to calculate AL and MPL would appear warranted.
Unfortunately, the relationship between acceptable load and
musculoskeletal morbidity has not been investigated using a standard
,

epidemiological protocol. Some of Ayoub's military studies may help
'in evaluating this relationship even though a case control protocol
was not used in them. In other studies for Western Electric, he found
that a JSI of 1.5 was associated with increased risk of injury; the Job
Stress Index (JSI) is a measure of the load lifted divided by the
person's maximum aceptable lift capability (MAL) determined in a
psychophysical maximum voluntary lift protocol.

3.

�The sympathy of the group tended towards more reliance on the
available psychophysical data to establish the AL and MPL values
rather than using biomechanical stress as the primary
determinant. The reasoning for backing off on the disc
compressive force model is based on the following concerns:

1. We really do not know what levels of compressive force
are "safe" (and for whom) and the degree of risk for
injury/illness at the levels usually chosen for the AL (350
kg) and MPL (650 kg).

2. Our modelling is still based on static forces, not dynamic
ones, and peak forces are often not considered.

It was agreed that a careful examination of the literature should
be made on the relationship between lifting and spine compressive
and shear forces in order to predict "safe" levels. Chris Chi has
been asked to do this as part of her literature review file for the
User's Guide project.

Dr. Garg reviewed a recent study where he used the horizontal
distance (H) calculation recommended in the 1981 Guide (6 inches
plus one half of the box width) and actually measured the way
people handled it in a designated lifting task. There was a very
substantial difference between the measured and predicted H
values (hands to spine distance), suggesting that the actual H is
less than the predicted value. He believes that the H correction
factor should be modified to reflect these observations.

4.

�I suggested that there needs to be substantial revision of the
frequency factor (F) and the table of maximum frequencies for
different heights of lifting and durations (Fmax). The reason for
revision is that the frequency of lifting contributes to b..Q1h local
muscles fatigue and whole body fatigue. Thus, there needs to be
attention to the pattern of liftng, the degree of loading of the
affected muscle groups (% maximum strength required) and to the
holding time and available recovery time between exertions. This
can be predicted using work/recovery time data from work
physiology studies. The metabolic or total workload factor has to
be addressed through work intensity and duration relationships
These can be compared to the aerobic capcities of workers for the
types of tasks involved to determine the workload suitability.
I have not found metabolic considerations limiting unless the
frequency exceeds 6 per minute, the weights of objects handled
exceed 40 pounds, or the task duration is 2 or more hours. Usually
the strength limit or local muscle fatigue limit comes in before
the metabolic load is of concern.
It was requested, and agreed to by the committee, that we
develop a formula to calculate the AL and MPL for occasional lifts
and leave the frequency corrections to another part of the
analysis, after other situational factors have been accounted for
in the occasional lift calculation. For example, the work/recovery
information could be used to interpret the impact of increased
holding time in a carrying or holding task even if the repetition
frequency is not too high. Also, there will be other factors that

5.

�modify occasional lifting AL and MPL values and will be applied
sequentially as correction factors only if they are relevant, e.g.
assymetric lifting, gripping conditions, load stability, etc.
The constant in the AL calculation formula is based on
biomechanical considerations and Ors. Ayoub and Garg think it is
probably too conservative. In my experience, it is sometimes too
high and sometimes too low, depending on the lifting conditions.
The vertical height correction factor is one of the calculations
that stymies my classes because of the absolute difference
markings. New Math seems to have killed that part of people's
math education. There is a need to better define how to analyze
handling tasks where Vi is changing (pallet or truck unloading,
etc.). I also have a significant problem with the concept that a
lower and a lift are not different in the AL and MPL values. Most
handlers would very seriously dispute the assumption that these
are the same, much preferring lowering to lifting. I suspect that
some of the difference between them is in holding time (shorter
for lowering unless the load has to be carefully positioned). The
Snook data shows quite a substantial difference for women
between lifting and lowering in infrequent lifting tasks but less
difference in the 1/minute to 4.3/minute tasks. Since lowering
instead of lifting is a very common and effective work practice to
reduce handling problems, it would be wise to review the Vi and
absolute difference concept for the revision.

6.

�C. What Should Be Added to the Work Practices Guide ?
(The ideas below are my thoughts supplemented by some comments
in the discussion.)

Most people would like to have guidance on a range of handling
tasks, including holding, carrying, pushing, pulling and lowering, as
well as lifting. They need to know how much effect a difference in
the task assumptions, compared to the

Guide' s, will make.

For example, if the task involves assymmetric lifts, how much
should the AL be reduced ? If the item's dimensions exceed the
compact load limit, how much effect will they have on the AL?
Other correction factors that would be helpful would be for
handleability, including stability of the load and grip
requirements, for unbalanced loads where the center of mass is
not equally distributed between the hands, and for handling across
the body instead of up and down in the sagittal plane.

One-handed lifting guidelines should be included in the revised
WPG as a separate item. It is my opinion that they can be best
derived by evaluating grip requirements first, determining the
limiting factors affecting available grip strength and then using
work/recovery time data to assess the potential for local muscle
fatigue.

In assessing the total workload of handling tasks there should
be a method for relating the handling workload to the energy

7.

�requirements of the other job requirements. Similarly, I think it
is important to evaluate the postural requirements of the tasks
done before and after the handling activities, because the risk for
injury should be greater if the supporting muscles are also loaded
(as in bending or leaning to one side) during the other job tasks.
A "How to use the formula" section that is set out in terms of a
flow chart or list rather than as text would be a great advantage
for the person who wants to work with the formula rather than the
simplified User's Guide presentation. Generally, I find that
industrial engineers and safety managers (not safety
representatives) like to work with the formula, so the explanation
of how to use it can be written with them in mind.

8.

�D. Philosophical Points
As part of the discussion on what was needed for the revision of
the MMH Work Practices Guide , the group formed a consensus that the
design guideline should remain at the level where 75% of the females
and99% of the males are capable of doing the job. I suggested that
the User's Guide should include information on the% of the potential
·

workforce (50/50 , males and females) that would be accommodated,
so the implications of design changes could be evaluated. In that case,
I would use 4 zones, where90%, 75%, 50%, and 25% of the workforce
is accommodated. The90% value is essentially where 75% of the
females and99% of the males find the lift acceptable (based on
psychophysical data).
Discussions in connection with both the User's Guide and WPG
emphasized the importance of showing how to go from the AUMPL
calculation to an analysis of what can be done to make the job better
and "reduce the risks for injury." In the User's Guide, the approach
favored by Ors. Drury and Rodgers includes a flow chart that leads one
to a series of approaches rather than only to enginering changes or
aids or workplace design modifications. I feel that one can do a great
deal of ergonomics education through a carefully structured problem
analysis (using the magnitude of correction factors and the impact of
changed design on those factors) that will lead to administrative,
engineering, and worker methods and "behavioral" (e.g., fitness level)
approaches to reduce risk.
9.

�E. The User's Guide
In a discussion about the users of the MMH WPG, it was agreed that
they should be identified and their needs defined in order to get the
best criteria for the User's Guide format and content. A first cut on
that is attached as Table 1 to this set of notes.
It is difficult to complete a User's Guide until the formula
revisions have been agreed upon. Much of the work over the next
month will be to try out different methods of displaying the AL
formula graphically so problem solving can be done on the plant floor
without requiring a slide rule, calculator, or computer. The goal will
be to structure the information so the impact of a given alteration in
the handling task can be evaluated in terms of the percent of the
workforce accommodated. The display should be set up so one can
look at weight and location interactions in the handling task and can
• identify what factors limit the load or force. These limiting factors
should then be used to access the menu of possible approaches for
reducing the overexertion risk.
In connection with the Guide, a videotape will be developed to
demonstrate how to evaluate lifting tasks using the graphics of the
User's Guide and the formula of the WPG. The audience for the
videotape should be production supeNisors and health and safety
representatives from the staff and unions. The section on how to use
the formula for calculating AL and MPL can be geared to the engineers
who should be using that approach in new designs or major
renovations.
10.

�I would make the explanation of how to use the Guide as problem­
oriented and non-technical as possible. I would also keep the tape
,

within a 20- to 25-minute duration if it is to be useful to the key
people mentioned above. Eventually, one might want to do a
supplementary 20 minutes of examples of specific jobs where the
applications are more involved, but the basic tape should be able to
cover the most common types of lifts, etc. and show how to apply the
User Guide information. As we discussed in connection with the WPG,
the most common request Dr. Drury and I receive when showing people
the curent guidelines is "Don't tell me how you get the answer, just
give me the answer and tell me what things can be done to make it
better." So the theoretical material should be in the WPG and the
"How To" and examples will make up the User's Guide after the
simplified graphic and/or table or flow chart display has been
presented.

F. Action Items - S.H. Rodgers
1. Week of August 3rd - send Dr. Ayoub and Dr. Badger my
suggested approach for revision of the frequency factor for the
WPG as well as other thoughts on the formula. Complete draft
of report on frequency factor for publication.
2. Week of August 3rd - meet with Dr. Badger and Mr. Sinclair in
St. Mary's Ohio (or nearby) to develop plan for videotape content
and approach and to draft script outline.
11.

�3. With Dr. Drury and Christine Chi - develop format and display
ideas for User's Guide that convert the formula into a graphic
that will permit rapid problem solving on the production floor.
Review recent literature and continue to add to the literature
data base so the graphic can be tested against the empirical
data.

4. As Soon As Possible - write up 1982 project analyzing lifting
tasks from industry using the 1981 lifting formula and
comparing the results to physological measurements and
accident experience, where available.

5. Identify an opportunity for Ray Sinclair to attend part or all of
one of my training courses, preferably one where production
people make up a majority of the attendees.

Respectfully Submitted,

Suzanne H. Rodgers, Ph.D.
7/16/87

12.

�Table 1: Manual Lifting Guide Users and Their Needs
User

Agglications

Implications for Guide

Safety Personnel

Identification of risk
for handling (LLPP and
Overexertion) Injuries.

Quantification of risk using
deviation from recommended guideline.

Establishing priorities
for need to change jobs
where injuries are seen.

Need relative ratings of
degree of problem.

Make recommendations
for improving jobs
where risk of injury
is fairly high.

Define limiting factors for
handling tasks.

Medical Personnel

Job placement/matching
individual capacities
and job demands.
Return-to-work
decisions after injury/
illness.

Clear relationship between
handling requirements
analysis and capacity
measurements. Quantification essential.
Identification of reasonable
accommodations on the job.

Supervisory Personnel

Identification of job
problems and more
appropriate designs.
Cost-effective
approaches to reduce
the risk for overexertion injuries.

Need to identify what % of
workforce may be at risk.
Enable the user to find
limiting factors in handling
task design and get idea of
relative effectiveness of
different interventions.

�Engineering Personnel

'
Workers

Management

Priority on need to redesign tasks.
Guidelines for new
design.
Determining most cost
effective ways to
improve existing jobs.

Quantification - relative
risk.
Identification of best
zones/weights/work
patterns for handling tasks.

Understanding of good
handling conditions and
patterns.
Identification of techniques to reduce risk of
injury - fitness, style of
lifting, work methods, etc.
Information for distinguishing degree of deviation of job requirements
from a design that
would be suitable for
most people.
Support for requests for
job changes in situation
where injuries have been
found (objective criteria).

Recommended lifts in best
conditions.

Amount of risk seriousness of problem
(People or job?).
ldentifcation of ways to
improve job.

Work practices section.

Quantification in terms
of% of deviation from the
recommended design.

Objective data on% of
population affected; ability
to show impact of specific
solutions in terms of% of
people capable of tasks.
Quantification - degree of
deviation from a recommended value and ease of
improving the job.
Work practices and engineering approaches to improve handling tasks

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>Suzanne H. Rodgers, Ph.D.
r"nsultant In Ergonomics
Huntington Hills - Center
Rochester, New York 14622

A.

(716) 544-3587
(716) 266-8749 (FAX)

General Guidelines for Chair Selection

The choice of a chair for a job where a person wiJl be sitting for a
majority of the shift depends very much on what tasks are being
done. Ergonomically-designed chairs may be very comfortable
when a person can sit back to work and very uncomfortable if the
work requires one to sit forward to write or reach controls. One
can use the ANSI-I 00 guidelines for the ergonomic design of
office furniture for many office applications, but they assume that
the chair user is sitting upright, not having to lean forward.
Most of the guidelines for chair selection that are found in
ergonomics text books and training manuals are ultimately derived
from ANSI-100 and its European and American predecessors. They
are based on anthropometric data that measures the distance between
bony prominences on the body, but they do not consider the
functions performed by the person who is seated. Based on our
experience with 911 in Rochester, Dr. Inger Williams and I have
learned that consideration of population measurements of leg
length, elbow height, and forearm length are only the first step in
specifying chairs for office or production workplaces. I addressed
this in 1985 in my book, Working With Backache by including both
a set of measurements and a flow chart to determine what are the
most important chair characteristics for different types of tasks
(see Figure and Table Bl attached). In reviewing those
recommendations today, I would update some of the tabled values
and add or expand a few of the flow chart breakouts, but the basic
idea has held up. The process for deciding on the best chair for a
job should probably run as fallows:
1. Define the tasks performed and % of work time on each
one.
2. Determine the most important chair characteristics for the
primary tasks (e.g., need to reach forward, working at more
than one surface height, etc.)

�3. Define the hands' working height for the primary tasks and the
type of activity (e.g., typing, assembly, operating tools, etc.)
4. Choose the chair height adjustability range needed based on the
working height of the hands so people can work at or below
elbow height.
5. If the job requires sustained activity in the same hand location
(e.g., using a calculator or mouse), arm rests should be
considered, preferably ones that adjust in a 4-inch range and
can be moved horizontally and laterally as well.
6. Footrings are not an appropriate footrest for continuous
sitting because they tend to increase thigh and lower leg
discomfort through reduction of leg circulation. They are a good
alternate foot support for short seated periods, however.
7. The choice of back rest characteristics depends on the tasks done.
If a person is leaning forward to work or see, a back rest that
adjusts in and out about 6 inches is recommended. Adjustability
in back rest height of 4 inches is also recommended if people are
sharing workplaces or sitting for extended periods.
8. Seated comfort also depends on the hardness or softness of the
seat, arm rests, and back rests and on the type of material used.
Unless there are FDA or other regulation to follow, a
"breathable" fabric is most comfortable for extended sitting.
A little more detail on these characteritics follows:
1. If the workplace does not allow height adjustability of the
working surface (or a keyboard holder), determine the range
of seat heights needed to accommodate the population's hand
working height minus 7 to 11 inches. For office work, this
should be in the 15 to 22 inches range. For laboratory or
bench work it will be higher, and foot support will be needed
(a footring is not satisfactory for continuous sitting, though).
2. Arm rests are usually used for support of the arms between
task elements. They occasionally can be used to support the arm
during sustained work in the same location, as in mouse,
trackball, or keypad use or in operating controls on a

�microscope. In order to accommodate the shorter and taller
operator, one needs at least 4 inches of adjustability in the arm
rest, and it should be within the range of 7 to 11 inches
below where the hands are located in the workplace. Arm rest
length should be kept under IO inches to clear the work surface
while seated.
3. Back rest adjustability is very important when people have to
work forward to write or reach or see for sustained periods.
Many of the new "ergonomic" chairs do not have a back rest that
adjusts horizontally (in and out); they use a tilt mechanism on the
chair back instead. This is often uncomfortable, for people with
short legs especially, because the forward tilt of the back rest
changes the lumbar support point and also tends to push them out
of the chair. Tall people find the back rest tilt shortens their
thlgh support too much and complain of discomfort in the
buttocks. The better design for people who have to work
forward on their work surface is to have in and out adjustability
of the back rest as well as movement up and down to locate the
lumbar support appropriately. A horizontal range of 6 inches
and a vertical range of 4 inches should be satisfactory for most
workers. Chairs that have a horizontally sliding seat and a fixed
back rest can be a good alternative, too, providing there is at least
17 inches of thigh support available for tall people.
4. The material used on the seat, back, and arm rests of a chair
can make a significant difference in comfort. Sometimes the
range of materials available is limited by FDA or other
regulations, so those requirements have to be honored. For
places where machine oils or other environmental situations make
it difficult to keep a fabric clean, one may have to go to an
easily cleanable material. For most offices, fabric that breathes
is an important design feature, and this is particularly needed in
areas where there is no air conditioning. Rounded surfaces on
arm rests and a waterfall front at the front edge of the seat are
also important design features for comfort.
C.

Suggested Approach for Chair Selection

To make sure that chairs coming into the plant or office have
ergonomics characteristics, one can specify a few features and then
trigger the need for additional characteristics through a job checklist.

�This would be a MUST and a WANT prioritization of features so
, Purchasing has some leeway in finding vendors. The "MUSTs" I
usually suggest are:
• 5-leg base
• seat length about 17 inches
• hydraulic cylinder height adjustability
(16 to 21 inches or higher for higher work surfaces)
• Breathable fabric (unless FDA or other rules apply).
• Waterfall front on seat pan
• No sharp edges
• At least 17 inches between arms
• Back rest adjustability in and out 6 inches and up and down
4 inches
• Arm rests at least 2 inches wide and 6 inches long, but no
more than 10 inches long.
The "WANTs" include:
• Tilt capability on seat pan (0-10 ° )
• Seat length adjustability
• Arm rest adjustability laterally and horizontally as well as
vertically
• Foot ring for chairs that adjust above 21 inches vertically
(but foot rest still needed)
• Lumbar support - inflatable
• Compressible seat - foam or fabric
• Easily adjusted back rest
As a general rule, I have learned that one can have all the right sizes but
still have large numbers of people uncomfortable in an "ergonomic"
chair. That usually relates to how they have to use the chair to get their
work done. It also puts a real burden on purchasing to get too specific
on some of the measurements. The most successful approach is
probably to identify which chairs are in the desired price range, check
to be sure they have the "MUST" features, and then have the vendor
send a chair or two over for trial before they are ordered. That way
any potential problems can be identified and remedied before the
purchase is finalized.
6/13/96

SHR/mes

.,,,-:r.

"'- .,. •;-

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
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l:&lt;:...._ ...��

An Integrated Ergonomics Program At
The Goodyear Tire &amp; Rubber Company
The Forcing Strategy
D T Geras, CD Pepper, SH Rodgers

Spiraling workers' health care cost necessitated a
systems approach to employee safety managemen� at
The Goodyear Tire &amp; Rubber Company. Our mission
w2.s charted, "To eli.IT!i'!.1ate loss and maxJ.mJ.ze our
resources through the application of ergonomic
principles, in support of tqe perfection strategy."
The following reviews Goodyear's approach to
establish a global ergonomics awareness program by
utilizing a forcing strategy to create change.
INTRODUCTION
The Goodyear Tire &amp; Rubber Company has traditionally
taken the approach of providing the needed safety and
health res.:iitrces to maintain or exceed the reauired
Corporate, Federal, State and local safety pe;formance
standards.
During 1986, the safety department analyzed the
corporations' injury and illness data. It was determined
that approximately 62! of our total workers' compensation
payout was a result of strains and sprains due to lifting.
pushing and bending. The 42! frequency of cumulative
trauma type cases resulted in expenditures of millions
of workers' health care dollars for ergonomic type
problems.
These accidents were classified into situations
resulting from the poor application of equipment design,
plant layout, operator/equipment systems a�d the general
work environment.
During 1986, (Mihelick, 1986) developed the concept of
"PERFECTION STRATEGY." This vision of a manufacturing
perfection environment, dealt with both present and
future concepts of the ideal work place. Mr Mihelick
then developed nineteen points of critical inter�st for
manufacturing management to monitor, in terms of plant
performance. The first item listed in terms of
importance dealt with employee safety. The perfection
performance is "ALL Injuries
strategy regarding satety
1
Ar2. Prevenr::able." In order to achieve this goal, we
needed a oraac:ive ergonomics approach.

...

�-2-

This approach would have two phases. The first phase
dealt with establishing ergonomics awareness in all
manufacturing facilities worldwide. Then, we would
incorporate ergonomics principles into the initial design
of equipment, plants, and people/machine systems.
METHOD
During 1986, a request from our Logan, Ohio, General
Products plant, revealed the benefits of ergonomic
intervention in solving carpal tunnel syndrome (CTS). The
CTS was a result of unusual stresses on the operators hands
and wrist while fabricating automobile dashboards. ·The
plant study consisted of work station evaluations and
suggestions to correct and prevent future ergonomi�
problems. Also, plant engineering discussions allowed for
initial orientation to the benefits of applying ergonomic
principles in the plant.
Due in part to the success at our Logan plant, we
determined that all facilities would benefit by establishing
a structured ergonomics program within the plant . . At this
time, Goodyear was evaluating each manufacturing facility's
c ory
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The plant's audit score is then reported to executive
management and carries the same importance as other
manufacturing pe4formance indicators.
The decision was made to incorpo�ate an ergonomics
section into our existing safety program audit manual.
This section emphasized establishing an ergonomics
committee, general awareness training for all personnel,
employee involvement, repetitive trauma evaluation and
requirements to conduct routine ergonomics audits to
ide�tify proble�s in the plant. Thus, we created a need
for the ergonomic program before it actually existed.
Soon afterwards, our plants were calling for assistance
to meet the audit requirements. We actually forced the
plants into accepting ownership for the program.
0

J

Phase One - Reactive Ergonomics
As the heading notes, the reactive ergonomics phase
dealt with the plants and their existing problems. As in
most situations, we needed to correct design and plant
layout errors. Unfortunately, we corrected these errors
after they were exhibited as injuries and illnesses. But,
we were on the right track and moving forward with a
program to prevent these problems.
Pilot Programs
A pilot training program was conducted at our St Marys
plant, St Marys, Ohio. The plant safety manager was
requested to videotape several problem jobs within the
plant. Those jobs involved accidents resulting i�
strains and sprains, CTS, absenteeism, quality and
productivity problems. The videotapes would then be used
as part of the problem solving workshop. A five d�y
training program was scheduled.

..

�-j-

The following table breaks do"711 the weekly activities.
Table 1.

Ergonomics Pilot Training Program
Day 1

- Couduct Plant Ergonomics Survey
Present Plant Management Orientation
Review Videotape of Problem Jobs

Days 2-4

- Conduct Ergonomics Committee Training/
Problem Solving Workshop

Day 5

- Conduct General Awareness Training
(4 hours)/Key Plant Personnel

Training Pro�rarn
The pilot training program proved a success and this
precipitated additional requests from other division plants
for training assistance. The forcing strategy worked. Due
to the competitive nature of our plants, no facility wanted
to be outperformed on the safety audit. In order to
facilitate plant trai�ing requests and establish the
ergonomics program as rapidly as possible, we devised the
following agenda.
A training schedule was established for each
manufacturing division. Each plant in the division was
requested to send three representatives to participate in
a four day ergonomics training and problem solving workshop.
The training participants would then create the nucleus
for an ergonomics committee within the plant. The training
participants were the movers and shakers within the plant.
They all had reputations ·for their problem solving
capabilities, teamwork, and communication skills.
Table 2.
-

Suggested Training Program Participants

Plant Nurse
Safety Manager
Training Specialist
Industrial Hygienist
Industrial Relations

-

Industrial Engineers
Workers Compensation
Production Specialist
Union Safety Personnel
Engineering Maintenance

Each plant was also asked to provide a videotape of
several problem jobs to be used as topic material in the
problem solving portion of the program.
The training participants had four goals {Rodgers, 1988):
1. Become familiar with the field of ergonomics and
resource books.
2. Be able to identify and analyze ergonomics problems
in the plant.
3. Be able to generate multiple approaches to solving
•
the problems.
4. Understand how to go about incorporating ergonomic
principles into daily plant activites.

�-q-

An ergonomics awareness manual was created to assist the
participants during the course and after their return to
the plan.t. This manual had to be user friendly. It was
designed·· to provide all the necessary information to
accomplish the audit requirements and implement the program
with the least amount of difficulty.
The awareness manual contained a provided ergonomics
training syllabus; a section on committee makeup; goals
and roles; an outline of the required plant activities
report; a guide to achieve lOOZ of the audit requirements;
an example of an implementation plan; a training section
which provided the plant with four one-half hour training
modules; and a section for ergonomic articles and reference
materials. Each participant also received a set of resource
text books for their personal use (Eastman, Kodak, 1983,
1986).
The training syllabus (Rodgers, 1988) covered the
necessary topics in ergonomics which could be applied to
solve problems in an industrial setting.
General awareness training involving all manufacturing
pe=sonnel is a mandatory safety audit item. To assist
the plants, fou.:- one-half hou:?:" training modules were
created. These training modules were in the sta�dardized
company performance based training format. A trainers
script was provided as well as videotapes concerning
the particular ergonomics topic. Also, copies of suggested
overheads for each training module were supplied to the
plant on a personal computer disc. The canned training
program enhanced the acceptance of the training
requirement of the audit program.
The training modules covered the following topics:
Module 1 - Ergonomics Overview
Module 2 - Repetitive Motion Injury
Module 3 - Work Postures &amp; Manual Material Handling
Module 4 - Identifying Ergonomic Problems/Problem Solving
Additional training modules will be provided in the
future. This will maintain the program awareness after the
general awareness training is completed.
Program Implementation
Training participants were given the charge to implement
the program soon after their return to the plant. The
following implementation process was then developed as a
guide:
1. Develop an action plan.
2. Introduce the topic to gain the support of management,
union leaders, and the safety committee.
3. Establish an Ergonomics Committee structure, assign
roles, designate coordinators, and committee members.
4. Train the trainers (committee members) and all plant
personnel in general ergonomics awareness.
;
5. Identify problem areas, utilize computer safety and
compensation information systems, and employee
inte::-views.

�-J-

6.
7.
8.
9.
10.

Conduct audits: Identify problems, videotape jobs,
and conduct committee reviews.
All plant Ergonomics Committees conduct problem job
reviews for solutions and input from all.
Communicate success by plant public relations work,
keep the program fresh by using newsletters, pamphlets,
etc.
Ergonomics Committees report monthly activities to the
plant coordinator. Plant coordinator reports to
plant management and corporate office.
Develop outside resources: consultants, texts� and
future training.

To assure program participation, each plant was required
to submit an activities re?ort on a monthly basis. This
would continue for the first six months following the
training program. Then, this report would be filed at
quarterly intervals. Updates of division progress were
submitted to the respective production director on a
quarterly cycle. Plants with little or no progres�·were
highlighted for follow up by the production director.
Liker (1987) found thut the most effectiv� activity
process in correcting ergonomic-type problems was to:
- Start small and simple
- Implement ea�ly projects fast
- Learn by doing - training - doing
- Develop and maintain operational groups
Incorporate review process - new and changed equipment
- Communicate, communicate, communicate
- Look at problems as opportunities
The training program was completed on schedule with all
87 manufacturing plants worldwide represented. This
c.•.; ,,r., ,..._...,.: _,; ,,...,.,... __ ,...rr..,....R'"" e f=f=--r si...--,,...ened ou'-'-06"""'"'-"""..,•""'5.Lf..A.U
p-o•--!lm
implementation time by approximately one and a half years.
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L.

Phase Two - Proactive Ergonomics
The most effective time to incorporate ergonomic
principles is in the initial design phase. Unfortunately,
senior engineering personnel with ergonomics training are
not widely available in the Goodyear Tire &amp; Rubber Company.
We decided to initiate general ergonomics awareness
training programs for all of our engineering staff personnel.
We began this training with an awareness presentation for
corporate engineering management. The presentation was
followed by additional training for corporate engineering
staff and engineering consultants. This involved approximately
250 personnel in the engineering disciplines. Concurrently,
we conducted awareness training for executive management in
order to gain their support and to assure that we had a
driving force behind the program.
As a part of the ergonomics development training for
our engineering staff, a video library was established
(Rodgers, 1988). This video library contains analyses
cf the plan: problem jobs that were submitted as part of

�-6-

the plant training programs. These analyses would then be
categorized and used as training aids for new and existing
staff personnel. Also, a training needs analysis will be
completed in the future. The purpose is to determine
what additional and specialized training is essential for
the engineering staff.
Ergonomics reviews were recently mandated as part of
dn equipment safety approval system. This standard practice
requires an ergonomics, safety, industrial hygiene, and
environmental assessment of the equipment before final
approval fo� fabrication is given. A safety engineer was
assigned the responsibility of coordinating new equipment
safety/ergonomics review activities between the receiving
plane and vendor/design consultants.
The ergonomics safety review led to the establishment
of the X-Plant concept. The program involves the review
of existing plant modernizations in order to evaluate those
activities for ergonomic equipment design and plant layout.
We will take this information and correct design errors
as part of the initial design of future plants.
The entire ergonomics program is reviewed on a yearly
tasi� ia order to raonitar progress. adjust the ?ra;ra� as
needed and to chart future activities.
RESULTS
The Ergonomics plant program has been iu existence for
less than a year. Due to the varying size of the plants,
they are reporting different levels of progress in meeting
the audit requirements. But, all plants are actively
pursuing the 100% goal. I would like to reflect on the
two facilities that received initial ergonomics
intervention and the pilot training program. Both
facilities are in the Industrial Produces Division wich a
broad range of job activities that may subject the employees
to ergonomically related injuries and illnesses.
A key safety performance indicator is the lost time
incident rate that the plant reports. This rate deals
only with cases involving actual days away from work
for a work related injury or illness.
Table 3. Lost Time Incident Rate Comparison Logan and
St Marys Plants (Year End Statistics)
Plant

1984

1985

Logan

4.9

4.4

4.5*

Sc Marys

9.7

5.6

8.9

1986

1987

o·. s

(7.4/0.8)+

1988

o. 9

2.6

* Initial Ergonomics Intervention, 10-86
+ Pilot Training Program - 9-87, YTD 8-87 (7:4)
Beth plants reduced their lost time incident rates
dramatically after the intervention and training programs.
The St Marys plant improved from last to first place in
their division for this performance indicator. The Sc
'---•� �����P�c rate inc�eased at yea�s end due to

�-7-

a slowdown in program activities. This was a result of
key committee personnel being involved in contract
negotiations. The plant is improving their activities since
the negotiations ended. We cannot say what amount of this
improvement can be attributed to the ergonomics program.
But, the plant management has informed us that the overall
plant communications have benefited from the training
program. The plant manager has also stated that team work
in problem solving is evident throughout the plant, and
that all levels of employees are contributing to the
development of improved work stations.
The following is a compilation of some of the success
,stories submitted by the plants.
The Greensburg plant has improved a large air spring
fabrication station by eliminating unnecessary operator
floor movement and extended hand reaches. This modification
resulted in less opera�or fatigue and improvement in
productivity of over 60Z. The change was submitted by an
hourly employee and no Crtpital improvement budget was
required. The success of this change resulted in operator
-::-eq-:.iests to change the additional three similar work
s tatic,r,s.
The St Ma�ys plant modified a tank track shoe production
line to eliminate unnecessary handling of two and one half
tons of m2 terial over t·..;o shifts. This change wRs
department funded and did not require a capital budget.
The Madisonville plant needed an operator sit/stand
inspection seat that resembled a saddle to reduce operator
back and leg fatigue as a result of long duration standing.
An appropriate pod seat was found but replaced with an
employe� E=gonomics Committee suggestion. The employee
cc..:::r- ----fn11nd nn
fic::hi"nao boat!'-� - Th1"s...
--t&gt;b _____
- T'\rnn-t-vno
r--r -..1r- -----idea was evaluated and ac�epted for triai use resulting in
a considerable savings while producing the same results.
Operators have not complained of back and leg fatigue
since the installation of this equipment.
These are some of the changes being incorporated in
our plants as a result of the ergonomics program.
Improvements in operator safety productivity and quality
are noted. The initial results are in and they point to a
win-win situation for all the parties involved.
C,11(TOOC,!-O�

::,

SUMMARY
In evaluating the key factors in this program, we have
concluded that the general awareness trai�ing for all
employees, auditing the program implementation and program
participation at all levels are integral to the success of
an ergonomics program.
For maximum impact, ergonomic programs should be
implemented into the design phase of equipment, plant
layout, operator/machine systems and the gener�l
· work
environment.
Emplo�ees when given a basic understanding of ergonomics
and then allowed to interact with fellow ecployees, will
d�rive a common sens.e approach to eliminate stressors at
thei= wcrk s�ations. In manv situations, corrections to
·-- ---.�1 a�c
��� be �a�2 with mini�al capital

�-u-

expenditure.
An additional benefit of the program will be improvements
in communications and team work at all levels of plant
employees.
The acceptance of chis program by union personnel
probably would not have been possible ten years ago. The
economic realities of global competition have changed chis
attitude, however, the need for company productivity
improvements are vital. With their participation in the
ergonomics program, employees will have a say in the
development of their work environment, and job requirements
and together more efficient and effective designs can be
developed.
The proper application of Ergonomics will result in
improvements in employee safety, productivity, and quality.
REFERENCES
Eastman, Kodak Company, Human Factors Section, Ergonomic
Design for People At Work, Volume 1 (1983) and Volume 2
(1986), New York: Van Nostrand Reinhold.
. ·
Liker, J.K., 1987, Org2nizational Aspects of Ergonomics
?rogramG. !rr: Procecdi�2s cf the EneinceriD£ Su���r
Conference on Occuoational Ergonomics, the University
of Michigan.
Mihelick, S.J., 1936, PerfE:c:tion Environment3. In:
Proceeding of the Organizational Development Training
�rogram, Niagara Falls, edited by D. T. Geras.
Rodgers, S.H., 1988, "Four Day Ergonomics Training PrograI!l
for The Goodyear Tire &amp; Rubber Company", training
syllabus for ergonomics problem solving course;
S. H. Rodgers, Ph.D., 169 Huntington Hills, Rochester,
No,.1 Y/"lrk'
---··
· ---·
---·--, -1 !.,F,.??

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                <text>The Forcing Strategy: An Integrated Ergonomics Program At The Goodyear Tire &amp; Rubber Company</text>
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                <text>Spiraling workers' health care cost necessitated a systems approach to employee safety management at The Goodyear Tire &amp; Rubber Company. Our mission was charted, "To eliminate loss and maximize our resources through the application of ergonomic principles, in support of the perfection strategy." The following reviews Goodyear's approach to establish a global ergonomics awareness program by utilizing a forcing strategy to create change.</text>
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                    <text>�

A Proposed Revision of the Frequency Factor for the

i

NIOSH Work Practices Guide for Manual Lifting
by Suzanne H. Rodgers, Donald E. Badger, Vincent Ciriello,
Arun Garg, Hollis Hohensee, Gary Lovested, Anil Mital,
Stover H. Snook, and J. W. Yates.
In 1981 the National Institute for Occupational Safety and Health
published the Work Practices Guide for Manual Lifting (NIOSH, 1981 ).
The purpose of the Guide is to provide state-of-the-art information
about manual lifting tasks and how to design them to reduce the risk
of strain, sprain and overexertion injuries at work, The committee of
experts that developed the Guide used biomechanical, psychophysical,
epidemiological, and physiological information to establish two
levels of object weight where either most people were accommodated
by the task design (the Action Limit, or AL) or where most people
were at risk of overexertion (the Maximum Permissible Limit, or
MPL).
Although these guidelines are intended for use in designing lifting
tasks, there has been interest in using them to set standards for safe
workplaces and jobs in order to prevent overexertion injuries. In one
pilot program (OSHA, 1986), compliance officers are looking for
excessive incidence of low back problems and strains and sprains and
will then evaluate the jobs using the NIOSH Manual Lifting Guide
formula. Presumably, if the Guide values are being exceeded, the
employer may be cited against the OSHA general duty clause for not
providing a safe workplace.

1.

�There are several reasons why this use of the NIOSH Manual Lifting
Guide information must be reviewed. They include the following
observations:
1. The Guide is for the design of lifting tasks in order to reduce
the risk of injury. If the guidelines are not met, it does nQ1
follow that people will be injured. Other factors such as self­
selection or "natural selection" on the job may be reducing that
risk without the use of administrative or engineering controls.
2. Low back pain incidents are more likely to be reported on
lifting jobs because of the effort required. This does not mean
that the lifting caused the low back problems but rather that
repetitive lifting cannot be performed when a person is
experiencing low back pain. About 67% of the low back pain in
industry is probably associated with degenerative disc disease
(Rowe, 1983), and episodes of low back pain may occur to people
who are doing even well-designed lifting tasks. Because there
is not a direct relationship between low back pain incidence and
the lifting task requirements, one cannot assume that following
the NIOSH Lifting Guide guidelines will prevent low back pain at
work.
3. Although the NIOSH Work Practices Guide for Manual Lifting
represented the state-of-the-art in 1981 when it was
published, more recent research and experience in trying to
apply the formulae to industrial tasks have identified some
areas for improvement:
2.

�a. The frequency correction factor does not correspond to
the laboratory data or reflect the industrial experience,
especially at lifting frequencies above 6 per minute for
more than 1 hour per shift (Garg and Saxena, 1983;
Rodgers, 1982; Snook, 1982). For example, the current
frequency factor correction suggests that the AL is O
pounds if compact boxes are handled from a floor
pallet to a conveyor at 12 times per minute for more
than 1 hour per shift; or, in other words, the task cannot
be done safely, even with no weight. Since there are
many such jobs performed in industry without a
significant history of musculoskeletal injuries (Rodgers,
1982; Rodgers and Pilarski, 1986), the validity of the use
of the guidelines to cite a job as unsafe can be
challenged.
b. Most industrial lifting tasks are done assymmetrically,
not in the sagittal plane with compact loads using
handholds and sharing the weight with both hands
(Rodgers, 1982). Deviation from those assumptions
reduces the AL and MPL values further, so even small
errors in their calculation can have a significant impact
on the assignment of risk to a given lifting task if the
guidelines are used in compliance reviews.
c. The lifting tasks need to be looked at in the context of
the work pattern and the other physical job demands,
such as postural demands and total energy requirements
3.

�(Garg, 1985). The lifting pattern will influence local
muscle fatigue development and the metabolic demands
of that part of the job. A 1-hour vs. 8-hour duration
distinction gives equal weight to 72 minutes of 1 O per
minute lifting and 6 hours of 2 per minute lifting,
workloads that are very different physiologically,
especially from the standpoint of local muscle fatigue.
d. The linearity of the relationship between AL and MPL
(3AL = MPL) in the Guide is debatable, if convenient. The
MPL values thus calculated often do not agree with
psychophysical data collected empirically (Garg, 1985;
Snook and Ciriello, 1983).
In the summer of 1985, NIOSH formed an ad hoc committee to
evaluate the frequency factor of the Lifting Guide and to suggest
ways to improve it. Representatives from industry and researchers
from universities who have studied frequent lifting tasks discussed
applications of the frequency factor and where it could be improved.
This paper summarizes those thoughts and presents a revised
frequency factor that more accurately predicts the observed AL and
MPL values for industrial men and women.

4.

�I. Review of the Current Frequency Factor (NIOSH, 1981)

The 1 981 NIOSH Work Practices Guide for Manual Lifting presents
a formula for calculating the Action Limit (AL), in terms of the
acceptable weight of a load that 75% of the women and 99% of the
men should be able to lift at the locations, lifting frequency, and
duration indicated. That formula is:
AL(kg) = 40(15/H) (1-0.004 IV-75I) (0.7+7.5/ D) (1-F/ Fmax),
where H is the horizontal distance, in cm, from the ankles
(the distance from the weight-bearing hands to the
ankles in a sagittal plane lift)
V is the initial vertical location, in cm, of the hands in the
lift,
D is the vertical distance of the lift, in cm, or the
difference between the destination height and the starting
height in most cases,
Fis the average frequency of lifting, in lifts per minute,
and Fmax is the predicted maximum lifting frequency for that
location and duration of lifting.

5.

�The Fmax table gives the maximum lifts per minute that can be
sustained for one or up to 8 hours (more than one hour) when lifting in
either an upright (standing) or stooped posture.
Standing

Stooped

(V &gt; 75cm)

(V &lt; 75cm)

1 hour

18

15

8 hours

15

12

Thus, if a job requires a person to lift from a floor pallet to a bench
at a rate of 6 per minute for 15 minutes out of every hour on an
8-hour shift, the "stooped" and "8 hours" Fmax of 12 will be used. The
frequency factor for correcting the occasional lifting (less than 1 per
5 minutes) AL would be (1- F/ Fmax) or 1- (6/12) = 0.5. Two hours a
day of lifting at 6 per minute would, therefore, reduce the load
weight by 50% to be acceptable for 75% of the women and 99% of the
men.
The basis for the Fmax table is the metabolic demands of frequent
lifting, especially when that lifting is done below knuckle level. In
low lifting, the object being handled is only part of the weight being
moved. The upper body is also moved, and this increases the
metabolic work load by about 20% for lifting at the same frequency as
6.

�when standing upright (Garg, 1978; Hamilton and Chase, 1968). In the
Fmax table, the 8-hour workload would use a Fmax of 12 for stooped
lifting. This is 80% of the value of 15 for lifting while standing
upright. For one hour of lifting or less, the total metabolic load is
less critical. About 50% of maximum aerobic capacity can be used for
one hour of continuous work (Astrand and Rodahl, 1970). The stooped
workload is still 20% greater than the standing load, so the Fmax
again has to be reduced by approximately 20%, or from 18 to 15 lifts
per minute. The percent of aerobic capacity that can be used in
lifting for 1 hour versus 8 hours changes from 50% to 33%. The
reduction in Fmax is also approximately 17%, moving from 18 to 15
lifts per minute.
Studies by Lind, Petrofsky and Webster (1976, 1978) on box lifting
showed that the aerobic capacities for lifting tasks varied with box
weight and frequency. They found that the metabolic component of
the lifting task became most important at frequencies above 6 per
minute for low lifting. These data do not appear to have been
integrated into the existing frequency factor correction except in
recognizing that metabolic, as well as biomechanical and
psychophysical factors are to be considered as lifting frequency
increases.
Other data that were used in establishing the AL values and
against which the frequency factor could be tested are the
psychophysical data of Snook and Ciriello (1983) and Ayoub et al
(1978). Tables showing the 25th percentile female and 75th
7.

�percentile male's acceptable loads (that is, the load acceptable to
75% of the women and 25% of the men) can be used to test the
appropriateness of the existing frequency factor in determining AL
and MPL values, respectively, for fixed values of H, V, and D.
Another area for improvement of the current frequency factor is in
the calculation of lifting frequency and duration. In the NIOSH
Work Practices Guide for Manual Lifting, the authors recommend that
the average number of lifts per minute be used to determine lifting
frequency. Lifts of less than one every 3 minutes, even if done for the
majority of the shift are considered infrequent and do not have a
frequency correction for acceptable weight. Lifts that are done more
than once every 3 minutes for a period of up to one hour per shift are
considered "occasional high frequency," and lifting at more than
once every 3 minutes for more than one hour continuously is
considered a "continuous high frequency" task.
Many occupational lifting tasks involve intermittent lifting. A
truck may be unloaded, a pallet loaded, supplies may be obtained for
delivery to another location, raw materials may be loaded into
reaction vessels, etc. The lifting frequency during the� work
periods may be 10 per minute, but there are equal periods of no lifting
that might reduce the average lifting frequency to 5 per minute over
the shift. Physiologically, the 1 O per minute load and the length of
the recovery period probably have a greater impact on the risk for
muscle overexertion.

8.

�Suggestions of how to calculate lifting frequency are given in the
examples at the end of Chapter 8 of the NIOSH Manual Lifting Guide.
For frequent lifting tasks such as loading and unloading pallets and
handling several different products on an assembly line, the lifting
frequencies are calculated individually for each tier of the pallet and
each product handled. For the palletizing task, for example, the rate
of lifting was 12 per minute, but in evaluating the task tier by tier, a
lifting frequency of 2.4 per minute was used for each of the five
tiers. Since the actual frequency of lifting at each tier is still 12
boxes per minute, this approach is not appropriate, although it is a
necessary one to get a reasonable AL using the current frequency
factor. If a 12 per minute rate is used at each tier, the AL drops to 0
(and, therefore, the MPL = 0, too) for the 3 tiers below 75 cm. This
suggests that the task cannot be performed safely by anyone.
The availability of 2 durations only, 1 hour or less versus
more than 1 hour, does not recognize the variability in work patterns
in industry and the extreme differences between the demands of
lifting very frequently for short periods intermittently throughout
the shift and lifting continuously at lower frequencies for a full
shift. The metabolic considerations can be largely accounted for
through the use of two duration categories. But, the local muscle
fatigue factor, which probably plays an equal role in determining job
suitability in these tasks, is determined by the recovery time
available as well as by the actual frequency during the work period.

9.

�II. Comparisons of Predicted vs Observed Frequency
Correction Factors
In developing a correction factor for lifting frequency,
one must express a complex set of relationships in as
simple a form as possible. Some accuracy can be sacrificed
for this simplicity, but the degree of error should be known
and understood when using the formula to make decisions
about the risk factors for manual lifting injuries.
A study of industrial jobs that had been studied by
measuring the physiological responses of workers during
handling tasks found that the frequency correction factor
was too conservative. It predicted much lower AL and MPL
values than those that were routinely obseNed in trailer
loading, can handling, conveyor unloading, and bag handling
tasks (Rodgers and Badger, 1988). A 1.5 to 2.0-fold
difference in the AL appeared to be acceptable in many
cases.
A plot of the NIOSH 1981 frequency correction factors
and the factors derived from Ciriello and Snook's 1986
summary of their psychophysical studies of acceptable load
is shown in Figure 1. The NIOSH formula best reflects the
empirical data from psychophysical studies between 1 lift

every 5 minutes and 2 lifts per minute but gives too low
values at very low and at high frequencies (&gt; 6/minute).
10.

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>Comments on the June 4, 1993 ANSI 2365 Draft
"Control of Cumulative Trauma Disorders"
Page#

Comments

1 -1

" ...intended for use by persons who have responsibility for
design and operation of work equipment..." - there is very
little in the proposed standard that addresses the design of
work equipment. I think there should be more general
m aterial in this category, but right now I would say that that
purpose of the standard has not been met by this document.

3- 1

"ergonomic stressors" - the use of this term (and "ergonomic
hazard") must be stopped as it is oxymoronic and inaccurate .
If something is ergonomic, the stressors are minimal. Either
use "non-ergonomic stressors" or use "stressors" without a
modifier.

3-2

2nd paragraph - labor§ important but not2 times in one list.
Perhaps it should be labor representatives (union) for one and
the wage worker (associate, hourly worker on the job of
interest) for the other.

Figure3-1

3-3

This still represents only the reactive side of the program.
Should include another block for the proactive side which
includes the design of facilities, equipment, environments,
and jobs within ergonomic guidelines. Could also include
team involvement in process safety reviews, accident
investigations, etc.
3rd paragraph - "... Medical. . ." should be "Health and Safety ... "
since many plants do not have medical personnel on site and
safety or human resources fulfills their role along with an
off-site clinic.
3.4 Employee Participation - add problem solving sessions and
"fiddle sessions" where they make things work. These are
essential roles that the hourly workers play in the successful
implementation of ergonomic changes.

�2.
Page#

Comments

4-1

Include California State Standard, Title 8, Chapter 4, Group
15, Article 106: Ergonomic Hazards, 1993.
Also include new ANSI Standard on Machine Tools as it should
be out by the time this one is printed.

5- 1

2nd big paragraph " ...ergonomic risk factors ..." should be
"non-ergonomic risk factors... "

5-2

5.2.2 Active surveillance definition - need to distinguish
between "symptoms" and "discomfort" more carefully. They
tend to get used interchangeably and they should not be. Need
a better discussion of how this information will be used
(paragraph 2) since many people do not report discomfort so
their jobs will not be changed.
5.3 Surveillance ... - this is still primarily a reactive
approach. A major function of a good ergonomics program is
to reduce work-related musculoskeletal problems through
ergonomic design of workplaces, tools, equipment,
environments, and jobs.

5-3

5.3.2 Role of Screening in CTD Surveillance - 2nd paragraph use of electrodiagnostic testing - since it's not recommended
for routine screening, please leave it out. It is a reasearch
study, not something that should be done as part of a
cumulative trauma disorders control program. The base data
(nerve conduction time) is weak and such a unidimensional
study would yield little useful information, anyway. The
workers will give more accurate readings of their discomfort
or symptomatology.

5-5

Figure 5-1 : - Risk Factor Surveillance - I have many problems
with this whole approach, especially the surveillance for
CTDs that says 1 case per 100 employee years is enough to
require level 2 risk factor evaulation and level 2 CTD
surveillance. Although, it is stated that there are many ways
to do risk factor surveillance at levels 1 and 2, the chart is
tied into the trigger score approach that is presented in
Appendix A. Has that approach been validated ? If it is
required by this standard, then it should be validated and
tested on a large range of jobs. A quick application of the

�3.

technique to jobs I have studied shows that it over weights
the biomechanical elements of work and badly under weights
the physiological components. For example, the scores
suggest that lifting a heavy object slowly is better than
lifting it at a moderate pace. This decision was affected by
concerns about peak velocities but ignores the potential
muscle fatigue and increased recovery time needed when the
lift is made more slowly. There are other parts of the
weighting of factors that seem arbitrary (e.g., the
multiplicative psychosocial factors). Since it is likely that
Appendix A will be used by OSHA compliance officers if the
DOL accepts the ANSI standard as "notification of hazard", it
is essential that any "endorsed" risk factor evaluation and
quantification scheme be validated and tested across all
types of jobs.
5-6

End of last paragraph "... (less than 5% incidence on passive
surveillance") - how does this relate to a 1 % incidence used
to trigger level 2 surveillance and risk factor evaluations ?
Does it include low backs?

5-7

Last paragraph - still confusing discomfort and CTDs in many
of the level 1 and 2 surveillance questions. True level 2
surveillance should result in diagnoses if symptoms are
present. Much of the discomfort relates to sustained postures
- light effort sustained for minutes/hours. Job pattern and
job control determines how likely it is that the discomfort
will lead to a diagnosis of a bursitis or thoracic outlet
syndrome, for example. It is not appropriate to just count
risk factors and take the jobs with the greatest number first,
because these factors are interactive and are modified by job
patterns. Using a risk factors checklist approach where the
number rather than the interactions are sufficient to trigger
a positive RF rating, one can expect to find a lot of RF+/CTD­
jobs. I have found it much more fruitful to follow a
discomfort survey (where both the frequency and intensity of
discomfort are rated by the workers) with a review of factors
that could contribute to discomfort in each body part
identified. This works across all body parts, not just the
upper extremities.
Figure 5.2 - neck disorders should be included (cervical
spondylitis, costal-clavicular syndrome, etc.)

�4.

5- 8

Throughout this discussion there is an interchanging of
"symptoms" and "discomfort" that should be clarified. Also,
too much checklist reliance. Could we agree that "symptoms"
are collected only if a medical professional is administering
the questionnaire?

5- 9

Comparing national data to company data is only appropriate
if we are asking the exact same questions in all cases. A
great benefit of this document would be if it phrased the
questions to be asked in Levels 1 and 2 active surveillance.
For many plants, the need to do statistical studies of their
potential problems is small. Once they have identified
problems and defined where they can reduce them, they will
make the changes and monitor their effectiveness. The
statistics will come in if they don't appear to have a problem
and someone tells them they do (based on an outside
evaluation of the job in most instances). Some companies, in
an attempt to avoid a costly intervention, will then play the
numbers game and try to prove the problem is less significant
than the consultant suggested. The money spent to prove the
point is often more than a more creative, less expensive,
solution would cost to improve the job. I'd rather see the
time spent on workplace improvements than on consultants,
statisticians, and lawyers. CTD prevalence data by industry,
region, age groups, sex, and by length of service would be very
valuable to help in prioritizing which jobs to attack firs1, but
I do not think such data is available now. A national
prevalence rate is only helpful to a company if they collect
their company data using the same instrument.
Table 5.2 - Is this suggested as the comparison data for the
users of the standard to compare their rates to? If so, even
with non-occupational cases included, why is the value of 1
case of CTDs per 100 employee years used as a trigger point
when more than 10% of the population may have hand/wrist'
finger discomfort for more than 1 week and&gt; 20 times per
year?

5 - 11

Same problem with trigger at a CTD rate of 1 per 200,000
hours or 100 employee years. - not consistent with
background rate data.

5 - 12

5.5.2 - 3rd paragraph - "Mean scores should decrease over
time (Appendix A1)." This is only the case if everything

�remains the same, which is rarely the case ! Still same
difficulty accepting the rating scheme for risk factors
without a validation study. Too much reliance on this tool as
a quantitative technique. The best analytical tools are the
ones that lead you to solutions that are effective and
reasonably inexpensive. I don't think that the risk factor
analysis approach shown in Appendix A will meet that need.
5.6 - Additional Surveillance Tools - this should be moved up
in the section so more than one analytical technique is
offered. Although the standard should not force companies to
use .Q.llii method for analysis of risk factors, it could indicate
a number of different approaches that are currently in use in
American or international companies. Then, the company can
chose the ones that apply most to their types of jobs, using an
ergonomist to assist them in that decision but not
necessarily to do the evaluations.

5

�Job Analysis and Design

6.

Page#

Comments

6- 1

6.1 Risk Factors and Definitions - this philosophy should be
put forward in the other sections, too, especially surveillance
and training. A need to reconcile the sections for consistency
is apparent.
"The greater the exposure to a single risk factor, the greater
the risk." - Define the parameter intended here - is it the
intensity of exposure or the freguency or the duration? Or
all three?
6.1.1 In the example, if the effort level is the same in both
motions (raising and lowering the hammer), then it could be
considered one motion instead of two. It becomes 2 motions
if the effort level changes or if there is a break in the effort
between parts of the over-all motion.

6-2

Thanks for adding duration and recovery time. There are still
some areas of confusion, but it's much closer to the original
intention. I use holding time (work time), recovery time
(light dynamic work or rest) and total time of sustaining that
work pattern before another pattern occurs. The latter could
be task time or time to the first break. Duration in terms of
total time per shift may also be relevant in some jobs.

6-4

6.1.5 Posture - It is not a neutral posture to hold the elbow
angle at go 0 - unless you are supporting the arm. The usual
neutral posture for the forearm is with hands to the side and
forearms supinated slightly. Keeping the elbow at go 0 entails
muscle work, whether standing or seated, unless the forearm
is supported.

6-5

6.1.6 Work Organization - for an important topic this came
out very small in the document. Perhaps this is a place to
explore the multiplicative effects of psychosocial factors
that have been included in the trigger point risk factor
analysis approach given in Appendix A.
6.1.7 Environment - !:ie.a.t is also a risk factor for carpal
tunnel syndrome and possibly for other nerve entrapment
syndromes. It probably acts through an effect on body water
balance (increases retention) and contributes to symptoms as

�an individual risk factor. It should be included in this section.
6- 6

Methods of Measurement - These measurements should be
described without making it part of the standard to measure
them one way ("should, must, etc."). Direction in the analysis
is appreciated, but there can be legitimate differences of
opinion about how to do the measurement depending on which
analytical technique you use. For example, I do not use range
of motion to describe repetition rate. I use it to determine
effort level, since using a joint at an extreme range of motion
often results in reduced capacity and, therefore, a higher
percentage of maximal effort used for the task.
Repetition rate - I thought there was a paper suggesting that
at a rate of 30/minute even light effort contributed to CTDs.
Should that be mentioned here ?

6-7

6.2.4 Force - Measurements of force beyond force gauge use
and psychophysical measures are inappropriate for inclusion
in the standard since the techniques are invasive and not very
applicable to on-site use (laboratory use of them is even
questionnable !). Psychophysical scaling of forces (repeat the
exerted force on a gauge set up to ressemble the task) is
quite repeatable and should be included here. I find that
estimates of force (in terms of light, moderate, or heavy) are
not difficult to obtain from the workers on a job as long as
they do not confuse duration or frequency with effort level
(how it feels if the effort is done just once for 3 to 4
seconds).
Internal force measurements cannot be measured using EMG
unless you use needle electrodes. Then you are only looking at
a few fibers and not the whole muscle. Use of EMG to state
how much force is being exerted is a very inexact science
with surface electrodes since the muscle mass changes when
the link positon changes (moving forearm from the neutral
position to pronation, for example) and one does not know how
to interpret the data when this happens. EMG is best used to
detect gualitative muscle use (which ones are active) and
static muscle loading. It is also useful for looking at work
and recovery times for active muscles in repetitive tasks. I
would leave it out of this document entirely.
More detail is needed in the calculation of forces for direct

7.

�8.
force measurement if that paragraph is to be left in. I'd keep
it simple as the real question is, is it of concern in terms of
tissue injuries (peak loads that can result in tearing of
tendons or muscles fibers) or in terms of sustained efforts
and repetitions that could result in CTDs?
Need to include velocity and acceleration in here.
6.2.5 Posture - Measurement of posture is a research project,
not one that is needed to define risk in a plant. One can
estimate angles and bends in the body and define them in time
to establish how they influence the effort level required. If
one collects the electrogoniometer data for several joints,
how is it going to be used to determine risk ? I know of no
data that quantifies how much deviation of a joint at
different rates contributes to the etiology of CTDs. I do know
that the deviation of joints contributes to the % of effort
required to do a task because there is less strength available
when wrist or shoulder joints reach their extremes of motion.
The interactions can be described in a risk factor listing and
do not need extensive measurement. I have collected much of
that kind of data and finally concluded that I do not know how
to interpret it. Problems can be solved without that degree of
analysis, and that is what the standard should be addressing.
6-8

The postural angles can be measured quite simply through
grouping them into ones where there is slight, moderate, or
extreme deviation. There is very inadequate data available to
be able to relate the angles to changes in strength or capacity
of the muscles and support structures. If you want to suggest
these techniques as ones that will quantify posture, please
put it in an Appendix and not as part of the standard. I find
that too much time is spent in analyzing the postures and not
enough in analyzing the reasons for the postures that will
lead to problem resolution.
6.2.7.1 Vibration - I have not measured vibration extensively
but isn't much of the needed information provided by the tool
vendors? If you give the plants a value to shoot for, couldn't
they ask the vendor to do the tests and establish that the risk
is minimal ? Refer to vibration standard here.
6.2.7.2 Cold - add "Heat" and suggest that the temperature
should be measured with a WBGT (wet bulb globe

�thermometer) system. This will give you shielded dry bulb
(non-radiant heat dry bulb temperature), globe (radiant heat),
and natural wet bulb (humidity/dewpoint) readings of the
ambient environment. A thermistor could be useful if surface
temperature readings are needed (as in assessing the cold
generated by an air tool venting over the wrist).

6 - 10

9.

" ...but in the hands of inadequately trained people, checklists
can and have been grossly misused." - I hate to say it, but they
are grossly misused in the hands of some highly trained
people, too. The usual problem is that the interactions are
not evaluated together and some factors get very heavily
weighted because they appear in multiple places on the
checklist while others (that are not risks if they occur
independently of the interactions) are not included. An
example of the latter is light work that is sustained for more
than 20 seconds continuously and where the pattern is
repeated for many hours during a shift.
The interactive form-based approach shouldn't be discarded
because of cost and time because there are methods available
that are already developed and are being used effectively in
several industries. Efficacy studies have not been done on
many of them, but their focus is to initiate the problem
solving process, not to prove linkages between work and CTDs.
The most effective methods lead from risk factor
identification and quantification to determinations of how
much the risk factor has to be modified (in simple terms) to
reduce the problem.
6.3.1 Preparation - add "production needs" to the list of
information collected. It is unrealistic to assume that one of
the things you can change is the production goal by slowing
down rates or increasing break times, for instance. One can
most often achieve the production goals while reducing the
risk for injuries by defining what impacts the job or task
demands have on productivity and quality performance (as
well as on injury and illness).
6.3.2 Step Breakdown - Here is a place where the ANSI
standard should follow the ADA legislation rather than
creating a whole new way to analyze jobs. Using a listing of
the "essential" and "non-essential" tasks first, one can then
home in on the priorities for modification of the job. What

�10.
you miss in using a standard human factors job analysis
approach is the recognition of conditions or situations that
can add to risk but are not a regular part of the job. For
example, a seasonal task, such as shovelling snow, may be
part of a building custodian's job on an occasional basis, yet
it might trigger a shoulder or back problem. If the job is
reviewed in the summer, this task might not get evaluated.
By splitting the job tasks into ones that are done all of the
time (mopping, sweeping, emptying trash, etc.) and those that
are done less frequently (seasonal jobs or rare events), the
need for workplace modification versus administrative
changes will be clearer.
6.3.3 Description - This should be simple but should include
some quantification. If it is a handling job, for instance,
make a rough estimate of how many lifts are made per shift
(that is not necessarily the same as the number of products
made since some items are handled several times a shift). If
some of the work is heavy, estimate what% of the shift time
is spent doing these tasks. If it is machine paced, indicate
that. Also indicate the shift schedule (8- or 10- or 12-hour
shifts, which shift, any regular overtime, etc.) and the degree
of control a worker has over their pattern of work.
6 - 11

6.3.5 Step Problems - Add "poor visibility" to the list of
problems that might result in the extreme wrist flexion. This
opens up the possibilities a little more to show that the
problem isn't always a height, orientation, tool, or fixture
issue.
6.3.5 Risk Factor and Problem Summary - My problem solving
form is very simple. Column 1 = "Body Parts of Concern" (the
ones mentioned by people doing the job). Column 2 is a listing
of "Risk Factors" for each of those body parts identified in the
job analysis. Column 3 is "Why?" and becomes an analysis of
the problems that result in the risk factors identified. For
example, if the wrist is flexed strongly, all of the reasons for
that flexion are identified (orientation, height, tool, product
design, etc.). This will often uncover problems that are
outside of the team's control now but could be passed on to
selectors or designers of the next workplace, product, tool,
etc. Column 4 is "Strategies to Reduce the Risk" and includes
ways to reduce the intensity of effort, duration of effort,
repetition frequency, etc. so the risk factor is minimized.

�11.
The value of the form comes from how well the team does the
"Whys?" and identifies root causes for the risk factors so
they can be reduced. This invariably leads to inexpensive and
effective interventions rather than automation and major
workplace changes. It also empowers the team to solve their
own problems with assistance from engineers and
maintenance specialists.
6.3.8 Solutions - "opinions of the workers doing the job are
invaluable " - change "invaluable" to "essential" - without
their input there will be many well-meaning white elephants
generated. Re-emphasize root cause analysis to get the
solutions since very often the change that is needed relates
to improved communications and more involvement of the
workers in process changes.
6.3.9 Implementation and Follow-Up - emphasize the
importance of communicating and involving the workers
across shifts. Too often the analysis and changes are made on
the day shift with little involvement of the other shifts'
personnel. As a result, something that worked well on day
shift was thrown out during the afternoon or night shift. This
can be avoided by good communications and involvement of
people across all shifts.
6 - 12

The references on job analysis are heavily biased towards
University of Michigan publications and do not recognize
methods that are in the literature and are in use in many
companies. I attach a copy of my own "A Functional Job
Evaluation Technique" paper that was published in October of
1992. It is currently being used in Ford, GE, Goodyear, Amoco,
SmithKline Beecham, Mobil, GM, Kodak, Arco, and several
smaller plants around the country. While no validation
studies have been done, it has proved very effective as a way
of training people to work together to solve problems and to
implement change. In one comparison study at a meat packing
plant, the rating scheme predicted the jobs where CTDs might
be expected better than two other analysis techniques based
on risk factor checklists (one being the instrument published
with the red meatcutters OSHA guideline). The value of the
rating technique has been that it stimulates discussion (to
agree on the ratings), involves measurements of duration and
frequency from videotaped or observed jobs, requires the
person doing the job to participate because of the need to

�define effort levels by body part, and has the interactions
between intensity, duration of effort, and frequency built into
the priority rating process. By defining the greatest
contributors to risk for each body part, the problem solving
process is started, and a solution can be evaluated before it
is implemented using the same approach. It takes about 6
hours to teach people how to use this approach, I find and a
little 1 hour follow-up will catch any methodological errors
quite quickly. The best part of it is that the solutions are
creative, not often the same from problem to problem, and are
less likely to create new problems when implemented.
Other job analysis approaches that should be referenced
include Nigel Corlett's work, Colin Drury's analyses, the
Ergonomics checklists, the National Safety Council checklist,
the EEC ergonomics checklist and analysis methods, etc.
Perhaps the literature was not searched for job analysis
methods, but the current reference list is very limited and
must be expanded.
Last paragraph - add "communications improvements" to the
administrative controls. I find that at least half of our
inteNentions have an "administrative control" focus and they
rarely relate to rotation or changing line rates. They run from
agreeing to schedule maintenance on machines (instead of
waiting until they break down), to changing the shipping
orders on products or parts, to modifying a policy on
utilization of grinding wheels until they can no longer do the
job (resulting in excessive time to grind a part), to changing
the wage grade on a job to permit more people to rotate
through it (a physically demanding job aerobically), to
agreeing to train machine operators to do minor maintenance
tasks on their production equipment so set-ups are more
consistent. The definition of administrative controls is too
narrow in the meatcutters' guideline and in this document.
6 - 13

First paragraph - I agree that engineering changes are very
effective, but they are also often apt to eliminate a person's
job. With the job picture looking rather bleak in U.S.
manufacturing today, I think we may want to reduce the
emphasis on engineering out the "problems" and focus more on
helping the worker work without much risk. The problem
solving approach usually helps to reach that goal and to do it
at low cost. Helping to define when a task is best done by a

12.

�13.
machine than by a person would be a valuable tool for
designers and would help companies put a priority on jobs
that are likely to contribute to CTDs. For example, I use the
following as indicators for possible overexertion risk:
Handling any objects weighing more than 51 pounds
(begins to limit available workforce significantly because
of strength requirements).
2. Handling objects weighing more than 40 pounds at rates
of or above 1 lift every 5 minutes.
3. Handling any objects at a rate of 6 times per minute
below knuckle height for 4 hours or more (aerobic limit).
4. Sustained work above shoulder height or below knee
height.
5. Lifting objects above shoulder height unless they can be
boosted.
6. Doing light repetitive work with the same muscle groups
for several hours per shift at rates greater than 30 per
minute.
7. Doing heavy repetitive work at rates greater than 6 times
a minute for 2 or more hours continuously.
8. Exerting forces or handling materials more than 20 inches
in front of the body.
9. Grasping objects repetitively when grip span exceeds 3.5
inches (2 parallel surfaces) or 2 inches in diameter.
10. Controlling material with pinch grips exceeding 15 pound
of force.
11. Sustained work with the torso twisted to one side
because of access or clearance problems.
1.

There are others, but this is a start. These help to define
some design parameters for engineers but also give the teams
a way to prioritize which problems they should select first.
"Specific postures that workplace design should seek to
eliminate are:" - This is both unrealistic and inappropriate.
The postures are not a problem if they aren't sustained or
happen infrequently. I would either eliminate this or use a
tabular form to define good, okay, and poor postures. Page
697 of my paper (attached) uses such a technique for effort
estimation. To take an example from the paragraph in this
draft, if the forearms should never be rotated fully or almost
fully in either direction, we will have to eliminate all typing

�14.
tasks except with specialized keyboards (which are neat
ideas and totally impractical - try answering the phone and
typing a note simultaneously with one of the specialized
keyboards !). Avoid the use of the term "eliminate" but focus
on the need to minimize the sustained use of the muscles and
joints in these postures.
6 - 13

6.4.1.1 Workplace Design - the key factor in good workplace
design is allowing flexibility in choosing postures for the
work. The problems that arise relate both to awkward
postures and also to the task performed and the duration of
postural stress. Keeping the body in a neutral position may
rule out work in many cases and still will be problematic if
the person has to remain in that position for several hours.
Paragraph 2 under Workplace Design - define what is meant by
" ...for a range of operators". What parameters are used to
define the design needs ? Example of choosing a tool for a
particular work location will not work if you have people
doing their jobs in several planes (vertical, horizontal,
lateral, etc). People will use� rather than 3 tools if they
can when working on a paced line on for incentive pay.

6 - 14

First paragraph - Workers who have to hold their arms above
their shoulders do not need "frequent work breaks,"
necessarily; they need an opportunity to get adequate
recovery time for the shoulder, neck, and back muscles. That
can be accomplished by varying the tasks so not all of the
work is done overhead. Avoid "should" statements like this
one as they assume that there is only one solution to a
problem. Overhead work is a problem when it is sustained or
when the recovery time is inadequate because the work is
repetitive and the effort, duration, and frequency interact to
produce significant fatigue in certain muscle groups. It is not
a problem if recovery time is built into the work cycle by
following the overhead work with a task that can be done
closer to elbow height.

�15.
Page#

Comments

6-14

Paragraph 3 - "location and orientation of a tool... " to
" ...accommodate workers of different sizes." - this should be
broadened to include more than tools. All equipment is
relevant here, and the important individual characteristics
are not just body size data (especially not height !) but
strength, endurance, and visual capabilities as well.
5th paragraph - define "extremely repetitious tasks" 30/minute ? Suggested use of a hoist for extremely
repetitive tasks is inappropriate since they usually take too
long even in low repetition rate tasks.
6.4.1.2 Tool Design - 1st paragraph - " ...by sizing and shaping
the tool to fit the human hand." - This is only a good idea in
some cases such as in power tool (pistol grip) design. One has
to consider the motions required when using the same concept
for knife design, for instance. A knife that sits beautifully in
the hand and is optimized for cutting becomes very difficult
to manipulate when changes in orientation of the tip are
required.

6 - 15

Paragraph 1 - the maximum grip span of 3.5 inches is only
appropriate for pliers and wire cutters with that type of
inverted V-shaped handles. If the grip is across two parallel
surfaces, the span should not exceed 2.5 inches.
Paragraph 2 - the soft coatings may not be a good idea if
particles (metal shavings, dirt, or chips) can get embedded in
them.
The design issues should be given their own section or put
into a more detailed Appendix. The material is lost in here
and is very narrow in range. Consider specifying good design
and indicating where the engineers or purchasing people
should review the design from an ergonomic standpoint.
There should be more on equipment design other than air tools
and hand tools. Refer to ANSI Standard on Machine Tools in
future (in review now). Avoid the use of the word "shall" in
the specifications of designs - it should be recommendations,
not standards, because many of these tools are not yet
generally available.

�16.
6.4.1.4 Methods Design - the whole section will run into
problems because it directly affects union and management
prerogatives in the setting of job requirements and
productivity goals. This can be avoided by focussing on the
design of job activities to minimize the development of
fatigue rather than talking about "job enlargement" (a trigger
phrase based on some mistakes made in the 1970s).
Basically, the methods design should be designing� for
people by recognizing their physiological, physical, and
mental needs. Pace issues should be addressed by
determining what the stressors are and finding ways to
optimize the rates for the highest quality, largest volume
production.
6 - 16

3rd paragraph - There is still some confusion here on job
design approaches to reduce risk. It is best handled through
modification of the task cycle's work and recovery pattern
rather than by adjusting the larger task and light work cycles.
Incentive work - good theory, very difficult to alter; I doubt
you'll get very far by including it in the standard. That tells
companies and unions how to reward performance and really
doesn't belong in a standard, no matter how appropriate it
might sound.
6.4.2 Administrative Controls - needs a more global approach
as discussed earlier in root cause evaluations. "Ergonomic
stressors" should be "non-ergonomic stressors".
6.4.2.1 Work Scheduling - extended workdays not only
increase task duration, they reduce recovery time.
Management does not have the information to be able to
determine the best recovery time schedule, so it is best to
design the recovery into the task rather than increasing the
number of breaks (other than the increase that occurs
naturally with added hours per shift (every 2 hours)).
Management can set the stage to be sure employees are given
adequate rest breaks, but it is not feasible to expect them to
enforce the breaks. That will be determined by production
needs and individual work styles.

6 - 17

Top paragraph - I'd eliminate computer monitoring for other
reasons, but this is not appropriate in this document.

�17.
Where is the evidence that shift work and CTDs are positively
linked ? Is there an increased incidence on late night shifts
or an increased reporting rate ? I have heard of no studies
that show a link between the two ! Some people prefer shift
work to day work and have less stress when they are less
bothered by day shift service groups and supervision, so the
link with occupational stress is not necessarily present.
Machine pacing's effect is mainly through its restriction of
options for the worker to regulate work and recovery times in
the task cycles. Self-paced tasks are by nature "designed" for
the worker as they set their own pattern of work.
6.4.2.2 Training - Initial job training not done at line speed
and return to work or job change "break-in" training should be
included here as ways to reduce early cumulative trauma
disorders in a new job.
6.4.3.1 Vibration - the requirement for workers to wear A/V
full finger gloves does not take into account the dexterity
requirements of the job which may make glove use
impractical. This should not be a "should" statement.
" ...taking non-vibration rest breaks..." should read "recovery
periods" as it could be another light activity without
vibration exposure. Avoiding smoking is a good idea, but can
you put that in a standard ? I don't think so.
6 - 17

"... No acceptable levels for exposure for the hands to the
cold..." - There is data on this from Army Studies in 1957 by
Dusek, ER (Manual Performance and Finger Temperatures as a
Funtion of Ambient Te mperatures. Tech Report #EP-68,
Natick, Mass) and by LS. Rubin in 1957 ("Manual dexterity of
the gloved and bare hand as a function of the ambient
temperature and duration of exposure", J. Appl Psycho!
il!m,:377). The studies are summarized in Kodak's Ergonomic
Design for People at Work, Volume 1, page 254, Figure VD-2.

Section 7

Medical Management
I have not had time to thoroughly review this section. There
are some general concerns about it, though, and they relate to
the appropriateness of a committee largely made up of allied
health professionals writing methods of diagnosis and

�18.
descriptions of illnesses that are usually written by
specialists in orthopaedics or neurology. Any definitions and
diagnoses should be passed through the professional
standards committees of The American Orthopaedic,
Occupational Medicine, Hand Surgeons, and Neurological
Societies, before they get into a national standard.
"Ergonomic risk factors" should be "non-ergonomic risk
factors".
Any procedures suggested here should be similar to the ones
required in the ADA legislation (Americans with Disabilities
Act of 1991) so the company doesn't have to follow two sets
of procedures for the same basic process (getting a person
back to work in a timely manner).
8-1

8.0 Training, Table 8.1 - The approach is too narrow. In
addition to educating the managers and supervisors about the
risk factors for CTDs, you should be talking about how the
risk factors reduce the employees' ability to perform or
sustain their performance on the tasks. You have to relate the
ergonomics advantages to the business as well as to the
health and safety concerns if you want to get their
commitment. A lecture on anatomy is quite ineffective
unless you address the performance issue.

8-2

Too much reliance on the recommended checklist (Appendix A)
unless it has been tested much more widely than it appears to
have been. How much time does it take to train people to
apply it consistently, and how much variability is there in
individual ratings ? I really do not want to see one approach
"blessed" by this standard unless it has been used and
accepted widely, is shown to be very accurate in determining
risk on a job and is agreed to be superior to other methods.
There are other methods that are successfully used by many
companies, and this endorsement of one will lead to much
duplication of effort without necessarily improving the
implementation of needed changes.

8-2 to 8-10

The entire training section tends to "institutionalize" one way
of doing surveillance for CTDs and risk factor evaluations. I
find the model acceptable in some ways, but by no means the
only way to address CTD control in the workplace. I do not
mind having this material set forth as one example of an

�approach for employers to use, but that is not how it is set
out. It is full of "should" and "must" and suggests that no
other approach would accomplish the goals of controlling
CTDs. Many programs exist where training and surveillance is
less rigorous, yet ergonomic improvements are made on a
regular basis and people with less content training are
effectvely resolving problems on the floor. Incidence rates
and prevalence of CTDs in these plants has fallen 58 to 85% in
2 years, so we know that the goals are being met. By getting
so specific about training and analytical techniques, the
ergonomics process becomes more mystical than it needs to
be and companies will think that they need to hire outside
consultants to deal with their ergonomic concerns. I don't
think they should feel constrained in that way, if only because
there are not enough applied ergonomists available to help
them. Also, this approach moves away from the current trend
of "empowerment" of their people to solve their own
problems. The outside expert is seen as the owner of the
problem unless he/she empowers the workers to solve their
own problems. If the outside expert "solves" the problem, the
chances are about even that it will get implemented. The
chances that the solution will be accepted by the workers are
also about even, unless the consultant developed their
interest through involvement in the problem solving process.
There is practically no training of plant personnel here in
good problem solving techniques; it focusses on how to
analyze the risk and surveillance data. I have found that the
most effective training is in teaching people to get to the
reasons for the risk factors being present (the "Whys?" of the
analysis approach discussed in the attached article). It is
through this analysis of the root cuases that the individual
contributions to the team become recognized and are built on
to come to a concensus for solving the problem. If all of the
training is designed to define the risk and none goes to
teaching them how to reduce that risk through problem
solving, the team work is less effective. The people with
more education will take over the analysis and the people
with less education will sit back and answer questions or
wait to see what the engineers come up with. Their next role
is to explain why the suggested solution won't work, and an
adversarial relationship, rather than a symbiotic one, is
perpetuated. Using a simple problem solving approach (Why?
and What Else?), the people who know the most about the job

19.

�are on an equal footing with the technical people and they
learn to respect each other's knowledge and contributions.
The solutions invariably succeed because they have emerged
in an atmosphere of respect for each other's opinions and
concerns. The process can be repeated on other shifts and
with other groups; more solutions can be generated if the
first ideas meet with some resistance. It is a powerful
process and the team always comes up with solutions that an
outside ergonomist is unlikely to have thought of. Most are
quickly implemented.

20.

Some other basic skills are important to give the ergonomics
team because they relate to the team's effectiveness in
making change. The team members should have some training
in how to make good presentations and would benefit from
basic courses on how to lead meetings and how to make
decisions and analyze problems (Kepner Tregoe training is a
good example of the latter). I don't know if this belongs in a
standard, but it does belong in an Appendix that gives
examples of training programs.
8-7 to 8-9

The references in this section are very naive. I have a feeling
that the person who suggested them only read the titles and
didn't check out the content. Either improve the referencing
here or reserve all of the references to the end (section 9)
and just cite appropriate references in the text (e.g., Corlett
et al, 1986).

9-1 to 9-8

References - This reference list appears to be an adaptation
of the original list prepared by Dr. Armstrong and handed out
at the first meeting. As I indicated earlier in a ANSI 2365
meeting, that list is woefully short of physiological
references. It is my understanding that over 1500 references
were evaluated by the 2365 committee and I heard a very good
presentation about many of them in a Job Analysis and Design
session. Where is that summary ? Why are there no
references in languages other than English? The work of
Jacques Monod, Walter Rehmert and his colleagues at
Dortmund, and many others deserve to be included in the
bibliography. I would also appreciate it if the attached paper
was referenced since it is directly relevant to the topic and
is based on 25 years of experience in addressing cumulative
trauma disorders in industry.

�Appendix A
- 2&amp;3

Comments on this analytical tool have been given earlier in
responding to the Surveillance section. I did not comment on
the ambient temperature scaling, which does not follow the
physiological data very accurately. It is not just the ambient
temperature but the ambient airflow that determines the
impact on dexterity and manual coordination in a hand task.
The factor that has to be measured to anticipate the degree of
impairment there is for hand work in a cold environment is
the hand's skin temperature. A person who is using the hands
dynamically may have less CTD risk at a lower temperature
than does a person using the hands statically at a higher
temperature, for example.
I have trouble accepting an analytical technique that treats
these factors additively ad then multiplies the score by a
psychosocial rating that is additive and not weighted for the
importance of each of the factors. Are incentive pay,
electronic monitoring, and monotonous work really egually
contributing to the risk of CTDs ? Are they each as important
as lack of control of the job, routine overtime, and machine
pacing ? And if they are all present, should they increase the
risk of CTDs 1.6 times or should it be more like 4 or 5 times ?
My guess is that, if all of those factors are present, you will
see much more reporting of CTDs but I don't know that the
true incidence will be much higher. Again, too much weight is
given to this particular analysis method, and I am not
convinced that it is superior to other analytical techniques
that seek to quanitfy the risk for CTDs.

A-4

This checklist is more to my liking because it tries to relate
total work duration to specific risk factors. I believe the
second column should be &lt;1 hour (not &lt;4 hr). The incentive
work ratings should probably be 1, 2, 2 not 2, 2, - as shown,
but that would have to be tested. There is too much
separation between category 2 (1-4 hour) and category 3 (&gt;4
hrs) in the ratings of risk for the load and force values. For
example, lifting 15 to 30 lbs every few minutes for 1 to 4
hours would get 1 point and if it is the same task for more
than 4 hours, it gets 3 points. In physiological terms, the
difference in metabolic cost or muscle fatigue between 3
hours and 8 hours would be minimal if the lift time is short
and is only done once every few minutes.
All typing jobs will probably have to go to a level 2

21.

�22.
surveillance and risk factor evaluation because postural
stresses are heavily weighted (neck, forearm and wrist all
get 2 points if the task is done more than 4 hours) and high
repetition gets 3 points even if the force is light. That
appears to overweight light, repetitive tasks, especially with
the additional factor of continuous keyboard use (how can
that have ratings of &lt;1 hour or 1 to 4 hours ? If it is
continuous, it is &gt; 4 hours and we have double weighted that
variable). With improvements, I'd rather see this kind of
checklist recommended than the more complex one on A2 and
3 that is less specific about forces and weights.
A-5 to A-7

Symptom Questionnaire - I have real problems with symptom
surveys done in workplaces when there is no system set up to
address the concerns. I have seen serious problems occur in a
plant because the employees were given a symptom survey to
fill out and there was no follow-up on their responses. The
company was accused of not caring about the workers when
the real problem was that the outsiude consultants never gave
the company the information needed to do the follow-ups.
Discomfort surveys are better. I use the type of survey shown
on pages A-8 to 9 but use the G. Borg Large Muscle Group
Activity Scale along with the body diagram. Follow-up on
individual concerns is done during the job analysis and
training sessions. From the discomfort surveys for people on
a given job, we can go right into the fatigue analysis and
problem solving process to identify contributing factors and
root causes. People who are not highly literate have not had
difficulty with this approach. The simpler these instruments
are, the better their participation in the over-all process.

A-1O to11

The example is useful but the decision about which jobs will
be addressed will not be made on a scientific basis. The
questions that are more likely to be asked are:
1) How many people are affected ?
2) How much has the problem cost us in the past 2 years ?
(Workers' Comp, absenteeism, training time, turnover,
restricted time, etc.)
3) What will it take to make it better ?
Because there are often only a few people on a given job,
incidence rates get blown out of proportion (like the Shipping
job in the example cited). The basic information needed in the

�plant to decide which problems to tackle first is to know how
much of a problem the job or task is an d how it can be made
better. The rest is primarily of interest to researchers,
lawyers, and statisticians, not production personnel.

23.

B-1 to B-9

Are these the 1500 references summarized ? I wish that the
categories were more extensive and included psychosocial as
well as physical factors. The main problem with this format
is that the interactions between factors are not clear (since
they were assembled by risk factor). There is no way to
evaluate the interactions, particularly those interactions of
force with frequency and duration.

C-1 to C-3

The forms should not be "recommended", but rather presented
as an example of a data collection instrument. Most
industrial medicine practitioners get unhappy if someone
tells them how to do their work.

D-2 to D-6

These descriptions should be sent to the appropriate
professional societies for review before they are published as
part of this standard. To my knowledge, the majority of the
subcommittee members who developed these definitions were
not practicing orthopaedists or neurologists, so the experts
should be asked for their input.

Appendices - I would like to see the following additions to the appendices:
A. A more detailed set of ergonomic design guidelines to
accomplish the standard's goal of providing information
that can be used pro-actively in the design of
workplaces, tools, jobs, and environments to control
cumulative trauma disorders.
B. A listing of resources in applied ergonomics for the plants
to use that would include more general references,
training courses, educational programs, professional
societies, journals, govenmental agencies, etc.
C. A more complete summary of the literature reviewed and a
summary table showing where there are holes in the
research and where more work needs to be done (somewhat
like the matrix developed by Herrin and Chaffin prior to
the Manual Lifting guidelines project initiation).

�24.

D. More examples of levels 1 and 2 suNeillance and job
analysis techniques in Appendix A.

Respectfully submitted,
,
C,
\0i
.,di..,:..,_J Ci-,'\_ "'-L- '- �
K4__.)......-,G

Suzanne H. Rodgers, Ph.D.
9/10/93
(716) 544-3587

Suzanne H. Rodgers, Ph,D.

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

169 HUNTINGTON HILLS
ROCHESTER, NEW YORK 14622

�Suggested Questions for Review of ANPR of 29 CFR Part 1910,
Ergonomic Safety and Health Management Program
(Start with an introductory statement but please avoid the use of terms like "ergonomic hazards"
or "ergonomic risk factors". If anything they should be "non-ergonomic hazards" and
"injury/illness risk factors". Suggest that if a company has more than one program and they are
substantially different, they should submit information or. each separately.)

A. General Information

1. What level of ergonomics activity is present in your company today ?
_ None, see no need for it
_ None, but planning to start some
_ None, some in past, let drop _ None, some in past, not effective
_ Some activity, not formal
_ Activity in localized areas in company
_ Pilot projects in process now _ Some activity related to citations
_ Company-wide activity
Other ___________

2. If you have had an unsuccessful experience with ergonomics, why do you
think it failed ?
_ Management commitment low _ Lack of employee participation/support
_ No depth - "one-man show" _ Lack of expertise in-house
_ Budget and personnel cuts
_ High costs relative to benefits seen
_ Impractical solutions recommended by outside consultant
_ Inability to give ergonomics a priority
Other _______________________
3. If you do have some ergonomics activity or are about to start some, what
stimulated your interest in it ?
_ Low back problems
_ Repetitive work problems
_ Union grievances
_ Employee discomfort
_ Union negotiations
Cost control measures
_ Increased knowledge of field
Discussions with other companies/plants
OSHA citation
_ Anticipation of legislation
_ Team approach philosophy
_ Continuous improvement philosophy
_ Design improvement process _ Competitivity issue
_ Corporate policy
_ Media attention to topic
_ Concern about long term health of employees
Other _______________________

=

4. What department/person is charged with the responsibility of overseeing the
ergonomic activity in your company/plant :· ____________
5. Please describe briefly the organization of vour ergonomics program/process
and attach any examples of documentation ·on the program that you can.
Problem Identification Approaches: ______________
Problem Analysis and Resolution Approaches: __________

�2.
Project Prioritization Techniques: _______________
Approval Requirements: __________________
Funding Sources: _____________________
Implementation Processes: __________________
Follow-Up Procedures: __________________
Program Evaluation Techniques: _______________
Communications Techniques:----�-----------Education and Training Strategies: _______________
Use of Outside Consultants and Trainers: ____________
6. Do you have an ergonomics process in place for your office workers ? _ Yes
_ No Describe any concerns you have about a general ergonomics standard
that includes office workers' jobs ? _______________
7. What have been some of the impacts of ergonomics approaches to reduce
overexertion injuries and discomfort in the workplace m your company? Please
mark the extent of the impact in the columns to the right for those measurement5
you have observed.
Impact
# of Injuries
Cost of injuries
Absenteeism Level
Job Turnover Level
# of Job Restrictions
Job Reputation
Training Time
Quality Performance Level

�Impact

�

�

�

3.

Sienificant Very Lar2e

Productivity
Amount of Rework
Scrap or Waste Levels
Employee Morale
Supervisory Stress Levels
Lost Time Days
Ability to Meet EEO Goals
Other _______
Other --------

B. W orksite Analysis
1. Which of the following guidelines/information have you used to develop
ergonomic policies or for analysis of problem jobs?:
_
_
_
_
_
_
_
_
_
_
_
_
_
_

OSHA Red Meat Cutters' Ergonomic Program Standard, 1990
NIOSH Guidelines for Manual Lifting (1981, 19'.)1 ?)
NIOSH Guidelines on Vibration Exposure (198�)
NIOSH Guidelines on Exposure to Hot Environments (1972, 1978, 1986 ?)
NIOSH Monograph on Cumulative Trauma Problems - V. Putz-Anderson
Biomechanical Models (U of Michigan, etc)
Metabolic Models (Garg, U of Mich, etc)
Fatigue Models (Work/Recovery Needs)
Liberty-Mutual (Snook) Tables
Checklists
Methods Provided by Outside Consultants
Methods Developed Internally
Methods Learned at Conferences/Courses
Methods Taken from the Literature
Methods/Guidelines Developed by Other Plants/Companies
Other --------------------------

Which 3 sources of information have you found to be most effective and useful
in your program? ________________________
2. Who performs the worksite analyses and develops
the solutions ? _____
'
Who is involved in looking at ergonomics issues in the design of new
workplaces, jobs, and layouts or in the reworking of an existing workplace or
machine? -------------------------3. How is a proposed solution introduced to the floor? __________

�4.

What control do the :people affected by the change have during the
implementation penod? ____________________
I

4. Videotaping can be an important tool for analyzing jobs, particularly jobs that
are highly repetitive and ones that are done intermittently. Do you have any
concerns about suggesting videotaping as a recommended part of the worksite
evaluation process ? _ Yes _ No Explain your concerns, if there are
any.
5. What qualifications have/will you look for wh�n having a worksite evaluation
performed by either an inside or outside "expert"? __________
How will/did you find an expert in ergonomics ? __________
C. Hazard Prevention and Control
1. Which of the following hazard prevention and control strategies have you used
to improve jobs/workplaces/equipment/environments from an ergonomic
standpoint ?
Automation
Assist devices (hoists, lifts)
Outsourcing
Reduce speed of line/machine
Change specs on parts
Job rotation
_ Splints, belts, restraints
_ Employee education/awareness
_
_
_
_

_
_
_
_
_
_
_

_
_,_
_
_
_
_
_

Semi-automation
Height adjustability
Add labor to job
Modify production goals
Redesign product for better assembly
Job reassignment
Job redesign (changed content)
Fitress/wellness program

Team approach - self-directed workforce for problem solving
Environmental improvements (lighting, noise, vibration controls)
Workplace redesign (heights, reaches, clearances)
Improved processes to reduce more difficult tasks
Selection of employees for more difficult tasks (or Swot teams)
Set Purchasing guidelines to value ergonomic qualities of furniture/equipment
Build safety/ergonomics performance into personnel rating system
Other -----------------------

2. Which of the above strategies used have appeared to be the most cost-effective ?
1. -----------------------

2. ----------------------3. _______________________

What are the average times for implementation of the above most effective
ergonomics intervention strategies ?
1. ---------------2. ----------------

3. ----------------

�5.

3. Have you documented before/after measurements of productivity, quality,
personnel issues, health, and safety statistics to determine the impact of your
ergonomics program ? _ Yes _ No If not, why not ? ______
4. What size of budget do you think is needed to initiate and to sustain an
ergonomics process/program in a plant/company ? __________
What level of expenditure requires a high level of approval in your company ?
How much can be commited by a department head without having to go to
higher levels (except in the initial budget process) ? _______
D. Medical Management
1. What processes have you used to detect early signs of potential ergonomics
problems in the workplace ?
_ OSHA 200 logs
_ Employee suggestions
Grievances
_ Productivity problems
_ Symptom surveys
Absenteeism data
Job turnover rates
_ High repair or rework
_ Long training times
Other ________

_ Medical or first aid logs
_ Safety meetings
Job restrictions
_ Qu�lity performance problems
_ Usr- of outside expert to survey jobs
_ Use of internal audits to survey jobs
_ Difiiculty staffing jobs
_ High scrap rate
_ Die:iculty meeting EEO goals (women,
older workers)

Which three of th�se I?rocesses have you found most effective for identifying
areas for ergononncs nnprovements ?
1. --------------

2. -------------3. ______________

2. What processes have you set up to encourage employees to report early signs of
sustained musculoskeletal discomfort ? --------------3. What approaches have you used to decrease discomfort after an employee has
reported symptoms ?
_ Sent to dispensary
Sent to clinic

_ Referred to own physician
_ Sent to specialist

_ Observed employee at work and recommended approaches to reduce the stress
on the affected muscle/joint
_ Initiated an ergonomics review of the job
_ Identified a job accommodation and implemented it
_ Provided assistance to employee for the tasks most difficult to perform

�_ Provided employee with a brace/splint/assist device
_ Educated empoyee about risk factors at job and at home

6.

_ Removed employee from her/his job for: _ a few hours
the shift
less than a week
a month
the forseeable future
until the symptoms abated
_ until the job was modified

=

Other ______________________

4. What are the most effective parts of your company's job restriction and return to
work policies? _______________________
What areas for improvement do you see ? ______________
5. Symptom surveys have been used in many meat cutting plants to identify the
magnitude of ergonomic problems. What are tbe positive and negative aspects
of doing employee symptom surveys in your company?
Positive Impacts
1.

Negative Impacts
1.

2.

2.

3.

3.

How else can the magnitude of the symptoms in the workforce be determined ?

6. Have you been successful in returning people to their original jobs (unmodified)
after an absence of more than 3 weeks for a musculoskeletal problem without
incurring a repeat problem? _ Yes _ No What approaches were used?
_ Employee awareness/education
_ Work hardening
_ Reduced job demands or help given

_ SpEnts/protective equipment
_ FitI'.ess/wellness program
_ Ch,mged tools/workplace intuitively (not
aware it was ergonomics)

7. Do you have a process for evaluating jobs when a person has been out for more
than 3 weeks with a musculoskeletal injwy/illness that may be work-related?
_ Yes _ No If so, please describe the process and how the job
information is communicated to the medical people making the return-to-work
determination for the employee. _________________

�7.
8. If a person enters a new job, is there a pol;icy of phasing her/him into that job
gradually so the skills and strengths can be developed without excessive stress
during the break-in period? _ Yes _ No
What concerns would your company have if a policy of work "acclimatization"
is suggested to reduce the risk for injuries in the initial stages of learning a new
job?

E. Training and Education
1. For the following people or groups in your company, please indicate the type of
ergonomic training or awareness you think is needed to provide the basis of an
effective program/process. N= None, A= Awareness, B= Basic training, I= Intensive Training
_
_
_
_
_
_
_
_
_

Top management
Line supervisors/Dept heads
Key operators
Medical specialists
Industrial engineers
Job Placement specialists
Process engineers
Skilled trades specialists
Facilities engineers
Trainers
Office workers
_ Purchasing specialists
_ Industrial hygienists
_ Product engineers
Other --------

_ Middle management
Foremen
Union stewards
_ Safety specialists
_ Labor Relations specialists
_ Production planners
_ Design engineers
_ Tocl and Die specialists
_ Maintenance specialists
_ Materials Handling specialists
Production workers
Service workers
_ Wellness/Fitness specialists
_ Union leadership
Other ________

2. In what order were people made aware of ergonomics in your plant?
First: ------------------Second: -----------------Third: ------------------Fourth: ------------------Would you change this order if you were starting again?
What changes would you make and why ?

Yes

No

3. Who has done the employee awareness training in your company?
_
_
_
_
_
_

Outside consultant/trainer
Ergonomics team members
Internal company ergonomist
Industrial hygienist
Industrial engineer
Production supervisor
Other: ________

_
_
_
_
_
_

Internal company trainer
Ergonomics Coordinating Committee
Safety specialist
Medical or Fitness/Wellness specialist
Personnel specialist
Co-op student or summer employee

�4. Where have you obtained the materials for your awareness courses?
_
_
_
_

8.

Developed by the corporation _ Developed in-house
Purchased commercially
_ Obtained from seminars, courses
Taken from publications
_ Adapted from published programs
Purchased or taken from other companies with programs

5. What approaches have you used to obtain more intensive training for your staff
and employees?
_
_
_
_
_
_
_

Outside consultant on site
_ Outside training firm on site
Sent people to outside courses
_ Sent people to outside seminars
Purchased training packages
_ Hired ergonomist
Hired student with ergonomics training
Developed an ergonomics library
Brought in experts from other plants
Sent people to professional meetings
Visited other plants and studied their programs and approaches
Other ______________________

Which of the approaches has appeared to be the most cost effective? ___
5. How often do you provide ergonomics awareness or training programs or
schedule a discussion of ergonomics topics in a typical year (once the initial
phases of the program have been completed)? __________
Is ergonomics included in employee orientation or new job training programs?
No
Yes
6. What means have you used to communicate ergonomics program successes inand outside of your company?
_ Grapevine
_ Safoty meetings
_ Production meetings
Conferences
_ Quarterly meetings
_ Joint meetings of teams
Bulletin boards
_ Conpany newsletter
Plant newsletter
Union newsletter
_ Recognition ceremonies
_ Suggestion System tie-in
_ Videotape on internal TV
_ Health and safety reports
_ Audit results reports
_ Ergonomics reports
_ Local community media
_ Presentations at professional meetings
_ Management reports
_ Health fairs/Open houses
_ Lobby displays
_ Professional publications
Other: ___________

F. Other
1. Do you think there is a need for an OSHA regulation for the establishment
of an Ergonomic Safety and Health Management Program to reduce
No
Yes
musculoskeletal Injuries and illnesses in the workplace?
Please explain why or why not. _________________

�9.
2. If you already have an ergonomics program, which three of its elements do you
think have contributed the most to its effectiveness ?

1. ------------------------

2. -------------------------

3. ---------------'----------

Thank you for your assistance in responding to this request for comments.
Please mail your responses to:
Hersha! W. Hensley, Director
etc.

(8/12/91 S.H. Rodgers, Ph.D.)

(716) 544-3587

Suzanne H. Rodgers, Ph.D.

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

169 HUNTINGTON HILLS
ROCHESTER. NEW YORK 14622

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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Comments on Protocol for Cumulative Trauma Disorders Manual
Suzanne H. Rodgers, Ph.D.
6/19/82
Overall ·Organization:
Since this is a manual for occupational health and safety
practitioners in industry, the major sections should reflect
subject matter that they are familiar with or the answers to
questions that they might ask. Although all of the appropriate
material is covered in the three sections given, there is sub­
stantial overlap; this could produce an editorial problem,
as well as confuse the medical newcomer to this field.
As an occupational health practitioner, one is interested
in the following information:
Diagnosis of the problem - which includes the part of the
upper extremity (and shoulder) affected and the path­
ology or functional limitation;
Determination of whether the person can go back to the
job, needs work restriction, or needs further medical
treatment; and
Evaluation of the ability of the patient to return to work
after further treatment. Also, assessment of the proper
placement of a person on a repetitive motions task if
he or she has a history of CTD.
Because the last two topics cover much of the same information, I
would suggest that the material be rearranged to the following
three sections:
1. Recognition of Cumulative Trauma Disorders
• Definitions, using ICD classifications
• CTD statistics: prevalence, incidence, severity, etc.
• Diagnosis methods for the most common CTDs
2. Job or Workplace Characteristics Associated with CTD
•
•
.
•
•

Position of joints, limb, etc •
Forces or strength required
Repetitiveness
Duration
Environmental factors, such as vibration or time
pressure

�3. Programs to Control CHO in Industry
• Monitoring of health and safety data
• Administrative controls
• Engineering Controls
With this overall structure, it should be possible to con­
solidate the statistical and ergonomics analyses that would
otherwise be being written by more than one person. A breakdown
of how the individual sections might be handled follows.
1. Recognition of Cumulative Trauma Disorders, CTD
In this section all of the possible diagnoses for upper ex­
tremity CTD should be listed by !CD code number. This is needed
be able to differentiate, for example, between true tendonitis
diagnoses like "sore arm" or "arm strain". It also is a basis for
analysis of medical records so one can define the true incidence
of CTD in a given workplace.
After the !CD diagnoses have been presented, their prevalence,
etc., should be given. Then, those with the highest probability
of occurring in the workplace should be defined, and the accepted
methods to differentially diagnose them should be presented.
Comment: One of the biggest problems in defining the extent of the
the CTD problem in industry is in having the appropriate diag­
nosis made when a person complains of a sore arm, hand, wrist,
elbow, or shoulder. People who are skilled at detecting tendon­
itis report a great deal more of it than do their less special­
ized colleagues. It is, therefore, important to define each of
the major diagnostic entities in a way to assure that reporting
will be somewhat consistent from place to place and between
medical practitioners. I believe that this section should
be written by an orthopedics or rheumatology specialist who
can speak the medical person's language. Dr. Hadler would be
be an exellent choice. Dr. M. Laurens Rowe, now retired from
Kodak, is very knowledgable in this area and has done this
type of classification; he may be willing to help out too.

�2. Job or Workplace Characteristics Associated with CTD
This section would focus on the work factors that appear
to be associated with CTD of the upper extremity as we under­
stand them. One could start with a listing of the industries
and jobs most often associated with CTD problems, using the
Department of Labor job classification scheme to standardize
jobs between industries. There is a fair literature in this
area, even though some of it is misleading. A further breakdown
could be by tasks within jobs (e.g., housewife is the job, win­
dow washing and weeding are the tasks).
After the initial analyses of industries, jobs, and tasks
that gre associated with upper extremity CTD, some specific
biomechnical, physiological, environmental, and behavioral
analyses of motions, work patterns, and task requirements
associated with CTD should be given. This allows the studies
of Armstrong, Arndt, Keyserling, and others to be presented
in a form that the medical people can appreciate. With that
background they should have little trouble extrapolating to
the tasks and jobs in the industries they serve.
3. Programs To Control CTD in Industry
From the material that has been left out of section two in
the original outline, it would appear that this would be a
massive section. However, I think all of the remaining material
can be included under three headings: monitoring of data, admin­
istrative controls, and engineering controls.
3.1 Monitoring of Health and Safety Data
The first part should include a description of data that
can be used to assess the seriousness of CTD in a plant or
job and how reliable it is. The latter task is not an easy
one to quantify, but at least a qualitative appreciation of
how accurate CTD reporting is would be valuable. For exam­
ple, I have observed that OSHA data has about 331 of cases
seen in a medical department, and about 151 of the symptoms
reported in worker's interviews and questionnaires).
The second part of this section should include some in­
formation on how to do an epidemiological evaluation of the
seriousness of the situation once a job or task is identified
as having CTD problems. Too often we jump in with a shotgun
to solve a problem before identifying whether it is real or

�,,
a chance occurrence. Because of problems in the way people re­
port accidents and illnesses and differences in the diagnostic
skill of medical practitioners, there are opportunities for
misinterpretation of the seriousness of a CTD problem
unless a proper epidemiological study is done.
The third part of this section should provide a des­
cription of how better health and safety data can be collec­
ted to control CTD in the plant. This is often linked to
awareness programs for workers in repetitive jobs, which
is covered under training in the next part.
3.2 Administrative Controls
The first part of this section should identify the
roles played by different people in the plant, as shown
in 3.1 of the original outline. This then leads in to
the other types of controls available.
Worker rotation should be discussed from both a
medical and administrative standpoint. In some unionized
industries, the person may not have an opportunity to
move to another less-demanding job because he or she does
not have the seniority to take it. The impact of a job
restriction (versus redesigning the job, for instance) is
very large in that situation. Whoever writes this section
should be familiar with the feasibility of worker rotation
in different types of industries.
Worker training can be discussed in terms of initial
placement on the job, return to work after an absence that
is not CTD-related (such as vacation), and return to work
after a CTD-related problem.
Worker placement should be discussed both in terms of
whether a person is susceptible to CTD illness (from the
medical history or other validated tests), and as related
to decisions about a person's return to the job after a
problem with CTD •

.3,J

c---._

Engineering Controls
This section could follow up on the second one by sug­
gesting ways to improve workplaces, design products, select
tools, and organize the work in repetititive jobs in order
to reduce the potential for CTD to occur. Simple solutions as
well as more elegant forms of automation should be included,
preferably illustrated with case studies. Case studies should
be available from NIOSH studies and in the literature. Per­
haps some could be solicited from industries that have
done work in this area.

�Suggested Outline for Cumulative Trauma Disorders Manual
1. Recognition of Cumulative Trauma Disorders of the Upper
Extremity, CTD
1.1 Diagnostic Categories Associated With CTD of the Upper
Extremity
1.2 CTD Statistics - Prevalence, Incidence, Severity, etc.

1.3 Definitions and Testing Methods for Most Common CTDs
2. Job or Workplace Characteristics Associated With CTD
2.1 Industries, Jobs , and Tasks Associated with CTD
2.2 Ergonomic Evaluations of CTD-Related Workplace and
Job Characteristics
2.2.1 Biomechanical factors
2.2.2 Physiological factors
2.2.3 Environmental factors
2.2.4 Work organization factors

3. Programs to Control CTD in Industry

3.1 Monitoring of Health and Safety Data

3.1.1 Data sources available and their reliability
3.1.2 Epidemiological determination of the seriousness
a CTD problem
3.1.3 Improved data systems to monitor health and safety
data

3.2 Administrative Controls
3.2.1 Human resources available and their roles
3.2.2 Worker rotation
3.2.3 Worker training
3.2.4 worker placement

3.3 Engineering Controls

3.3.1 Ergonomically-designed workplaces and jobs
3.3.2 Case studies

�Suggestions for Writing Assignments Based on Revised Outline
Section 1

Dr. Hadler
Dr. Rowe

Section 2

2.1
2.2

Or.
Dr.
Dr.
Dr.
Dr.

Section 3

3.1
3.2

NIOSH, DSHEFS, OSR, DBBS
Dr. Hopkins
Dr. Hadler (placement)
Dr. Tichauer
Dr. Armstrong

3.3

Hadler
Armstrong
Arndt
Keyserling
Konz

These are based primarily on your existing list; Dr. Drury is
not included because of my ignorance of his experience in this
field� not from any feeling that he may not be capable of writ­
ing a section. I can see that this new outline produces addi­
tional problems for dividing up the material to be written. In
sections such as 2.2, perhaps one person could do the initial
write-up with the others acting as referees. That might save you
some expense but still permit several investigators to have
their views incorporated in the final Manual.
I have assigned Dr. Hadler several sections you had original­
ly assigned to others. This is because those sections need the
perspective of a physician more than the others. Having read
most of Dr. Hadler's articles over the past 10 years, I am sure
that he can successfully get the attention of his medical col­
leagues so that �hey will consider the manual 'theirs' •

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
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                    <text>"THE HEAVY JOB"

A talk given by Dr. Suzanne Rodgers at the Symposium on "The
Advancement of Women in Industry", sponsored by the Advisory Committee
on the Economic Role of Women, Washington, D .C., on September 20, 1973.
For the past 15 years, the Human Factors Section of the Health
and Safety Laboratory at Kodak has been studying the physiological re­
sponses of people doing physically demanding jobs. The purpose of the
studies has been to eliminate unnecessary effort by optimizing ,job,
equipment, and workplace design, thereby bringing the heavier jobs
within the capacities of most people. Our work in this area has allowed
us to develop an approach to the 11 heavy 11 job that reduces barriers to
the advancement of women in production departments.
Research in the United States and Scandinavia has shown that the
averap:e worr an has about '55% of the muscle strength of the average rran
(this ranges from 42 to 75% depending on the nmscle group) (Figure I)
and about t7;0 of his endurance capacity (Figure II). The overlap of
the distributions is such that about 1/3 of the men have capacities
within the range of the women's capacities. If a job requires high
strength or extended heavy work r:,cre wor:-,en than men will be likely
to find it limiting. What can be done to resolve this situation?
The following analysis of the "heavy" job will serve to direct
our thindng (Figure III). The first question to ask is "Is the ;job
really heavy?" If not, the probler. can be resolved by education of
manacenent and employees. If so, the next question would be "Does
the hea,.ry part of the job exist rnore than 5}; of the time?" In sorce
11
cases the 11heavy element may only occur seasonally or as part of
occasional maintenance work, or in rssponse to a low probability
emergency situation, or as a low derr.and production item, and may not
occur 5% of the time. In this case it is usually possible to redesign
that activity or to move it to some other job that does not lie in the
path of progression. If the heavy activity requires more than 5% of
the work period, one should note if the job is in the line of progression.
If not, then redesign is at the discretion of the department; but if so,
redesign of the job to bring it within the capacities of most people,
removal of the job from the progression line, setting up a parallel
progression line or restructuring the job requirements would each be
ways to assist advancement through the department.

1

�2

The remainder of this presentation will focus on misperception
of effort and ways to redesign jobs.
The most common form of misperception of effort results from ne­
glecting the presence of handling aids which significantly reduce the
physical work load. Pushing a cart weighing 2000 pounds does not require
a force of 2000 pounds if the casters are chosen properly, the handle is
positioned at the best level and the floor surface is well rraintained. A
person handling large size packing board on a square cutter can have a
significant reduction in work load if levelators and air tables are used.
Another area of misperception is in neglecting the effect of the
acquisition of skill in reducing the physical work load. It may take
several days or weeks or months to develop the skill, but as skill in­
creases, physical work usually decreases. Operating an industrial elec­
tric floor buffer may require a great deal of effort for the untrained
person who is struggling to control it, but only minimal effort as one
learns to rrake it do the work.
Once a job with a heavy element has been identified, the feasi­
bility of redesign should be considered. Several questions should be
asked, such as: How heavy is the job at present? What % of the labor
force would find it difficult to perform? Is there above-average attri­
tion on the job? If the job appears to be heavy enough to limit a
majority of the labor force from performing it safely and/or if it is
hard to find people to do it or stay on it, redesign is the most feasible
alternative. One should also ask uWhat �{; of the job needs redesign?,
How many people are doing the job?, and What is the probable cost of re­
design?". If a relatively small % of the job needs redesign, it is
usually more feasible to take this route than if a large part of the job
is involved. If the customer desires a large-sized product whose pro­
duction cannot be easily redesigned, removing the job from the depart­
mental progression line may offer the best alternative.
Some ways in which jobs can be redesigned have been shown earlier.
1.

The use of handling aids such as overhead hoists, levelators,
air tables, and carts, and the reduction of friction through
the proper selection of casters and the polishing of work
surfaces can reduce the energy requirements of many produc­
tion jobs.

2.

Physical effort can also be reduced by designing the pro­
duction sequence to minimize rehandling of materials.

3.

Work-rest cycles can be structured to reduce total work
load and bring it within the capacities of most people.

�3

4.

Awkward biomechanical work postures can be eliminated by
redesign of equipment or the workplace as an example from
a paper making operation studied in 1968 shows. Before
redesign, the employee had to lift waste paper weighing up
to 55 pounds from the roller to the side of the machine
where it could be carted away. The limited work space
required twisting the body while lifting, a poor biomechanical
work posture. The simple expedient of cutting a hole in
the machine floor to allow the paper to be pushed down to a
bin below for mechanical removal considerably reduced the
effort and brought it within the capacities of a majority
of the labor force.

This presentation has only dealt with the possible "barriers" that
physically demanding jobs may have to the advancement of women in pro­
duction departments. Miny of these same barriers exist for about 1/3 of
the men. It is important to note that redesign of heavy job activity
will most often benefit all people working in a pr.eduction area, parti­
cularly if the effort required is not really necessary but a result of
non-optimally designed equipment, workplaces, or jobs.

�FIGURE I

RELATIVE fflUS[lE STREDGTHS OF womEn us mEn
MUSCLE GROUP

WOMEN'S STRENGTH AS
PERCENT OF MEN'S

FOREARM FLEXORS AND EXTENSORS (B) .................... 55%
ELBOW FLEXORS (A) .......................................46%
TRUNK EXTENSORS AND FLEXORS, AND
FINGER FLEXORS AND FOOT EXTENSORS (B) ...............60%
ANKLE EXTENSORS (A) .....................................73%
FINGER ADDUCTORS, SHANK EXTENSORS,
AND ARM SINKERS (B) ................................... 65%
KNEE EXTENSORS (A) ......................................60%
HAND EXTENSORS AND FLEXORS, AND
FINGER ADDUCTORS (8) .................................75%
SHOULDER FLEXORS (A) ...................................42%
REFERENCES
A. CHAFFIN, D. B.: "A COMPUTERIZED BIOMECHANICAL MODEL
FOR ANALYSIS OF SYMMETRIC SAGITTAL PLANE LIFTING,"
JOURNAL OF AMERICAN INSTITUTE OF INDUSTRIAL ENGINEERING,
VOL. 11, MARCH, 1970.
B. HETTINGER, T.: PHYSIOLOGY OF STRENGTH,
CHARLES C. THOMAS CO., SPRINGFIELD, ILL, 1961.
THIS TABLE FROM CHAFFIN, D. B., "SOME ASPECTS OF PHYSICAL
EXERTION," JULY 1972.

�FIGURE II

AEROBIC CAPACITIES OF AD IDDUSTRIAL POPULATIOD

% OF POPULATION
30.

WOMEN N =35
x = 1.88

MEN
N = 132
x = 2.98

20·

31% OF MEN FALL WITHIN
CAPACITY RANGE OF WOMEN

10·

1.0

.

2.0

.

3.0

.

4.0

LITERS/MINUTE OXYGEN CONSUMPTION­
PREDICTED MAXIMUM

5.0

�FIGURE III
C'

ADALY515 OF THE .,HEAUV" JOB

I

I

EDUCATION

CONSIDER
REDESIGN

1

"HEAVY" JOB

1�

MISPERCEPTION?

L----.L--­
' NO
---7 YES
s,r=
YE
"HEAVY" ACTIVITY LESS � REDESIGN �
REDESIGN
��_j
FEASIBLE?
lHAN
5%
OF
JOB?
�
ACTIVITY
�
:...:.:.:,�
-__:__:,___J
.____:_:,
I =NO
NO

f

NO
..,_1
JOB IN PROGRESSION

I

LINE?
YES

t

REDESIGN FEASIBLE? , �

f

YES

REDESIGN
JOB

t

RESTRUCTURE
JOB

r-_-_-_-_-_-_-_-:.....-_-_-_-____
REMOVE JOB FROM
PROGRESSIVE LINE
OR SET UP ALTERNATE
ROUTE

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                  <text>IN COPYRIGHT - EDUCATIONAL USE PERMITTED &#13;
&#13;
This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                    <text>The Physiology of Playing the Flute
Summary of the Major Points Made in a Talk on August 25, 1984
to the National Flute Association Convention, Chicago, Ill.
I. Review of Ergonomics - Fitting the Job to the Capacities of
the Workforce - Design Within Most People 0 s Capabilities.
A. Whole Body Effort - study of the total energy demands of
jobs and their 8-hour requirements as well as peak demands.
Limited usually by the fitness of the cardiovascular system
(heart and blood vessels). Job demands are measured by
looking at a person ° s heart rate and energy usage (oxygen
consumption) throughout the shift. Can measure the capa­
cities of workers by having them do a staged exercise test
(treadmill, bicycle ergometer) and determining their max­
imum aerobic capacity for this type of work. Job demands
have to be related to the number of active muscles, usually
broken down into whole body or upper body work. Upper body
work capacity is about 70% of whole body work capacity.
For 8 hours of work - should not average out to more than
33% of maximum aerobic work capacity
For 1 hour of work - 50% of maximum aerobic capacity is �
upper limit
For 20 min�tes of work - 85% of maximum aerobic capacity
is the upper limit.
When you work at more than 50% of maximum aerobic work
capacity, you begin to need almost as much recovery time as
you have work time. At 65% of maximum, you need equal
amounts of rest for every minute of work. Above this value
you need more rest time than work time. Therefore, it is
unwise to ask a person to work for very long at very heavy
work loads.
B. Local Muscles and Joints - Study of the strengths and
endurances needed to perform tasks, including highly repe­
titive light effort tasks. The limits to performing this
type of work are the strength of the muscle of interest,
how long that effort has to be sustained, and how often the
effort has to be repeated (how much recovery time between
efforts). Using grip strength, for instance, the amount
of grip strength available will vary according to the posi­
tion of the wrist, the span over which the grip is exerted,
and whether the person is wearing gloves or not. Endurance
is related to the percent of strength required by the task

�and this can be measured using a force gauge, like a fish
scale.
A task that requires 100% of grip strength can only be
sustained for a few seconds.
If a task takes 50% of grip strength, it can be sustained
up to 1 minute.
If it takes 70% of grip strength, it can be sustained for
about 40 seconds.
A task that requires a sustained effort for up to 4 min­
utes should require only about 15% of maximum strength.
Recovery times are much greater for static than for dynamic
muscle work, requiring sometimes up to 45 minutes to com­
pletely recover from a few seconds of maximal muscle
effort.

c.

Repetitive tasks can result in muscle and joint soreness,
particularly if the force being exerted is a high percent
of the muscle 0 s strength in that position. The repetitiv­
ity will influence the amount of recovery time after an
effort, and higher repetition rates can result in inade­
quate recovery between exertions. This will result in a
build-up of fatigue in the muscles and can cause swelling
and soreness in the joints, too. Design of the task so
the person has the maximum amount of muscle strength
available for a task helps to reduce this overload sit­
uation.
In the case of gripping tasks, the design should
permit the wrists to remain as close as possible to their
neutral position, not be cocked up or down or angled to the
thumb or little finger side of the hand.
Time Pressure - study of the effects of social and envi­
ronmental factor that may influence the pattern of
work. Time pressure can be imposed on a job through
external factors, such as a conveyor line speed, peer or
supervisory pressure, or equipment response times (as in
using computers). It may be inherent in the task, as in
the timing requirements of performing an orchestral job.
Time pressure can also be generated internally by sched­
uling tightly, a desire to make extra pay by working above
the job standard, or by setting deadlines that are not
comfortable. The major effects of time pressure are to
reduce an individual 0 s ability to organize the job demands
so they can be done most comfortably. Time is constant
and people are variable, so the tighter the time con­
straint is, the more people are going to feel uncomfortable
with it. The feeling of being controlled rather than
controlling one 0 s performance is one that produces dis­
satisfaction if sustained for long periods. It can result
in stress-related symptoms of stomach problems, anxiety,
and nervousness.

�II. Reserve Capacity and Work
The ability to perform work implies a capacity for work,
whether it be a strength, an aerobic work capacity, an ability
to handle information, or a tolerance of an environmental ex­
posure like heat. The true maximum values of these capacities
are only attained with hard work (or practice), but we all have
maximum values that depend upon our current level of condition­
ing or learning. In addition, we all have minimum, or resting,
values of these capacities which may be zero for muscle strengths
but are above zero for resting oxygen usage and heart rate. The
latter is called our basal metabolism, the energy needed to keep
our organs working and to sustain life.
Our reserve capacity is the difference between our current
maximum capacity and our minimum, or basal, level. It can be
increased by improving the fitness of the circulatory system
(running, swimming) or of the muscles ("working out"), depending
on which capacity is involved. Other factors decrease reserve
capacity, however, in addition to the deconditioning associated
with not keeping up an exercise program. These other factors
increase the basal or resting levels so that reserve capacity is
eroded from the bottom up.
Examples of them are tension, which
is an increase in the resting muscle effort often caused by
anxiety-producing situations. For instance, muscle tension may
be elevated in jobs where the timing is tight and a person
never gets to relax totally between operations. Tension can
also be present because of the social conditions, including
performance requirements for a soloist or the tension of perfor­
ming a solo passage in the orchestral repertoire where peer
pressure as well as "supervisory" pressure can be felt. Another
environmental factor that influences the minimum level of a
capacity is heat, which elevates the demands on the heart prior
to doing work and then very dramatically increases the demands
when work is done in the heat.
Illness or injury usually erode our reserve capacities from
the top. We have less capacity to either perform or sustain
performance, thus our reserve capacity is less. By giving our­
selves recovery time and by reconditioning our muscles, we can
reestablish much of the lost capacity, or we can find other ways
to do the task that require less strength or endurance.
Posture adds to our minimum level requirements in many jobs.
Static muscle loading associated with poor or awkward postures
robs energy from productive work. Examples of static muscle
loading include:
standing still
twisting the trunk
holding objects
crouching

raising the elbows
leaning to one side
hyperextending the back
unsupported feet sitting

�slouching
extended reaches

wrists out of neutral position
bending forward

The best postures distribute the weight over the spine and have
minimal static loading of muscles. The Alexander and Feldenkrais
Methods both teach ways to keep this minimum level of effort low.
III. Applying These Ergonomics Principles to Flute Playing
A. Factors Affecting Maximum Capacities for Flute Playing
muscle fitness, breathing capacities, and endurance capa­
bilities are best brought to their highest levels by alot
of PRACTICE. Regular shorter periods of practice (45 min­
utes every day) are better than occasional longer practice
periods (2 hours every third day) as far as keeping the
muscles fit. If long hours will be practiced each day, it
is better to break them up into one hour periods with about
30-60 minutes between them than to sustain one 4 hour prac­
tice period.
For breathing capacities, abdominal breathing exercises
should be done. Inhalation through the nose during
those exercises will force you to take deeper breaths
because the resistance to breathing is higher that way.
Practicing rapid inhalation of air through the nose should
strengthen the abdominal muscles and diaphragm the best.
B. Factors Affecting the Minimum Levels of Effort in a Capa­
city - Tension is the primary robber of capacity in flute
playing, so techniques to reduce it should improve perfor­
ance. Poor postures can be remedied to reduce this level
of effort. Unnecessary static loading of the face
muscles involved in forming the embouchure can be
eliminated by appropriate coaching. Often a student is
not aware of the amount of tension in the embouchure until
he or she can maximally tense those muscles and then to­
tally relax them. By defining the range of tension in the
muscles, it is easier to determine where one is in that
range and, therefore, to be able to move towards the "less
tension" end.
Learning to cope with the strains of performance can
also best be done through practice and experience, but the
best reducer of performance tension is probably excellent
preparation of the music. Memorizing the music and
then still using the music in performance is possibly the
combination where the least non-productive tension will be
generated.
Some tension is good but not so much that it
seriously degrades capacity.
One other factor associated with tension that influ­
ences flute performance is the resting level of carbon
dioxide tension in the blood. This level increases during
the performance of a sustained phrase because that playing
is similar to holding one 0 s breath. No new air is coming

�in to help get rid of the carbon dioxide and to reduce its
concentration in the blood. The need to breathe is con­
trolled primarily by the amount of carbon dioxide in the
arterial blood. The oxygen level also contributes to a
drive to breathe as do receptors in the lungs that sense
lung volume. During the playing of a long phrase, the
carbon dioxide level of the arterial blood is increasing,
the oxygen level is falling, and the lung stretch receptors
are initially activated and then later the deflation recep­
tors come into play. All of these factors are telling the
flutist to breathe. By practicing, the flutist can learn to
ignore the oxygen level and lung receptor drives in order
to complete the phrase. He or she cannot ignore the carbon
dioxide drive, but it will take a little longer to reach
the top level ("breaking point") if the other inputs are
ignored. A tense player increases the amount of carbon
dioxide produced and oxygen used and may not be able to
get in a large breath because the shoulder muscles may be
less involved due to tension. Thus, all of the factors
that limit the breath holding capability of the player will
be coming to their critical values sooner and the phrase
will not be sustained.
Finally, time pressure can increase general body ten­
sion, as can be seen when you take an exam and are madly
rushing to write out the last essay as the teacher is
asking to have all of the papers collected. Handwriting
usually deteriorates badly due to excessive grip and tremor
associated with the time pressure stress. In flute playing
this pressure may result in less agile finger movements,
problems with the embouchure and throat muscles, and
shoulder tension that reduces breathing depth capabilities.
Time pressure is best dealt with by avoiding it where it is
under one 0 s control, such as arriving in plenty of time for
a performance or not procrastinating in preparing for a
performance, and by being fully prepared for solo or
orchestral performances so that timing problems are not
severe. Learning to relax is another way of coping with
time stress, e.g., developing a way of thinking that re­
duces the stress of time pressure. The use of beta
blockers or other drugs to reduce the tension of perfor­
mence, however, is not generally recommended since they
change many other physiological variables. Their primary
effects will be on the upper capacity levels, by reducing
the endurance times for muscle work and possibly by chang­
ing the sensitivity of the body to the carbon dioxide,
oxygen, and lung receptor drives in breathing.
IV. Summary - Practice is the best way to sustain one 0 s capacity
for flute playing. This assumes that good technique is
practiced! Good posture and techniques to relax can help
to keep the resting level of effort as low as possible so
that the reserve capacity is large.
9/1/84 SHR

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>5/05
Curriculum Vita
Suzanne H.Rodgers, Ph.D.
Consultant in Ergonomics
Address:

169 Huntington Hills
Rochester, New York 14622-1121

Phone:

(585) 544-3587; (585) 266-8749 FAX
e-mail: SHRODGERS @ AOL.com

Education: A.B. 1961 Vassar College- Physiology major
Ph.D. 1967 University of Rochester School of Medicine
and Dentistry, Physiology major
Work Experience:
1966-1968 Postdoctoral Fellow (USPHS), Middlesex Hospital Medical
School, London, England, Department of Physiology
1968-1982 Eastman Kodak Company, Health, Safety and Human Factors
Laboratory, Physiologist/Ergonomist inHuman Factors
1968-1989 University of Rochester School of Medicine and Dentistry,
Assistant Professor of Physiology, Part-time
1982- 1988 State University of New York at Buffalo, Industrial Engineering
(Human Factors), Adjunct Lecturer
1982- Now Consultant in Ergonomics (Self~Employed)

Areas of Expertise:
. Manual Materials Handling
Heat Stress
The Aging Worker
Rehabilitation to Work/ADA
Accident AnalysisComputer Workplaces
General.&amp;gonomics

.Repetitive Motions Injuries
Women in the Workplace
· Job Design ·
Work Physiology
Respiratory Physiology
Hours of Work/Shift Work
Low Back Pain

Publications:
Technical editor and principal author of the 2-volume work on industrial human
factors/ergonomics by Eastman Kodak Company, Ergonomic Design for People at Work
(Volume 1 published 1983, Volume 2 in 1986by Van Nostrand Reinhold, now owned by
JWiley &amp; Sons). Co-editor of and contributor to the revised edition out in October, 2003.
Author of Working With Backache, published July, 1985. New, revised edition due in 2006.
Editor of "Repetitive Motions Injuries", the March, 1987 issue of Seminars in
Occupational Medicine.
Several chapters and articles in medical and ergonomics proceedings and books.

Principal Clients: General Electric, City of Rochester, Eastman Kodak, State Compensation
Insurance Fund of California, Blue Cross/Blue Shield of Rochester, Reflexite, Industrial
Management Council of the Greater Rochester Area Chamber of Commerce, CalOSHA, Amoco
Chemical, Mobil Chemical, General Motors, and Ford/UAW Joint Safety and Health Committee.

�2.
Professional Positions, Honors, etc.:
President, Western New York Human Factors Society (1971~1972) ..
Group Leader, Plant, Human Factors, Eastman Kodak(1975-1979)
Acting Supervisor, Human Factors Section, Eastman Kodak
(most of 1976)
Fellow, U.S. Public Health Service, 2-Year Postdoctoral Fellowship,
Middlesex Hospital Medical School, London, England (1966-1968)
Current Member of HFES, ACSM, Greater Rochester C of C
Who's Who in the USA, World, Science, American Women (2000s)

Consulting:
US Air Force (1979)- Women in Non-Traditional Jobs
NIOSH (1979)- One-Handed Lifting Proposal Review
(1983) - Review of Manual Handling Guidelines
(1985)- Developed Improved Lifting Frequency Factor
(1986-90)- Manual Lifting Guide Revisions
(1992)- Retail Food Worker Epidemiology Study .
(1996)- Reviewed Monographs on Model Ergonomics Programs and
on the Epidemiology of Repetitive Motions Disorders of the
Upper Extremity; Seminar on Ergonomics and Accident
Analysis for the Safety Research Division
(1998)- Seminar on Accident Analysis from an Ergonomics Perspective
Eastman Kodak (1982- now)- Training, Guidelines Development (especially in Job Design),
Surveys, Project Team Training, Program Development Consulting, Production Line
Consulting, Methodology Development, EDFPAW Revisions; General Consulting
Mobil Chemical -Plastics, Film, Consumer Product Divisions (1983-1994) -Ergonomics
Training Programs, Consulting on Back and Repetitive Motions Problems, Control
Panel and Machine Design, Ergonomics Program Development, Line Design
Wegmans Food Markets, Inc. (1983)- Repetitive Motions- Cutting Meat
George Heisl Company (1982)- Ambulance Dispatching
St. Mary's Hospital (1984)- Manual Handling- Linen
University Health Service, U. of Rochester (1984-1988)- Paced Work on
Cafeteria Tray Line, Overexertion Injuries, Training, Facilities Design, and
Patient Transportation Studies
Bausch and Lomb (1985-7, 1993- 1999)- Ergonomics Awareness Courses,
Computerization of Anthropometric Data for Engineering, Ergonomics
Program Development, Engineering Training, Production Team Training, and
Project Work re Workplace Design and Evaluation and Product Development
General Motors Corporation (1984-95 ) -Ergonomics Training (Courses given at BuickOlds-Cadillac Assembly, Engine, and Fabricating Plants, Chevrolet~Pontiac-GM Canada
Assembly and Engine Plants, Truck and Van Assembly and Fabricating Plants, DelcoMoraine Brake Plants, Delco (Roch), and Rochester Products). Disability Management
Program, Training, Consulting,Workplace and Job Analyses. Team Training in
Production Areas and Engineering Training. Problem Solving Consulting in Many of
Plants.
City of Rochester (1987- now)- Trash Collection Injury Prevention, 911 Center Ergonomics
(including design of new Center), Recycling Study, Police Records Study,Water
Treatment Plant Shift Schedule Research, Office Ergonomics, Physical Capacity

�3.
Assessment for Waste Collection, Library Book Handling, Parks Operations Equipment
Handling, Accident Data Analysis, Ergonomics Awareness Training
Westinghouse/Electric Power Research Institute (1985-87)- Reviewing Heat Stress
Management Program
Kidde Consumer Durables, Keystone Lamp Manufacturing
Co.(1985)- Overexertion Injuries and Workplace/Job Design
Crouse-Irving Memorial Hospital (1986)- Low Back Management Program
Goodyear Tire and Rubber Company (1986-1993)- Ergonomics Team Training, Program
Development, Manual Handling Problem Solving, VDT Workplace and Job Design,
Surveys, Engineering Project Training and Consultation (87 plants- Worldwide Program)
John Deere Company (1987-91)- Training and Program Development, Consulting on
Overexertion Injury Prevention (4 plants)
General Electric Corporation (1988- present) Job Analysis- Repetitive Motions Disorders
(Bridgeport); Team Training and Program Development in 6 Aircraft Engine,? Engine
Services, 3 Aerospace, 4 Appliances, 3 Medical Systems, 1Transportation Systems, 1 Gear,
1 Electrical Distribution, 1 Meter, 2 Power Systems, 1 GE Capital Company, 1
Superabrasives, and 5 Motors Plants. Training of Nurses across Corporation, Participation
in Corporate Handbook on Ergonomics, Computer Workplace Studies
Xerox Corporation (1989-96)- Study of Furniture Movers, Trash Collection,
Ergonomics Problem Solving Training, Product Assembly Review, Program
Development, Consulting, Assistance in Corporate Design Guideline Development,
and in Development of Ergonomics Design Resource Center
International Paper (1989-92)- Overexertion Injury Prevention, Ergonomics Training,
Program Development, New Plant Construction Input
Amoco Corporation (1989'- 96)- Ergonomics Training for 15 Foam, Fabrics and Fibers,
Chemical Plants; Program Development, Corporate Office Ergonomics
IBM (1989)- Ergonomics Training, Awareness, Consulting (Rochester, MN and Corporate)
E.l. deNemours DuPont Co. (1989)- Overexertion Injury Prevention, Engineering
Awareness, Program Development Assistance
Crouse-Hinds Company (1989)- Evaluation of Repetitive Tasks for Injury Prevention,
Syracuse, NY
Occupational Rehabilitation Center, Rochester, N.Y. (1988-91)- Program Development,
Ergonomics Training, Job Evaluation Techniques, Capacity Assessments (multidisciplinary
team), Food Warehouse Lifting Evaluation
Rohm &amp; Haas (1989-91) -Ergonomics Training and Program Development, 4 plants
Erie Plastics (1989-91)- Ergonomics Training, Consulting- Repetitive Work, Manual
Handling
Oneida Silver (1989-91)- Ergonomics Consulting/Training, Program Development
Owens Coming Fiberglas ( 1990) - Ergonomics Awareness Training
Astro-Valcour (1991-95)- Ergonomics Program Development, Training, Consulting
U.S. Computer Services (1991-3, '99)- Ergonomics Program Development, Engineering
Training
Sacramento Valley Insurance (1992)- Ergonomics Consulting
EBI, Milwaukee (1992)- Ergonomics Training for Loss Control Reps

�4.
SmithKlineBeecham (1991 - 98) Worldwide Ergonomics Program Development and Team
Training for Clinical Labs &amp; Manufacturing Plants in USA, UK, Singapore, Argentina,
Puerto Rico. (15 Clinical Labs and 15 plants visited). Consulting in UK on Paced Bottling
Line Ergonomics for Medical Department.
Granite Hill Physical Therapy, Brunswick, ME (1990); The Source Physical Therapy, Boise,
ID (1992); Syracuse Pf Users' Group (1991) -Ergonomics Training and Consultation
in Program Development
Sara Lee Meatcutting Division (1991-1992) - Consulting Assistance
Touchstone (1993) - Ergonomics evaluations and awareness trainiug
Linq Industrial Fabrics (1994)- Ergonomics Team training
Thomson Publishers (1994-5) -Ergonomics Team Training and Consulting
Roche Pharmaceutical, Pao Alto, CA (1996)- Review of Jobs
Ford Motor Company (1996- 2001) - Ergonomic Job Analysis Consulting and
RFP Development; Ford/UAW Joint Health and Safety Committee -External
Reviewer of Occupational MSD Job Analysis· Project (1997-2001)
Blue Cross/ Blue Shield of Rochester, NY ( 1997- 99) - New Building Design and Equipment
Evaluation/Selection, Office Ergonomics, Employee Training
California OSHA (1998-1999)- Reviewed and Contributed to Easy Ergonomics
Manual for Small Businesses; Conducted 4 Training Courses for Compliance and
Research Personnel inCA (with Ira Janowitz); Reviewer of guideline documents.
OSHA (2000)- Expert Testimony at DOL Hearing on the 1999 Proposed Ergonomics
Standard Rulemaking
Eastman Kodak (2000) - Review of 43 Jobs in Paper Finishing Division
(2002-4) - Review of 36 jobs in Shops and Construction; team training for Logistics
and Shops/Construction
Food and Allied Services Trades H &amp; S (2001)- Ergonomic Job Analysis Training
Chiron (2001)- Review of Vial Inspection Jobs
Xelus, Inc (2001)- Survey of38 Office Jobs
B. G. Sulzle (2001, 2005)- Ergonomics Team Training, Train the Trainer Follow-Up Training
Industrial Management Council for the Greater Rochester Chamber of Commerce (2001) Ergonomics Training for Small Businesses - 5 Seminar Series
Reflexite (2003-4)- Consults on 2 inspection workplaces
State Compensation Insurance Fund of California (2001-present) -Advanced
Ergonomics Training for Loss Control and Ergonomics specialists; Development
of Low Back Injury Prevention program for clients of SCIF as part of a team ;
Literature Review of Occupational Low Back Injury Prevention Programs as part
of a team.

�5.
Topics On Which Public Presentations Have Been Made:
Quality Performance and Ergonomic Design - discussion of job,
tool design factors that may make it difficult to sustain quality
shift. Techniques to identify these factors and reduce them.

workplace and
work over a

Higher Productivity Through Job Design - how productivity can be increased by
designing jobs ergonomically to better utilize human resources and decrease job stress.
Repetitive Tasks - review of factors that may contribute to cumulative trauma disorders
at work. Examples of ways to reduce them through job and workplace design.
Low Back Pain in Industry- an analysis of workplace and job factors that contribute
to low back problems and extend disability. Design guidelines to reduce these factors
in the workplace and to help accommodate the worker with discogenic disease.
Manual Lifting Guidelines- review of the 1981 and 1991 NIOSH guidelines including
an analysis of how to apply them in the plant, places for improvement, guidelines for
carrying, 1-handed lifting, and force exertion.
The Partially-Automated Workplace· Who's In Control?- An analysis of the
human factors/ergonomics problems that need to be considered in assembly lines or
workplaces that are partially, but not fully, automated or computer-controlled.
Overview of Human Factors/Ergonomics - introduction to ergo as it relates to
manufacturing systems design and job design, especially. Also extended to include a
discussion of why it is difficult to get ergonomics into the design process.
Use of Human FactorS/Ergonomics Data in Assessing the Suitability of
Returning a Person to Work After an Extended Illness- discussion of
job demands relative to individual capacities for work which focuses on the person with
cardiovascular, respiratory, or musculoskeletal problems. Relate ADA needs for
"reasonable accommodation" to available ergonomic job and capacity assessment
techniques.
Working in Hot Environments - discussion of ways to reduce the stress of working
in high heat loads through job pattern control and work practices.
The Ergonomics of Shift Work and Overtime Schedules - A discussion of the
design of hours of work according to ergonomics principles. Information about the
psychosocial and physiological effects of different shift and overtime schedules.
Impact of overtime and extended work time on acceptable total workloads.
Women in the Workplace- discussion of physically-demanding jobs and their impact
on women trying to move into non-traditional jobs. Recommendations for ways to improve
these jobs.
Use of Heart Rate and Oxygen Consumption to Categorize Job Demands methods to quantify job demands in terms of stress on the heart and the amount of energy
required. Definition of appropriate job demands for most people in relation to work
capacities.
Job Fitness- discussion of the impact of physically-demanding jobs on a person's
cardiovascular fitness level, and on the responses of individuals with different fitness

�6.
levels to the same physically- demanding job. Programs to improve cardiovascular and
musculoskeletal fitness.

Office Ergonomics/VDT Workplaces - a review of the factors that contribute to reduced
performance and discomfort in office work. Special attention to visual and postural
needs and to job pattern control by the worker. Self-help assists to allow the worker
to identify ways to improve comfort at a VDT workplace.
An Ergonomic Approach to Accident Analysis · a technique for looking at all
aspects of an accident to get to root causes for injuries at work. Focuses on the individual,
task, environmental, and organizational factors that can contribute to accidents, and
identifies ways to reduce the risk through ergonomic improvements.
Do We Need an Ergonomics Standard?- discussion of whether we need an ergonomics
standard through OSHA legislation and what it should look like if the answer is "yes".
Includes information about what measurements are appropriate for cost/benefit analyses
of ergonomic interventions.
Applied Ergonomics in an Out-sourced World- a think-piece on the challenges of doing
applied ergonomics in different cultures and of finding better ways of designing work at
home. Keynote address at the 2005 Applied Ergonomics Conference.
Some Groups to Whom These Presentations Have Been Given (1974-2005):
American College of Sports Medicine
American Occupational Therapy Association/Canadian Occupational Therapy Assn
American Industrial Hygiene Association
American Occupational Medicine Association
American Society of Hand Therapists
American Society of Safety Engineers, Genesee Valley Chapter
Applied Ergonomics Conference - liE
Brouha Work Physiology Symposium
C.A.I.R.E. Conference (Rehabilitation)
Canadian Kinesiology Association
Center for Office Technology/OSHA/NIOSH Managing Ergonomics Seminar
Central New York Labor Agency, Inc.
Computer Automated Systems Association
Council of Economic Advisors' Subcommittee on the Advancement
of Women in Industry
Association of Canadian Ergonomists (old HFAC) Student Chapter
Eastwood Hospital Seminar Series, Memphis, Tenn.
ErgoCon '97 and '98 - Silicon Valley Ergonomics Institute Meetings
Genesee Valley Safety Conference ·
·
Governor's Safety Conference- Portland, OR
HFAC (now ACE) in Toronto, Kingston, and Halifax
Human Factors and Ergonomics Society
Industrial Accident Prevention Conference, Toronto
Industrial Health Foundation
Institute for Behavioral Medicine Seminar
International Ergonomics Association Meetings
International Occupational Safety and Ergonomics Symposium
Meeting Planners' Industrial Medicine for Physical Therapists, Applied Ergonomics
National Association of Rehabilitation Centers
National Institutes of Occupational Safety and Health

�7.
National Safety Council
NIOSHIOSHA Seminar on Successful Ergonomics Programs
NYS.National Association Rehabilitation Professionals Section
New York University Department of Rehabilitation Medicine
Occupational Health Northwest Seminar
Ontario (Canada} Physiotherapy Association
Organization Resources Counselors (ORC), Washington, DC
Physical Medicine Research Foundation, Vancouver, BC- Symposium
Polinsky Rehabilitation Center Functional Capacities. Network ·
Professional Training Seminars (Toronto, Vancouver, Calgary,,Edmonton)
Rehabilitation Research Conference, Halifax, NS
Rochester Chapter of the ATIE
Rochester Chapter of Robotics International
Rochester Safety Council and Industrial Management Council
Rocky Mountain Academy of Medicine
Safety Executives of New York
Texas Occupational Medicine Society
Toronto Academy of Medicine- Occupational Medicine Section
United States Post Office Training Program
University of Colorado Kinesiology Department
University of Iowa Physical Therapy Programs
University of Rochester Medical School
University of Windsor, Ontario Seminar on Ergonomics (IE Dept)
Wisconsin Physical Therapy Association
Wisconsin Safety Council

Teaching Experience:
1960-1961

Laboratory teaching assistant in the introductory Biology course, Vassar

1962-1989 · Respiratory physiology, some cardiovascular, neuromuscular, and metabolic
physiology - to 1st year medical students and graduate students - U of
Rochester Medical Center. From 1966-1968, teaching same material to znd
year medical students in London.
1964

7th grade natural science., 9th and 12th grade Biology in a private school
for the spring term (replacement for absent teacher)

1964-1966 Assisted in the physiology section of the graduate nursing program
(University of Rochester).
1969-1982 Overviews of Human Factors- awareness course offered through Kodak's
training department.
1975-1982 Assisted in training industrial nurses to analyze job effort levels, physical
environmental stressors, etc.
1978-1982 Human Factors section of Principles of Safety Management, course offered
through the Safety Department at Kodak Park - emphasis on safety-related
topics and accident analysis.
1982-1988 Physiological Basis of Ergonomics/Human Factors, course offered to seniors
and required of graduate students in SUNY Buffalo's Industrial Engineering

�..

8.
department - emphasis on learning to identify and analyze design problems in
existing workplaces and designing to prevent those problems in future
workplaces and jobs.
1982- now Ergonomics Awareness and Training Courses ranging from 1 hour to 8 days
with the preponderance being 3 to 4 days in length to train ergonomics teams
in a plant. About 450 courses given in past 20 years.

Hobbies : Music, reading, gardening, photography, sailing, silent films
Community Activities :
1978- 1988 Monroe County Board of Health - Chair of School Health Advisory
Committee,1978-1985; Vice President, 1982-84; President, 1984-1986
1981 - 1995 Rochester Friendly Home (private nursing facility) - Long-Range Planning
Committee
1985- 1987 Heart Health Education Committee, Genesee Valley Chapter, American
Heart Association
1977- 1986 Research Review Committee, Park Ridge Hospital; Chairman, 1984-86
1982 - 1986 Irondequoit Council of the Chamber of Commerce, Board of Directors
1969- 1980 Rochester Philharmonic Orchestra (RPO) Association, holding a variety
of positions: Vice-President of the Board (1973-1975), co-chairman of
Special Gifts Drive (1973 and 1974), member of Endowment Committee
(1973 to 1980), and head of team that did a functional analysis of Board
and Staff responsibilities (1974-5)
1971 - 1975 Opera Theatre of Rochester Board
1987- 1999 Citizens for a Quality Philharmonic, Steering Committee (RPO Public
Input Group)

Other Activities:
1981- 1987 Board of Corporators, Dana Hall School
1987- 1988 Rochester Torch Club (lecture club), President

5/05 SHR

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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Curriculum Vita
Suzanne H.Rodgers, Ph.D.
Consultant in Ergonomics
Address: 169 Huntington Hills
;.
Rochester, New York 14642
Phone:

(716) 544-3587; (716) 266-8749 FAX
e-mail: SHRODGERS@ AOL.com

Education: A.B. 1961 Vassar College- Physiology major
Ph.D. 1967 University of Rochester School of Medicine
and Dentistry, Physiology major
Work Experience:
1966-1968 Postdoctoral Fellow (USPHS), Middlesex Hospital Medical
School, London, England, Department of Physiology
1968-1982 Eastman Kodak Company, Health, Safety and Human Factors
Laboratory, Physiologist/Ergonomist in Human Factors
1968- 1989 University of Rochester School of Medicine and Dentistry,
Assistant Professor of Physiology, Part-time
1982- 1988 State University of New York at Buffalo, Industrial Engineering
· (Human Factors), Adjunct Lecturer
1982- Present Consultant in Ergonomics (Self-Employed)
Areas of Expertise:
Manual Materials Handling
Heat Stress
The Aging Worker
Rehabilitation to Work/ADA
Accident Analysis
Computer Workplaces
General Ergonomics

Repetitive Motions Injuries
Women in the Workplace
Job Design
.
Work Physiology
Respiratory Physiology
Hours of Work/Shift Work
·
Low Back Pain

Publications:
Technical editor and principal author of the 2-volume work on industrial human
factors/ergonomics by Eastman Kodak Company, Ergonomic Design for People at
Work (Volume 1 published in 1983, Volume 2 in 1986 by Van Nostrand Rembold).
Author of Working With Backache, published July, 1985.
Editor of "Repetitive Motions Injuries", the March, 1987 issue of Seminars in
Occupational Medicine.
Several chapters and articles in medical and ergonomics proceedings and books.
P~incipal

Clients: General Electric, City of Rochester, Eastman Kodak, Bausch
&amp; Lomb, CalOSHA, Blue Cross/Blue Shield of Rochester, US Computer Services,
U.of Rochester Center for Occ Rehab, and Ford/UAW Joint Safety and Health
Committee.

�..
2.
Professional Positions, Honors, etc" :
President, Western New York Human Factors Society
(1971-1972)
Group Leader, Plant, Human Factors, Eastman Kodak(1975-1979)
Acting Supervisor, Human Factors Section, Eastman Kodak
(most of 1976)
Fellow, U.S. Public Health Service, 2-Year Postdoctoral Fellowship,
Middlesex Hospital Medical School, London, England (1966-1968)

Consulting (open-ended dates mean current activity with that client) :
US Air Force (1979)- Women in Non-Traditional Jobs
NIOSH (1979)- One-Handed Lifting Proposal Review
(1983) - Review of Manual Handling Guidelines
(1985) - Develop Improved Lifting Frequency Factor
(1986-90) - Manual Lifting Guide Revisions
(1992)- Retail Food Worker Epidemiology Study
(1996) - Review Monographs on Model Ergonomics Programs and on the
Epidemiology of Repetitive Motions Disorders of the Upper
Extremity; Seminar on Ergonomics and Accident Analysis for
· Safety Research Division
(1998) - Seminar on Accident Analysis from an Ergonomics Perspective
Eastman Kodak (1982- ) - Training Others, Guidelines Development
(especially in Job Design), Surveys, Project Team Training, Program
Development Consulting, Production Line Consulting, Methodology
Development, EDFPAW Revisions; General Consultmg
Mobil Chemical- Plastics, Film, Consumer Product Divisions (1983-1994)
- Ergonomics Training Programs, Consulting on Back and Repetitive Motions
Problems, Control Panel and Machine Design, Ergonomics Program
Development, Line Design
Wegmans Food Markets, Inc. (1983)- Repetitive Motions- Cutting Meat
George Heisl Company (1982)- Ambulance Dispatching
St. Mary's Hospital (1984)- Manual Handling- Linen
.
University Health Service, U. of Rochester (1984-1988)Paced Work on Cafeteria Line, Overexertion Injuries, Training, Facilities
Design, Patient Transportation Studies
·
Bausch and Lomb (1985-7, 1993- 1999)- Ergonomics Awareness Courses,
Computerization of Anthropometric Data for Engineering, Ergonomics
Pro~ram Development, Engineering Training, Production Team Training, and
ProJect Work re Workplace Design-and Evaluation and Product Development
General Motors Corporation (1984-95 ) - Ergonomics Training
(Courses given at Buick-Olds-Cadilhic Assembly, Engine, and
Fabricating Plants, Chevrolet-Pontiac-OM Canada Assembly
and Engine Plants, Truck and Van Assembly and Fabricating
Plants, Delco Moraine Brake Plants, Delco (Roch), and Rochester
Products). Disability Management Program, Training, Consulting,
Workplace and Job Analyses. Team Training in Production Areas and
Engineering Training. Problem Solving Consulting in Many of Plants.

�'

.

'·

City of Rochester (1987-)- Trash Collection Injury Prevention,
3.
911 Center Ergonomics, Recycling Study, Police Records Study,
Water Treatment Plant Shift Schedule Research, Office Ergonomics,
Physical Capacity Assessment for Waste Collection, Library Book Handling,
Parks Operations Equipment Handling Activities
Westinghouse/Electric Power Research Institute (1985-87)Reviewing Heat Stress Management Program
Kidde Consumer Durables, Keystone Lamp Manufacturing
Co.(1985)- Overexertion InJuries and Workplace/Job Design
Crouse-Irving Memorial Hospital (1986)- Low Back Management
Program
Goodyear Tire and Rubber Company (1986-1993)- Ergonomics
Training, Program Development, Manual Handling Problem
·
Solving, VDT Workplace and Job Design, Surveys, Engineering
Project Training and Consultation (87 plants- Worldwide Program)
John Deere Company (1987-91)- Training and Program Development,
Consulting on Overexertion Injury Prevention (4 plants)
General Electric Corporation (1988- ) Job Analysis- Repetitive
Motions Disorders (Bridgeport); Training; Program Development in 6
Aircraft Engine,7 Engine Services, 3 Aerospace, 4 Appliances, 3 Medical
Systems, 1Transportation Systems, 1 Gear, 1 Electrical Distribution, 1 Meter,
1 GE Capital Company, and 5 Motors Plants. Training of Nurses across
Corporation, Participation in Corporate Handbook on Ergonomics, Computer
Workplace Studies
··
Xerox Corporation (1989-96)- Study of Furniture Movers, Trash
Collection, Ergonomics Problem Solving Training, Product
Assembly Review, Program Development, Consulting, Assistance in
Corporate Design Guideline Development and in Development of
Ergonomics Design Resource Center
International Paper (1989-92)- Overexertion Injury Prevention, Ergonomics
Training, Program Develo_pment, New Plant Consquction Input
Amoco Corporation (1989- 96)- Ergonomics Training for 15 Foam, Fabrics
and Fibers, Chemical Plants; Program Development, Corporate Office
Ergonomics '
ffiM (1989)- Ergonomics Training, Awareness, Consulting (Rochester,
MN and Corporate)
E.I. deNemours DuPont Co. (1989)- Overexertion Injury Prevention,
Engineering Awareness, Program Development Assistance
Crouse-Hinds Coml?any (1989)- Evaluation of Repetitive Tasks for
Injury Prevention, Syracuse, NY

Occupational Rehabilitation Center, Rochester, N.Y. (1988-91)Program Development, Ergonomics Training, Job Evaluation
Techniques and Capacity Assessments (multidisciplinary team),
Food Warehouse Manual Lifting Evaluation

�r

Rohm &amp; Haas (1989-91)- Ergonomics Training and Program
Development, 4 plants
Erie Plastics (1989-91)- Ergonomics Training, Consulting- Repetitive
Work, Manual Handling

4.

Oneida Silver (1989-91)- Ergonom~cs Consulting and Training, Program
Development
.
. ·
·
Owens Coming Fiberglas (1990)- Ergonomics Awareness Training
Astro-Valcour (1991 -)- Ergcmomics Program Development, Training,
Consulting
U.S. Computer Services (1991-3, '99)- Ergonomics Program Development,
Engineering Training
.
Sacramento Vallex Insurance (1992)- Ergonomics Consulting
EBI, Milwaukee (1992)- Ergonomics Training for Loss Coritrol Reps
SmithKlineBeecham (1991- 98) Worldwide Ergonomics Program Development
and Team Training for Clinical Labs &amp; Manufacturing Plants in USA, UK,
"Singapore, Argentina, Puerto Rico. (15 Clinical Labs and 15 plants visited).
Consulting in UK on Paced Bottling Line Ergonomics for Medical
Department.
Granite Hill Physical Therapy, Brunswick, ME (1990); The Source
Physical Therapy, Boise, ID (1992); Syracuse PT Users' Group (1991)Ergonomics Training and Consultation in Program Development
Sara Lee Meatcutting Division (1991-1992)- Consulting Assistance
Touchstone (1993)- Ergonomics evaluations and awareness trainiug
Linq Industrial Fabrics (1994)- Ergonomics Team training
Thomson Publishers (1994-5)- Ergonomics Team Training and Consulting
Roche Pharmaceutical, Pao Alto, CA (1996)- Review of Jobs
Ford Motor Company (1996-)- Ergonomic Job Analysis Consulting and RFP
Development; Ford/UAW Joint Health and Safety Committee- Extremal Reviewet
of Occupational MSD Job Analysis Project (1997-2000)
Blue Cross/ Blue Shield of Rochester, NY ( 1997- 99)- New Building Design anc
Equipment Selection, Office Ergonomics, Employee Training.
California OSHA (1998-1999)- Reviewed and Contributed to Easy Ergonomics
Manual for Small Businesses; Conducted 4 Training Courses for Compliance
and Research Personnel inCA (with Ira Janowitz)
OSHA (2000) - Expert Testimony at DOL Hearing on Proposed Ergonomics
Standard Rulemaking
Topics On Which Public Presentations Have Been Made:
Quality Performance and Ergonomic Design - discussion of job,
workplace and tool design factors that may make it difficult to sustain quality · .
work over a shift. Techniques to identify these factors and reduce them.
·
Higher Productivity Through Job Design- how productivity can be
mcreased by designing jobs ergonomically to better utilize human resources
and decrease job stress.

�r

5.

Repetitive Tasks - review of factors that may contribute to cumulative trauma
disorders at work. Examples of ways to reduce them through job and
workplace design.

Low Back Pain in Industry - an analysis of workplace and job factors
that contribute to low back problems and extend disability. Design guidelines
to reduce these factors in the workplace and to help accommodate the worker
with discogenic disease.
·

Manual Lifting Guidelines- review of the 1981 and 1991 NIOSH

~uidelines including an analysis of how to apply them in the plant, places for
Improvement, plus guidelines for carrying, one-handed lifting, and force
exertion.

The Partially-Automated Workplace- Who's In Control?-

An analysis of the human factors/er~onomics problems that
need to be considered in assembly bnes or workplaces that are
partially, but not fully, automated or computer-controlled.

Overview of Human Factors/Ergonomics - introduction to the area as it

relates to manufacturin~ systems design and job design, especially. Also
extended to include a discussion of why it is difficult to get ergonomics into
the design process.

Use of Human Factors/Ergonomics Data in Assessing the
Suitability of Returning a Person to Work After an
Extended Illness - discussion of job demands relative to
individual capacities for work which focuses on the person
with cardiovascular, respiratory, or musculoskeletal problems.
Relate ADA needs for "reasonable accommodation" to available
ergonomic job and capacity assessment techniques.

Working in Hot Environments - discussion of ways to reduce
the stress of working in high heat loads through job pattern
control and work practices.

The Ergonomics of Shift Work and Overtime Schedules- A
discussion of the design of hours of work according to ergonomics
principles. Information about the psychosocial and physiological
effects of different shift and overtime schedules.

Women in the Workplace - discussion of physically-demanding
jobs and their impact on women trying to move into non-traditional
jobs. Recommendations for ways to Improve these jobs.

Use of Heart Rate and Oxygen Consumption to Categorize
Job Demands - methods to quantify job demands in terms of

stress on the heart and the amount of ener~y required. Definition of
appropriate job demands for most people m relation to work capacities.

Job Fitness - discussion of the impact of physically-demanding jobs
on a person's cardiovascular fitness level, and on the responses of
individuals with different fitness levels to the same physically- demanding
job. Programs to improve cardiovascular and musculoskeletal fitness.

�Office Ergonomics/VDT Worl{places- a review of the factors
6.
that contribute to reduced performance and discomfort in office
work. Special attention to visual and postural needs and to job
pattern control by the worker. Self-help assists to allow the worker
to identify ways to improve comfort at a VDT workplace.
An Ergonomic Approach to Accident Analysis - a technique for looking
at all aspects of an accident to get to root causes for injuries at work. Focuses
on the individual, task, environmental, and organizational factors that can
contribute to accidents, and identifies ways to reduce the risk through
ergonomic improvements.
Do We Need an Ergonomics Standard ? - discussion of whether we need
an ergonomics standard through OSHA legislation and what it should look like
if the answer is "yes". Includes information about what measurements are
appropriate for cost/benefit analyses of ergonomic interventions.
Some Groups to Whmn These Presentations Have Been Given
(1974-1999):
American College of Sforts Medicine
American Occupationa Therapy Association/Canadian Occ Therapy Assn
American Industrial Hygiene Association
American Occupational Medicine Association
American Society of Hand Therapists
American Society of Safety Engineers, Genesee Valley Chapter
Brouha Work Physiology SymP.osium
C.A.I.R.E. Conference (Rehabilitation)
Center for Office Technology/OSHA/NIOSH Managing Ergonomics Seminar
Central New York Labor Agency, Inc.
Computer Automated Systems Association
.
Council of Economic Advisors' Subcomittee on the Advancement
of Women in Industry
Association of Canadian Ergonomists (old HFAC) Student Chapter
Eastwood Hospital Seminar Series, Memphis, Tenn.
ErgoCon '97 and '98 - Silicon Valley Ergonomics Institute Meetings
Governor's Safety Conference - Portland, OR
HFAC, Toronto and Halifax
'
·
Human Factors and Ergono~ics Society
Industrial Accident Prevention Conference, Toronto
Industrial Health Foundation
Institute for Behavioural Medicine Seminar
International Ergonomics Association Meetings
International Occupational Ergonomics and Safety Symposium
Meeting Planners' Industrial Med for Physical Therapists, Applied Ergonomics
National Association of Rehabilitation Centers
National Institutes of Occupational Safety and Health
National Safety Council
NIOSH/OSHA Seminar on Successful Ergonomics Programs
NYS Nat'l Assn Rehabilitation Professionals Section
New York University Department of Rehabilitation Medicine
Occupational Health Northwest Seminar
Ontario (Canada) Physiotherapy Association
Organization Resources Counselors (ORC), Washington, DC
Physical Medicine Research Fndtn, Vancouver, BC - Symposium
Polinsky Rehabilitation Center Functional Capacities Network

�7..
Professional Training Seminars (Toronto, Vancouver, Calgary, Edmonton)
Rehabilitation Research Conference, Halifax, NS
Rochester Chapter of the AilE
Rochester Chapter of Robotics International
Rochester Safety Council and Industrial Management Council
Rocky Mountain Academy of Medicine
Safety Executives of New York
Texas Occupational Medicine Society
Toronto Academy of Medicine - Occupational Medicine Section
United States Post Office Training Program
University of Colorado Kinesiology Department
University of Iowa Physical Therapy Programs
University of Rochester Medical School
University of Windsor, Ontario Seminar on Ergonomics (IE Dept)
Wisconsin Physical Therapy Association
Wisconsin Safety Council

Teaching Experience:
1960-1961
Laboratory teaching assistant in the
introductory Biology course, Vassar
1962-1989

Respiratory physiology, some cardiovascular,
neuromuscular, and metabolic physiology to 1st year medical students and graduate
students- U of Rochester. From 1966-1968
teaching same material to 2nd year medical
students in London.

1964

7th grade natural science, 9th and 12th grade
biology in a private school for the spring term
(replacement for absent teacher)

1964-1966

Assisted in the physiology section of the
graduate nursing program (U of Rochester).

1969-1982

Overviews of Human Factors - awareness
course offered through Kodak's training
department.

1975-1982

Assisting in training industrial nurses to analyze job
effort levels, physical environmental stressors, etc.

1978-1982

Human Factors section of Principles of Safety
Management, course offered through the Safety
Department at Kodak Park - emphasis on
safety-related topics and accident analysis.

1982- 1988

Physiological B,asis of Ergonomics/Human Factors,
course offered to seniors and required of graduate
students in SUNY Buffalo's Industrial Engineering
department - emphasis on learning to identify and
analyze design problems in existing workplaces and
designing to prevent those problems in future
workplaces and jobs.

�.

.

.
8.
1982- Now

Ergonomics Awareness and Training Courses ranging
from 1 hour to 8 days with the preponderance being
3 to 4 days in length to train ergonomics teams in a
plant. About 430 courses given in past 18 years.

Hobbies : Music, reading, gardening, photography, sailing, silent films
Community Activities :
1978- 1988

Monroe County Board of Health, chair of School Health
Advisory Committee,1978-1985; Vice President,
1982-84; President, 1984-1986

1981 - 1995

Rochester Friendly Home (private nursing facility)
Long-Range Planning Committee

1985- 1987

Heart Health Education Committee, Genesee
Valley Chapter, American Heart Association

1982- 1986

Irondequoit Council of the Chamber of
Commerce, Board of Directors

1977- 1986

Research Review Committee, Park Ridge
Hospital; Chairman, 1984-86

1969- 1980

Rochester Phill;larmonic Orchestra (RPO) Association,
holding a variety of positions: Vice-President of the
Board (1973-1975), co-chairman of Special Gifts
Drive (1973 and 1974), member of Endowment
Committee (1973 to 1980), and head of team that
did a functional analysis of board and staff
responsibilities (197 4-197 5).

1971 - 1975

Opera Theatre of R~chester Board

1987- 1999

Citizens for a Quality Philharmonic, Steering
Committee (RPO Public Input Group)

Other Activities :
1981 - 1987

. Board of Corporators, Dana Hall School

1987- 1988

Rochester Torch Club (lecture club), President

1/20/00 update

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
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                    <text>Biography of Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics, Rochester, NY
Sue received her doctorate in Physiology in 1967 from the University of Rochester
School of Medicine and Dentistry. After a 2-year USPHS Post-Doctoral Fellowship in
London where she studied the control of blood pressure, heart rate, and respiration, she
joined the Human Factors/Ergonomics Group at Eastman Kodak Company. Working
with engineers, medical specialists, psychologists, and computer and statistical
specialists, Sue spent the next 13 years studying people at work and doing research on the
work capacities of a 27,000-person industrial workforce. In 1982, she left Kodak to start
her own ergonomics consulting and training business with the focus on building teams
within companies to do the ergonomics problem solving. Among her clients are and have
been Kodak, Xerox, Bausch and Lomb, General Electric, General Motors, BP-Amoco,
International Paper, Rohm and Haas, Glaxo-SmithKline Beecham, Goodyear, John
Deere, Exxon-Mobil, State Compensation Insurance Fund of California, the City of
Rochester, the University of Rochester Medical Center, Oneida Silver, and NIOSH. Sue
was the principal author and technical editor for Kodak's two-volume series, Ergonomic
Design for People at Work ( 1983 and 1986, now in revision for 2002), and has also
written a book on ergonomics for people with back discomfort , Working With Backache
(1985, in revision for 2003 ). She has contributed articles and chapters to several
ergonomics and medical publications and speaks frequently at professional conferences
on ergonomics and fatigue reduction.

119/02 SHR

�Suzanne H. Rodgers, Ph.D. - Biographical Information

Dr. Rodgers is a consultant in ergonomics/human factors with a
background in physiology and 19 years of industrial experience. She
is on the part-time faculties of the Physiology Department at the
University of Rochester Medical Center and of the Industrial
Engineering Department at the State University of New York at
Buffalo. Research interests include manual materials handling and
repetitive motions injuries. She is the author of Workino With
Backache (1985) and principal author and technical editor of the 2volume source books on industrial ergonomics, Ergonomic Design for
People at Work by the Eastman Kodak Company Ergonomics and Human
Factors Groups (1983 and 1986). She is also the editor of the March,
1987 issue of Seminars in Occupational Medicine on "Repetitive
Motions Injuries". She is a member of the Human Factors Society and
its Western New York Chapter.

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>Exercise Physiology Laboratory

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University of Louisville
Louisville, Kentucky 40292
(502) 588-6649

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PHYSIOLOGICAL COST OF ffiGH FREQUENCY LIFTING: A REVIEW
by
· J.W. Yates, Ph.D.
Exercise Physiology Laboratory
University of Louisville, Louisville, Ky 40292

and Suzanne H. Rodgers, Ph.D.
169 Hunting Hills
Rochester, Ny 10016

Reprint Requests: Dr. J.W. Yates, Exercise Physiology Lab, Crawford Gym,
University of Louisville, Louisville, Ky 40292

�r, ,., ..

2

(:August 1 5, 1 990

1. Introduction

Ergonomists spend much of their time evaluating a task relative to the
potential for injury and then redesigning the job in order to reduce the
incidence of injury to the worker. Therefore, all ergonomists are well aware
of the tremendous costs associated with injuries that occur during manual
materials handling. Due to the magnitude of the problem, a large volume of
literature dealing with repetitive lifting has been published over the past 30
years.
Scientists have attempted to define lifting limits using a number of
different methods, including biomechanical models, psychophysically
determined limits, and measurements of metabolic rate. It seems to be the
general consensus that biomechanical models best define limits for
infrequent lifts (&lt; 1 lift/min) while the psychophysical method is the most
appropriate for lifts from 1 to 4 or 6 per minute. Physiological
measurements seem to be more valid when the lifting frequency exceeds
4 lifts/min (NIOSH, 1981).
The goal of this paper is to provide a critical review the body of
literature dealing with high frequency lifts. For the purpose of this paper,
high frequency lifts are define as a rate of 4 lifts/min or higher. This lifting
frequency includes limits which are determined using the psychophysical
method as well as the physiological method. Recent publications suggest
that the psychophysical method for determining the maximum acceptable

�\August 1 5, 1 990

lift is valid up to a frequency of 4 to 6 lifts/min (Ciriello et al., 1990;
Karwowski and Yates, 1984; 1986; Mital, 1983)
A number of factors affect the metabolic cost of repetitive lifting. The
weight lifted and the frequency of lift are the two most important
parameters and will be discussed in detail. Factors such as the distance of
the lift. its beginning position, the lifting posture used, and the container
dimensions also affect the physiological demands of the job. Each of these
factors and their interactions will also be discussed.

2. Measuring the Metabolic Cost of Lifting Activities

Direct determination of the metabolic demands of industrial tasks has
not always been readily available or possible. Therefore, in the past, work
physiologists often relied on measurements of heart rate to estimate the
physiological demands of the job. However, portable devices such as the
Oxylog are now readily available which allow the direct measurement of
oxygen consumption during the performance of the task. This device is
light weight and does not interfere with the movement of the worker. Thus
it is possible for the ergonomist to measure the oxygen demands of manual
materials handling on the job itself and not during a laboratory simulation.
This is best accomplished by having the worker complete several cycles of
the job so that a steady state oxygen uptake is reached. Monitoring the
heart rate also provides valuable information concerning the physiological

3

�C:

f\ugust 15, 1990

finding was probably due to the variation in the relationship between 02
consumption and work load and lifting efficiency seen among subjects.
One possible explanation for the different findings involves the
relationship between lifting frequency and weight of lift. It is known that for
a given height of lift, the metabolic demands change (Frederik, 1959).
Thus, if a progressive test increases the weight of the lift and holds the
frequency of lift constant, efficiency changes. This change in efficiency is
illustrated by the data of Garg and Herrin (1979). These authors plotted the
frequency of lift which resulted in a metabolic rate of 5.2 Kcal/min against
weight of the lift in kg. A weight of 25 kg could be lifted over 5 times/min
while a weight of 7 kg could be lifted 11 times/min. Over 125 kg of weight
can be lifted per minute when lifting 25 kg while only 77 kg of weight is
lifted per minute when a 7 kg unit is handled, yet both work loads result in
the same metabolic cost. Thus, for this situation, 02 uptake and work load
are not linear. Other data shows that the relationship between the two
variables changes with the height of lift and the muscle mass involved
(Genaidy et al., 1985). Given the complexity of lifting activities compared to
treadmill or cycle ergometer activity, it not unreasonable to suspect that the
relationship between metabolic rate and work load is non-linear in certain
situations.

3. Factors Influencing the Metabolic Costs of Lifting Tasks

5

�(

!jAugust 15, 1990

3.1 Beginning Position of Lift and Vertical Travel Distance

When considering the physiological cost of lifting, it is necessary to
account for the cost of moving the load as well as the cost of moving the
body. When a lift is made from the floor, the worker must lift his/her own
body weight in addition to the weight of the box. The cost of lifting the body
increases the energy requirements of the task when compared to the energy
needed to lift the same weight from a table upward. Therefore, lifts which
begin from the floor require more energy expenditure than lifts which begin
from table level. For example, Aquilano (1968) published 02 consumption
values for 6 men who were lifting 10 and 25 pound cartons from the floor to
waist level and from waist to head height. Estimates from figures published
in the article show that when lifting a 25 pound carton at a rate of 11
lifts/min, required a total energy expenditure of 4.4 Kcal/min for the waist
to head lift. However, lifting the same carton from the floor to the waist
resulted in a caloric expenditure of 6.3 Kcal/min, a 43% increase in energy
expenditure. The data of Frederik (1959) shown in Figure ????? supports
this point by showing that the most efficient lifting range is from 40 to 60
inches for materials ranging from 20 to 60 pounds. Lifting from 0 to 20
inches results in the greatest energy expenditure for weights ranging from
20 to 55 pounds. These data emphasize the important role played by the
beginning position of lift in determining the total energy expenditure of the
task.
The data are quite clear concerning the effect of lifting distance on
metabolic rate. As lifting distance increases, so does the energy

6

�August 15, 1 990
requirement of the job (Aquilano, 1968; Genaidy et al., 1985; Khalil et al.,
1985). When a 11 kg weight was lifted from the floor to waist height (92
cm) or to head height (168 cm) at a pace of 11 and 10 lifts/min
respectively, the corresponding energy expenditures were 5.21 and 6.58
Kcal/min. The exact relationship between metabolic rate and vertical travel
distance is affected by the body posture used to lift the weight. This aspect
of lifting will be discussed below.
3.2 Lifting Technique

The method used to lift the weight from the floor also has an impact
on the physiological cost (Brown, 1973; Garg and Herrin, 1979). Three
body postures used to lift objects from the floor have been studied: squat
(straight back, bent knee), stoop (bent back, straight knee), and free style
(as chosen by the worker). The squat lift results in higher levels of energy
expenditure than the other forms of lifting. Garg and Saxena (1979) showed
that at a work load of 60 kgm/min, the free style lift resulted in a metabolic
rate of approximately 4.2 Kcal/min while the squat lift yielded a metabolic
rate of 5.7 Kcal/min. This 36% increase in energy expenditure is partially
the result of raising and lowering the center of gravity of the body during the
squat lift. The differences in metabolic rates between the styles of lifting is
a function of the total work performed, or in this case the frequency of the
lift. At a work rate of 30 kgm/min, only a 14% difference exists between
the two lifting styles (3.15 Kcal/min vs 3.60 Kcal/min). Garg and Saxena
followed up on this study by evaluating the lifting techniques of 6 male

7

�,f,ugust 1 5, 1 990

industrial subjects filling dry grocery orders in a warehouse (1985). They
reported that the energy expenditure rate was 5.8 Kcal/min when using the
free style technique compared to 7 .5 Kcal/min with the squat technique. In
addition, the workers were able to meet their performance index using the
free style technique, but failed to meet the standard using the squat
technique. Brown (1973) plotted the relationship between the weight of
the lift and energy expenditure in Kcal/kg body weight/min. This method of
expressing the energy expenditure serves to normalize the data relative to
the body weight of the subject. The free style form of lifting was still found
to be more efficient than the squat lift.
Kumar (1984) reported that the stoop technique was less
metabolically expensive than either the free style or the squat technique.
This investigator measured the 02 consumed while lifting a 10 kg weight a
beginning position of 13.5 cm to a final position of 91cm, at a frequency of 6
lifts/min. The 02 consumption for the stoop, free style and squat
techniques of lifting was .676, .804, and 1.06 liters/min, respectively.
However, the distance between the subjects and the weight was kept
constant at 3/4 of reach distance. This constraint probably contributed to
the higher oxygen consumption of the freestyle lift when compared to the
stoop lift. On a subjective basis, the squat technique was rated as the most
tiring and the free style technique the least tiring. Even though the stoop
technique resulted in a lower metabolic rate, it was more tiring,
subjectively, than the free style technique. Kumar also reported that, for the
same lifting task, the absolute 02 consumed (liters/min) was always higher

8

�I.

f\ugust 15, 1990

for males; however, when the values were adjusted for body weight (ml/kg
· body wt/min), the females' oxygen consumption rates were higher. Thus,
when performing the same lifting task, females are working at higher
percentages of their maximum 02 consumption than males and are
therefore more susceptible to fatigue.

3.3 Effects of Work load (Frequency and Weight) on Metabolic Rate

Lifting frequen�;r and the weight of the lift are so entwined that it is
impossible to separate them when discussing their impact on physiological
parameters. Manipulation of either one of these factors will change the total
work performed by the· worker and, hence, their energy expenditure (02
consumed). The efficiency of the work performed is also a function of the
weight-frequency combination used during the lifting task.
Frederik (1959) was one of the first to publish data concerning the
metabolic cost of lifting. These data indicated that the cost of lifting loads
was a function of the weight of the object and the starting location of the lift.
Lifts performed from a height of 40 to 60 inches required less energy per
foot-pound of work than lifts from other heights. Of the range of weights
and heights studied, a lift of 40 pounds from 40 to 60 inches resulted in the
highest efficiency. Lifts in the range from the floor to 20 inches resulted in
the greatest energy expenditure.
Hamilton and Chase (1969) also collected data concerning the
relationship between 02 consumption and work rate when lifting IO to 25

9

��ugust 15, 1990

pounds a height of 10 in. These authors stated that the relationship
between the variables was linear over the range measured. The authors
incorrectly interpreted this finding to mean that no optimal work load
exists over the range of variables measured. However, the data published in
Table 2 of the paper by Hamilton and Chase clearly shows that when two
combinations of frequency and load result in the same work rate, the
combination with the greatest weight and lowest frequency results in a
lower metabolic rate. For example, lifting a 25 pound carton 9 times/min (a
total weight of 225 pounds/min) yielded an energy expenditure of 5.85
Kcal/min (1.17 liter O2/min). However, a lift involving a 15 pound carton
and a frequency of 15/min (also 225 pounds/min) resulted in a metabolic
rate of 6.88 Kcal/min (an 18% increase). The lift in this case involved
raising a carton from a table and placing it on a conveyor belt 10 in above the
table. Even though this study used a lifting height of only 10 in, all of the
weights studied (10, 15, 20, and 25 lbs) resulted in a metabolic rate greater
than 5 Kcal/min when lifted at a frequency of 15/min. At 12 lifts/min only
the 10 pound weight yielded a metabolic rate of less than 5 Kcal/min. At 6
lifts/min all of the weights were acceptable when based on a limit of 5
Kcal/min.
The data cited above suggests that when metabolic demands become
too high, the weight of the lift should be increased while the frequency of
the lift is decreased. These changes will lower the metabolic demands of
the job. However, there is clearly a trade-off when balancing the metabolic
demands with the biomechanical stresses imposed by lifting more weight

10

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4\ugust 1 5, 1 990

less frequently (Garg and Herrin, 1979). Biomechanical data suggests that
in order to minimize stress to the low back, the load should be reduced and
the lifting frequency should be increased. Thus the problem becomes one of
balancing the metabolic demands with the biomechanical stresses on the
muscles and low back region.
Along this line Yates et al. (1990) recently measured changes in blood
lactate that occurred during a progressive lifting task using various weights
and lifting frequencies. These data showed that lifting a light weight (7 kg.)
from the floor to a table at a high frequency results in higher blood lactate
levels than lifting a heavy weight (28 kg.) at a lower frequency even though
the total amount of product moved was kept constant. The increased
metabolic demands, as indicated by blood lactate levels, was partially a
function of moving the body of the worker. Thus high lifting frequencies
impose additional stress to the worker when they require him/her to raise
and lower their center of gravity. Interestingly, these authors did show that
a lifting frequency of 12 lifts/min was more efficient than 6 or 24 lifts/min.
This lifting frequency may be a compromise between the muscular demands
of 6 lifts/min with a heavy weight versus the metabolic demands of 24
lifts/min with a light weight.
Asfour and his colleagues (1990) reached similar conclusions to those
of Yates et al. (1990) by measuring the endurance time when lifting various
combinations of weight and frequencies. These authors had subjects lift 5,
10, or 15 kg. loads at 8, 12, or 16 lifts/min. They concluded that lifting
frequency had a more pronounced effect on endurance than did the weight

11

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4\Ugust 15, 1990

of the load. Thus, these data also support the need to find a compromise
between frequency and weight of the lift. Genaidy et al. (1990) had subjects
work at 3 and 6 lifts/min but allowed them to adjust their work and rest
periods. Despite working less total time when lifting at 6 times/min, the
subjects handling 1.8 times more load than when lifting at 3 times/min.
Therefore it is possible to. maintain high productivity with high frequency
lifting if sufficient rest is_ allowed.
A number. of investigations have determined the relationship between
work load and oxygen uptake during lifting. When work loads are matched
between cycling and lifting activities, 02 uptake is always higher during
lifting activities than during cycling, but VO2 max is almost always lower for
lifting than for cycling (Petrofsky and Lind, 1978a). Williams and colleagues
(1982) did report that when a group of females lifted using the squat
technique, 02 uptake for heavy loads was equal to VO2 max on the cycle
ergometer. Petrofsky and Lind (1978a) also reported that the VO2 max
achieved during a lifting task was directly related to the weight being lifted.
As the weight of lift increases, so does the VO2 max. Heart rate and minute
ventilation (VE) follow a pattern similar to that for 02 uptake. At the same
submaximal work loads, HR and VE are lower during cycle ergometry than
during lifting. As the weight of the lift increases, so does the peak HR and
VE. However, the values achieved during lifting do not reach the highest
values seen while riding the cycle ergometer.
In an attempt to evaluate time standards set for industrial tasks,

12

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August 15, 1990

Aquilano (1968) had male subjects lift cartons of 10 and 25 pounds from the
floor to waist, floor to head height, and waist to head height. Depending
upon the height of the lift, lifting frequencies ranged from 4 to 26/min. As
the subjects increased the lifting frequency for a given weight, 02
consumption increased in a linear fashion. However, the slope of the
increase varied depending upon the weight being lifted and the location of
the lift. For a given increase in work performed, the increase in energy
expenditure was less for the heavier weight. This finding was related to the
lesser change in frequency necessary for the heavier weight in order to
result in the same absolute increase in work load. Data of Mital, Asfour and
Ayoub (1982) support this principle.
Genaidy and Asfour (1989) measured the endurance times for a group
of 11 young males during a lifting task. The subjects were asked to lift boxes
weighing 5, 10, 15, and 20 kg from the floor to a table at frequencies of 4,
6, 8, and 10/min. Subjects continued lifting using the squat method (up to
8 hrs) until they were unable to continue due to fatigue. The average
endurance time for a lift of 5 kg at a frequency of 4/min was 471 minutes
(7.85 hrs). However, subjects were able to continue for only 27 minutes
. when lifting 20 kg at 10/min. Endurance times were 400 and 132 minutes
for a load of 15 kg at 4 and 8 lifts/min, respectively. These data are not in
agreement with those published by Mital (1984). Using the psychophysical
method Mital reported that subjects were willing to lift 15.42 and 14.99 kg
for 8 hours at 4 and 8/min, respectively. However, subjects in Mital's study
used the free style technique while the squat method of lifting was used by

13

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f\ugust 15, 1990

Genaidy and Asfour. This difference could account for some of the
differences between the two studies. Legg and Pateman (1984) reported
that eight soldiers were able to lift 22.4 kg, 12 times/min for 54 min before
becoming exhausted. Furthermore, these same subjects lifted 44.8 kg at a
· rate of 4/min for one hour and estimated they could have lifted that load for
a total of 104 minutes.
Khalil et al. (1985) used a progressive resistartce lifting test to
estimate VO2 max for different combinations of weight, frequency and
height of lift. The authors then used 33% of the predicted VO2 max to
recommend the lift load for combinations of frequency and lift height;
however, the exact method used to arrive at these values is unclear. These
data suggested that no lifting work should be performed at frequencies
above 10/min for any height of lift. These data are not supported by others.
Garg and Herrin (1979) found that a weight of approximately 7 kg resulted
in a metabolic expenditure of 5.2 Kcal/min when lifted 11 times/min from
the floor to knuckle height. Mital (1984) reported a 02 uptake of .92
liters/min (4.6 Kcal/min) when subjects lifted a weight of 11.3 kg from
knuckle to shoulder height at 12/min. Samanta and Chatterjee (1981)
published data showing a metabolic rate of 4.89 Kcal/min when lifting a 9 kg
load a vertical distance of .66 meters at 12 times/min.
It is unclear why such dramatic differences exist between the data of
Khalil et al. (1985) and those of others. However, it is reasonable to assume
that some errors result when VO2 max is estimated from submaximal work
loads which is what was done by Khalil et al. (1985). When performing this

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calculation it is assumed that the relationship between HR and work load
and HR and 02 uptake are linear. This relationship is under dispute as was
discussed earlier.
Jorgensen and Poulsen (1974) tested four males and four females
while lifting loads of 10, 25, 50, and 75% of maximum single lifting capacity.
Each of these loads was lifted for 20 min at frequencies ranging from 2 to
12 L/min while HR and 02 uptake were measured. They reported that, on
the average, the maximum lifting capacity of females was 70% of that of
males. This work also suggested that during repetitive lifting, capability was
determined by maximum aerobic capacity in addition to back strength.
Doolittle (1989) supports the impact of aerobic capacity on repetitive lifting.
He contends that many frequency-mass combinations, as determined from
the NIOSH guide, will result in metabolic rates which exceed a lifting
capacity based on 33% of maximum aerobic capacity. Thus, even with sound
ergonomic design, some aerobic testing of subjects is in order if an attempt
to remain below 33% of maximum capacity is made for all individuals.
The frequency and weight of the lift directly effects the metabolic rate
of the task, however, it also has an impact on local muscle fatigue. As
frequency increases, the rest interval decreases. The rest period needed to
recovery from a static holding task increases as an exponential function of
the intensity of the holding task (Rohmert, 1960). Therefore, as the weight
and frequency of the lift increase, so does the local muscle fatigue. The
weight increases the intensity of the task while the increase in frequency
results in a shorter recovery time. Both of these factors will result in

15

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August 15, 1990

greater local fatigue and could therefore have an impact on short term or
long term performance.

3.4 Lifting'Versus Lowering

An eccentric movement (or negative work) occurs when muscle
length increases while contracting. The metabolic requirements of negative
work are much less than those for doing an equivalent amount of positive
work. When a job requires the lowering of an object, negative work is being
done. Thus, the capacity of an individual to lower objects differs from the
capacity to lift objects. This is true for force generation as well as from a
metabolic standpoint. Many industrial tasks are combinations of negative
work and positive work. A task that involves both forms of work is less
physiologically demanding than one requiring positive work only. Failure to
account for this factor may play a role in the discrepancies that occur
between the AL or MPL recommended by the NIOSH Guide (1981) and
actual performance seen in industcy. It has recently been suggested that the
maximum acceptable weight for a combination task is limited by the lowest
acceptable weight of any of the components (Ciriello et al., 1990).
Petrofsky and Lind (1978a) measured the effect of lifting and lowering
loads on metabolic rate when lifting and lowering from 6 to 60 cm. For light
weight boxes and low work loads, the difference between the two tasks is
minimum. However, at a work load of approximately 500 kgm/min (a high
work load), lifting requires over 75% more energy expenditure than does

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•August 15, 1 990
lowering. Investigations ·using the psychophysical methodology showed that
subjects are willing to lower more weight than they will lift (Ciriello and
Snook, 1983; Mital et al., 1982). Despite this difference, negative work
(lowering) results in an 02 consumption of approximately 15% less than
that of positive (lifting) work (Ciriello and Snook, 1983; Ciriello et al.,
1990).

3.5 Special Lifting Situations
A limited amount of physiological data are available for special lifting
situations. These are discussed below.

3.5.1 Sittin" - Yates and Karwowski (1987) measured the physiological
demands of lifting from a sitting posture and compared them to standing
lifts. Eight males subjects used the psychophysical method to chose MAWL
while lifting at rate of 1 and 4/min. Subjects lifted significantly less weight
(8% to 25%) during sitting positions than during standing lifts. HR during
sitting lifts was less than 88 b/min while 02 consumption was always less
than 1 7% of V02 max.

3.5.2 Asymmetrical - If the psychophysical method is used to determine the
MAWL during an asymmetrical lift, the resulting load will be less than that
acceptable during a sagittal plane lift (Garg and Banaag, 1988; Mital and
Fard, 1986; and Yates and Karwowski, 1987). Even though the MAWL is less

17

�.August 15, 1990

18

during asymmetrical lifts, 02 consumption does not change when the
results are compared to symmetrical lifts (Mital and Fard, 1986; Yates and
Karwowski, 1987).

3.5.3 Special Postures - Morrissey (1987) reviewed the effect of task posture
on the physiological demands of lifting. Walking in a stooped posture (such
as would occur in a medium or low seam coal mine) will increase 02
consumption. Walking at a height of 60% of normal almost doubles 02
requirements. When shovelling at a fI.Xed rate, working in the kneeling
posture will increase 02 uptake over that which occurs while in normal
posture. Gallagher and associates (1988) showed that lifting in the kneeling
posture is more demanding that lifting in the stooped posture in terms of
HR and 02 uptake.

4. Relationship Between Psychophysically Acceptable Weights and the
Metabolic Cost of Lifting

Determining the maximum acceptable weight during repetitive lifting
is a complex task affected by many different factors. In attempting to solve
this problem, investigators have taken a number of different approaches.
The first approach, which was discussed above, involved determining the
relationship between work rate and 02 consumption and finding which

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;.ugust

19

15, 1990

loads resulted in fatigue of the subjects. The occurrence of fatigue was
judged by a variety of methods. The second approach involves letting the
subject choose the weight which he feels is acceptable to lift given the
requirements of frequency and height of lift (psychophysical method). Many
investigators have used the psychophysical method to determine acceptable
lifting loads and then measured the resulting metabolic rate.
Garg and Saxena (1979) compared the physiological fatigue criterion
of 5 Kcal/min with psychophysical fatigue criteria. These authors reported
that physiological fatigue criteria resulted in more liberal standards of work
load at low frequencies of lift while the psychophysical method resulted in
higher standards at high frequencies of lift. This conclusion is supported by
others (Asfour et al., 1985; Fernandez and Ayoub, 1988; Karwowski and
Yates, 1986). Based on these data, numerous investigators have concluded
that the psychophysical methodology is invalid for high· frequencies of lift
(Asfour et al, 1985; Ciriello and Snook, 1983; Ciriello et al, 1990; Fernandez
and Ayoub, 1988; Karwowski and Yates, 1986).

5. Oxygen Consumption Prediction Models

Garg, Chaffin and Herrin (1978) published an extensive prediction
model based on the measurement of metabolic rate during 28 manual
materials handling tasks. A basic assumption of the model was that the job
could be divided into simple tasks and that the metabolic expendifure of

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11

August 15, 1 990

complex jobs could be predicted by summing the energy demands of the
simple tasks. ·In validating the model, a total of 48 comparisons were made
between measured and predicted metabolic expenditure rates. The model
validation showed a correlation coefficient of .95 between the predicted and
measured metabolic rates and a coefficient of variation of 10.2 percent.
However, the absolute difference between the predicted and the measured
metabolic expenditure rates ranged from .2 to 33% (mean absolute
difference = 8.6%). The model over predicted energy expenditure in 34 of
the 48 cases and under predicted for the remaining 14 cases.
Ayoub et al. (1980) points out t:1?-at this model and others prior to 1980
(Aberg et al., 1968; Qhaffin, 1967; Frederik, 1959), were valid for lifts in the
sagittal plane but did not take into account the effect of task variables such
as frequency of lift and box size. In addition, authors of the models
mentioned above failed· to train their subjects. Genaidy et al. (1985) pointed
another weakness of the Garg et al. model. These authors found that the
separate tasks were not additive. For example, the metabolic cost of lifting
from the floor to shoulder height does not equal the sum of lifting from the
floor to knuckle height plus the cost of lifting from knuckle height to
shoulder height. Therefore, a basic assumption of the model is invalid and
probably contributes to the errors involved in prediction of energy
expenditure. Nevertheless, these models do allow the investigator to divide
a job into various tasks which can show which component requires the
highest energy expenditure. This capability can be useful in job redesign.
Mital (1985), Mital and Shell (1984), and Mital et al. (1984)

20

�.August 15, 1990
developed models to predict energy expenditure over extended work
periods using the psychophysical method to determine the acceptable
weight. A low correlation was obtained between task variables and oxygen
· .. consumption and therefore may limit the application of these data.
Energy prediction models can provide valuable information to an
informed user. However, often the user is unaware of the assumptions and
limitations of the model, hence misapplication of the data can occur.
Therefore these models should be used with caution and the scope of their
application should be limited.

6. Determination of Work Capacity Limits Based on Aerobic Work Capacities

To establish guidelines for frequent lifting tasks based on physiological
data, it necessary to find some value of oxygen consumption which should
not be exceeded for the work period involved (1 hr, 2 hr, 8 hr, etc.).
Astrand and Rodahl (1970) reported that well-trained men could perform
up to 50% of their cycle ergometer maximum oxygen consumption (VO2
max) for an 8-h workday but they were fatigued. Untrained workers could
work at 50% of VO2 max for 1 hour and at 25% of VO2 max for 8 hours.
Initially, these criterion were applied to other types of work, however, more
recent evidence shows that VO2 max is task specific. Hence, the VO2 max
for lifting is different from VO2 max for walking on a treadmill or riding a
cycle ergometer.

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.August 15, 1990

Petrofsky and Lind (1978) addressed this issue by using a progressive
resistance test to measure 02 consumption on a cycle ergometer and a
staged lifting task using boxes of different weights (.91, 6.82, 22.73, and
36.36 kg) at increasing frequencies. The subjects used the free style
method to lift from a height of 6 cm to 60 cm ( 24 inches). 02 consumption
was linearly related to work load for boxes of all weights; however, the
slopes of the relationships• were dramatically different. For the two lightest
boxes, the limiting factor reported by the subjects was their inability to raise
and lower the trunk, head, and box at a faster rate. With the heaviest box,
the limiting factor was reported to be fatigue in the arms or hands. VO2
max was highest for the cycle ergometer and progressively decreased as the
weight of the lift decreased. HR followed a pattern similar to 02
consumption. When the same amount of work was performed lifting boxes
as when riding the cycle ergometer.L 02 consumption was significantly
greater for lifting boxes than for riding the cycle ergometer. A follow-up
study found that 50% of VO2 max for each specific box weight could be
maintained for 4 hour periods; however, clear evidence of fatigue was found
(Petrofsky and Lind, 1978b). Blood lactate showed little increase up to 40%
of VO2 max but increased dramatically when 02 levels increased above 1.0
liter/min.

These data are in agreement with those of Astrand (1967).

Williams Petrofsky and Lind (1982) reported slightly different results
on seven female students. Measured VO2 max values for treadm�ll. cycle
ergometer and for lifting boxes of 15.9 and 22.7 kg were not significantly

22

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August 15, 1990

different. The differing results were ascribed to the fact that the women in
this study preferred to use the squat method of lift while the men used the
stoop method. Since the squat method of lifting involves the use of the legs
and therefore requires more energy expenditure, the women achieved VO2
max values for box lifting. Both methods of lifting resulted in a linear
relationship between work load and 02 consumption. Based on loss of grip
endurance following the lifting tasks, the authors recommended 30% of
VO2 max be used to set lifting standards.
Legg and Pateman (1984) took a different approach in an attempt to
answer this question. These investigators had 11 soldiers lift loads
corresponding to 25, 50, and 75% (22 .4, 44.8 and 67.2 kg) of maximum
lifting capacity from the floor to 40% of their height. Lifting rates varied
from 2 to 12/min. Subjects were asked to lift for l hour or until exhausted.
If the subjects were able to complete the 1 hour period, they estimated how
long they could have continued at the same lifting rate. Lifting times were
as short as 30 minutes when lifting 75% of maximum lifting capacity (MLC)
at a rate of 4 /min and were estimated as long as 158 min when lifting 25%
of MLC at 8 lifts/min. Based on these data the authors recommended that
lifting activities should not exceed 23% of treadmill VO2 max.
Based on a studies of industrial lifting, Rodgers (1976) supported a
value of 33% of either whole body or upper body capacity. Rodgers suggests
that this level of 02 consumption will involve integration of factors such as
biomechanical aspects of the materials to be handled, environmental

23

�• August 15, 1990

conditions of the work place, individual fitness and skill levels, and static
components of the job. The 33% ofVO2 max (treadmill) value was chosen
as the upper limit of oxygen consumption by the first edition of the NIOSH
Work Practices Guide for Manual Lifting and, therefore, has received
widespread application. Based on an assumed aerobic capacity of 3.0 liters
O2/min for an average, young man, this puts the upper limit of 02
consumption at 1.0 liter O2/min for sustained manual materials handling.
One liter of O2/min is equivalent to 5 Kcal/min. These values are often
quoted when determining maximum work capacity for lifting situations.
However, as discussed above, VO2 max is job specific. Therefore, one must
be cautious when using the 1.0 liter O2/min for all types of jobs. In addition,
average VO2 max for young females is closer to 2.0 I/min, therefore an
upper working limit of 1.0 liters O2/min is closer to 50% of VO2 max for
females. Another factor which cannot be ignored is the decline inVO2 max
that naturally occurs with increasing age. As workers age, their maximum
work capacity decreases, hence the work load which results in a percentage
ofVO2 max also decreases. Jobs involving leg work have higher maximum
work capacities than jobs involving arm work. Therefore, 33% of treadmill
or cycle ergometer VO2 max may exceed the capacity of the worker when
performing a job consisting primarily of arm work.
Many of the studies discussed above measured physiological
parameters such as muscular endurance and blood lactate to determine if

24

�.August 15, 1990
the work loads were of sufficient intensity to result in fatigue. The purpose
of making these measurements was to set a work load, as a percentage of
VO2 max, which would not cause undue fatigue and, thereby, increase the
incidence of injuries. Other studies have taken a different approach.
Numerous investigators have used the psychophysical method to decide the
maximum acceptable weight of lift (MAWL} and have then measured the
resulting 02 consumption. By using this method the investigators are
assuming that the psychophysical method is a valid way of setting lifting
limits and that these values will be reflected by the 02 consumption.
Ciriello and Snook (1983} reported that subjects were willing to handle 22
kg when lifting from the floor to knuckle height at a rate of 12/min. . This
lifting frequency resulted in an 02 consumption of 1.46 liters O2/min.
When the lifting frequency was reduced to 9 or 6 lifts/min, 02 consumption
decreased to 1.11 and 0.93 liters O2/min, respectively. The 02
consumption resulting from the two highest frequencies is higher than that
recommended as the upper limit by the previous NIOSH guideline of 1.0
liters 02/min. Garg and Saxena (1979) reported much different MAWLs for
frequencies of 9 and 12 lifts/min of 0.97 and 1.11 liters O2/min,
respectively.
The differences between the results of Ciriello and Snook (1983} and
Garg and Saxena (1979} may be due to the inability of people using the
psychophysical method to accurately predict lifting capacity at high lifting
frequencies. Numerous authors have come to the conclusion that the

25

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26

. ,.August 15, 1990

psychophysical method over estimates work capacity at high lifting
frequencies (Ciriello and Snook, 1983; Karwowski and Ayoub, 1984;
Fernandez and Ayoub, 1987; Karwowski and Yates, 1984; 1986; Mital,
1984a; 1984b; 1987). Karwowski and Yates (1984; 1986) showed that
female subjects are unwilling to lift the psychophysically chosen weight at
frequencies above 6 / min over a period of 4 hours if given the chance to
change it. At the end of the 4-hour period, subjects had decreased the
weight of the lift by 23% from their MAWL, predicted at a lifting rate of 8 or
12 lifts/min. These data lead to the suggestion of 25% of treadmill VO2 max
as the upper limit for 02 consumption when lifting for a 4-hour period.
Mital (1984) has suggested that 28% of MAWL can be maintained for an 8
eight-hour work period.
In summarizing the data concerning the limits of work capacity, it
becomes clear that jobs requiring 50% of treadmill or �ycle ergometer VO2
max will exceed the capability of most workers. Values in the range of 40%
of the job specific VO2 max may be tolerated by some workers, however,
most data now suggests that the range should between 25 and 30% of
treadmill or cycle ergometer VO2 max.

6.Summary

When reviewing the literature dealing with high frequency lifting it

��

.. . August 1 5, 1 990

becomes clear that the volume of data is large and growing quickly. It is the
opinion of these authors that much of this data is misinterpreted and
misapplied, hence leading to problems in it's application. While black and
white statements can rarely hold up under severe attack, we believe the
following statements concerning high frequency lifting to generally be true.

1. The relationship between work load and oxygen uptake is linear in
some situations but non-linear in others.
2. Lifting from the floor to a given height is more metabolically expensive
than lifting from a table to a given height. The added metabolic cost
comes from raising and lowering the center of gravity of the body.
3. The freestyle forn1 of lifting is less metabolically expensive than the
squat or stoop lift.
4. If the total amount of work is held constant, it is oxygen consumption
is higher when the lifting frequency is high and the weight is low as
compared to a low frequency and a high weight. Some compromise
between the two variables may be the most efficient in terms of
oxygen consumption.
5. Lifting a weight requires more oxygen than lowering a weight.
6.

Lifting limits determined using the psychophysical methodology are
probably too high when used for frequencies above 4 to 6 lifts/min.
For lifting frequencies above 4 lifts/min, limits should usually be based
on physiological methods.

7. Work capacity limits based on energy expenditure should probably not

27

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.. ,, August 1 5, 1 990

exceed 25 to 30% of the job specific maximum oxygen uptake for an 8
hour shift.

Acknowledgments

The authors would like to thank Arun Garg for his review of this
manuscript prior to submission for publication. This work was supported in
part by Contract#?????????? from the National Institute for Occupational
Safety and Health.

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0

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. ·•

11

August 15, I 990
for manual materials handling jobs. American Industrial Hygiene Association
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31

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32
-'··

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�,1 •

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34

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�The effect of wrist position on grip strength
Mao-Jiun J. Wang
Department cf Industrial Engineering
National Tsin Hua University, Hsin Chu, Taiwan, ROC
1

i

Suz.;:\nnf.:1 H. Rodg(;?l'"t:S
Consultant in Ergonomics
169 Huntington Hills, Rochester, N.Y., 14622, USA
Awkward wrist position can be induced

by

the use cf hand tools. It has been reported that
grasping force exertion in extreme

wrist

trauma disorders.The purpose cf this study is to
evaluate

how wrist position changes can

affect

grip strength performance.
Thi F"ty

mii:\le,.;;

p,articipated

the

experiment. The experiment design included
positions
ulnii:\r
deivia\ticin)

!•

and

(1rwist

li·Jl'"iSt

f 1 en-, .ic,n �•

and

devi.;ition !'
thr�e

fou�

levels

within

position. The wrist position was controlled
a goniometer. The
strength

was

subject's dominant hand

measured by a

hand

each
by
grip

dynamometer.

Results indicated significant reduction on

grip

strength

from

was

found when

wrist

deviated

neutral position fer all the four positions •
.1.. Intrc.1d1.1c:tic:)n
Grip
force

strength

is defined as the maximum

momentary

exerted en a hand dynamometer. The force is

squeeze

generated

by

�isometric

contraction

of hand and forearm

muscles.

The

first

reported use cf hand grip as a test for determining strength

was

early in 1880 by Sargent. Since that time, g(ip strength has been
used

as

routine

disability

and

Further,

grip

design

I

of

the

examination

of

rehabilition evaluation ,and
strength

hand

maximize

neurologic

�
l.'r

ratio

hand

also an important

tools. An efficient

·hand

patients,
skill

test.

parameter
tool

of tool force output to

hand

in

design

hand

the

should

force

input

(Tichauer and Gage, 1977).
In the literature, many factors have been reported to have an
effect

on

grip strength. For handedness, among 231

male

steel

workers, the main grip strength was found to be 5.8 perc-nt
the

major hand predominating (Toews, 1964). As per

and

height, a multiple regression n�del on 57 college wo�en
G � 6

calculated:
was

0.58 H

+

body

correlation
and

height

(H)

and

body

weight

coefficient (r) was 0.32.

age

weight

0.19 W; the dependent va�iable

the major hand grip strength, and the independent

were

sex

+

body

with

(W).

The
and

(G)

variables
reported

(Lunde, et al. 1972).

effect, a study with 1,128 males

was

80

For

females

concluded that grip strength was directly proportional to age

up

to 32 years and then inversely proportional there after ( Schmidt
and

Toews,

1970). Also, the mean grip strength

for

males

was

significantly higher than females.
In
such

addition to the individual factors, some
as

handle

significant
indicated

task

spacing and gloves were also found

effect on grip strength. For span

variables
tc

spacing,

that maximum grip strength is exerted when

have

a

studies

separtaion

�between the grip span is between 2
1982).
grip
et

II

to 2.5

II

(Hertzberg, 1955

With respect to gloves, significant

and

reduction

strength has been reported (Riley, et al., 1985, and
/

.,,\1. ,

gloves

1987). The l�vel of reduction depends on
worn. · All these findings are useful for

the

on

Wang,

type

of

evaluating

the

dei;;;ign of hand tc)c.1lr"' ,t\nd its rf.�lated jGbs.
A

poorly designed hand tool may cau-e abnormal

position

wrist which may increase the risk of wrist injuries (e.g.
tunnel

syndrome, and tenosynovitis). It has been

on

carpal

reported

that

excessive application of hand .force�in a pecular position with
repetitive manner are the main stress components to wrist
Tichauer

and

Gage,

1977). The position

of

the

a

trauma

wrist

can

directly influence gripping ability of the fingers. The objective
of

this

study

is to evaluate how wrist

position

changes

can

affect grip strength.
2. Experimentation
Thirty
handed.
positions

male subjects whose ages range from 20 to

The

experiment

which were:
1··.,1 •.e&gt;_
� , •.

deviation

30

r;l

design included

(1) .Neutral 0

.;011 .·..:,_5,_·0,

ui.::._J.
v � �"1__ ...

o

,

years

different

wrist

,(2) Radial deviation

IJ'Jr�·,
. .• 1&lt;::, r d"''V.;"'
,.:
·•·&lt;=• ti·on

(L')
·1·

(6) Fle&gt;d.c.m ,..,. •.,_:i

nine

30

.
,:_•o
\
r-.
'7)
-1 f:l:-:.1.rJn oO ,

1 ,.Jr._Cj ,

w1··ist
trials.

The maximum one of the two was ta�en as the performance for
v-Jith ·:;;pan dist,ance se�t o:\t 5 • .1. (:m ( 2 ").

hand

,

E:-:t.ension

(f.3)

position with at least two minute rest scheduled between
Tha grip strength was measured by a

)

Ulnar-

( �5)

,i,::·O
�J
, ancI (9) Extension 60'.). Two trials were taken fclr· each

position.

C:
,.__
1!"\

each

dynamometer

�The

wrist position was controlled by a goniometer which

1n Figure 1. The angle was marked on a semi-circular
can

which

frame

be turned to
.(

either

is

wood

horizontal

position. A steel rectangular ring with a slotted plate encircled
the

frame. The ring can be moved along the frame to be

various

set

angle positions. A steel rod welded on a plate was

for sewn

on a adjustable open fingers glove (Figure 1).
Tc measure grip strength under certain poosition, the
ring was first moved to the specified position. Then the
who

was in a sitting position was asked to wear the

steel
subject

glove.

steel rod was inserted in the slot cf the steel ring on the
Once
dynamometer

the

wrist position was

The
wood

carefully- set,

was placed in the subject·s hand. In the mean

timG! ,,

break was scheduled after each trial and the subject's wri�t
allowed in a neutral position. After finishing two

was

replications,

goniometer was then adjusted for the next position.

" • 1

HJ. ,L

grip measurements were taken in a random sequence.
2.1 Ulnar and radial deviation
Ulnar

deviation is movement of the hand towards the

finger side, and
thumb

radial deviation is movement of the hand toward

side. For grip strength measurement under ulnar or

elev i,,,1.ticn,

the

lit.tlE,�

semi-circular wood frame of the

radial

goniometer

position. The subject was seated and

&lt;=\dj U�::-tE•id

was
hr:1d

the hand dynamometer with his dominant hand. The forearm was laid
D!"l

the

table

and was properly aligned

in

position

with

the

adjustable wood track. The subject was then instructed to exert a

�maximum force. See Figure 2.
2.2 Wrist flexicn and deviation
Wrist
between

flexicn

adjacent

iJ movement of the hand w�ereby

bones

is decreased, and

wrist

the

angles

deviation

•i

r00

..t..:.":1-

movement of the hand whereby the angles between adjacent bones is
inc: r·E;i.;;\ Sf?d

For

•

grip

strength

measurement

under

flexion

or·

the semi-circular frame of the goniometer was set
v&lt;;?r·t.i.c,a 1

pc.is.i.tion.

Again, the subject was seated

grasping

the

hand dynamometer with his dominant ��nd. The forearm was laid
the

table

and

was

properly

adjusted

in

position

with

in
on
the

f.:\djus;t,-abl&lt;?. woc:ic:I t1··ack. Thf? isub.:i€�ct was then instructed to e:{ert a
maximum force. See figure 3.

A one-way analysis of variance CANOVA) was computed fdr
of

four positions ( wr+st flexion; wrist

the

deviation
range

and radial deviation). In addition,

ulna1··

extension,
Tukey's

test was applied to evaluate the significant

each

multLple

differences.

Table 1 shows the results of ANOVAs for the four positions.As was
expected,

wrist

positions.
reduction

Figure

position
4

was

a

significant

to 7 presents the

mean

factor
and

cf mean grip strength within each wrist

the

for

all

percent

position

for

all the four positions. The results in general indicated that the
more wrist deviation from neutral position, the larger

reduction

on maximum grip strength •
. Table

2

summarizes the results of the

results

of

Tukey's

�multiple

range test. The result cf pair comparisons
the

statistically
30

°

differences (ulnar

15

°

..... .... ......

and

significant. The line between ulnar 15

th,::,t

shew
..::.•...!

°

and

ulnar

indicates that ther� is no significant reduction on mean grip

strength

when wrist deviated from 15

°

to 30

°

in ulnar

position.

The lack of significant differences may be explained by the

fact

that

'-�() CJ

the

limit

maximum

for ulnar

deviation

:.i.. S::-

ei 1--··cJLtn cl

Perhaps, a significant reduction can be found when the
ii;;; c 1 ose

•I• ,..

•... •...)

•• 1... r•,

C, le:.:

J••••,.1,1�.
w •• i••
...

1' /I {") 0 ',

, .,.,..

;

ti

deviation

•t

.; ••• ,.• . .:so.,C.
r•, ., •!
.,.I,:::,

4. Discussion and Conclusion
The

ANDVA

results

indicated

that

wrist

position

significant effect en maximum gripping abilities of the

fingers.

The significant reduction en maximum isometric grip strength

can

be explained by Gordon's force-length curve (Gorden et al.,1966).
When wrist deviates from neutral position, the muscle sacromeres'
the forearm shortens which causes a
therefore, less force is

drop

of

muscle

exerted.

disadvantages, some cumulative wrist disorders can be induced

by

performing job in a pecular wrist position. Armstrong and Chaffin
that
membranes

median nerve in

surrounding

thE!

tunne1
e;-;t.r".ini:::. .i.c::

tendons can be compressed when app1ying grip fcirce with the wrist
f1exed

or extended. Pro1onged irritation of the median nerve

is

ccinductive to carpal tunnel problem . Furthermore, strong
and

ulnar deviation may produce high incidence of tennis
tEinci·,;,;ynovi ti�::-

deviation

of

wrist

elbows

(Tichauer and Gage, 1977).
in occupational envir�iment

can

not

only

�impair

productivity

but also stress tissues in hand

and

wrist

severly.
Awkward

wrist positdons can very often be induced by the

use

I

of hand tools. A poorly designed hand tool (e.g. plier) can cau=e
ulnar deviation of the wrist. Force exertion in an extreme
position

�an aggregrate the incidence of wrist trauma

carpal

(e.g.

is

tunnel syndrome). Therefore, it

wrist

disorders

necessary

design a hand tool so that the handle can permit the wrist to
kept

straight

offseting

tool

during force exertion. Simple
can often

handle

modification

the

reduce

wrist

be

like

deviation

problem.
factor

Another
workplace
layout

layout.

of

that

can cause poor

wrist

The height of the workbench

workpiece,

and the pos�ticn

of

posture

the

and

chair,

the

tools

Lctil

machine

directly affect operator's working posture and wrist position. In
general,
the

solutions like changing work surface height or

worksurface ( or workpiece) towards the operator

tilting

can

often

help. One fundmental approach to evaluate the poor wrist position
biomechanical

job

analysis. The job can be analyzed element by element through

the

problem

in

application

the

workplace is to

conduct

a

of video recording technique. Element involved

with

poor wrist posture can be improved by changing work methods,
hand

tool and workplace design. Wherefore,

and productivity can be promoted.

occupational

and

safety

�Table 1. Results of ANOVA for the Four Wrist Positions
d.f.

Source

Mean squares

F

Ft? !I g·7 , n.n�l
Significant
"

----------------------�----------------------------------------w,�ist pr.&gt;sition
( E:-:tEmsir.m)
Er ,,. c:l ,,. �s
Total

l-'-Jr·i:;t pc:!sition
(Fle&gt;:icJn)
E1··rc:Jr1::;
Total

2

\.

J-

.1

..

._

.,

1506. •:ii

:l.24. 07

87
E!9

18 .. 6
6241..7

2
Wrist position
(Ulnar deviation)

::::; u

Yes

.1.:::::

E r-· i--· o 1·· r,;

Ti::it,m.l

Wrist position
2
(Radial deviation)
Errors
87
Total
89

:375. 4.

:3: 13
n

24. �3

Table 2. Results of Tukey's Multiple Range Test
!&gt;Jd.st po:;ition
Flt':!&gt;:ion

Angles (

C

)

0

45

60

0

45

60

UlrH::i.r- di;,�viation

0

• r.:·
.L .:i

�)()

Radial deviation

0

1. 5

25

�Figure 1. The goniometer.
Figure 2. Grip strengt� measurement under ulnar deviation.
Fiqure

Grip strength measurement under wrist extension.

Fiqure 4. Mean and percent reduction of grip strength
under wrist extension.
Figure 5. Mean and percent reduction of grip strength
under wrist flexion.
Figure 6. Mean and percent reduction of grip strength
under ulnar deviation.
Fiqure 7. Mean and percent reduction of grip strength
under radial deviation.

�(.:1 ,.... rn 1:s t.r.. C) n
f.:\ '.:::• p •::? C t �;;

F;: 1?. t '"'' 1'-E� n c (\:: is
T.
J., and Chaffin, D. B., 1979, Some biomechanical
Bicmechanics,12,
567Cl i' the carpal tunnel. Journal of

1�� ,

. ·t .(
1 r.;1 f:.:, l::z ,
M .. , Hu:-:. 1:,�y 1, Pi .. F., ,:ind ,JulL::-,n, F. J.,
f:3ci1·..·c:ic)r1
f�
li?.nf1th
J.. '.::,
if�OmE,tl''·ic tension with sacromere
\! �1. ,..- i t:':\ t:. :i. C) n
Journal of Physiology, 184,
VE: I''. t !*: b I'.. &lt;i:\ t (:·? mu�;;c 1 i-2 f i bl''.€'21::;.
!'

II

'T'hE�
iri

Hertzberg, H. T .. E .. , 1955, Some contributions of applied physical
anthropology to human engineering. Annals of New York Academy,
&lt;":':\ n c.i
t:3 C.i 1·... c:: i 21 !' :···· " A
t_ t.l r! cf(:;;� !i I-:3
i&lt; !I :B r· &lt;-=: v-..., e: i · , l-·..J " [)
strength of college women. Archives cf Physical
Rehabilitation, 53, 491-493 ..
u

,1

r

ti

,

Riley, M. W., Cochran, D. J., and Sfhanbacher, C ..
capability differences due to gloves, Ergonomics,

II

i1

1. r9 ·7 �2 , t3i--i.p
Medicine and

{1. '

1985 !'

FOl'"C:(:"'

1880, Strength test and the -�=-t i---c; n c;J tn 12 n
Physiological Education Review, .LL:, lOB ..

f::lc.,\1'··/JE,n t :•
H-:::l.i'.. va1'"c!,

Schmidt, R. T .. , and Toews, J. V., 1976, Grip strength as measured
by the Jamar c!ynamcmeter, Archieves cf · Physical Medicine and
Rehabilitation, 51, 321-327.

·r i c: h ,:::i. u. i!:? ;-·· :• �- R., and Gage, H. G ..
b ��·t �:; .i C:
hand tool design.
t. CJ
Association Journal, 38, 622-634.

;I

·J c&gt;•-.
-;.·--·i•
.-• I .-•

,.!.,

!l

Ergonomic principles
Industrial
Hygiene

l C) f:.� V·J s:..:;. ?i i.J
V., 1964, A grip strength study among
hi V('!:11::; 01° Physical Medicine and Rehabilitation,
If

f�ll'"C

Wang, M. J., 1982, A study cf grip strength from static efforts
and anthropometric measurements, Unpublished Masters project,
University of Nebraska-Lincoln.
Wang, M. J.,Bishu, R .. R., and Rodgers, c:�
changes when wearing three types cf
Interface 87, 349-354 ..

....} It

H., 1987, Grip strength

�Figure 1. The goniometer.

�Figure 2. Grip strength measurement under ulnar deviation.

�I�
I
I
I

Figure 3. Grip strength measurement under wrist extension.

�).y;l
c.d,) "
50

43.Z57

37,£,7°�..

.&gt;f/. 710

10

0

-

Figure 4. Mean and percent reduction of grip strength
under wrist extension.

r

�;

"
43.25'}

�f-o'.70

-'b-• 22?

1.0

/D

'

0

60°

Figure 5. Mean and percent reduction of grip strength
under wrist flexion.

�,I'

.(

/1.3.257__

..)C&gt;

I

�8.. 98]

�6.140

"

(0

Figure 6. Mean and percent reduction of grip �trength
under ulnar deviation.

�'
'

.

4j.J5?

:3.7.54?

.

:34.17°
"

,o
0

15 °

Figure 7. Mean and percent reduction of grip strength
under radial deviation.

�</text>
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                  <text>Suzanne Rodgers Collection</text>
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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                  <text>University at Buffalo. University Libraries.</text>
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                <elementText elementTextId="1605343">
                  <text>IN COPYRIGHT - EDUCATIONAL USE PERMITTED &#13;
&#13;
This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                <text>Draft Manuscript: The effect of wrist position on grip strength </text>
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                <text>1989-01-31</text>
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                    <text>1

2-Day Ergonomics Training Course Evaluations,
SBCL Chicago, April 23-24,1997
I. Over-all Evaluation of the Course
1. Very informative and easily demonstrated. I feel confident that I will be able to
go back to my lab and evaluate jobs to help employees' workstations (CRC
Detroit).
2. Excellent (CRC).
3. I enjoyed the course for its content and direct impact on my present working
environment (Cytotechnologist).
4. Excellent!! Organization of course was efficacious (Group Leader- Specimen
Proc/DE).
5. Very informative - lots of information that can be used immediately
(Microbiology Technologist).
6. Very good, valuable information (Processing).
7. Good (QA/Safety St. Louis).
8. Good. Kept my interest for 2 days (16 hours) (Supv, Branch /Lab Operations).
9. Great information and very applicable (Supv, Chemistry).
10. Excellent. Learned how to evaluate problems or complaints and relate these to
how individual is using body to perform job functions (Supv, Client Services).
11. The course was very informative- as to what ergonomics really means, how to
look at situation- what to look for; what to change (Supv, Distribution,
Cleveland).
12. Excellent, especially the in-depth statistical analysis (Supv, Distribution).
13. Good (Not Indicated).

II. Most Useful InFormation
1. Hands-on evaluations (CRC Detroit).
2. SBCL is committed to making employees comfortable. Employees don't have to
live with discomfort. There is a "simply better" way (CRC).
3. Awareness of the need to be sensitive to the employee (associate)
(Cytotechnologist).
4. Methods for analysis of problems. Anecdotes were especially helpful (Group
Leader - Specimen Proc/DE).
.
5. Adjusting positions for optimal comfort in the work environment (Microbiology
Technologist).
6. Analysis of problem solving and resolution (Processing).
7. New ideas (QA/Safety St. Louis).
8. Principles of good ergonomics. Analysis tools (references, etc.) (Supv, Branch
/Lab Operations).
9. Project analysis. Consultant evaluation of specific job (Supv, Chemistry).
10. Value the subjective complaints of the individual with the problem. Learn how
to use the data- statistics - to evaluate
particular problem (Supv, Client
Services).
11. Changing one thing may put everything else off kilter ! Find core problem and
start from there ! (Supv., Distribution, Cleveland).
12. The way the analysis tries to accommodate the median in order to optimize the
best approach to solve a problem (Supv, Distribution).
13. Liked real life examples from work experience. Helped put things in perspective
(Not Indicated).

�2

III. Least Useful Information
1. N/A (CRC Detroit).
2. Very detailed scientific data (CRC).
3. Not least useful, but too many numbers over short period to digest
(Cytotechnologist).
4. I enjoyed it all (Processing).
5. Graphs (Supv, Chemistry).
6. Info related to activities not concerned with (Supv, Client Services).
7. In some cases, possibly too many statistics (Supv, Distribution).
8. Just me, but measurements were dull. I understand importance of
measurements, but actually doing, looking at ranges, etc., dull (Not Indicated).

IV.

Specific Suggestions for Improvement
1. Possibly longer by a day or two so that we could do more case problems (CRC
Detroit).
2. None- unless it could be longer (CRC).
3. Overwhelming amount of information - maybe longer seminar
(Cytotechnologist).
4. Make this a longer and even more informative course (Group Leader- Specimen
Proc/DE)
5. None (Processing).
6. More examples, more time training, evaluating (QA/Safety St. Louis).
7. Well balanced. Good presentation and opportunity for questions and observation
(Supv, Client Services}.
8. More hands-on projects- Continuing education (Supv, Distribution, Cleveland).
9. Maybe give examples put on overheads (Supv, Distribution).

4/25/97 SHR

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
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M~~-----·~~--~~------Subject:_ _ _ _ _ _ _ _ _ _ _ __

Age:

Job:

Height: _ _ _ _ __

------

---------------------------

Department: _ _ _ _ _ _ _,.,..______

Weight: _ _ _ _ _ _ __

Division: _ _ _ _ _ _ _ _ _ _ _ __

Surface Area: _ _ _ _ _ _ __

Reason for T e s t : - - - - - - - - - - - - - - - - - - - - - - - - - - - -

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--------

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Grade

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Men

Women

4.5i(l02)

3.4 (108)

6.0 (114)

4.5 (121)

10%

8.1 (129)

5.8 (141)

15%

10.1 (146)

7.1 (157)

Resting Blood
Pressure: 134/86

"You

114/77

Average Maximum Caloric Expenditure:
Men

14."8

Women

9.4

You

Cardiovascular Fitness Score: (Maximum Oxygen Usa.ge Adjusted for Surface Area and Age).

-Men

Women

1.62

1.20

Your Fitness Percentile:

-You

�Standing Arm Capacity = _____%of Whole Body Capacity (Treadmill)
Your ResEonse to the Job
Average Calories per minute; _ _ _ _ _ __

Peak Calories/minute: _ _ _ _ _ __

Average Heart

Peak Heart Rate:

Rate~_....._

_ _ _ _ __

----------------

%of Capacity used: _ _ _ _ _ _ __

Comments:

For further information please

contact~

Dr.

c.

I. Miller

Ext. 73808

Dr. s. H. Rodgers Ext. 73303

�</text>
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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>DRAFT

Suzanne H. Rodgers, Ph.D.
Consultant in Ergonomics
169 Huntington Hills
Rochester, NY 14622-1121

585-544-3587 phone
585-766-8556 cell
shrodgers@aol.com

Anne McFarland, Safety Program Assistant
Sherman G. Manchester, Safety Coordinator
Ontario County Employee Safety
3019 County Complex Drive
Canandaigua, NY 14424

Proposal for Training Ergonomics Problem Solving Teams for Injury Prevention in
the County of Ontario, NY
Goals: To train 3 teams to be able to identify, analyze, and develop risk reduction

solutions to job and workplace factors that have or may contribute to injuries in
Public Works, Health Care, and Office jobs in Ontario County. The focus will be
on musculoskeletal injuries and illnesses, particularly those of the back,
shoulders, upper extremities, and knees.
To work with the teams to develop short training programs for employee training
in risk factor reduction and problem solving for each area.
To provide the teams with analysis and prioritization forms they can use in
proactive surveys ofjobs where injuries have been seen.
Techniques to Achieve the Goals:

1. Use the Ontario County incident data base for the past 2 years to identify the
types of injuries and incidents in each of the 3 areas, Public Works, Health
Care, and Office Work. This information will be used to identify examples of
problems that will be used in the 2-day training course for each area.
2. Train 3 teams of 6 or more people for 2 days on how to identify, analyze, and
develop solutions for musculoskeletal risk factors on their jobs. See
attachment for an outline of the course content.
3. Provide team members with a survey form to be used by them in training
employees and in doing proactive work.
4. Work with the teams to develop a short injury prevention and ergonomics
awareness problem solving course appropriate to their areas that they can
provide to other employees.
5. Provide the teams with information on how to prioritize risk factors and show

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>VISU·A-L CO N CE.R NS

··.

. at the computer wo~kstati~~-

..·

\

'

:

.

'

'

··.

··.

.... . ,........ ..
:. ~

·'

,.. ____.. __
·.
.·

.-'

·lm·

·•

Inger M. ·Williams: Ph.D.

0

Suzann~ H. ~&lt;.?d~ers! Ph.D.

Consultants iri Ergonomics:

. Inget M. Williams, Ph.D.
$uz~nne H. Rodgers, Ph.D.

28 Shel_ter'Creek Lane • Fairport • NY :14450. • Phone P .16) 3l_l-7i91 '• .Fax (716)266-8749
·: This infOfmation d.oeS not replace y0ut Ofganiz.a.tion's hea'tth a.nd safety policies.
·- 0

.

~

,.

.

. . .. . .
. ..
'otnoer M. Wiliafns, Ph.08tld SuzaMi t:.t. Ac:lcSgtn.Ph.O.
..
.
·.

'

~.

.

. Consult;nts in Ergonomics

• .

�J.

l

'-.

I

I

'\. ._.,

'\.

'\.

-:,

-

1

~

-

. inadequate.contrast,
the display
·

.1

f~cus, and/~r brightness of text on
.

"-

__..,.;;;;;;

J

'-.

.1: _.....-::;

-~

-~

_....,.

~--

Learn how to adj):JSt the dis~lay. En-sure the display is pr6p.er1y maintained

'

Glare and reflections from overhead l_ights, windows,
an_d task lights

Pr9vide overhead lights with louvers. or baffles.: Install, preferably, vertrcalblird.s or coat wirdows with dark f ilm.' Ensure
that task iights:are properly positioned. The computer display should be peq:~endrcular to .overhead flu9rescen.t lights
and ~indows
·
·
'
·
·
·

Glare and.reflections from wails and table tops

Ensure that ·wallpaper has ·~- matte finish. En~ure that tabl-e tops do nofhav·e a gl;ssy fin'ish; 'if they do, cover ..;,ith
!ntrod~ce a11ti-gfare filter:; on the disp-lay
·
·

Glare and reflectioos from clothes'

The display might need an anti-.glare filter or anti-glare

Overhead light'levels too high

~educe overall. light ie:vekto 300-400 l~x (30-40 footcandl~s). T~sk lights, if neede~, s~0uld be ~OO. lux (50 f~ot candle~)

Viewing distance not adjusted properly for individval

'Adjust display an·d work·f!laterial until both are dearly seen .

.

.

pap~r.

coating: Wear darker clothes until-'changes are made

YQ\.Ir_ability to focus at ne~r .viewing distances is impaired
· perhaps·due to natural.change~ in ·vision, with age.

Eye e?&lt;arl)inatiori recommended and a reass~ssment of~uirently· used eye_glasses prescription could.be made.
Cons\Cler.prescriptions for computer work
.
.

Your focusing .ability foF far distances .tempo~arily impaired
· due to long periods ofn~ar work
·
··

Reduce th~ cont iriu.ous lef')gth of t ime you vi~w a display and otrer material at close
does not require near viewjng .
.

'.
· General fatigue

l~troduce physical stretch exercises a~d readjust the eyes b~ looking.into the distance frequently. tntrod_uce a new task
Examination ·of e'ye r:riuscle balance and vergen~e if s~mpt()ms persist .

You might have an ~ye musde balan~e prab~e·m,
problem)

~Iewing di~tan~e~. l~tr~dU&lt;;e a task that ·
.

..

_.

_(vergenc~

,·

.

.

'

White objects can appear pink after p'rolonged viewing' of ·.
a greeri _disP.Iay. Similarly, white objects might appear bluish
·
·
after prol.ong~d viewing of an .a!f~ber display.

These ·perceive_d colo~ ch~ng~s·are normal adaptive proc~sses that occur' automatically within the eye: If you find t~em
botliers_ome, chan·~e~ the polarity of the. screen occasionaily .

..

Infrequent blinking; sustained staring at"th~ display.
·_
s quinting for -l~ng periods o.f time due to poor vi!;ibility of the
display . . · .
· .
. .
0

•

•

. Feelings of dry ·eye$ could.be .caused:by dry air and/or the
use ·of c;ontact lenses
·
High contrast.-.fine detail and/c;&gt;r llibrant colors on nearby
surrowiding pan,els and ~orfaces ·
·
.

Try to reduce long periods of closeJup wor~. Adjust the.image quality of the display: increase contrast, change brightness,
· and adjust text sharpness .
·
.

Eval~ate
. the hu.midity
. in the office..If you are
.. using contact le'nses, ~ye d·~ops. can reduce the symptoms
~

lntrodu~e less pattern~d and colorful material in the immediate vicfnity of the co_IT!P..uteJ display

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&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                    <text>POSTURAL CONCE-RNS
. &lt;;tt t h e .computer WQtkstatioh

..

-

, ·,·.

..

· 0;

.. ,

..

:

·,

·.
Inget M: Williams;Ph:D. • Suzafrne H. Rodgers; Ph.D:
Consultants in E rgohomics
~.

:

.

Inger M . 'wHfiams, Ph.D.
Suzanne H. Rodgers, Ph.D,

.

.-. 28 Shelter Cre.~k Lane • fairport • NY • 14450 • Phone (716) 377''1791 ·· Fax "&lt;716)266-8l49 _
· This information does not ~eplace your .Organizatiqn·~ health_and safety·policies.

·,

..

Consultants in Ergonomics ·_

,

�Chair height is not adjusted properly

Adjust the chair height to fit yo·ur personal needs. In multiple user v.iorkstations and in workstations where you mus.t work at
more than one height, use chairs thatcan. be easilyadjusted, preferably with a pneumatic. adjust mechanism
·.
:

'

•

'

t

I

·

'

~·

Feet not pla~ed flat on the floor .
, · _

'

-

-·.

Chair and/or keyboard heights need to be ·aajust~d and/or footrests shol!ld be available

I

.

Sitting ont~e edge of the chair, therefore riot getting
adequate lowe·r back support
·
. Confined. posture from contoured seat pan

Adjust backrest to SL!pport the small of yourback, Ensure .tha:t the backre.st canbe adjusted both in/ oUt a~d up/down and/or
:. pr?videa separate attachable back support. Evaluate c~air and keyboard heights. Check thigh .clearance-remove obstructions
A

Improper alignment of work mate'rial making you
and/or turn t~e bodyawkwardly

t~ist

. Poor visibility of text on the display ca~sing you to lean
forward, move head forward, and/or squint

sorn~what flat seat pan is recomrrl~nded for- prolonged seated work. Use pillow tO reduce contour .

·· Reposition keyboard, display, and hard copyto help organize work space. Deterrnine optimal placement of work material
according to.task req.uirements : ·
·
··
··
·
·Adjust display ()rightness at:~d contrast. Reduce reflections and glare by reducing overhead light /e~e/s, installing louvers,. placing ·
bJinds on windows, installing anti-glare filters, or reorienting the display relative to overhead lights a~d windows. ProVide
·
individual.task lights if needed , Confirm glasses prescription.
.
.

Awkward head; neck, and sh.oulderl&gt;ostures assumed
due to us~ of bi-· .trifocals
..
.

Adjust display height and viewir1gdistance. Re"assess eye glasses prescription with an optometrist'or.ophtha/mologist

Continu,c)u~ seated work for too long a ti.:Ue ..

Do sOme tasks that alt_ow you to walk avv.ay period[ca/Jy. Also, look away from the dispiay and

or

.

'

.

.·

.

·,

.

·'

··.

d~c.~ments regularly

lr.~trodu~e appropriate· armrests on .c::ha.i·r.
Sp~~ify
ne~ chair.
design Qeeds for f~tuce purchases
:&gt;.
·;;·
_,,.
.
. -:;:.. .
''•

No ·placeto.resn1r~sand/or t)ands .on keyl:loardand/or ~

j

•

works~,Jrface

.

. ..

.

.

.

·..~

while ·usinga . rrn:&gt;d~e

· · · · ·· · · ·

· ·.·

,, , . .

::f,:' .

_,,_ ' '

..:.

··:&lt;· '·

Proyide corhfortable rest space

. .

W~i~ts and/orarm·s restiQg o~~harp~dge whiletYpirig
or

.. .....;;,,

"''

. · Highly repetitive finger activi*y condUcted over iong:
periods of't!rne.
. . . . ..
.
....
Use·of keyboard holder with

hi:&gt; roor:n forn;wus.e.and

'.

--~· -

.

'

•

bY adtu~tirig pla&lt;i~·rD~.ntof work rna:te;!al onthewbrk ~urface''

. 'instal/ soft padded' i'n~teri~l th,at can q)Ver sb;irp, ¢9ges ..;Prqvicte wrist ~uppqtts "ot_approprjate·thic~nyss. Reorient wo.rkstatron .to
provide better: artr;~ stipp(?rt f$5(the: ar!Jl an:d hand that is using the mouse or p.r~vide surta~e ~extensionJor ther~ouse · · · •··• .

·a

' lntrodu~e~orn·e other task that a.'iio~syou .to take an: arm ; :.i'nand,
·~nd•• -•.wris'
t break,'Ev~ldate
the;w .ork/pad
.
•
-.
•
• "j

' · .·

~,

.

.

.- .

-

•

.,~ .

molls~ pad ..cat,~sing ybu to .reach for. moys~ and iean

•

',.

'

''

. ,f ;;· ..

..

.

· place keyboard and, fl10U5e dos~ to15ether, especiaUylfor. frequent mou.se anct keyboard user{ LooK .into the us~ ~f a ·
.· .turbo
(trackhali).mouse
,
· .· . ·
· .· • ·I .· · · . ·
· ·
. ·· . · • · · · · '
· . · ·. .
. . .. .. . .
. . ." .
.
.

·arm. ag(li'r1st sharp edge·
~·· ·~·

Adjust workrhaterial or-iedtation and workhtights. Keep arms,
· · :Remove qrm'rests' ifth~y inte.lfei:~ with good,wor-king. postures

Pressure on the back of thighs

· .: ..

loqk into seat height adjustment Pad seat pan

'

.. ..
;~

,

han~s;and ;_,r,ists app~oxirnately para/1~1 ~o the working sJrfa~e'
·

·

·

· '

•

·

to provide a. contoured front edge, ·

hei~hts. Ch~nge tah/e,

Thighs ~om pressed betweendesk and chair

l.nappropriateworkstation

Inadequate:forward leg clearance at knee arid .footlevel ;

.Inappropriate. workstation design. Adjust articulating keyboard holder, and/ or,.rem6ve material underthe table .

keyboard, and/ or chair he,iglits

·

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                <text>Susanne Rodgers Collection</text>
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                <text>&lt;a href="https://rightsstatements.org/vocab/InC/1.0/"&gt;IN COPYRIGHT&lt;/a&gt;. This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. For other uses you need to obtain permission from the rights-holder(s).  Copyright Estate of Suzanne Rodgers</text>
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                  <text>Suzanne Rodgers Collection</text>
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                  <text>Human engineering</text>
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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                  <text>Rodgers, Suzanne H.</text>
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                <elementText elementTextId="1593149">
                  <text>University at Buffalo. University Libraries.</text>
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                  <text>University at Buffalo. Department of Industrial and Systems Engineering.</text>
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              <elementTextContainer>
                <elementText elementTextId="1605343">
                  <text>IN COPYRIGHT - EDUCATIONAL USE PERMITTED &#13;
&#13;
This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                  <text>Copyright Estate of Suzanne Rodgers</text>
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                <text>Rodgers, Suzanne H.</text>
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                <text>Dr. Rodgers' created several drawings for use in her work.  This is a collage of those drawings.  </text>
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                <text>2018-12-13</text>
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                <text>1 p.</text>
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                <text>Susanne Rodgers Collection</text>
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                <text> IE-001</text>
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                <text>&lt;a href="https://rightsstatements.org/vocab/InC/1.0/"&gt;IN COPYRIGHT&lt;/a&gt;. This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. For other uses you need to obtain permission from the rights-holder(s).  Copyright Estate of Suzanne Rodgers</text>
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                    <text>Dr. Rodgers’ Edits and Feedback on Several
Pages from the Draft Chapter of a Book She
Contributed To

�glucose

blood

FFA

gl,ucose

lactic acid
(anaerobic)

FFA

l

r} ~

f

Glycolysis

rj/c---,

:J!_~J

\

\

~

If oxidation

H20 + C02

---+-r::;2\ _:_~a:_SfJ~-~t-l
;ATP \~ ~p

PvnMo Ao;d

2 ATP*

.

\

mitochondria
(aerobic)

ATP

Contraction

muscle fiber

Figure II-1:
-

(!.)L&gt; "

~ v-r-·

..

X

ADP

icp,j

L, __

Anaerobic and Aerobic Metabolism

~__/ fiA~-W=~~~J
a "~ \

~t~~

C

~4 ... r~ooJUII' I
Tr
&lt;1

The chemical pathways for the metabolism ofAglucose and free
fatty acids are ahQxn_ror work done in ~~~usence (~~~-~obi~-~­
col~sis) or the presence (aerol&gt;rc;:....g:r----ci:tri.c. aci:_~..J?..l..C?..~e) of oxygen
(02 • The upper level represents blood, which supplies_, the glucose,
and free fatty acids (FFA) and removes some lactic acid from
the muscle fiber. The muscle fiber also gets its oxygen from the
blood, shown at the lower margin of the diagram. Inside the
muscle fiber are found mitochondria in which the aerobic, or oxidative, and electron transport reactions take pla
uvic acid
and the free fatty acids form acetyl-coenzyme A
B-oxidation·
this enters the Krebs citric acid crcle to be bro en own 1n o
carbon dioxide (C02) and water (H20). The hydrogen released in
oxidation reactions is trapped by the electron transport system and
passed on eventually to 02 to form more H20. Anaerobic glycolysis
involves the phosphorylation (adding a high-energy phosphate bond)
~~d 1
of glucose to form glucose-6-phosphate (G6P). This form can be
.A·Jtr: '\'C._ b~-. J;~o molecu~~!£ aid by' .~he ~nz_l!!l~ho\_(r_uctokinase JmL oi-" lt can be condensed vltn aaditional G6P
mOiicUiii~to build up glycogen, the storage form of glucose.
Pyruvic acid accumulation in anaerobic work will trigger the
formation of ~actic acid. In the rresence of oxygen, about 20~
cl~
of this is oxldi.zeU,o__~uviQ a...o.id an9 .the rest 1!~v~_rted
~ 4 LC" t~. .n.~l~y_th.!il liY!U:. . .lHarper, 1959). The primary differ~ence between anaerobic and aerobic'li:1'e:taDolism is the amount
~~of ATP formed in each. This is indicated in the middle part of
Jb.A. ~c£- the diagram. The ATP so formed is used 1 in muscular contraction,
~~~.forming ADP (adenosine diphosphate). The creatine phosphate (CP)
~
store supplies a high-energr phosphate bond to ADP to !"estore the
ATP level. This is shown in the lower left side of the diagram.
See the text for further discussion.
p~

5h,

�3)

ADP

------;&gt;

ATP

+ Lactic Acid

This describes how the formation of lactic acid in anaerobic metabolism helps to restore some of the ATP needed
for muscle work.

4)

Glycogen and Free Fatty Acids

+

-------~

. o.J..

~~

+ ADP + -9-26&amp;2 + -H26
+ ATP
C-D~
H2,.o
N.

This describes how aerobic metabolism generates ATP. ~b~~
_cL..uMk (C-Ol-) ~ l.da..t~ ( ~l..o) o..r~ oJ-a .t,-rd w\u.., o"-j~ ( o~..-)
IS f"..fs-4" c;k..t.M."'j T~ ~"\ o{- ~l:.uky~":t;; ~ ,?.:t; ,

Figure II-2:

High Energy Phosphate Systems

The ATP (adenosine triphosphate) and CP (creatine phosphate)
high~energy phosphate systems are described. The four primary
reactions where ATP and CP are formed or used are given at the
bottom half of the figure, with a short definition of the importance of each. See the text for more information.

A ~ p~

"'&lt;M.AJ...

'-(10-.v.._-'

A ~~~~ ._.N&gt;.cl·-''-"""'~~ ~·
~ ~.l.t

C\"-.'&lt;..

"--Q.

dA-Pc~:.'",&gt;~R_J

{Vt;;U.J,"'Vl~

~

0-Jv--..

~"i ~J .$ ~c.sz.

~~ l _;,j:- d..~ ~ f3.1\A.J jc}..M._ lvv-.~

~-to -:1;~4 ~r&lt;..J:-.

"(.v

~J-

.

�Figure II-3:

Energy Supplies in the First Minutes of
Moderately Heavy Work
'")

rek-hv~ ~

..l;v.. ~

Four curves are shown representing the percent usag~ (vert ical axis, left side) of high energy phosphate stores, ATJ:' (
)
and CP (
), anaerobic glycolysis (lactic aid)(
), and aerobic metabolism (
) to provide energy for moderately
heavy muscle work. Only the first few minutes of exercise are shown
(horizontal axis). The ATP stores are exhausted in a few seconds,
while the CP stores last about 45 seconds at this workload (02 inintake, right side vertical scale). Anaerobic glycolysis supplies
less and less of the energy required as the duration of exercise
increases and aerobic metabolism takes over. The im before 100~ ~
of the energy suppl~ is provided by ~ero~=~__g. glycolY:~~s represents-··? l .J
an "oxygen. debt" wh1ch must b.e. "repa1d" \·ur1ng .fie subsequent re- (J2.-o..r.t
covery per1od.
·
··
.
.&lt;1:. a- -~o
~ec...-'· C...
I

.

0-9--A,J_~(_ ~~".~•"~~ f::F-A ~'t~.~, .

~

~1':••.&lt;::&amp;.·

ENERGY SUPPLY

0 2 INTAKE

"

100.

I/ min

1

50

0

1

2

4

3

TIME min

I

�Figure_II-4 : Gross and Microscopic Anatomy of Human
Skeletal Muscle
The gross structure of a skeletal muscle, such as the
gastrocnemius musle of the lower leg (calf), is sho·wn in
part "a". A cross section of the whole muscle is designated as
"AA" and shows multiple bundles, or fasciculi, of muscle fibers.
The membranes surroungJna..:::~JuLJ.Adi.Llli.!!J. fibers, fasc;icu~i, and
whole muscle are
endomysium t.o:r ... saoPe&amp;ie.Diilia:D, per1mys1um, and
epimysl\iii"; respectively. · ey jon~ muscle tendon,
which attaches the muscle to the skeleton. ~ par:t? "b" the di vision of the muscle fiber into myofibrils ~_sho~jthese are
made up of sarcomeres, the functional unit of muscle. The sarcomere is composed of filaments of actin and myosin, which combine
to form actomysin in muscle contraction. The Z discs, I, H, and
A zones of the sacomere are indicated. They are discussed in
etail in the text.·
·

..ft.N..J ttY'A"t~~SG-/\ C..~-·-~•.N"~'&lt;''"'l

'

'

�motor nerve fiber

plasma

membrane

synaptic

cleft

Figure II-6:

The Myoneural Junction

A muscle fiber (voluntary muscle) is shown with its outer
membra~r

sarcolemma. A motor nerve fiber, which is the axon

.lfsv·~""~~o.!-_a.~i!!_!!.P motor neuron, is shown as. it joins the muscle
J\.u

~.:-.;;;

f1ber. The axon has several knobs at 1ts end, or end feet, and
-~~.DJUUL.~a.~,@t'ache"d-to~~·a:m·em~. ~is plasma memb.r.a,ne_i.~n '?
1
direct contact with the sarcomeres of the. mu.gu::.l..e.-~iluu'_,,~~bJli..,!QX..ms
''
~..:::::&lt;::1 ef.1; . . . ili.~.QJ:l.~~!!~E!-Jl.§.t..Y.~""Jmp,y,l,M~,.JJJY..§_"t.-~..cr..osa....t.o~~-.:t.Ua.:t~e_,_,;t.h.e-.m.ae.:
SJC'~~--!-~ The chemical acetylcholine is released at the end feet
and crosses the synaptic cleft t~aetivate the m-u-s-ele fiber. The
excitation-contraction process is described in the text.
•"''''''•·-'·• "''''--'''"''""

j''''-'"'1i""""u'...'"""'""""""'•~----~"'-'O'I .......'~'""J!~~-~-;&gt;/f0~~·~"'"'~

---rl-L
1'\".~c·.N;.J,I\~t,~

~~ '{\....s._

...su.....d

~tt ~

a.._

f(}.;d;o,.~,

ol't tt~

C~1-RSJ1.{:;

/'1.

�~-

~-

)&lt;t n-,,, 1;

\

I

'

l

SYNArTIC

I

·I
.• I

I

i

I
I.

I
I

II

II

1

1 plate patenttat

1

~

'

1

nerve termonatl

"

I

1

)
• •

J

)

......

I
I.

II

I
· I LOQI
I) actoon_

I

Co- 1'1'-

II '"'·ht ........
........,r-t e.,..,...
II dePOiarozation
II
I

CA.\ i...,......e..

·

I

I
I
1

I
I

II
II

I

II

I

I

I"

I

Figure II-8:

I

I

I

1

I

reouorong

Ca·"

II

II

II

1
usr~
1

I
I
1

I
I

I

I

'

1

·

t

wt

I Retene of
1repressoon
of
Klon-myos,n
I mteract•on
due to trooonon

I

Ca .. bo&amp;.nd
by ••opon.n

1
I

hy~roly~·s of

I Formahon •ofAlP
I Khve acton.
I mYoson link

I
I
I

Release ot ~ [MilSion ot
Ca • ,. frOM
Ca • • to
ler"'•nal
contr.achte
SICS) w¥'
fll.amenls

soread

of
ll""ulus

(I(

ATP prc..:bc::~;
ADP • work • hE-at

,

1

Inward

""4

(1I t

1

~

! ca·HJ,~"

I 1010 S•h~'iPIM~
I actove """.

·
~ c:...,o..t;

I

I
1

ACTIN~~~-

I ~"'""
Ot'VE-h.JIJ'•d

ATP ._,. A•f' ,

I

ACH KrOSS

1

-&amp;

1-~~

~
!
s~ ••.•t.~Ao. I
c•.,. .~" , ... ""' I

.

CONTRACTILE
FILAMEtnS OF

I

I·

svsTEM _ _

-!PrOPagated
lllftUICie actoan
1)'
II DOtential •
II
I
II
I

ttvsoon of

tYNDtoc: gap
.. ,

I

I

SARCOPLASMIC!
RETICULUM
ts.R 1
. SARCOPLASM!

Loal ell'.l

1

I

by dei)Oiarozation

I TRANSVERSE }eyJ"I TUBULAR

:I
.. ~

Storall't of ACH
in pac~e:s
. p.DePOiarozlloon

wu.nla release
of ACH oncreaMd •

II
II

II
,
!I

A&gt;te&lt;r,._

........

I
1
I

SEIIUES
ELASTIC
ELEMF...,T

I
1
1

LOAD

I
!
I

,s..,.,..
~nt4sto~;.

I ) 5llerc:~o
i

I$

.,., COOIIolCh~
k••C:t.' unttl
lt-nso:&gt;:\ 1n ,1
eQuals !O.Jd

w·

"""'='CUCK'n
m"""' Shorte:~s

1
I
I

1
I
I

L-·"'

..... ''

llhed anc:t
work .,
cton. by

muscte

I

I
I

1

I

I

The Sequence of Events in the Control of
Muscle Contraction

Nine muscle and nerve elements that play a role in muscle
contraction and the beneficiary of that effort, the load, are
shown across the top of the figure. A flow diagram indica~~~"-W:h_~t
t
happens in each element. The role of acetylcholine ( ACH) C!Jt s_!!_c&gt;l!ID """'··""'"r~.c.c_
in the end feet of the motor axon, and in the synaptic clef~. The
depolarization of the muscle cell occurs after a local effect requiring calcium ions (Ca++) in the plasma membrane. This action
potential is carried by the T-tubule system to the sarcoplasmic
reticulm where the events described in Figure II-7 occur. Once
contraction occurs, ATP (adenosine triphosphate) is used to pump
theCa++ back ~to the sarcoplasmic reticul~, preparing the
sarcomere for the nex~-~-t..lo.n_~pa:t..e.
• ThE¥~~1as_ll_c_e_l.eJ!~!!t_
. _ _
. ., .
_.· h~.r J_.,.Q..J
of the muscle (a_~-~-~~~-~_E~d.J:.!.te,.r~-~ilL_the tex ~es thE? load~.,u, ~r~o.'t:c_t,~J u.rx-~c.~O tti:&gt;J""'.r"" ~~J ~:-k- DY-±&gt;t.J
requirements to the force developed by the actomysin l1nks,
~~r--~~''\5i..J.."-.ll..,-:±:e. ~\ +~ }.A
-~ ~-·rand the load is lifted.
'
~

'jJ

M

L

tL..

J ~3;

fJJ':;f·.,..t.,.R-4

{6.-l~r, _

~jn'\Q.J\A..i:::-1

�··---- .............---...

+

Shorten
Velocity

Figure II-13:

...M.
·.
. I lf'J...O

Force-Velocity Curv~s at Different Percentages
of Muscl~ii--P·e-n-g.th .!!."'Concentric and
Eccentr"1c Contractions

The amount of force that can be generated by a muscle (vertical axis) as it is affected by the speed, or velocity, of
shortening or lengthening (horizontal axis) is shown. Curves are
given for four strengths of contraction, 25, 50, 75, and 100% of
maximum voluntary contraction tension. Increasing positive velocity
is a concentric, or shortening, contraction. The amount of force
generated talls sharply as the speed of concentric contraction
i&gt;~H~r~.~~-~-a,-L.reflecting a reduction in cross-bridge formation in
~he sarcomere~ A lengthening of the muscle during contraction is
known as an eccentric contraction. As the speed of this contraction increases, more force can be developed by the muscle,
reflecting a!Pontinued optimum condition for cross-bridge formation
/1n the sarcomereS\ Eccentric contractions can occur when a person
1/ picks up a heavy~oad and is unable to support it in the desired
Y position. The muscles lengthen even though the signals to them are
/ stimulating them to shorten. More discussion of eccentric
! and concentric contractions can be found in the text.
\:;
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D

Figure II-15 : Muscle Fiber Arrangements
Four kinds of skeletal muscle fiber arrangements are
illustrated in "a:" fusiform, or longitudinal ("A"); unipennate ("B"), bipennate ("C"), and multipennate ("D").
The pennate, or penniform, muscles can develop higher forces
than the fusiform ones can, but they have less range of
motion because they shorten over less distance. The reason
penniform muscles can develop more tension is illustrated
in "b." Muscle strength is proportional to its physiological
cross-sectional area. The fusiform muscle exerts tension on
the bones at the ends of either tendon. Its cross-sectional
,
area is shown by the line horizontal to the fibers at the
j,)
~~- ·\\~
belly of the muscle. The penniform muscle on the right of .)_ -1(~ ,_,.. ·.t\ ··'·"'
-the drawing is attached to the upper bone at two points. _:;::;;j d-"-~~~)~~~..~9:.-~-&lt;&gt;
The p~ysiological cross-secti~nal area for tens!on develop- ~;,y~~c""-:~~.;;:. 1
ment 1s the sum of the four l1nes drawn perpend1cular to
}~ ".-&lt;:5"--~"-'_,.o-i,}j. u:r-.
the fibers, or the distance ~et!een the two ends of the
\~. ~ :Js.::·:i;,a:J'·a'
muscle on the upper bone. Th1s 1s represented by the dotted
_;-~ '-'~1:···
line to the right of the lower cross-section. The greater
~~~
cross-sectional area of the pennate muscle gives it almost
3.5 times as _much strength as a fusiform muscle of the same
thickness.

j

�a--t--Alpha motor neuron
Gamma motor neuron

Figure II-18 : The Muscle Spindle Proprioceptor
A muscle spindle and its neural connections in the
spinal cord and to the brain are illustrated. The spindle
lies parallel to the muscle fibers and monitors their
changes in length. Any stretch of the spindles, as will
~roccur ~the muscle is loaded in a handling task, will
send impulses out the sensory neuron to the anterior horn
of the spinal cord. Here they will ifl-e-P-ea-s-e-the--s-e-n-s-itlvJ:ty
o_f_t_h.e-m-et-e-p--n-euron·s (-AMNs-,--or·-alpha--motor---n.eur.ons.)~..and increase the activation of motor units to produce more muscle
tension. The spindles can also be stimulated to b.Jeftd- impulses -.5"''".-t
to the cord by aetivity i~~ the sensorimotor cortex.
This pathway is important in voluntary movement as it triggers
the development of appropriate muscle tension prior to actually loading a muscle. Impulses travel from the brain to
the spinal cord where they influence the activity of the
gamma motor neurons. These are smaller than the alpha motor
neurons and innervate the spindle, rather than the muscle,

~!~:~~~t~!~:~i~~i~~~~n c~~~r~~~m:t:~~~~ ::~~~E_T_J!r;fo=s ;J

.

C

1~tretch on the part ·of 'tai··-e_···.·s_]&gt;T·ii·····_al_ e that monitors musc_ _ le_. ·:r-urey
it .J.J:.ltQ thinking the muscle has .. b_~~.!L~----··e···~
&lt;13,~~~1gb~~ })y -a-:roa;a~~oth the alpha and gamma motor neurons
~llow close moni~~i1rig and adjustment of muscle tension in

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+~ f\j'\;U.A.J1C..~ U.I~.._,_\Q.d. b.€_ }.,_r:,..i:, 5 '/,

�Mechanism

------------------

Effect on Blood Flow

Local muscle temperature increase
Increased C02 and metabolites in a muscle

Increased blood flow within the
muscle - opening up of additional
capillary beds

Increased sympathetic
nervous system vasoconstrictor discharge
- stimulated via baroreceptor reflexes or
skin thermal receptors

Increased resistance and decreased
blood flow through the vessels of
the digestive system organs, kidney,
and resting muscles. More blood flow
is shunted to the working muscles.

Increased sympathetic
vasodilator activity triggered through the
midbrain, associated
with emotional stress

Increased dilatation of the vessels
of the active skeletal muscles results in increased blood flow to
them.

Increased body temperature

Increased blood flow to the skin diverted from the working muscles,
if necessary

Release of adrenaline
from the adrenal glands

Increased blood flow in the working
muscles due to vasodilatation - very
large effect initially; it is quickly
reduced, and a slight vasodilatation
is sustained for some time afterward.
This may be related to local metabolites in the muscles.

Mechanical pressure on
limb blood vessels intermittent
A/~

/ti+~
( \&gt;( ) )
~/

·

P(\(..{ )

(~ d. ~"J(W\~ 1.\,,.:,~"Q
.

Increased venous return through
better pumping of the blood back to
the heart against gravity. This will
increase cardiac output and deliver
more blood to the working muscles as
long as the pressure is intermittent
(see text).
.

l'Y\ ~

\--;,_~, ~ ~"·-' ~1.c·. ~ ~&lt;&gt;-·"'-·* A,&lt;lV··'·'[~

\o-IJ..r&lt;&gt;J) .j(J:ie,_,t;,,,,/

Table II-6:

~),0 ~,,.,Jl.tf::sL9

_Yo

Circulatory Controls to Adjust Blood
Flow During Work

Si~ circulatory control mechanisms are given in column one
and the1r effect on blood flow is described in column two.
Muscle blood flow is given primary consideration as it is the
t regulation of blood flow and its distribution during work that .
\~ ~~~ · determinesa person's maximum aerobic work capacity. The cardiovasc~lar controls are designed to maximize blood flow to the
work1ng auscles at the expense of blood flow to most other parts
of the body, except for the beart muscle and the brain.

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Heart Rate Calculations from the
Electrocardiogram

A technique for calculating the heart rate, in beats per
~~~c~t~rocardiogram (ECG) trace is shown. The trace
_
the
e heart's electrical activity, or its
~tage, on t
ver ical axis and time on the horizontal axis.
Time is determined by the speed of the recording paper when the
ECG is made. The electrocardiogram has three distinct components.
The P-vwave represents the depolarization of the atria, or upper
chambers of the heart. The QRS complex represents the depolarization of the ventricles. The R spike can be used to measure the
time between beats of the heart; the interval is the time for
one beat. The transformation of this to the heart rate in beats
per minute is shown below the trace. This technique permits one to
measure changes in heart rate over short intervals and is more
accurate than taking a pulse rate over the same time period.
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�</text>
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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                <elementText elementTextId="1605343">
                  <text>IN COPYRIGHT - EDUCATIONAL USE PERMITTED &#13;
&#13;
This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                    <text>Handwritten Draft for Section of Book
Chapter Regarding Motor Control

�,·_.-

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-L__________ _J.___ .... ----···

lt&gt;tor Control

A oanplex ·and versatile machine like the hllnan body· rEqUires ari
~l.aborate control systfllll.
-

.

. .

r

our D&gt;tor control system continually
..

.

.

.

.

.

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processes senaory information relating to oUr .JIOVanent and force
.

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requirements and initiates the carmarids. necessary for suc~sful task
. .
~
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. Caapletion. ibis sensory information 'is sen~all levels of the_

.·

'

. .central netvpus ayst~. (~), .th~ cerepra1 oottex, cerebellum, brain .·
--------:---~

stan, ·lnd sp~ cor~. · ·'lhe }ntegratf!CS res~~ of the systan
detemnes' what Woilllltion ,. the anterlot DK&gt;to~ '~euron (AMN) t~iv~
and translates irito mavanent"

1
·.,.·,··:·'

! •

,.

• ••

~

1

··~e major
~t-er-:.~Ubdi~i;io~······of: th~ ~. ·., .· . nervou~ systen ~.
1J
-='·
I~

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f.~.

, &lt;):[of' c.. cr·N&lt;.:-'·..._v,~(J~~~ -~

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ProcessiJ;lg of M,l'lSC)ry information and initiation of mtor ~ctivity

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Pigure II-8 shOAs· a block diagran of . .·

,

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each of these mtor .. rontrol

.

e

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.

~~I eoiltrpl is, :OOWever, a oanplex process.' ~e
'

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.·

.

·..

interested r~ader .,uld refer to standard texts on neurophysiology,
JOotor behaviOr 1 and neuroanatany for detai~ed infOrmatiOn (ChUSidr
··· l979l ~gui·rre; 1969; Sage,_~)?'77J.

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                    <text>Dr. Rodgers was a significant contributor of
the Eastman Kodak series: Ergonomic
Design for People at Work
Eastman Kodak Company. Human Factors Section., &amp; Eastman Kodak Company. Ergonomics Group.
(1983). Ergonomic design for people at work: A source book for human factors practitioners in
industry including safety, design, and industrial engineers, medical, industrial hygiene, and
industrial relations personnel, and management. Belmont, Calif.: Lifetime Learning Publications.

Eastman Kodak Company. (2004). Kodak's ergonomic design for people at work. Hoboken, N.J.: Wiley.

�ERGONOMIC DESIGN FOR PEOPLE
AT WORK.
VOLUME I

,•",\

�ERGONOMIC DESIGN FOR PEOPLE
.AT WORK
Suzanne H. Rodgers

Technical Editor

Elizabeth M. Eggleton, Editor

Commercial. Publications
Eastman Kodak Company

Volume I
Workplace, Equipment, and Environmental besign
and Information Transfer

Contributing Authofs
Stanley H. Caplan
Paul C. Champney
Kenneth G. Corl
Brian Crist
William H. Cushman
Harry L. Davis
Terrence W. Faulkner
Richard M. Little
Richard L. Lucas
*Thomas J. Murphy
Waldo J. Nielsen
*Richard E. Pugsley
*Suzanne H. Rodgers
John A. Stevens

Human Factors Section
Eastman Kodak Company

I

A Source Book for Human Factors Practitioners in
Industry including safety, design, and industrial
engineers, .r.nedical, industrial hygiene, and industrial
relations personnel, and management.

by: The Human Factors Section
Health, Safety and Human Factors Laboratory
Eastman Kodak Company

Designed by William Sabia
* No longer associated with Eastman Kodak Company

Lifetime Learning Publications
Belmont, California
A division of Wadsworth, Inc.

T .nnrlnn «:;ino-::innrP. SvdnPv. Toronto. Mexico Citv

�NOTICE
The Human Factors Section of Eastman Kodak Company acknowledges
with gratitude permission received froin the following companies and
organizations to use material reprinted from their publications in the
development of· this book. Specific references are noted in the text,
complete citations follow in the bibliography at the end of each chapter.
American Book Company, New York, N.Y;
American Institute of Physics, New York, N.Y.
ASHA Publications, Rockville, Md.
Butterworth Scientific Ltd., Guildford, Surrey, U.K.
CMP Publications, Inc., Manhasset, N.Y.
Flournoy Publishers, Inc., Chicago, ill.
Journal Publishing Affiliates, Santa Barbara, .Calif.
McGraw-'Hill Book Company, New York, N.Y.
Pendell Publishing Company,· Midlan�, Ml
Prentice-Hall, Inc�, Englewood Cliffsi N.J.
Taylor and Francis Ltd., London, England
The Human Factors Society, Publications Div.,
Santa Monica, Calif. 90406
University of California Press, Berkeley, Calif;
Western Electric Company, New York, N.Y./
John Wiley and Sons, Inc., New York, N.Y.
Van Nostrand Reinhold Co., Inc., New York, N.Y.
© 1983 by Eastman Kodak Company. All rights reserved. No part of this
book may be reproduced, stored in a retrieval system, or transcribed, in
any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of the
copyright owner, Eastman Kodak Company.
Library of Congress Cataloging in Publication Data
Main entry under title:
Ergonomic Design for People at Work
Volume I
Bi�liography: v. 1, p.
Includes index.
1. Human engineering-Handbooks, manuals, etc.
I. Eastman Kodak Company. Human Factors Section.
T59.7.E714 1983
. 620.8'2
83-719

We believe the information provided in this work is reliable
and useful, but it is furnished without warranty of any
kind from either the author, Eastman Kodak Company, or
the publisher, or the editors and contributing authors.
Readers should make their own determination of the
suitability or completeness of any material or procedure for
a specific purpose and adopt such safety� health, and other
precautions as may be necessary. Of course, no license
under any patent or other proprietary right is granted or to
be inferred from our provision of this information.

�CONTENTS
List of Illustrations
List of Tables
· Preface
Acknowled�ents
Chapter I. Using This Book for Ergonomics in
Industry: Introduction

xiv
xix
xxii
xxiii
xxvi

- 1. Ergonomics/Human Factors in Industry: An
Explanation and History of the Subject
a. Explanation
b: History of Ergonomics and Human Factors
2. Human Factors at Eastman Kodak Company
3. Scope and Purpose of the Book
-4. Summary of the Contents
--S. Criteria for Design: Who?
References•for Chapter I

5
6
8
8
11

Chapter JI. Workplace Design

12

Section IIA. Layout

14

1. Workplaces
�a. Sitting Workplaces
b. Standing Workplaces
c. Sit/Stand Workplaces
d. Special Case: Design of VDU (Video Display
Unit) Workplaces
e. Special Case: Design of Chemical Hoods and
Glove (Isolation) Boxes

3
3
4

15
18
23
26
28
30

2. Aisles and Corridors
3. Floors and Ramps
a. Floors
b. Ramps

34
36
36
40

4. Stairs anq. Ladders
a. Stairs
b. Ladders

41
41
45

5. Conveyors
-6. Dimensions for Visual Work
a. Viewing Angles

48
50
50

�CONTENTS

CONTENTS

c. Eye Glasses
d. Visual Work Area
Section IIB. Adjustable Design Approaches

52
52
52

1. Adjusting the Workplace
a. Shape
b. Location: Height and Distance
c. Orientation

55
56
56
57

2. Adjusting the Person Relative to the Workplace
- a. Chairs
b. Support Stools, Swing-Bracket Stools, and
Other Props
C; Platforms, Step-ups, and Mechanical Lifts
------ d. Footrests
e. Armrests

57
57
58
60
60
63

3. Adjusting the Workpiece or Product
a. Jigs, Clamps, and Vises
b. Circuit Board Assembly
c. Parts Bins
d. Lift Tables, Levelators, and Similar Equipment

63
63
63
65
65

4. Adjusting the Tool
a. Design and Location of Tools
b. Trays and Carriers

66
66
67

a. Auditory Presentation
b. Visual Presentation for Detection of a Signal
3. Visual Displays for Information Transfer
a. Dial Design
b. Viewing Dista,nce
c. Installation of Displays: Design and
Environment
d. Electronic Display Design and Installation
4. Video Display Unit (VDU) or Cathode Ray Tube
(CRT) Displays
a. Hardware Selection Characteristics
b. Software Enhancement of VDU Displays

.107
112
112
113
115
115
117
134
134
135
135
137
140
140

References for Chapter II

74

Chapter HI. Equipment Design

78

Section HID. Hand Tool Selection and Design

Section IIIA. Design of Production Machinery:
General Principles

82

3. Environment and Safety

89

Section IIIB. Displays

90

1. Signal Detection

90

101
101
103

--- 1. Population Stereotypes
· 2. Design, Selection, and Location of Controls
a. Location
b. Spacing
c. Shape Coding
d. Control Resistance
e. Types of Controls

67

86
87

97
98

107

Section UC. Clearance Dimensions

82
84

93
95
97

Section IIIC. Controls and Keysets

- 3. Keyboards for Data Entry
---· a. The Nature of the Task
b. Operator Proficiency
c. Keyboard Layout
d. Keyboard Parameters
e. Locating the Keyboard in the Workplace

1. Reaches and Clearances
2. Maintainability
a. Areas to Consider When Planning
Maintainability Needs
b. Other Maintenance Design Features

93
93

1. Factors of Concern in Hand Tool Design
a. Static Muscle Loading: Fatigue and Soreness
b. Awkward Hand Positions
c. Pressure on Tissues or Joints
d. Vibration and Noise
e. Pinch Points
f. Other Factors

140
140
142
144
145
145
145

2. Design and Selection Recommendations
a. Handle Length
b. Handle Diameter
c. Handle Span
d. Other Features of Handle Desi1m

146
146
146
147
147

�CONTENTS

· CONTENTS

150
150
152

References for Chapter III

154

2. The Effects of Electric Shock
a. The Body's Resistance to Sh,ock ·
b. Threshold Perception
c. Pain

Chapter IV. Information Transfer

160

Section IVA. Person-to-Person Transfer

162

3. Prevention of Electric Shock
a. Protecting the Worker
b. Workplace Design Considerations

e. Switches and Stops
f. Tool Weight and Suspension
g. Special-Purpose Tools

1. Instructions
2. Forms
a. Sequence
b. Readability and Comprehensibility
c. Space and Content

-3. Questionnaires
a. Design of the Questions.
· b. Design of the Questionnaire Format
·- c. Use of the Questionnaire Data
4. Labels and Signs
a. Comprehensibility
b. Legibility
c. Readability
5. Coding
a. Alphanumeric Coding
b. Shape Coding
c. Color Coding
Section IVB. Product-to-Person Transfer: Visual
Inspection
1. Factors Influencing Inspection Performance
a. Measures of Performance
b. Individual Factors
c. Physical and Environmental Factors
d. Task Factors
e. Organizational Factors

2. Guidelines to Improve Inspection Performance

162
164
166
166
166

166
167
167
168

168
168
170
173

174
175
177
178
179
180
180
182
183
187
190
191

References for Chapter IV

194

Chapter V. Environment

198

Section VA. Electric Shock

201
... ,..,.,

�

T.....- ......... _£ 'I...J ____ ...;i .... !- LL-. 'IAT--la_l ___

Section VB. Noise and Vibration

203
203
208
208

208
208
209
209

1. Noise
a. Criteria for Noise Exposure
b. Performance Effects of Noise
c. Approaches to Reducing Noise in the
Workplace
d. Special Considerations

210
211
218

2. Vibration
a. Effects on the Body
b. Ways to Reduce Vibration Exposure

221
221
224

Section VC. Illumination and Color
1. Illumination
a. Recommended Light Levels for Different
Tasks
b. Selection of Higher-Efficiency Light Sources
c. Direct and Indirect Lighting
d. Task Lighting
e. Miflimizing Glare
f. Special-Purpose Lighting

2. Color
Section VJ?. Temperature and Humidity

219
219

225

225

226
228
228
230
230
234
240

241

1. Body Heat Balance
2. The Comfort Zone
a. Zone Definition
b. Factors Affecting the Feeling of Comfort
Within the Zone

242
244
244

3. The Discomfort Zone
a. Guidelines for Acceptable Heat Exposures in
the Discomfort Zone
b. Guidelines for Acceptable Cold Exposures in

250

thP Oi!'.cnmfnrt ZnnP

244
252
?.f:i?

�CONTENTS

CONTENTS

c. Techniques to Reduce Discomfort in the Hot
and Cold Discomfort Zones

4. The Health Risk Zone
a. Zone Definition
b. Cold Injury
c. Heat/Humidity Illness and Injury
5. Working in Wet Environments
a. Wet Oothing
b. Hand and Forearm Water Immersion
c. Using Safety Showers and Eye Baths

6. Surface Temperatures
a. Hot Surfaces
b. Cold Surfaces
References for Chapter V
Chapter VI. Appendices
Section VIA. Appendix A: Anthropometric Data
1. Limitations in the Use of Anthropometric Data in
Design
a. Defining the Population
b. Effects of Oothing and Posture
c. Designs Involving Several Anthropometric
Variables

2. Anthropometric Measurements
a. The Data
b. The Definitions
3. Examples of the Use of Anthropometric Data
a. Criteria for New Design
b. Evaluation of Existing Design
Section VIB. Appendix B: Methods

1. Aids for Human Factors/Ergonomics Field
Surveys
a. Survey Techniques
b. Presentation of Survey Results
2. Environmental Measurement Protocols
a '. Temperature, Humidity, and Air Velocity
b. Noise

254

263
263
263
265

268
269
269
269
270
270
270

273

282

284
285
285
287
288
289
290
299
311
311
312

313

313
313
319

320
320
328

3. Psychophysical Scaling Methods
a. Types of Scales for Psychophysical
Evaluations
b. Interval Scales in Psychophysical Data
Collection
c. Rating of Perceived Exertion

333
333
334
338

Section VIC. Appendix C: Problems with Solutions

342

1. Workplace Design
a. Problem 1-Seated Workplace
b. Problem 2-Standing Inspection Workplace

342

2. Equipment Design
a. Problem 1-Selecting a Pop Riveter
b. Problem 2-Safety Shower Handle Height

348
348
350

3. Information Transfer
a. Problem-Inventory Control Card Design
4. Environment
a. P;�blem 1-Warning Alarm Characteristics
b. Problem 2....,..Noise Levels in Office Area
c. Problem 3-Humid Heat Exposure
References for Chapter VI
A Selective Annotated Bibliography on the Subject of
Human Factors
1.
2.
3.
4.
5.
6.
7.

Genetal
Workplace Design
Equipment Design
Information Transfer
Environment
Human Capacities
J9urnals

342

344

353
353

355
355
356
358

361

365

·365
367
368
369
369
370
372

Glossary of Human Factors Terms

375

Index

389

�LIST OF ILLUSTRATIONS

UST OF ILLUSTRATIONS
Chapter I. Using This Book for Ergonomics in Industry:
Introduction
Figure 1-1:
Designing with Anthropometric Data
Chapter II. Workplace Design
Figure IIA-1: The Seated Workspace
Figure IIA-2: Forward Reach Capability of a Small Operator,
Seated
Figure IIA-3: Recommended Dimensions for a Seated Workplace
With a Footrest
Figure IIA-4: Recommended Dimensions for a Seated Workplace
Without a Footrest
Figure IIA-5: The Standing Reach Area, One Arm
Figure IIA-6: The Standing Reach Area, Two Arms
Figure IIA-7: Recommended Standing Workplace Dimensions
Figure IIA-8: Seated VDU Workplace Dimensions
Figure IIA-9: Standing VDU Workplace Dimensions
Figure IIA-10: Example of a Glove Box
Figure IIA-11: Minimum Oearances for Aisles and Corridors
Figure IIA-12: Workplace Catch-Trough
Figure IIA-13: Shoe Sole Design to Reduce Slippage
Figure IIA-14: Ramp Design for Pedestrian and Vehicular Traffic
Figure IIA-15: Fixed Stairway Design
Figure I¼-16: Fixed Stair Slope Range
Figure IIA-17: Handrail Design Guidelines
Figure IIA-18: Design of Stair Ladders and Ladders
Figure IIA-19: Portable Stairs and a Step Stool
Figure IIA-20: Standing Workplace at a Conveyor
Figure IIA-21: Preferred Viewing Angles
Figure IIA-22: Visual Work Dimensions for Seated Workplaces
Figure IIA-23: Visual Work Dimensions for Standing Workplaces
Figure 11B-1: Seated Workplace with a Cutout to Reduce Reach
Requirements
Figure 11B-2: Recommended Chair Characteristics
Figure 11B-3: Examples of Support Stools
T,_! ____._ TTD

A.

r'\LL-.- D---.-. /.-- ("\_-_,.....,.,__.,.� ;_ C-1-""'-,-1;'"-rr lA7n'1'"1,'1"11'!1,...0C!

10
19
20
21
22

24
25
27
29
31
33
35
39
40
41
42
44
45

46
47
49
51
53
54
56
58
59
�1

Figure 11B-5:
Figure 11B-6:
Figure 11B-7:
Figure 11B-8:
Figure IIC-1:
Figure IIC-2:
Figure IIC-3:
Figure IIC-4:
Figure IIC-5:
Figure IIC-6:

Examples of Footrests for Seated Workplaces
Circuit Board Assembly Aid
Parts Bins for Small Parts Assembly
Lift Table for Adjusting the Height of a Pallet
Minimum Clearances for Walking
Work Area Clearances, Horizontal
Work Area Clearances, Upright and Prone
Clearances for Entering Open�Top Vessels
Some Selected Clearances for Arms and Hands
Minimum Full-Body Access Port Clearances

· Chapter HI. Equipment Design
Figure IIIA-1: Industrial Lathe Design: Human Interface
Figure IIIA-2: Examples of Fasteners
Figure IIIB-1: Examples of Visual Displays
Figure 111B-2: Target Zone Markings on Dials
Figure IIIB-3: Alignment of Dials to Detect Normal Functioning
Figure IIIB-4: Examples of Poor and Good Display Panel Dial
Design
Figure 111B-5: Segmented and NAMEL Font
Figure 111B-6: Examples of Dot Matrix Character Styles
Figure IIIB-7: Response Time to Locate Information as a Function
of Display Density
Figure IIIC-1: Movement Stereotypes for Rotary Controls
Figui;e IIIC-2: Arrangements of Controlling Knobs and Their
Displays on a Control Panel
Figure IIIC-3: Examples of Poor and Good ControlMovement
Design
·
Figure IIIC-4: Toggle Switch Ch.µacteristics
Figure II(C-5: Push-Button Characteristics
Figure IIIC-:- 6: Examples of Rotary Selector Switches
Figure IIIC-7: · Recommended Design Criteria for Rotary Seledor
Switches
··c
Figure IIIC-8: Knob Design Recommendations
Figure IIIC-9: Criteria for Valve Design
Figure IIIC-10: Recommendations for Crank Design
Figure IIIC-11: Criteria for Lever Design
11.;.,....... n,r_ 1 ?•

r,-Hp,-i::i fn,- H:mdwheel Desi1m.

62
64.
65
66
67
68
69
70
71
72

85
88
95
96
98
99
99
100
105
108
111
116
119
121
122
123
124
126
128
130
131

�LIST OF ILLUSTRATIONS

LIST OF ILLUSTRATIONS

Figure IIIC-13:
Figure IIIC-14:
Figure IIIC-15:
Figure IIIC-16:
Figure IIIC-17:
Figure IIIC-18:
Figure 111D-1:
Figure 111D-2:
Figure 111D-3:
Figure IiID-4:
Figure 111D-5:
Figure 111D-6:
Figure 111D-7:
Figure 111D-8:
Figure IIID...;9·:
Figure 111D-10:
Figure 111D-11:
Figure 111D-12:

Foot Pedal Dimensions and Counterpressures
Touch Telephone Numeric Keyset
Adding Machine Numeric Keyset
Scholes Keyboard
Dvorak Keyboard
Recommended Key Design
Shoulder Abduction (Elbow Elevation) with
Soldering Iron Use
Soldering Iron with Tip Designed to Reduce
Shoulder Abduction
Electric Drill With Stabilizing Handle
Wrist Angles During Tool Use
Pressure Point in Palm
Stops on Two-Handled Tools to Reduce Pinches
Handle Dimensions for a Cutout Handle
Handle Span for Force Grips
Handle Design: Grooves and Ridges
Handle Design: Finger Recesses
Thumb Stop on a Tool
Holding Tool for a Chisel

· Chapter IV. Information Transfer
Figure IVA-1: Examples of Fonts
Figure IVA-2: Definitions of Font Characteristics
Figure IVA-3: Spacing and Borders That Improve Readability
Figure IVA-4: Shape Coding of Controls
Figure IVB-1: Percentage Errors in Using Three Aids to Assist In
Color Inspection of Electronic Chips
Figure IVB-2: Increase in Agreement Among Inspectors Resulting
from Use of Photographic Aids
Figure IVB-3: Defec;:t Rate and Inspection Accuracy
Figure IVB-4: Inspection of Moving Product; Direction of Viewing
Chapter V. Environment
Figure VA-1: Examples of Current Flow in Contacts with
Electricity
Figure VB-1: Guidelines for Noise Exposure to Protect Hearing;
Recommended Maximum Duration Versus Noise

132
136
136
137
137
138
141
141
142
143
144
145
147
i48
149
149
150
153
171
171
174
177
186
187
188
192

204
........ "'

1

Figure VB-2:
Figure VB-3:
Figure VB-4:
Figure VB-5:
F�gure VC-1:
Figure VC-2:
Figure VD-1:
Figure VD-2:
Figure VD-3:
Figure VD-4:

Preferred Noise Criterion (PNC) Curves
Evaluation of Pump Noise in a Foreman's Office
Preferred Speech Interference Levels (PSIL} as a
Function of Distance and Ease of Communication
Whole-Body Vertical Vibration Tolerances
Direct and Indirect Glare Zones for an Operator
Direct and Indirect Glare Zones for a Luminaire, or
Lighting Unit
The Thermal Comfort Zone
The Effect of Cold on Manual Performance
Ice Vest for Improving Heat Loss in Hot
Environments
A Vortex Suit for Use in High-Heat Areas

Chapter VI. Appendices
Figure VIA-1: Percentiles and the z-Statistic in an Anthropometric
Data Distribution
"
Figure VIA-2: Functional Hand Grasp Dimensions
Figure VIA-3: Anthropometric Dimensions, Standing and Sitting
Figure VIA-4: Anthropometric Dimensions, Hand, Face, and Foot
Figure VIA-5: Measurement of Abdominal Extension Depth
Figure VIA-6: Measurement of Functional Overhead Reach
(Standing)
Figure VIA-7: Measurement of Elbow-to-Fist Length (Forearm
Length)
Figure VIA-8: Measurement of Hand Breadth
Figure VIA�9: Measurements of the Range of Wrist Motion
Figure VIB-1: Instrumentation for Workplace Measurements of
Temperature, Humidity, and Air Velocity
Figure VIB-2: Temperature and Humidity Levels in a
Manufacturing Workplace
Figure VIB-3: Frequency of Occurrence of Given Temperature
···
Conditions, Rochester, New York
Figure VIB-4: Instrumentation for Noise Measurement
Figure VIB-5: Instrumentation for Measuring Illuminance and
Luminance
Figure VIB-6: Example of a Scaling Experiment
Figure VIB-7: Paired-Comparison Study of Mail Routes
T'.'.!----·- -..:TTD

. O.

D-----1 .... .L.:-- c�....� ..... -...... �n� 1- c.��lo.o

214
216
217
222
231
231
245
254
259
259

286
298
300
301
302
304
306
308
309
322
326
327
329
331
335
337

':l.':l.Q

�LIST OF ILLUSTRATIONS

Figure VIB-9: The Rating of Perceived Exertion (RPE) Scales
Figure VIB-10: Force Changes with Constant RPE Handgrip
Figure VIC-1: Existing Design of a Bottle Inspection and
Bottle-'Packing Workplace
Figure VIC-2: Design of a Paper-Web Inspectipn Workplace
Figure VIC-3: Examples of Pop Riveters
Figure VIC-4: Safety. Shower. Handle Height
Figure VIC-5: Example of an Inventory Control Computer Card
Used for Order Picking
Figure VIC-6: Recommended Changes to Control Carq. Used in
Order Picking

340
341
343
346
349
352
354
355

UST OF TABLES
Chapter I. Using This Book for Ergonomics in Industry:
Introduction
Scope and Purpose of the Book
Table 1-1:
Chapter II. Workplace Design
Table IIA-1: Choice of Workplace Type by Task Variables
Table IIA-2: Effect of Fixed Stair Slope on Recommended Riser
Height and Tread Depth
Table IIB-1: Levels of Adjustment .
Table IIC-1: Minim.um Clearances for the Working Hand
Chapter III. Equipment Design
Table IIIA-1: Humans Versus Machines
Table IIIB-1: Task Conditions Affecting Signal Detectability During
Extended Monitoring
Table 111B-2: Visuat Versus Auditory Presentation of Signals
Table IIIB-3: Types of Information Displayed and Recommended
Displays for Each
Table IIIC-1: United States Stereotypes for Up and Down Switch
Settings
Table IIIC-2: Recommended Separations for Various Types of
Controls
Table IIIC--:3: Characteristics of Common Controls
Table IIIC-4: Maximum Torques That Can Be Applied to a Round
Knob as a Function of Knob Diameter and Depth
Table IIIB-1: Power Tool Weights and Trigger Activation Forces
Chapter IV. Information Transfer
Table IV-1: Examples of Error Opportunities
Table IVA-1: Use of Two-Column Format in an Instruction Set
Table IVA-2: Factors Affecting the Written Communication Process
Table IVA-3: Letter or Number Height Versus Viewing Distance for
Labels
Table IVA-4: Legibility of Color Combinations in White Light
Table IVA-5: Error Opportunities in Coding
Table IVB-1: Factors That May Influence Inspection Performance
Table IVB-2: Reasons for Not Reporting Defects by Two Groups of

7

16
43
55
73
83
91
92
94
110
114
118
125
151
163
165
169
172
173
176
181
183

�LIST OF TABLES

LIST OF TABLES

Table IVB-3: Amount of Information in Absolute Judgments of
Various Stimulus Dimensions
Table IVB-4: Effects of Task Variables on Inspection Performance

185
· 189

Chapter V. Environment
Table V-1:
Health and Performance Effects of Some Physical
Environmental Factors
Table VA-1: Skin Resistance for Various Contact Conditions
Table VA-2: Electric Shock Thresholds
Table VB-1: Noise Complaints Over a Twenty-Year Period
Table VB-2: Recommended PNC Curves and Sound Pressure
Levels for. Several Categories of Activity
Table VB-3: Characteristics of Vibration That Are Within the Safe
Range for Transmission to the Hands
Table VC-1: Recommended Range of Illuminance for Various
Types of Tasks
Table VC-2: Artificial Light Sources
Table VC-3: Techniques for Controlling Glare
Table VC-4: IES Recommended Maximum Luminance Ratios for
Visual Tasks
Table VC-5: Special.;.Purpose Lighting for Inspection Tasks
Table VD-1: Body Heat Balance
Table VD-2: The Influence of Several Factors on the Thermal
Comfort Zone Limits
Clothing
Table VD-3: The Insulation Value (do) of Various
·
Ensembles
Table VD-4: Recommended Maximum Work Loads, Heat
Discomfort Zone
Table VD-5: Metabolic Demands of Industrial Tasks
Table VD-6: Equivalent Temperatures for Several.Combinations of
Low Temperature and Air Velocity
Table VD-7: Recommended Maximum Temperatures for
Short-Duration Exposure to High-Heat Environments
(up to 70°C, or 158°F)
Table VD-8: Contact with Hot Surfaces, Maximum Temperatures
Chapter VI. Appendices
Table VIA-1: Percentile Rankings for Several Hand Dimensions
Table VIA-2: Anthropometric Data, Centimeters

202
205
206
210
215
223
227
229
232
233
235
743
247
248
251
257
264
266
271

288
290-297

Table VIA-3: Anthropometric Data, Inches
298
Table VIB-1: Advantages and Disadvantages of Human
Factors/Ergonomics Field Surveys
314
Table VIB-2: Human Factors/Ergonomics Survey Descriptor List
316
Table VIB-3: Survey Checklist
317-319
Table VIB-4: Examples of Workplace Situations in Each of the
/
Survey Result Categories
321
Table VIB-5: Examples of Measurement Scales
333

�PREFACE

ACKNOWLEDGMENTS

Ergonomic Design for People at Work, Volumes I and II, are definitive works on
industrial human factors/ergonomics. This book, the first in the series, is
directed to a practical discussion of workplace, equipment, environmental
design and of the transfer of information in the workplace. Its contents and
purpose are further explained in Chapter I. The second volume will include
guidelines for job design, manual materials handling, and shift work.
The application of human factors/ergonomics principles to the workplace
has been of interest to Eastman Kodak Company for many years. This series
summarizes current data, experience, and thoughts assembled from the pub­
lished literature, internal research, and observation by the members of the
Human Factors Section. The selection of material has been guided by the
types of problems the section has been asked to address over the past 22 ·
years. The guidelines and examples of approaches to design problems are
most often drawn from case studies. The principles have been successfully
applied in the workplace to reduce the potential for occupational injury,
increase the number of people who can perform a job, and improve perfor­
mance on the job, thereby increasing productivity and quality.
Members of the Human Factors Section have each brought their special
expertise to the material included in these volumes. It is our hope that the
experience w e have gained from p roblem solving in an industrial setting with
a group that includes many disciplines will be of value to others with fewer
resources available to them, and that the material will be useful in the solution
of human factors and ergonomics problems in industries in many countries.

Members of the Human Factors Section who contributed' to the research and
writing of each section of this book are listed opposite the title page and at the
beginning of each chapter.
1 Lending support to the proje ct were Harry L. Davis, Supervisor of the
fJuman Factors Section; Kenneth T. Lassiter, Publications Director, Con­
sumer/Professional and Finishing Markets; and Alexander Kugushev, Pub­
lisher, Lifetime Learning Publications.

Eastman Kodak Company

The following people reviewed a draft of the manuscript and offered valuable
suggestions for its improvement:
Thomas S. Ely, M. D., Assistant Director, Health, Safety and Human
Factors Laboratory, Eastman Kodak Company
David Alexander, M.S., and Hart Kaudewitz, M5., Human Factors
Group, Tennessee Eastman Division, Eastman Kodak Company
Stover H. Snook, Ph.D., Liberty Mutual Insurance Company
Thomas Bernard, Ph.D., Westinghouse Corporation
Harry Snyder, P�_.D., Virginia Polytechnic Institute &amp; State University ·
Thomas J. Armstrong, Ph.D., The University of Michigan School of Public
Health
W. Monroe Keyserling, Ph.D., Harvard University School of Public
Health
Eliezer Kamon, Ph.D., Pennsylvania State University, and David Kiser,
Ph.D., Human Factors Section, Eastman Kodak Company, each review ed the
temperature and humidity section.
Carol McCreary, Human Factors Section, provided extensive technical as­
sistance and tr�ce� m�ny of the ref�r�nces for this project; she has our grati­
tude and admiration. Our appreciation also goes to Anne Wilkinson and
Gerry Bommelje of the Photo Services Section, Research Division, Eastman
Kodak Company, for their initial artwork. Elaine Villa and Shereta Harris are
especially thanked for typing the manuscript. Allan Fink and Leslie Smade s
of �e Kodak Park Ind�strial Studio provided the pho.tography.
F�ally, �e woul� like to th�nk McGraw-Hill, publishers of Human Engi­
neering Guide to Equipment Design by Morgan, Cook, Chapanis, and Lund
(1963), for permission to use much of the material in the equipment design
·· ··
chapter of this book.
.
The Human Factors Section
Health, Safety and Human Factors Laboratory

�DESIGNING FOR PEOPLE AT WORK
Volume I: Workplace, Equipment, and Environmental Design,
and Information Transfer
By the Eastman Kodak Co., 600 pages, 6½ x 9¼
From Eastman Kodak's Health, Safety, and Human Factors Laboratory comes the latest tech­
niques for designing jobs, workplaces, and equipment that improve job performance. Focusing
on current research in the multidisciplinary field of ergonomics, this book includes data from a
cross section of the U.S. industrial population. Numerous tables and illustrations help explain
human capabilities and workplace designs that stimulate high output.

BEHAVIORAL ISSUES IN OFFICE DESIGN
Edited by Jean Wineman, 256 pages, 6 x 9
Are the needs of office workers important to organizational effectiveness? Is worker satisfac­
tion relevant to productivity? How does the design of the physical workspace affect employee
satisfaction and productivity? It has been projected that by 1990 over 10 million new workers
will be employed in the white-collar sector. As the number of office jobs grows, the above ques­
tions and other pertinent matters will spur designers, architects, office managers, and admini­
strators to seek better guides to office planning and design. Behavioral Issues in Office Design
offers a compilation of research on current issues in the field as well as theoretical explorations
of the role of human behavior and values in the planning, design, and management of office
settings.

PROGRAMMING THE BUILT ENVIRONMENT
Edited by Wolfgang F. E. Preiser, 192 pages, 8½ x 11
Architectural programming-the analysis of any given environment to best satisfy users'
needs-has become a given prerequisite to the design process. Preparing such a program to
meet these needs in a cost-effective way is one of the keystones to successful architectural
design. In Programming the Built Environment, 11 prominent architects examine a range of
applications for different client groups. Included are a variety of programming approaches for
health-care facilities, cross-cultural student housing, and community markets. Every aspect of
the programming process, from initial planning considerations to post-occupancy evaluation,
is explored in these case studies. Wolfgang F. E. Preiser received a 1984 Progressive Architec­
ture award for architectural education.

INDUSTRIAL TOXICOLOGY
Safety and Health Applications in the Workplace
by Phillip Lindly Williams and James Leland Burson, 416 pages, 6½ x 9¼

Ergonomic
Design
for
People at Work
••• ••
• •• •••• •
•
•
•
•• • • •• • •• ••
•
•
••
• • • • •• •
\'OLUME2

Essential information for preventing, mitigating, and treating industrial toxicological problems
is provided in this practical sourcebook. Williams and Burson explain how toxic agents in the
body are absorbed, distributed, and eliminated. They discuss the effects of heavy metals, pes­
ticides, and solvents on the blood, liver, kidneys, nerves, skin, and lungs. Coverage includes
epidemiological manifestations and significant research on carcinogenesis, mutagenesis, and
reproductive toxicology.

BV EASTMAN KODAK COMP4NV
Ergonomics Group
Health and Environment Laboratories
ISBN

□ -442-22103-7

�About the Authors

ERGONOMIC DESIGN
FOR PEOPLE AT WORK
Volume 2
Job Design and Manual Handling
By Eastman Kodak Company
Ergonomics/human factors is a multidisciplin­
ary science that uses knowledge of human
capacities and capabilities to assist in the
design of safe and productive jobs, workplaces,
equipment, and products. Eastman Kodak,
with over twenty-five years of applied research
and practical experience in ergonomics, is at
the forefront of this developing field.

The Ergonomics Group and Human Factors
Section of the Eastman Kodak Company
have been involved in applied ergonomics
research and problem solving for over twenty­
five years. Their focus has been on the preven­
tion of accidents and injuries in the workplace
while at the same time optimizing the perfor­
mance of people. The guidelines and data
presented in this book are taken from suc­
cessful ergonomic applications within the
Eastman Kodak Company.

The first volume of this comprehensive
ergonomics resource presented principles by
which safe and highly effective workplaces,
equipment, and environments could be
designed.
This second volume complements Volume I by
drawing on physiology, psychology, engineer­
ing, medicine, and environmental sciences to
provide practical information for the design of
jobs and work tasks. The guidelines and pro­
cedures included are based on ergonomic ap­
proaches that have proven to be effective
within Kodak. Topics covered in this volume
include:
• The Physiological Basis of Work
• Evaluation of Job Demands
• Patterns of Work with Information
on Repetitive and Paced Work
• Hours of Work Including Shiftwork and
Overtime
• Manual Materials Handling
Ergonomic Design for People at Work, Volume
2 offers a realistic approach to the science of
ergonomics. Special consideration is given to
the broad range of capabilities of the industrial
population as determined by their age, sex, and
health status. Over 140 illustrations graphically
present key concepts that help identify solu­
tions to many problems.
Ergonomics and human factors specialists,
health and safety professionals, industrial
hygienists, industrial engineers, equipment
designers, architects, and labor relations
specialists will find this volume an indispens­
able reference.

VAN NOSTRAND REINHOLD COMPANY
A VAN NOSTRAND REINHOLD BOOK

�ERGONOMIC DESIGN FOR PEOPLE
AT WORK
Volume 2
The rDesign of Jobs, including Work Patterns, Hours of Work,
Manual Materials Handling Tasks, Methods to Evaluate Job
Demands, and the Physiological Basis of Work
Suzanne H. Rodgers

Principal Author and
Technical Editor

Deborah A. Kenworthy, Editor
Elizabeth M. Eggleton, Editor

Commercial Publications
Eastman Kodak Company

Contributing Authors
David M. Kiser
*Thomas J. Murphy
*Waldo J. Nielsen
*Suzanne H. Rodgers

Ergonomics Group
and Human
Factors Section
Eastman. Kodak Company

A Source Book for Human Factors Practitioners in
Industry including safety, design, and industrial
engineers; medical, industrial hygiene, and industrial
relations personnel, and management.

by: The Ergonomics Group
Health and Environment Laboratories
Eastman Kodak Company

Artwork by William Sabia
*No longer associated with Eastman Kodak Company

� VAN NOSTRAND REINHOLD COMPANY
� ______________ New York

�The Ergonomics Group of Eastman Kodak Company acknowledges with
gratitude permission received from the following companies and
organizations to use material reprinted from their publications in the
development of this book. Specific references are noted in the text, and
complete citations follow in the bibliography at the end of each chapter.

© 1986 by Eastman Kodak Company. All rights reserved. No part of this book may
be reproduced, stored in a retrieval system, or transcribed, in any form or by any
means, electronic, mechanical, photocopying, recording, or otherwise, without
the prior written permission of the copyright owner, Eastman Kodak Company.'
Printed in the United States of America
Van Nostrand Reinhold Company Inc.
115 Fifth Avenue
New York, New York 10003
Van Nostrand Reinhold Company Limited
Molly Millars Lane
Wokingham, Berkshire RG 11 2PY, England
Van Nostrand Reinhold
480 La Trobe Street
Melbourne, Victoria 3000, Australia
Macmillan of Canada
Division of Canada Publishing Corporation
164 Commander Boulevard
Agincourt, Ontario MlS 3C7, Canada
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2
Library of Congress Cataloging-in-Publication Data

Main entry under title:
Ergonomic design for people at wo�k.
Includes bibliographies and indexes.
Contei:ts: v. 1. Work place, equipment, and environmental design and
.
mformation transfer-v. 2. The design of jobs including work patterns, hours of
work, manual materials, handling tasks, methods to evaluate job demands, and
the physiological basis of work.
1. Human engineering-Handbooks, manuals, etc.
I. Eastman Kodak Company. Human Factors Section.
T59.7.E714 1983
83-719
620.8'2
ISBN 0-534-97962-9 (v. 1)
ISBN 0-442-22103-7 (v. 2)

Academic Press, Inc., New York, New York
Amer;tan Academy of Orthopaedic Surgeons, Chicago, Illinois
American Congress of Rehabilitation Medicine, Chicago, Illinois
American Industrial Hygiene Association, Akron, Ohio
American Physical Therapy Association, Fairfax, Virginia
British Association of Rheumatology and Rehabilitation, London, England
Butterworth Scientific Ltd., Guildford, England
Flournoy Publishers, Inc., Chicago, Illinois
Gower Press, Industrial Society, London, England
Human Factors Society, Santa Monica, California
Karolinska Institutet, Stockholm, Sweden
Lea and Febiger, Philadelphia, Pennsylvania
Alan R. Liss, Inc., New York, New York
McGraw-Hill, Inc., New York, New York
Methuen, Inc. New York;·New York
NASA Scientific and Technical Information Office, Yellow Springs, Ohio
National Institute for Occupational Safety and Health, Washington, D.C.
Pergamon Press, Inc., Elmsford, New York
S. P. Medical &amp; Scientific Books, Jamaica, New York
W. B. Saunders Co., Philadelphia, Pennsylvania
Scientific American, Inc., New York, New York
Taylor &amp; Francis, Ltd., Basingstoke, England
George Thieme Verlag, Stuttgart, Germany and New York, New York
C. C. Thomas, Springfield, Illinois
Van Nostrand Reinhold Co., Inc. New York, New York
John Wiley and Sons, Inc., New York, New York
Wright Air Development Center, Wright-Patterson AFB, Ohio
Year Book Medical Publishers, Inc., Chicago, Illinois

�NOTICE
We believe the information provided in this work is reliable
and useful, but it is furnished without warranty of any·
kind from either the author, Eastman Kodak Company, or
the publisher, or the editors and contributing authors.
Readers should make their own determinations of the
suitability or completeness of any material or procedure for
a specific purpose and adopt such safety, health, and other
precautions as may be necessary. Of course, no license
under any patent or other proprietary right is granted or to
be inferred from our provision of this information.

Contents
List of Illustrations
List of Tables
Preface
Acknowledgments

xix
xxv
xxxi
xxxiii

PART I. Introduction

1

Chapter 1. Introduction

2

A. The Contents of This Book
B. Industrial Need for Ergonomic Job Design
1. Improve Worker Productivity
2. Increase Available Work Force by Reducing Problematic Tasks
3. Provide More Jobs for Older Workers and Women
C. Possible Impacts of Poorly Designed Jobs
D. Options Other Than the Ergonomic Design of Jobs
for Addressing Difficult Jobs
E. Whom to Design Jobs For
References
PART II. The Physiological Basis of Work

4
6
7
9
9
9
11
13
15
17

, Chapter 2. Muscular Contraction and Movement

20

A. Metabolism, Energy Transformation, and Energy Utilization
1. Aerobic and Anaerobic Combustion of Nutrients
2. The Formation and Utilization of High-Energy Compounds
,, B. Anatomy of Muscle and Muscular Contraction
1. Anatomy of Muscle
2. Muscular Contraction
C. Motor Units

24
24
25
27
28
28
30

�viii

CONTENTS

D. Muscle Mechanics and Movement
1. Muscle Mechanics
2. Movement
E. Motor Control
1. Proprioceptors
2. Supraspinal Control
a. Motor Control Areas of the Brain
b. Ascending and Descending Pathways for Motor Control
F. Motor Learning and Skill Acquisition
G. Fatigue and Performance Impairment
References

Chapter 3. Circulatory and Respiratory Adjustments to Work
A. The Circulatory System
1. The Role of the Blood
a. Oxygen Transport
b. Carbon Dioxide Transport
2. Blood Flow
a. Determinants
b. Distribution
c. Muscle Blood Flow
3. Measures of Circulatory and Respiratory Adjustments to Work
a. Heart Rate
b. Blood Pressure
B. The Respiratory System
1. Lung Capacities and the Work of Breathing
2. The Control of Alveolar Ventilation
3. The Relationship Between Gas Exchange
in the Lung and Tissue Metabolism
References

Chapter 4. Biological Rhythms
A. Biological Rhythms-Terminology and Descriptions
1. Terminology
2. Descriptions
a. Internal versus External Generation
b. Entrainment of Rhythms
c. Amplitude Changes in the Rhythm
d. Hormonal Rhythms
e. Effects of Time Zone Changes on Body Temperature Rhythms
f. Menstrual Cycle
g. Physical, Emotional, and Intellectual Biorhythms
h. Ultradian Rhythms

CONTENTS

32
32

34

39
39

41
41
41
42
43

45

48

50
50
50
51
52
54
54
57
59

61
62
64

64
67

67

68
70
72
72
72
72
74
74
74
76
77
78
78

B. Body Temperature Rhythm and Performance
1. Twenty-Four-Hour Temperature Rhythms
2. Less Than 24-Hour Temperature Curves in Shift Workers
3. Body Temperature Rhythm Adaption Over Longer
Shift-Rotation Periods
4. Body Temperature and Task Performance
C. Activity Cycles and Sleep
D. Sleep Loss and Performance
References

ix

79
79

80

83
83

86
88
90

PART III. Evaluation of Job Demands

95

Chapter 5. Survey Methods

98

A. Primary Analysis of the Problem
B. Measuring What the Person Is Doing on the Job
C. Performance Measures and Physiological and Psychophysical
Responses in the Evaluation of Job Demands
1. Performance Measur�s
2. Physiological and Psychophysical Responses to Work
D. Strategies for Resolving Problems with Job Demands
, References

Chapter 6. Timed Activity Analyses
A.
B.
C.
D.

Job Activity Analysis
Work Task Analyses
Work Cycle Analysis
Methods-Time Measurement (MTM)
References

Chapter 7. Biomechanical Analyses of Work
A. Force and Torque Relationships in the Body
1. Lever Systems
2. Torque and Moment
a. Calculation of Simple Torque
b. Calculation of Torque for Nonperpendicular
Force Applications
c. Torque Calculations Including Body-Segment Contributions
: .
B. Biomechanics of the Back
1. Lifting and Back Stress
2. Postures and Back Stress
, ,Shoulder Biomechanics
Biomechanics of Grasp
-

100
101
102
102
103
108
108
111
113
114
118
118
121
122
124
124
127
127
129

132
135
135
142

145

1."i1

�X

CONTENTS

CONTENTS

E. Dynamic Biomechanical Relationships
1. Force-Mass Relationships
2. Lifting Dynamics
F. Steps in Identifying and Solving Biomechanical Problems
References

151
153
154
156
157

Chapter 8. Techniques for Analyzing Human Motion

160

A. Direct Measurement Techniques
1. Electrogoniometers
2. Force Transducers
3. Accelerometers
4. Force Plates
B. Indirect Measurement Using Imaging Techniques
1. Cinematography
2. Video Recorders
3. Multiple Exposure Techniques
4. Optoelectric Techniques
C. Summary of Motion Analysis Techniques
References

162
162
163
167
167
169
169
172
172
172
173
173

Chapter 9. Heart Rate Interpretation Methodology
A. Methods for Collecting Heart Rate Information on the Job
B. Information Available From Heart Rate Recordings
1. Heart Rate Level, Elevation, and Percent of Range
2. Upward-Sloping Heart Rate Patterns
a. Fatigue or Heat Accumulation
b. Frustration
3. Peak Loads
C. Use of Recovery Heart Rate Information To Evaluate
Work Stress and Individual Fitness Level
1. Recovery From Physical Work-Indication of Fitness Levels
2. Recovery From Emergency Stress-Duration Effect
3. Recovery Heart Rates with Light Activity
4. Recovery From Work in the Heat
5. Whole-Body Fatigue From Sleep Loss
D. Use of Individual Heart Rate Data to Assess Group Responses
to Job Demands
References
Chapter 10. Estimation of the Energy Demands of Jobs
A. Primary Physical Effort Requirements
B. Supplementary Physical Effort Requirements
C. Estimate of Total Job Energy Demands

174

176
177
178
179
179
180
181
183
183
183
186
186
186
186
191
192

194
199
200

xi

PART IV. Patterns of Work

203

Chapter 11. Work/Rest Cycles

206

A. Physically Demanding Jobs
1. Dynamic Work
.;i.. Duration and Intensity Relationships
rb. Estimating the Percentage of Maximum Aerobic
Capacity Used
c. Guidelines for Acceptable Workloads in Dynamic Tasks
d. Determining Rest or Recovery Times Needed
in Dynamic Tasks
2. Static Work
3. Environmental Effects-Heat and Humidity
B. Light Effort and Perceptual Work
1. Performance Effects
2. Guidelines to Reduce Performance Decrements in Light
Effort and Perceptual Work
a. Varying the Tasks
b. Making the Tas�s Easier to Do
References
Chapter 12. Work Pace
A. Variability in Work Rate
B. Machine Pace and Productivity-A Case Study
1. The Job
2. The Analysis of Job Requirements
3. Determination of the Time Stress on the Operator
4. An Ergonomic Approach to Reducing
the Machine-Pacing Pressure
C. Job Pacing and Stress
D. Design Guidelines for Paced Jobs
References
Chapter 13. Repetitive Work
A. Repetitive-Motion Disorders
B. Individual and Task Factors Associated
with Repetitive-Motion Disorders
1. Individual Factors
2. Job and Workplace Factors
C. Guidelines for the Design of Jobs with Repetitive Activity
1. General Guidelines
:· �pee�� D��ign Guidelines

209
210
210
210
213
213
217
220
222
222
223
224
226
227
230

232
234
234
234
236
237
237
240
241
244

246

247
249
251
253
254
255

�xii

CONTENTS

CONTENTS

4. Management of Repetitive-Motion Disorders in the Workplace
References
Chapter 14. Training
A. Job Design That Minimizes Training Time
B. Physically Demanding Jobs-Training Guidelines
C. Training Programs
1. Learning and Skill Acquisition in Training Programs
a. Task Complexity
b. Abilities of Trainees
c. Ability of Trainers
d. Type and Amount of Training
2. Training Methods
a. Lectures
b. On-the-Job Training and Simulation
c. Job Rotation
d. Sound Motion Pictures and Videotapes
e. Demonstrations and Other Visual Aids
3. Training Aids in the Workplace
References

256
257
260
262
266
267
268
268
268
269
269
271
271
272
272
272
273
273
274

PART V. Hours of Work

275

Chapter 15. Overtime

276

A. Job Demands in Relation to Choosing Overtime Schedules
1. Psychosocial Factors
2. Physical and Environmental Job Demands
3. Mental and Perceptual Job Demands
B. Other Factors Affecting Productivity in Overtime Schedules
1. Measuring Productivity
2. Type of Pay Plan-Incentive or Time-Based
3. Worker- or Machine-Paced Jobs
C. Overtime by Increasing the Days Worked Per Week
D. Guidelines for Overtime Scheduling
References
Chapter 16. Shift Work-Use and Effects
A. The Need for Shift Work
B. Patterns of Use of Shift Work
1. Type of Industry
2. Availability of Skilled Labor
3. Nature of the Work

279
279
279
281
282
282
283
283
283
283
284
286
288
289
290
292
293

4. The Economics of Shift Work and Product Profit Margin
5. Flexibility for Supervision
C. Factors to Consider in Designing Shift Work Schedules
1. Job Performance
a. Measuring Productivity
b. Error Rates
. c. Accident Rates
2, Psychosocial Effects
a. Worker Behavior
b. Leisure Activity
c. Family Life
References
Chapter 17. Shift Schedules
A. Five-Day Shift Schedules
1. Two Eight-Hour Shifts
2. Three Eight-Hour Shifts-Three-Shift Discontinuous Schedules
3. Twelve-Hour Shifts
B. Seven-Day Shift Sche.dules
1. Eight-Hour Shifts ...'._ Fixed
2. Eight-Hour Shifts-"Weekly" Rotation
3. Eight-Hour Shifts-Rapid Rotation
4. Eight-Hour Shifts-Combination Fixed and Rotating
5. Twelve-Hour Shifts
6. Combination Eight- and 12-Hour Shifts
_C. Special Five- and Seven-Day Shift Schedules
1. Five-Day with Consistent Saturday Overtime
2. Reduced Hours Per Week-Weekday/Weekend Plan
3. Reduced Hours Per Week-40 Hours or Less,
Five or Nine Crews
References
Chapter 18. Alternative Work Schedules and Guidelines
for Shift Workers
A. Alternative Work Schedules
1. Flextime
2. Compressed Work Weeks
3. Part-Time Employment and Job Sharing
B.
Guidelines
for the Design or Selection of Shift Systems
.
C. Guidelines for Shift Workers
1. Sleeping
2. Digestion
References

xiii

294
295
295
295
295
297
297
299
299
299
301
301
304
306
307
308
310
311
312
313
313
316
317
320
321
321
321
322
324
326
328
328
330
331
332
333
333
335
336

�xiv

CONTENTS

CONTENTS

PART VI. Manual Materials Handling

337

Chapter 19. Manual Handling in Industry

338

A. Manual Handling and Musculoskeletal Problems
B. Strategies for Reducing Manual Handling Injuries
1. The Systems Approach
2. Education-Teaching People to Lift
3. Selection
4. Redesigning Workplaces and Jobs
References
Chapter 20. Factors Impinging on the Manual Handling of Materials
A. Grasp
1. Pinch or Precision Grasp
2. Power or Cylindrical Grasp
3. Oblique Grasp
4. Hook Grasp
5. Palm-Up and Palm-Down Grasps
B. Design of Handles for Manual Handling Tasks
References
Chapter 21. Design and Selection of Containers, Hand Carts,
and Hand Trucks
A. Trays
1. Weight
2. Size
3. Stability
4. Grasping Characteristics
5. Large Trays
B. Shipping Cases and Boxes
1. Case Dimensions
a. Guidelines for New Case Design
b. Implications of Exceeding the Recommended Dimensions
c. Effect of Lifting Frequency on Acceptable Weight
and Case Dimensions
d. Maximum Dimensions
2. Provision of Handholds
C. Hand Carts and Trucks
1. Selection of Manual versus Powered Trucks and Carts
2. Design and Selection Factors
a. Wheels and Casters
b. Handle Type and Location
...,
T...... 1�1.,- ".'llo't"lrl r'3 .....f- n;manc;nnc

3. Handling Factors
References
Chapter 22. Exerting Forces

340
341
342
343
344
345
346

A.
B.
C.
D.

Chapter 23. Lifting

348
350
350
352
352
355
356
357
359
360

362
362
363
364
364
368
368
370
371
371
372
373
373
374
376
376
378
378
379

Horizontal Forces Away from and Toward the Body
Ver�ical Pushing and Pulling
Tr�nsverse or Lateral Forces Applied Horizontally
Forces Developed by the Hand
References

i

!

A. Factors Contributing to the Acceptable Weight for Lifting
B. The NIOSH Manual Lifting Guidelines and Industrial Tasks
1. The Assumptions Behind the Guidelines
2. The Guidelines for Occasional Lifts
3. Frequent Lifting
4. Other Limits to Lifting Capability
C. Occasional Lifts-Two Hands, Sagittal Plane, Compact Load
1. Guidelines
2. Load Location
a. Distance in Front of the Body
b. Height Above the Floor
3. Actions Defined by Weight-Limit Curves
D. Guidelines for Repetitive Lifts
1. Low Lifts
2. Higher Lifts
E. Guidelines for One-Handed Lifting
References
Chapter 24. Carrying and Shoveling
A. Carrying
B. Shoveling
1. Factors of Concern in Shoveling
2. Guidelines for Shoveling Workload
References
i:. �pter 25. Special Considerations in Manual Handling Tasks
,ti.. Drum, Carboy, and Bag Handling
1. Prum Handling
a. Metal Drums
b. Nonmetal 208-Liter (55-Gallon) Drums
c. Fiber Drums
�
•, . 2. Carboy Handling

xv

380
381
384
387
389
391
391
392
394
396
397
397
399
401
401
403
403
406
406
406
407
408
408
412
412
414
418
420
421
423
424
425
426
428
428
428
433
433
434

�xvi

CONTENTS

CONTENTS

3. Bag Handling
a. Chemical and Food Bags
b. Mail Bags
B. Wooden Pallet Handling
C. Large-Size Sheet Handling
D. Two-Person Handling
References

434
434
439
439
441
443
444

PART VII. Appendices

445

Chapter 26. Apppendix A: Human Capacities and Job Demands

446

A. Anthropometric Information for Biomechanical Analyses
1. Body Size and Segment Length
2. The Masses and Centers of Gravity of Body Segments
3. The Ranges of Joint Motion
4. Muscle Cross-Sectional Areas
B. Muscle Strength Data
1. Forearm Flexion and Extension
2. Forearm Rotation and Movements of the Hand at the Wrist
3. Grip Strength
4. Shoulder Flexion Strength
5. Isometric Lifting Strengths and Push-Pull Forces
6. Male-Female Strength Comparisons
C. Aerobic Work Capacity
1. Whole-Body Maximum Aerobic Capacities
2. Upper Body Maximum Aerobic Capacity
3. Maximum Aerobic Capacities for Lifting Tasks
D. The Energy Requirements of Occupational Tasks
1. Light Effort
2. Moderate Effort
3. Heavy Effort
4. Very Heavy Effort
5. Extremely Heavy Effort
References

Chapter 27. Appendix B: Methods to Evaluate Maximum Capacities
and to Measure Job Demands
A. Strength Testing in Industry
1. Static Stength-Testing Techniques
a. Standard Procedures for Static Muscle Strength Testing
(1) Measurement of Static Strength
(2) Subject Description

448
448
449
451
452
453
462
463
466
469
469
472
473
475
479
480
480
482
482
482
483
485
492
496
498
498
498
499
499

(3) Instructions to Subjects
(4) Test Procedures
(5) Reporting the Test Results
b. Tray-Lifting Strength
2. Dynamic Strength Testing
a. Psychophysical Methods
.b. Isotonic Dynamic Tests
, c. Isokinetic Strength Testing in Industry
B. Aerobic Work Capacity Tests
1. Whole-Body Aerobic Capacity Tests
a. General Design of Tests
b. Examples of Capacity Tests
2. Upper Body Aerobic Capacity Tests
C. Cardiovascular and Metabolic Measurements
1. Heart Rate
2. Blood Pressure
3. Minute Ventilation
4. Oxygen Consumption and Carbon Dioxide Production
a. Oxygen Consumption
b. Carbon Dioxide.Production
D. Review of Trigonome'try for Biomechanical Analyses
References

Chapter 28. Appendix C: Problems
A. Evaluation of Job Demands
1. Problem 1-Pulling Supply Rolls from Storage Shelves
to a Transfer Truck
2. Problem 2-Air Gun Design and Static Muscle Loading
B. Patterns of Work
1. Problem 3-Shipping Dock Workload
2. Problem 4-Determining Staffing Requirements
for a Production Machine Operation
3. Problem 5-Repetitive Motion and Knife Handle Design
4. Problem 6-Repetitive Motions in a Packaging Job
C. Hours of Work
1. Problem 7-Overtime versus Increased Labor
to Accomplish a Task
2. Problem 8-Scheduling of a Maintenance Project
D. Manual Materials Handling
1. Problem 9-Job Design for a Packaging Line
2. Problem 10-Loading Parts into a Hopper
on an Assembly Machine
3. Problem 11-Weight of a Sample Case
for a Sales Representative

xvii

500
500
501
501
505
506
506
507
509
511
513
515
517
520
522
525
527
527
527
529
529
530
534

536

536
538
540
540
542
545
546
548
548
549
551
551
553
554

�CONTENTS

xviii

E. Strength and Capacity for Work
1. Problem 12-Floor Scrubber and Handle Design
2. Problem 13-Wrapping and Packing Job Suitability
Selected Annotated Bibliography Relating to Ergonomics
and Job Design
1.
2.
3.
4.
5.
6.
7.
8.

General Ergonomics
The Physiological Basis of Work
Evaluation of Job Demands
Patterns of Work
Hours of Work
Manual Materials Handling
Human Capacities
Journals

555
555
556
559

559
560
561
563
563
565
566
567

List of Illustrations
PART I.
Chapter 1.

Glossary

569

Figure 1-1:

Index

591

PART II.
Chapter 2.
Figure 2-1:
Figure 2-2:
Figure 2-3:
Figure 2-4:
Figure 2-5:
Figure 2-6:
Figure 2-7:

Strength Distributions of an Industrial Population

Energy Supplies in the First Minutes of Moderately
Heavy Work
Gross and Microscopic Anatomy of Human
Skeletal Muscle
Length-Tension Curves As a Function of the Percentage
of Maximum Strength Used
Force-Velocity Curves at Different Percentages of Muscle
Strength-Concentric and Eccentric Contractions
The Lever Sy�tem of the Forearm
The Effect of Joint Angle on Measured Force
for Equal Muscle Forces
Nervous System Centers Involved in Movement Control

14

27
29
33
35
37
38
40

Chapter 3.
Figure 3-1:
Figure 3-2:
Figure 3-3:
&lt;figure 3-4:

4-1:
4-2:

The Anatomy of the Circulatory and Respiratory Systems
Muscle Capillaries
Functional Lung Volumes at Rest and During Exercise
Heart Rate Changes in Intermittent WorkSteady versus Nonsteady State

53
58
65

Terminology Used in Biorhythm Research
Daily Variation in Plasma Cortisol Levels

73
75

66

�xx

LIST OF ILLUSTRATIONS

Figure 4-3:
Figure 4-4:
Figure 4-5:

Average Oral Temperature Readings During
a 24-Hour Period
Average Oral Temperatures of 17 Packaging Operators
Average Oral Temperatures of Chemical Operators on a
Rapidly Rotating 12-Hour Shift Schedule

LIST OF ILLUSTRATIONS

79
80

Figure 7-25: Compressive and Shear Forces on the Low Back
During Lifting
Figure 7-26: Force and Acceleration Measurings During Lifting

84

Chapter 8.

Figure �1:
Figure iS-2:
Figure 8-3:

PART III.
Chapter 5.

Figure 5-1:

Primary Analysis of a Perceived Problem
in an Existing Job

Figure 8-4:

100

Figure 8-5:

Chapter 6.

Figure 6-1:
Figure 6-2:

Examples of Timed Activity Analyses
Identification of Problem Tasks in a Job

112
116

A First-Class Lever
A Second-Class Lever
A Third-Class Lever
Torque Calculations
Performance and Recovery Times as a Function
of Percentage of Maximum Strength Capacity
Calculating Muscle Force in a Static Equilibrium
Condition
A One-Handed Lifting Task
Static Torque at the Elbow Joint in One-Handed Lifting
Biomechanical Analysis of Box Handling
Tray Lifting
Lifting over a Vertical Obstruction
Lifting with an Extended Reach
Low Lifting of Sheet Materials
Biomechanical Analysis of Two-Handed Load Carrying
Biomechanical Analysis of Bending at the Waist
Biomechanical Analysis of Three Lifting Techniques
Sitting Posture at an Electronics Workbench
Compressive Forces on a Lumbar Disc
in Different Postures
The Lever Arm of the Spine in Sitting and Standing
Effects of Chair Design on Back Stress
Maintenance Work with Elbow Elevation
The Biomechanics of Shoulder Abduction
Shoulder Moment Arm Differences in a Handling Task
The Biomechanics of a Grasping Task

125
126
126
128

Figure 8-6:

Chapter 7.

Figure
Figure
Figure
Figure
Figure

7-1:
7-2:
7-3:
7-4:
7-5:

Figure 7-6:
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure

7-7:
7-8:
7-9:
7-10:
7-11:
7--12:
7-13:
7-14:
7-15:
7-16:
7-17:
7-18:

Figure
Figure
Figure
Figure
Figure
Figure

7-19:
7-20:
7--21:
7-22:
7-23:
7-24:

Measurement of Motion with an Electrogoniometer
Examples of Mechanical Force Transducers
Using a Mechanical Force Transducer to Measure Pushing
and Pulling Forces
Measuring the Forces Required to Push or Pull
a Hand Truck
Using an Electronic Force Transducer to Measure
the Forces Required in an Industrial Task
Using a Triaxial Accelerometer to Measure Movement
During an Assembly Task

xxi

155
156

163
164
166
168
170
171

Chapter 9.

130
131
133
134
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
152

Measuring Job Demands by Electrocardiogram
Example of a Fatigue Heart Rate Pattern
Heart Rate Elevation with Machine Jam Stress
Peak Heart Rate Response in Firefighting
Heart Rate Recovery from Physical Effort
Heart Rate Recovery from Emergencies
Heart Rate Recovery with Light Effort or Rest
During the Recovery Period
Figure 9-8: Heart Rate Patterns During Work in the Heat
Figure 9-9: Heart Rate Response Due to Sleep Loss
Figure 9-10: Heart Rate Responses of Several People Doing
the Same Job

Figure 9-1:
Figure 9-2:
Figure 9-3:
Figure 9-4:
Figure 9-5:
Figure 9-6:
figure 9-7:
1

177
180
181
182
184
185
187
188
189
190

Chapter 10.

··• lfigure 10-1: Categories of Physical Effort-Intensity and Duration
.· ,.figure 10-2: The Relationship Between Job Points and Average
::r
Oxygen Consumption Requirements

Effect of Duration on the Percent of Maximum Aerobic
Work Capacity That Can Be Used for Dynamic Work
Rest Allowance in Dynamic Work
Rest Allowances for Static Effort Activities
Effect of Work/Rest Cycle Patterns on Productivity
in a Light Assembly Task

195
201

211
215
219
226

�xxii

LIST OF ILLUSTRATIONS

LIST OF ILLUSTRATIONS

Chapter 12.

Chapter 22.

Figure 12-1: Variability in Time to Perform a Self-Paced Assembly Task 233
239
Figure 12-2: Catecholamine Excretion Rates in Different Occupations

Figure 22-1: Transverse Force Application

Chapter 14.
Figure 14-1.
Figure 14-2:
Figure 14-3:

Figure 14-4:

Training Time on a Repetitive Assembly Task
A Systems Approach to Training
The Relationship of Task Performance to the Amount
of Practice in Assembly Tasks
Performance Curve Variations-The Effects
of Practice with and without Feedback

Figure 15-1: Workload Limits as a Function of Continous
Hours Worked

264
269
270
271

281

Chapter 16.

Figure 16-1: Response Time and Workload for Teleprinter Switchboard
Operators on a Continuous Shift System
296
Figure 16-2: Number of Errors per Hour of the Day at Two Swedish
Gasworks and a Paper Mill
298
PART VI.
Chapter 20.

20-1:
20-2:
20-3:
20-4:
20-5:
20-6:

392

Chapter 23.

PART V.
Chapter 15.

Figure
Figure
Figure
Figure
Figure
Figure

xxiii

Figure 23.-1: The NIOSH Guidelines for Occasional Lifts
in the Sagittal Plane
I
Figure 23-2: The Vertical Location and Travel Distance Corrections
of the NIOSH Manual Lifting Guide
Guidelines for Occasional Lifts-Two Hands,
ure
23-3:
Fig
Sagittal Plane, Compact Load
Figure 23-4: Recommended Upper Limit for Design of Repetitive
Lifting Tasks Below 76 cm (30 in.)-Two Hands,
Sagittal Plane, Compact Load
e
23-5:
Frequency Adjustment for Medium-Height Range LiftsFigur
Two Hands, Sagittal Plane, Compact Load
Figure 23-6: Guidelines for the Upper Limit of Weight Lifted
with One Hand at Heights from 63 to 127 cm
(25 to 50 in.) Above the Floor

400
402
404
409
413
414

Chapter 24.

Figure 24-1: Guidelines for Carrying
Figure 24-2: Examples of One-Handed and Two-Handed Carrying

421
422

Chapter 25.
Pinch or Precision Grasp
Power or Cylindrical Grasp
Oblique Grasp
Hook Grasp
Palm-Up and Palm-Down Grasps
Recommended Handle Dimensions

351
353
354
355
356
358

21-1: Recommended Tray Dimensions
21-2: Examples of Tray Handholds
21-3: Comfort Ratings for Four Handle Configurations
21-4: Recommended Dimensions for Selected Tray
Handle Types
Figure 21-5: Large-Tray Handling
Figure 21-6: Maximum Dimensions Recommended for New
Shipping Case Design
J:;'.;.,........ ..,.a ?1-7•
�v:amnlP&lt;: of Hand Carts and Trucks

364
365
366

Figure 25-1:
Figure 25-2:
F1gure 25-3:
· Figure 25-4:
Figure 25-5:
lJgure 25-6:
F,�ure 25-7:

Examples of Chemical and Food Containers
Manual Handling of Drums
Drum Carts
Tipping Aid for Emptying Bottles or Carboys
Bag Handling
Pallet Handling Techniques
Large-Size Sheet Handling

429
430
432
435
436
440
442

Chapter 21.

Figure
Figure
Figure
Figure

367
369
371
375

re 26-1: Body Segment Length in Proportion to Stature-Males
e 26-2: Body Segment Length in Proportion to Stature-Females
e 26-3: Estimated Body-Segment Centers of Gravity Expressed
as a Percent of Segment Length
e 26-4: Ranges of Motion of the Forearm and Wrist
"� 26-5: Ranges of Motion of the Arm and Shoulder
f 26-6: Ranges of Motion of the Cervical Spine
and Spine Rotation

451
452
454
456
457
458

�xxiv

LIST OF ILLUSTRATIONS

Figure 26-7: Ranges of Motion of the Spine
Figure 26-8: Ranges of Motion of the Knee and Ankle
Figure 26-9: Effect of Elbow Angle and Velocity Changes on Elbow
Flexor Torque in Men and Women
Figure 26-10: Effect of Elbow Angle and Velocity Changes on Elbow
Extensor Torque in Men and Women
Figure 26-11: Effects of Grip Span on Maximum Isometric Grip Strength
Figure 26-12: Grip Strength Changes with Wrist Position
Figure 26-13: Maximum Isometric Push and Pull Forces Measured
with a Force Transducer-Two Hands Close Together
Figure 26-14: A Cumulative Frequency Distribution of the Maximum
Aerobic Work Capacities Measured on a Treadmill Test

459
460
464
465
469
470

List of Tables

474

PART I.
Chapter 1.

477

Table 1-1:
Table 1-2:

Chapter 27.
Figure 27-1: Static Force Development and Recommended
Measurement Time
Figure 27-2: Equipment for Measuring Static Strength Capacities
Figure 27-3: Measurement of Muscle Group Strengths for a Static
Lifting Strength Study
Figure 27-4: Vertical Lifting Locations for a Static Tray Lifting
Force Study
Figure 27-5: A Modified Isokinetic Device for Force and Velocity
Measurements
Figure 27-6: Force and Velocity Curves During a Simulated
Isokinetic Tray Lift
Figure 27-7: Whole-Body Aerobic Capacity Test Protocols
Figure 27-8: Upper-Body Aerobic Capacity Test Protocols
Figure 27-9: Heart Rate Calculations from the Electrocardiogram
Figure 27-10: Heart Rate Monitoring Equipment
Figure 27-11: Blood Pressure Measurement
Figure 27-12: Effect of Heart Rate on the Diastolic Blood
Pressure Reading
Figure 27-13: Oxygen Consumption Measurement
Figure 27-14: A Right Triangle for Trigonometric Analysis

499
502

Table 2-1:
Table 2-2:

504

Chapter 3.

508

Table 3-1:
Table 3-2:
Table 3-3:

526
528
530

8

Types of Muscle Effort in Several Work Tasks
Characteristics of Motor Units

22
31

Blood Flow Distribution in Different Working Conditions
Circulatory Controls to Adjust Blood Flow During Work
Circulatory and Respiratory Adjustments to Work

55
57
60

Departure and Arrival Time Coefficients
Body Temperature Curve Adaptations to Different
Work Schedules
Average Hours of Sleep at Night Following
Day-Shift Work
Average Hours of Sleep on Several Shift Schedules

77

PART II.
Chapter 2.

503

509
514
521
523
524
525

7

Ergonomic Input to the Job Design Process
Job Design Factors that Contribute to Losses
in Productivity

Chapter 4.
Table 4-1:
Table 4-2:
Table 4-3:
Table 4-4:

81
87
89

Chapter 28.
Figure
Figure
Figure
Figure

28-1:
28-2:
28-3:
28-4:

Paper Roll Handling Task
Air Gun Design and Static Muscle Loading
Production Machine Layout
Meat Cutting Knife Handle and Grip Style

537
539
543
545

Uses of Job Evaluation Techniques
Factors Analyzed to Assess the Physical Work Load
on a Job
Factors Measured to Assess Environmental, Mental,
. and Perceptual Job Demands
Performance Measures for Assessing Job Demands
Physiological and Psychophysical Measures Used
in the Assessment of Job Demands

96
102
103
104
105

�xxvi

LIST OFTABLES

Table 5-6:
Table 5-7:

Physiological and Psychophysical Measures Used
in Characterizing Job Demands
Strategies for Solving Job Problems

LIST OFTABLES

Table 13-3:

106
107

Table 13-4:
Table 13-5:

Chapter 6.
Table 6-1:
Table 6-2:
Table 6-3:
Table 6-4:
Table 6-5:

Job Activity Analysis for a Handler
Timed Activity Analysis of Job Tasks and Effort Levels
Analysis of Time-Shared Work Tasks in a Machine
Operator's Job
Work Cycle Analysis for a Shipping Dock Handler's Job
Motion Analysis of a Graphic Artist

113
115

Primary Physical Effort Requirements
Time Analyses-Percent of Time At Different Effort
Levels per Shift
Points-Primary Requirements
Supplementary Physical Effort Requirements
Points-Supplementary Requirements

196

Table 10-3:
Table 10-4:
Table 10-5:

Table 14-1:

117
119
120

Table 15-1:

Table 11-3:
Table 11-4:
Table 11-5:

214
216
218
221
225

Chapter 12.
Table 12-1:
Table 12-2:

Percentage of Time Spent in Different Activities
as a Function of Machine Speed
Impact of Increased Machine Speed on Time
for Inspecting One Pack of Product

235
236

Chapter 13.
Table 13-1:
Table 13-2:

Body Part Affected-Upper Extremity Disorders
Tasks and Occupations That May Aggravate
Repetitive-Motion Disorders

247
248

Estimated Repetition Frequency Needed to Become
Fully Skilled at a Task

263

Effect of Extended Hours of Work on Leisure Time

280

Chapter 16.

197
198
199
200

Table 16-1:
Table 16-2:
Table 16-3:

Maximum Workloads for Whole-Body Dynamic Work
Intermittent versus Continuous Work at an Extremely
Heavy Workload
Static Work Duration As a Function of Intensity
Effect of Temperature on Time for Work
at Different Effort Levels
Work Improvement with Task Variation

252
254

250

PARTY.
Chapter 15.

PART IV.
Chapter 11.
Table 11-1:
Table 11-2:

Individual and Workplace Factors Associated with
Repetitive-Motion Disorders
Percent of Time in Different Hand and Wrist Positions
and Carpal Tunnel Syndrome
Grip Strength Reduction with Glove Use

Chapter 14.

Chapter 10.
Table 10-1:
Table 10-2:

xxvii

;� .
f

Percent of Total Workers in Shift Work by Industry
Type-Unite1 States, 1975
Percentage of Shift Workers on Three Schedules
by Industry Type-United Kingdom, 1964
Shift Payment Differentials as a Percentage
of the Minimum Hourly Rate-United Kingdom, 1968

291
293
294

Chapter 17.
Five-Day Shift Schedules-Two Eight-Hour Shifts
Five-Day Shift Schedules-Three Eight-Hour Shifts
Five-Day Shift Schedules-12-Hour Shifts
Seven-Day Shift Schedules-Eight-Hour Shifts, Fixed,
12 Crews
Table 17-5: Seven-Day Shift Schedules-Eight-Hour Shifts,
Weekly Rotation
Seven-Day Shift Schedules-Eight-Hour Shifts,
Rapid Rotation
Seven-Day Shift Schedules-Eight-Hour Shifts,
Combination Fixed and Rotating
Seven-Day Shift Schedules-12-Hour Shifts
Seven-Day Shift Schedules-Combination Eightand 12-Hour Shifts
": le 17-10: Special Shift Schedules-Five-Day Shifts with Consistent
Saturday Overtime
le 17-11: Special Shift Schedules-Reduced Hours per Week,
Less Than 40 Hours
Table 17-1:
Table 17-2:
Table 17-3:
Table 17-4:

307
309
311
312
314
315
318
319
320
322
323

�xxviii

LIST OF TABLES

LIST OF TABLES

PART VI.
Chapter 21.
Table 21-1: Perceived Effort in Large-Tray Handling
Table 21-2: Impact of Increased Case Dimensions on the Acceptable
Load for Manual Materials Handling
Recommended
Limits in the Selection of Hand
Table 21-3:
and Powered Trucks and Carts
Chapter 22.
Table 22-1: Recommended Upper Force Limits for Horizontal Pushing
and Pulling Tasks
Table 22-2: Recommended Upper Limits for Vertical Pushing
and Pulling Forces in Standing Tasks

370
372
377

389
390

Chapter 23.
Table 23-1: Factors Influencing the Suitability of Manual
Handling Tasks
Table 23-2: Weight Handled per Minute for Low Lifts as a Function
of Item Weight and Lifting Frequency-Two-Handed
Sagittal Plane Lifts of Compact Objects

398
411

Chapter 24.
Table 24-1: Maximum Shoveling Workload for Three Conditions
and Two Durations

424

Chapter 25.
Table 25-1:

Table 26-8: Maximum Isometric Torques in Handle and Key TurningForearm Pronation and Supitllation
Maximum
Isometric Torques Generated in Movements
Table 26-9:
of the Hand Around the Wrist
Table 26-10: Maximum Grip Strength Values
Table 26:-11: Maximum Isometric Shoulder Flexor Strength and Torque
at Two Positions
Table 26-12: Maximum Isometric Pull Strength on a Tray
Table 26-13: Loss in Tray Pull Strength with Increasing Lift
Height and Distance from the Ankles
Table 26-14: Relative Muscle Strengths of Women and Men
Table 26-15: The Whole-Body Maximum Aerobic Work Capacities
of Industrial Men and Women
Table 26-16: Comparisons of Whole-Body Maximum Aerobic Work
Capacities for Industrial and Civilian Populations
Table 26-17: Upper Body Maximum Aerobic Work Capacity as a Percent
of Whole-Body Aerobic Work Capacity
Table 26-18: Lifting Task Maximum Aerobic Capacities as a Function
of Box Weight
Table 26-19: Lift Effort Tasks
Table 26-20: Moderate Effort Tasks
Table 26-21: Heavy Effort Tasks
Table 26-22: Very Heavy Effort Tasks
Table 26-23: Extremely Heavy Effort Tasks
Table 26-24: Effort Category Definitions in Terms of Aerobic
Work Requirements

xxix

466
467
468
471
472
473
475
476
478
479
481
483
484
486
488
490
492

Chapter 27.
Maximum Number of Bags to Be Lifted per Shift
by One Person

438

PART VII.
Chapter 26.
Table 26-1: Anthropometric Size Data-Centimeters
Table 26-2: Anthropometric Size Data-Inches
Table 26-3: Regression Equations for Estimating the Mass
of Body Segments
Table 26-4: Normal Ranges of Joint Motion
Table 26-5: The Approximate Cross-Sectional Areas of Selected
Muscle Groups
Table 26-6: Isometric Forearm Flexion and Extension StrengthsOne Arm
Table 26-7: Dynamic Forearm Flexion Strength and TorqueTwo Arms

449
450
453
455
461

Table 27-1: A Dynamic Lifting Profile for One Subject Lifting
at a Velocity of One Meter per Second
Maximum Simulated Lift Forces and Corresponding
Vertical Heights
Aerobic Demands of Step Test Work Levels
Aerobic Demands of Treadmill Levels
Aerobic Demands of a Staged Treadmill Task Used
in Industrial Stress Testing
Aerobic Demands of Bicycle Ergometer Work Levels
Equations for the Estimation of Energy Expenditures
During Various Activities
Equivalents for Standard Units in Capacity Testing

510
511
515
516
517
518
519
520

462

463

"e 2R-,-

Factors Influencing Selection of an Overtime Schedule
An-::1lT7&amp;'.."t�'"' ,,.....(. lAT..-.. .... 1., 1-. .... ....t f.-...,.. 0,...,,..,1, .... -.;._,.,.. T .;_.,.... (""\._,,....,,.,.,1--.....,r,

550

t::t::")

�KODAK'S

Ergonomic Design for
People at wOrk
mm
•

�T his newly updated, single-volume edition of the most respected and widely used
guidelines to ergonomics in the workplace, Kodak's Ergonomic Design for People at
Work, offers a concise and straightforward presentation of information, data, and
how-to guidelines for implementing solutions to human factors and ergonomics
problems in industries worldwide.
Written for those who are on the job but not necessarily professionally trained
ergonomists, the principles and approaches detailed here have all been imple­
mented in real-world workplace environments and proven successful in reducing
the potential for occupational injury, increasing the number of people who can
perform a job, and improving employee performance on the job.
More than 150 clear and informative illustrations and tables help convey data and
information in eight sections:
• Ergonomics design philosophy

• Human reliability and information transfer

• Evaluation of job demands

• Work design

• Workplace design

• Manual handling in occupational tasks

• Equipment design

• Environment

Complete with numerous case studies illustrating applied ergonomics, Kodak's
Ergonomic Design for People at Work, Second Edition is an essential guide for human
factors and ergonomics specialists, engineers, and occupational health specialists.

EASTMAN KODAK COMPANY, INC., is the global leader in imaging. Between 1911

and 1936, Kodak established a safety committee to evaluate workplace conditions,
became a charter member of the National Safety Council, and opened a Medical
Department and a Laboratory of Industrial Medicine and Toxicology. In 1960, Kodak
formed an Ergonomics Department, which became a global force in ergonomic
research, producing the first edition of Ergonomic Design for People at Work
(Vol. 1: 1983, Vol. 2: 1986). Kodak is committed to maintaining its position as a
leader in health, safety, and environmental performance, while driving continual
improvements in operations and products.

Cover Design, Anne Michele Abbott

Subscribe to our free Engineering eNewsletter at
www.wiley.com/enewsletters
Visit www.wiley.com/engineering

ffiWILEY
wiley.corn

�1

i

Kodak's Ergonomic Design
for People at Work

�Sec9nd Edition

The Eastman Kodak Company

WILEY

John Wiley &amp; Sons, Inc.

�Contents
This book is printed on acid-free paper.
Copyright © 2004 by Eastman Kodak Company. All rights reserved. Previously published by
Van Nostrand/Reinhold under the following titles: Ergonomic Design for People at Work,
Volume I, copyright © 1983 by Eastman Kodak Company, all rights reserved; Ergonomic Design
for People at Work, Volume II, copyright © 1986 by Eastman Kodak Company, all rights
reserved.
Published by John Wiley &amp; Sons, Inc., Hoboken, New Jersey
Published simultaneously in Canada
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by arty means, electronic, mechanical, photocopying, recording, scanning, or otherwise,
except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without
the prior written permission of the Eastman Kodak Company. Requests to the Eastman Kodak
Company for permission should be addressed to Corporate Clearance, Eastman Kodak Com­
pany, 1999 Lake Avenue, Rochester, NY 14650-2218, (585) 588-6323, fax (585) 477-9752,
e-mail: corpclr@kodak.com.
Limit of Liability/Disclaimer of Warranty: While the publisher, Eastman Kodak Company, the
editors and the contributors have used their best efforts in preparing this book, they make no
representations or warranties with respect to the accuracy or completeness of the contents of this
book and specifically disclaim any implied warranties of merchantability or fitness for a particu­
lar purpose. No warranty may be created or extended by sales representatives or written sales
materials. The advice and strategies contained herein may not be suitable for your situation. You
should consult with a professional where appropriate. Neither the publisher nor Eastman Kodak
Company nor any or the editors or contributors shall be liable for any loss of profit or any other
commercial damages, including but not limited to special, incidental, consequential, or other
damages.
For general information on our other products and services or for technical support, please con­
tact our Customer Care Department within the United States at (800) 762-2974, outside the
United States at (317) 572-3993 or fax (317) 572-4002.
Wiley also publishes its books in a variety of electronic formats. Some content that appears in
print may not be available in electronic books. For more information about Wiley products, visit
our web site at www.wiley.com.
Library of Congress Cataloging-in-Publication Data:
Ergonimic design for people at work Eastman Kodak Company.-2nd ed.
p. cm.
ISBN 0-471-41863-3 (Cloth)
1. Human engineering-Handbooks, manuals, etc. I. Eastman Kodak Company.
T59. 7 .E7145 2003
620. 8'2-dc21
2003001240
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1

Preface
Acknowledgments

XXV

xxvii

1
Ergonomics Design Philosophy

Ergonomics and Human Factors
The Scope and Purpose of This Book
Definitions
The Benefits of Ergonomics and Human Factors
Ergonomics at Eastman Kodak Company
Ergonomics Program Characteristics in Other Companies
Influences on Ergonomics Programs
Regulatory Influences
Level of Responsiveness
Mature Ergonomics Efforts: Programs to Processes
Participatory Ergonomics
Specific Ergonomks Process Issues
Globalization
Integrating Productivity Enhancements
Program Examples
OSHA Ergonomics and Record-Keeping Agreement in a
Manufacturing Facility
A Mature Ergonomics Process in a Moderate to Heavy
Manufacturing Facility
Some Program/Process Traps to Avoid
Summary
An Ergonomics Problem-Solving Technique
Background
Sources Contributing to This Problem-Solving Technique
The Problem-Solving Process
Step 1: Identifying Jobs with Ergonomics Opportunities

1
1
1
2
2
3
5
5
5
6
8
10
11
11

12
13

13

15
16
17
18
18
18
19
19
V

�vi

Kodak's Ergonomic Design for People at Work

Step 2: Defining the Job Demands
Step 3: Identify Risk Factors by Body Part for Each Task of
Concern
Step 4: For Each Risk Factor, Ask Why It Is Present Until a
Dead End Is Reached
Step 5: Develop Strategies for How to Address the Root
Causes and Generate at Least Three Solutions for
Each Task of Concern
Step 6: Choose the Solution(s) That Will Substantially
Reduce the Ergonomic Problems and Be Within
Affordable Cost Guidelines for the Plant
For Whom Do We Design?
Accommodate the Functional Capacities and Capabilities of a
Large Majority of the Potential Workforce
Why Design for the Large Majority?
Less Opportunity for Overexertion Injuries and Illnesses
Flexibility in Staffing When People Are on Vacation
Ability to Stay on the Job Longer
Enhancement of Cellular or Modular Teamwork
Ability to Meet EEO and ADA Regulations and Guidelines
Determining Whom to Design for So Most People Can Work
-Comfortably
Designing Airplane and Auditorium Seating:
Distribution of a Body Size Characteristic­
Buttocks-to-Popliteal Length (Upper Leg Length)
Determining the Maximum Heights for Valves or Controls:
Distribution of Overhead Reach (Standing)
Determining Force Requirements for Performing a
Repetitive Task (Manual Crimping): Distribution
of Grip Strength
Designing Tasks That Require Lifting Items Above
Shoulder Height
Determining Acceptable Workloads for Eight-Hour Shifts:
Distribution of Aerobic Work Capacity
Designing Tasks That Use Perceptual, Sensory, Cognitive,
and Memory Capabilities
Designing to Accommodate the Needs of Employees with
Disabilities or Reduced Work Capacities
General Design to Include People with Disabilities: Access
Specific Accommodations for People with Disabilities:
Workplaces

19
22

22
25
26

27

27
28
28

29
29
29
29

30

31
32

32
34
35
36
37
37
39

Contents

vii

The Effect of Aging on Perceptual and Cognitive Abilities
Perceptual Abilities
Cognitive Skills
. Design of Lifting Tasks for People with Low Back Disorders
Capacity and Capability Data
Anthropometric Data
The Data: United States
Other Ethnic or Regional Data
Range of Motion and Joint Centers of Motion
Cautions on the Use of Anthropometric Data in Design
Military Versus Industrial Population Data
Using Anthropometric Data for Design When More
than One Measurement Is Involved
Muscle Strength Data
Grip Strength
Upper-Extremity Strengths
Whole-Body Pulling Strength
Aerobic Wor½; Capacities of the Workforce and Aerobic
Demands of Tasks
Aerobic Work Capacities
Aerobic Demands of Some Occupational Tasks
United States and International Standards Related to Ergonomics
Internet Locations for European and International Standards
International Standards
International Organization for Standardization (ISO)
Other International Standards Groups
European Standards
European Union (EU) Mandatory Directives
Directive 89/391/EEC: Health and Safety at Work
Noise Directive 86/188/EEC
Machinery Directive 98/37/EC
Safety of Machinery: Human Physical Performance
Draft EN-1005
European Nonmandatory Standards
United Kingdom (UK)
Mandatory Regulations
Nonmandatory Standards
United States of America (USA)
Occupational Safety and Health Act: Mandatory
Americans with Disabilities Act (ADA): Public
Law 101-336

40
40

42

44
45
46

47

51
55
58
58
59

62

63
64
65
65
67
70

74

75
75
75
76
76
76
78
78
79
79
79
79
79
80
80
80
80

�viii

Kodak's Ergonomic Design for People at Work.

California Ergonomics Standard
Washington State Ergonomics Standard
Repealed Ergonomics Program Standard
ANSI Standards
ANSI/HFS 100-1988, American National Standard
for Human Factors Engineering of Visual
Display Terminals
ASC Z-365, Management of Work-Related
Musculoskeletal Disorders
ASC Z-10, Occupational Health Safety Systems
HFES 200, Software User Interface Standard
ACGIH TLVs
NIST
Miscellaneous Standard-Setting Groups
Canada
British Columbia (BC)
Ontario (ON)
Canadian Standards Association (CSA)
Australia
National Occupational Health and Safety Commission
(NOHSC)
Comcare
New South Wales (NSW) Workcover Authority
Victorian Workcover Authority
South Australian Workcover Authority
Worksafe Western Australia
Queensland Division of Workplace Health and Safety
Workplace Standards Tasmania
Australian Capital Territory (ACT)
Northern Territory Work Health Authority
Standards Australia
Japan
Ministry of Health, Labour, and Welfare
National Institute of Industrial Safety (NHS)
National Institute of Industrial Health (NIIH)
Japanese Standards Association (JSA)
Japan International Center for Occupational Safety and
Health (JICOSH)

81
81
81
82

82
82
82
83
83
83
83
84
84
84
84
84
85
85
85
86
86
86
87
87
87
87
88
88
88
89
89
89
89

Contents

Evaluation of Job Demands

Principles
Biomechanics
Biomechanics of Posture
Biomechanics of Holding
Biomechanics of Gripping
Dynamic Motion
Static Muscle Work
Dynamic Work
Psychophysical Scaling Methods
Psychophysical Scales
Subjective Rating Methods
Ratings of Perceived Exertion and Discomfort
Analysis Methods
Qualitative Methods
Job Safety A,.p.alysis and Job Hazard Analysis
Checklists
Semiquantitative Methods
MSD Analysis Guide
Rodgers Muscle Fatigue Assessment
Liberty Mutual Tables for Manual Materials Handling
University of Utah Back Compressive Force Model
Shoulder Moment
ACGIH TLV for Hand Activity Level
WISHA Hano-Arm Vibration Analysis
Quantitative Methods
Strength and Biomechanics
Static Work: Endurance and Work/Recovery Cycles
Dynamic Work: Endurance and Work/Recovery• Cycles
Estimation of Metabolic Rate
NIOSH Revised Lifting Equation
Moore-Garg Strain Index
Dynamic Work: Heart Rate Analysis

ix
99

101
101
102
106
110
112
112
115
117
117
118
119
121
121
123
124
127
127
137
152
159
159
162
165
165
165
167
168
169
174
180
181

3

Workplace Design

GeJJeral Workplace Layout and Dimensions
Sitting Workplaces
The Seated Work Area

191

191
194
194

�X

Contents

Kodak's Ergonomic Design for People at Work

Seated Workplace Height
Standing Workplaces
The Standing Work Area
Standing Workplace Height
Computer Workstations
Selection of Computer Equipment
Workstation Design
Work Surface Dimensions and Design
Clearances Under the Work Surface
Work Surface Height
Depth and Width of Work Surface
Type of Work Surface
Summary of Dimensions for Computer Workstations
Workstation Layout
· Workstation Placement
Computer Equipment and Work Material Layout
Laboratories
General Principles of Laboratory Bench Design
Workbench
Equipment Installation
Equipment Layout
Containment Cabinets and Glove Boxes
Containment Cabinets
Glove Boxes
Microscope Workstations
Standing Workstation
Seated Workstation
Workstation Modifications
Microscope Modifications
Liquid Dispensing Stations
Visual Work Dimensions
Visual Field
Viewing Angle
Viewing Distance
Size of Visual Targets
Floors, Ranips, and Stairs
Floors
Floor Material
Floor Maintenance
Footwear
Ramps

197
197
197
201

Stairs arid Ladders
Stairs
Stair Dimensions
Stair Surfaces
Visual Considerations in Stair Design
Handrails
Ladders and Step Stools
Conveyors
Adjustable Workstations
Adjusting the Workplace
Shape
Location: Height and Distance
Orientation
Adjusting the Person Relative to the Workplace
Chairs
Support Stools, Swing-Bracket Stools, and Other Props
Platforms, Step-Ups, and Mechanical Lifts
Footrests
Armrests
Adjusting the Workpiece or the Product
Jigs, Clamps, and Vises
Circuit Board Assembly
Parts Bins
Lift Tables, Levelators, and Similar Equipment
Adjusting the Tool (Design and Location of Tools)

203

203
204
206
208
208
211
212
213
213
214

215
217
218
218
219
220
220
221
223
224
226
226
226
227
227
228
228
230
233
233
234
237
237
238
239
240

xi
242
242
243
243
244
245
246
247
249
251
251
251
251
251
252
253
254
255
256
256
257
257
257
257
257

4
\

Equipment Design

Overall Considerations
Physical Capability
Environment and Safety
Maintainability
· Areas to Consider When Planning Maintainability
Requirements
Prime Equipment
Test Equipment
Maintenance Manuals
Tools
Installation and Accessibility

269
270
270
272
273
273
274
274
274
274
274

�xii

'
!

Contents

Kodak's Ergonomic Design for People at Work

Connectors and Couplings
Labeling
Design of Displays
Modes of Display
Tactile/Haptic Mode
Auditory and Visual Modes
Equipment Visual Displays
Light Displays
Instrument Displays
Dials and Gauges
Digital
Installation of Instrument Displays
Electronic Displays
Light-Emitting Diode (LED)
Cathode Ray Tube (CRT)
Liquid Crystal Display (LCD)
LCD or CRT?
Plasma Display Panel (PDP)
Installation of Displays
Design of Controls
Behavioral Stereotypes
General Population Stereotypes
Control Movement Stereotypes
Display and Control Relationship Stereotypes
(Compatibility)
Design, Selection, and Location of Controls
Location
Spacing
Shape Coding
Control Resistance
Types of Controls
Computer Input Devices
Keyboard
Types of Keyboards
Characteristics of Standard Keyboards
Numeric Pad
Alternative Keyboards
Notebook Keyboards
Mouse
Trackball
Mouse Versus Trackball

277
279
280
282
282
283
283
285
286
286
289
289
290
291
292
292
293
293
294
294
295
295
296
297
299
300
301
302
302
304
304
305
305
319
320
321
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Joystick and Touchpad
Graphic Tablet
Touch Screen
Voice
Computer Interface Controls
Understanding the User
Understanding the Control System
Technology Constraints
Total System Structure
. Designing Controls
Matching the User's Expectations
Limit Precision to What the User Needs
Match Order of Control with Objective
Make the System Consistent
Make the System Flexible
Control Relevant Data
Keep False Alarm Rate Low
Make Use qf Memory-Aid Principles
Make Each Control Self-Explanatory
Minimize the Need for the User to Translate,
Transpose, Interpret, or Refer to Documentation
Keep Input and Output Messages Brief to Minimize
the Probability of Error
Use Chunking for Lengthy Input and Output
Provide Computer Prompts
Provide Immediate Feedback
Avoid Perceptual Saturation
Aid Sequential and Timed Control Tasks
Aid Seldom-Performed Control Tasks
Group Controls
Consistency in Grouping
Label Controls
Label Coding
Code Selection
Feedback
Negative Response
Response Time
Error Messages and Error Handling
Control Integration
Wide Angle
Landmarks
1

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Kodak's Ergonomic Design for People at Work

Overlap
Evaluation
Reiteration
Task-Based Evaluation
Talk-Through
Mockup Procedure
Usability Testing
Tool Design
Postural Stress and Muscle Fatigue During Tool Use
Pressure Points on the Hand
Safety Aspects of Hand Tool Design
Design and Selection Recommendations for Hand Tools
Handle Design
Switches and Stops
Other Tool Characteristics
Special-Purpose Tools
Pipettes
Design to Reduce Repetition
Design to Reduce Forces, Especially on the Thumb
Lay Out the Workstation to Adopt a Neutral,
Relaxed Posture
Evaluation and Selection of Equipment
List of Criteria
Evaluation Scales and Scale Weighting
Evaluation Step
Scoring
Overall Ranking

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5
Human Reliability and Information Transfer

Human Reliability
Human Reliability Analysis (HRA) Techniques
Techniques for Human Error Rate Prediction (THERP)
Success Likelihood Index Methodology (SLIM)
Human Error Assessment and Reduction Technique
(HEART)
Absolute Probability Judgment (APJ)
Cautions When Using HRAs
Information Transfer
Warnings

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Contents

Visual Warnings
Auditory Warnings
Speech Signals
Nonspeech Signals
Evacuation Alarms
Alarms and Ear Protection
Auditory Icons
Instructions
Coding
Alphanumeric Coding
Shape Coding
Color Coding
Forms and Surveys
Question Design
Survey Design
Data Analysis
Labels and Signs
Compreheq�ibility
Legibility
Readability

xv

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404

6
Work Design

Organizational Factors in Work Design
· The Importance of Organizational Factors in
Work Design·
Organizational Factors Influencing Job Demands
Organizational Demands and Stressors and Their
Management
Workplace Stressors Associated with Occupational
Illnesses
'Stressors in a Computer-Based Workplace
Macroergonomics
Organizational Factors Contributing to Occupational
Stress from the Workers' Perspective
Guidelines to Improve the Organizational Factors in Job
Design
General Guidelines
The Design of Work in a Job Shop Production
Department

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�xvi

Contents

Kodak's Ergonomic Design for People at Work

Characteristics of Job Shop Work
The Impact of Job Shop Scheduling on Workers
Design Guidelines to Reduce the Stress of Job Shop
Work on Workers
Hours of Work: Shift Work and Overtime
Introduction and Regulations
Shift Work and Employee Health and Safety
Coronary Heart Disease (CHO)
Psychosocial factors
Sleep
8-Hour shifts Versus 12-Hour shifts
Overtime Considerations
Aging Considerations
Shift Work Characteristics
The Shift Work Design and Redesign Process
Case Study: Shift Schedule Redesign Project
History
Alternative Work Scheduling (AWS) Process Outline
Outcomes
Conclusions
Ergonomic Work Design
Goals in the Design of Jobs
The Measurement of Work Capacities
Designing to Minimize Fatigue
Signs of Fatigue
Workload and Fatigue
Static Muscle Work
Mechanisms of Static Muscle Fatigue
Recognizing Static Work
Work Design to Reduce Static Work
Dynamic Work
Mechanisms of Dynamic Work Fatigue
Recognizing Dynamic Work
Work Design to Reduce Dynamic Work Demands
Job/Task Control
Physical Fitness of the Workforce
Job Rotation
The Design of Repetitive Work
Job Risk Factors
Individual Risk Factors
Guidelines for the Design of Repetitive Work

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455

·'

General Guidelines
Specific Design Guidelines
Hand Tool Design for Repetitive Tasks
Management of MSDs in the Workplace
Special Considerations: Design of Ultra-Short-Cycle Tasks
Definitions and Concerns
Estimating Local Muscle Fatigue on Short-Cycle
and Highly Repetitive Tasks
Predicting Accumulated Fatigue
Responding to Short-Term, Highly Repetitive Task
Demands
Example: Predicting Muscle Fatigue in Short-Duration,High­
Volume Tasks to Determine Labor Needs or Line Speed
Changes
Ergonomic Design Approaches to Reduce Local Muscle
Fatigue
The Design of Visual Inspection Tasks
Measures of Inspection Performance
Individual Factors
Physical and Environmental Factors
Task Factors
Organizational Factors
Guidelines to Improve Inspection Performance
Ergonomics in the Construction Industry
The Need for Ergonomics in the Construction Industry
Construction Job Factors and MSDs
Responsibility fot Ergonomics
Controlling Risk Factor Exposure
Ergonomics Interventions in Construction
The Participatory Process
Example of Ergonomic Interventions
Building a Plant
Drywall Installation
Bricklaying
Operating Heavy Equipment
(,
Manuai Materials Handling
·.•· LL· Summary
)'}:Y�rk Design in Laboratory and Computer Workplaces
i::&gt;. Laboratory Task Design: Pipetting
Adopt a Neutral, Relaxed Posture.
Control the Amount of Continuous Time on the Task

xvii
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Kodak's Ergonomic Design for People at Work

xviii

Work Patterns in Computer Tasks
Recovery Breaks
Training Programs for Office Ergonomics

497
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498

7
Manual Handling in Occupational Tasks
11

Background: Manual Handling and Musculoskeletal Injuries and
Illnesses
Types of Musculoskeletal Overexertion Injuries Seen in
Manual Handling Tasks
Muscle Overexertion Injuries
Muscle Overuse Injuries
Inflammatory Response to a Sustained or
Repetitive Load
Work-Related.Musculoskeletal Disorders
Strategies to Reduce Manual Handling Risk Factors
Materials Flow Analysis
Unit Load Principle
Mechanization Principle
Standardization Principle
Adaptability Principle
Dead Weight Principle
Gravity Principle
Automation Principle
Education of Handlers
Types of Training
Guidelines for Lifting Training
Two-Person Handling Training
One-on-One Lifting and Force Exertion Training
Training Handlers on the Use of Handling
Assist Devices
Training in the Use of Back Belts and Gloves
Selection
Redesigning the Jobs and Workplaces
Guidelines For the Design of Manual Lifting Tasks
Factors That Contribute to Acceptable Weights for Lifting
The Size of the Object Lifted: Container Design
Tray Design
Case Dimensions
Location of the Lift

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519
520
521
521
521
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527

i'

Horizontal Distance from the Hands to the Lower
Spine
Horizontal Location of a Lift
Vertical Height at the Beginning and End of the
Lift
Vertical Distance of the Lift·
The Degree of Asymmetry of the Lift
The Type of Grip Used
Environmental Factors
Stable Footing
Stable Grasps
Stability of the Load
Guidelines for the Design of Occasional Lifts
NIOSH Guidelines for the Design of Occasional
Manual Lifts
Percentage of Population Finding Lifts Acceptable Based
on Location and Weight
Han&lt;!ling Doors into a Carousel on a Car Assembly
Line
Handling Items to Shelves in a Chemical Storeroom
Guidelines for the Design of Frequent Lifting Tasks
Metabolic Factors Contributing to Acceptable Loads
Local Muscle Fatigue Determinants of Acceptable Loads
Guidelines for the Design of Carrying Tasks, Shoveling, and
One-Handed Lifting Tasks
Carrying (Two-Handed)
Shoveling
One-Handed Lifting
Special Considerations in Manual Lifting Task Design
Manual Pallet Handling
Drum Handling
Carboy and Large Bottle Handling
Bag Handling
. . ·. , &gt;.
6 · Large-Size Sheet or Wallboard Handling
;c;he Design of Force Exertion Tasks
J1hHorizontal Forces Away from and Toward the Handler:
'
Hand Cart and Truck Design Guidelines
tOther Horizontal Forces: Overhead, Seated, and Kneeling
- Vertical Pushing and Pulling
Transverse or Lateral Forces Applied Horizontally
,
Hand Forces
.

xix
527
527
527
527
527
528
528
529
529
529
529
530
530
533
533
534
535
536
537
537
538
539
540
540
542
545
548
551
552
553
557
558
559
559

�xx

Kodak's Ergonomic Design for People at Work

Contents

8

Environment

Lighting and Color
Visual Work Demands
Basic Light Terminology
Recommended Illuminance Levels
Quality Issues
Age of the User
Glare
Shadows
Room Appearance
Natural Sunlight
Lighting Design
Types of Lamps
Direct and Indirect Luminaires
Task or Supplementary Lighting
Special Lighting Conditions
Computer Workplace Lighting
Inspection Workplace Lighting
Darkroom Lighting
Color
Noise
Hearing Loss
Annoyance and Distraction
Interference with Communication
Measuring Noise Levels
Instrumentation and Measurement
When and Where to Make Noise Measurements
How to Make Noise Measurements
Performance Effects of Noise
Approaches to Reducing Noise in the Workplace
Special Considerations
Thermal Environments
Thermal Balance
Heat Exchange for the Whole Body
Heat Exchange for Local Skin Surface
Assessment of the Thermal Conditions
Environment
Work Demands
Clothing

565
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566
566
567
567
567
569
570
571
572
572
574
574
575
575
575
576
576
578
579
579
582
584
584
585
585
586
587
588
588
589
589
591
592
592
594
594

,,

ik

�

f,

�

Qualitative Assessment
Thermal Comfort
Thermal Comfort Zone
Factors Affecting the Feeling of Comfort
Temperature
Humidity
Air Speed
Workload
Clothing
Radiant Heat
Warm Discomfort and Heat Stress
Warm Discomfort
Heat Stress
General Controls
Job-Specific Controls
Special Cases: Hot Surfaces and Breathing Hot Air
Cool Discomfort and Cold Stress
Cool Discoi;µfort
Cold Stress
General Controls
Job-Specific Controls
Vibration
Introduction
Measurement of Vibration
Accelerometers
Vibration Frequency Analysis
Resonance
Evaluation of Human Vibration
Whole-Body Vibration Exposure Guidelines
Hand-Arm Vibration Guidelines
Vibration Reduction and Control
Source Control
Path Control
Receiver Control

xxi

595
596
600
601
601
602
602
602
603
603
604
604
607
607
608
611

612
614
615
617
617
617
617
619
620
620
623
623
626
626
626
627
628
629

635
651
681

�Contributors
Steve M. Belz, Ph.D. Eastman Kodak Company Rochester, New York
Chapter 5
Thomas E. Bernard, Ph.D., CPE University of South Florida Tampa,
Florida
Chapter 2, Chapter 4. Chapter 6. Chapter 8
Somadeepti N. Chengalur, Ph.D., CPE Eastman Kodak Company
Rochester, New York
Chapter 1, Chapter 2, Chapter 3, Chapter 4, Chapter 8
Thomas M. Cook,; Ph.D. University of Iowa Iowa City, Iowa
Chapter 2
Donald E. Day Consultant
Chapter 1, Chapter 6
Leslie B. Herbert, Ph.D. Eastman Kodak Company Rochester, New
York
Chapter 5
Nancy E. Laurie, Ph.D., AEP Eastman Kodak Company Rochester,
New York
Chapter 2
Rob G. Radwin, Ph.D., CPE University of Wisconsin Madison,
Wisconsin
Chapter 8
Suzanne H. Rodgers Consultant in Ergonomics Rochester, New York
Chapter 1, Chapter 2, Chapter 4, Chapter 6, Chapter 7
tjohn C. Rosecrance, Ph.D., CPE University of Iowa Iowa···City, Iowa
·
Chapter 6
·· arol Stuart-Buttle, CPE Stuart-Buttle Ergonomics Philadelphia,
· Pennsylvania
Chapter 1, Chapter 3, Chapter 4, Chapter 6, Chapter 7
)1a N. Thompson Emb ry-Riddle Aeronautical University Daytona
each, Florida
�'.;hapter 5

:r

xxiii

�:xxiv

Kodak's Ergonomic Design for People at Work

Dennis A. Vicenzi, Ph.D. Embry-Riddle Aeronautical University
Daytona Beach, Florida
Chapter 1, Chapter 5
Robert S. Weneck, CPE Eastman Kodak Company Rochester, New
York
Chapter 8
Inger M. Williams, Ph.D. Cergos Rochester, New York
Chapter 2, Chapter 3, Chapter 6
John A. Wise, Ph.D., CPE Honeywell, AES Phoenix, Arizona
Chapter 4
Mark A. Wise, Ph.D. IBM Global Services Raleigh, North Carolina
Chapter 4

Preface
The application of human factors/ergono mics pri nciples to the w orkplace
has been of interest to Eastman Kodak Company for many y e ars.
Ergonomic Design for People at Work, Volumes I and II (published in 1983
and 1986, respectively) summarized data, experience, and thoughts assem­
bled from the published literature, i nternal research, and ob servations by
the members of the Human Factors S ection/Ergono mics Group at Eastman
Kodak Company.
Almost twenty y ears later, the field has evolved, much work and research
has taken place both inside and outside Eastman Kodak Company, and there
are many more publications in the field of industrial human factors/ergonom­
ics. However, we still think there is a continued need for a practical discussion
ofissues such as design (workplace, e quipment, j ob, and environment), analy­
sis (of j obs, e quipment, and workplaces), and the link to people 's abilities. To
reflect the spread and gro wth of information, Kodak and the editors have
· drawn on expertise outside the company to update and revise the material in
the original books.
In response to a number of comments and re quests from users of the
Kodak books, this edition has been condensed to one volume. However, the
focus of this work has. not changed: to distill a lot of information and give
fairly simple and straightforward guidelines and how-tos that can be used by
people who are not professionally trained ergonomists. A basic understanding
and knowledge of science, mathematics, and terminology on the part of the
reader is assumed. One of the criteria for inclusion of material is that it ha s
been tried in the plants, and it works ! In many instances, this . book provides
alternative way s of addressing ergonomics problems in the workplace com. j:,a:red to the traditional biomechanical and modeling approaches that are
•··· given in other books.
· " . The goal of this book is to provide information of a practical nature that
an b e used to solve problems i n the workplace. The intended audience is
ractitioners, rather than researchers, and so the book is not a compendium
state-of-the art human factors and ergono mics i nformatio n. The selectio n
material has been guided by the typ es of problems the authors have been
�ed to address in industrial settings. The guidelines and examples of
· roaches to design problems are most often drawn from case studies. The
_dp les have been successfully applied in the workplace to reduce the
XXV

�xxvi

Kodak's Ergonomic Design for People at Work

potential for occupational injury, increase the �umber of p�ople �ho can
perform a job, and imp rove perfor mance on the J o h, thereby mcreasmg pro ductivity and quality.
It is our hope that the experience gained from problem solving in an industrial setting by a group that includes many disciplines, will be of value to
ial will be
others with fewer resources available to them, and that the mater
industries
in
blems
ro
p
useful in the solution of human factors and ergonomics
in many countries.

Acknowledgments
We would like to thank especially all the contributors for the previous edition,
without whose work we would not have this book. In particular, we would
like to mention:

•l:

i

t

Stanley H. Caplan
Paul C. Champney
Kenneth G. Corl
Brian Crist
William H. Cushman
"
Harry L. Davis
Elizabeth Eggleton
Thomas S. Ely
Terrence W. Faulkner
Deborah Kenworthy

David M. Kiser
Richard M. Little
Richard L. Lucas
Carol McCreary
Thomas J. Murphy
Waldo J. Nielsen
Richard E. Pugsley
Suzanne H. Rodgers
William Sabia
John A. Stevens

For this edition of the book, particular thanks go to Kay S. Marsh for
working so hard behind .the scenes to make sure this book was publishable.
Chris Devries from K-odak Imaging services is responsible for much of the art­
work, uncomplainingly accepting each change in specifications for the art­
work. And, of course, thanks to Chris Pergolizzi and Apat'na Sharma for scan. ning anything that could be scanned into an electronic file.
To R. Hays Bell, David M. Kiser, and John O'Donoghue, thanks for their
'/guidance and support throughout the long months this book was "in pro­
\.cess."
Finally, we want to thank all of y ou who have written, telephoned or
therwise let us know that an update was too long in coming. Thanks in part
·'your requests, this edition of the book has finally been put together.
Somadeepti N. Chengalur

:xx:vii

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                  <text>IN COPYRIGHT - EDUCATIONAL USE PERMITTED &#13;
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-i

WoR &lt;ING
WITH
BACKACHE

SUZANNE H. RODGERS, Ph.D.

Consultant in Ergonomics

Illustrations by Leigh Ann Smith

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WORKING WITH BACKACHE
by Suzanne H. Rodgers, Ph.D.

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Consultant in Ergonomics/Human Factors
Rochester, New York
Assistant Professor, Part-time, Physiology Department,
University of Rochester School of Medicine and Dentistry
Adjunct Associate Professor,
Industrial Engineering Department,
State University of New York at Buffalo

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Illustrations

by Leigh Ann Smith

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foreword by Stover H. Snook, Ph.D.

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Project Director - Ergonomics
Liberty Mutual Insurance Company
Hopkinton, Massachusetts

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Copyright@ 1984 by Suzanne H. Rodgers, Ph.D.
Published July 1985
by
Perinton Press
All rights reserved. No part of this publication may be reproduced or transmitted
in 'any form, by any means, electronic, magnetic, mechanical, photographic, or
otherwise, including information storage and retrieval systems, without prior
written permission from the publisher, except for brief quotations by a reviewer.
Library of Congress Catalog Card Number: 85-61915
ISBN 0-931-15701-3
Printed in the United States of America

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FOREWORD

There is nothing new about backache. Bernardino Ramazzini,
the founder of occupational medicine, was concerned about it
back in 1690, and the ancient Egyptians suffered from it over 5000
years ago. The disorder appears to be as old as mankind itself probably even older, since four-legged animals are also known to
suffer from back problems. Over the centuries, medicine has not
progressed as far in understanding and controlling low back pain
as it has with other types of disorders. Consequently, as old as
low back pain is, it remains a major source of impairment,
disability and compensation in today's society.
Almost everyone suffers from low back pain at some time
during their working career. Low back pain is generally defined
as lumbosacral pain as well as buttock pain and leg pain; acute
pain as well as chronic pain; and lumbago as well as lumbar
insufficiency. It is generally recognized that low back pain of this
nature is experienced by 80% of the population at some time
during life.
Low back impairment represents a decrease or loss of ability
to perform various musculoskeletal activities, and is very de­
pendent upon the severity of low back pain. According to the
National Center for Health Statistics, approximately 6 million
Americans suffer from low back impairment at any one given
time; a prevelance of almost 3 in every 100 people.
Low back disability is defined as time lost from the job, or
assignment to restricted duty. Low back disability is very de­
pendent upon the nature of the job. A person with low back
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Working With Backache

impairment may not be able to perform a manual handling job,
but may be able to perform a lighter job. According to studies
from the Liberty Mutual Insurance Company, approximately 2%
of American workers will suffer disabling low back pain every
year.
Finally, low back compensation is reimbursement for lost
wages, and is very dependent upon the nature of the com­
pensation law. In the United States, compensation law varies
from state to state. The same low back disability may be
compensable in one state, but not in another. The important
point is that low back pain may or may not involve low back
impairment; low back impairment may or may not involve low
back disability; and low back disability may or may not involve
low back compensation.
There are many people who would like to believe that we can
prevent low back pain. However, the objective evidence in the
technical literature does not support that belief. Although we
may not be able to prevent low back pain, we can reduce low back
disability and compensation by training the patient, and re­
designing the workplace and the job. Dr. Rodgers recognizes this
fact by suggesting ways to work with low back pain. This is a very
practical and humane approach to backache. It is practical
because we can do it now without a major medical breakthrough.
It is humane because many authorities now advocate activity and
return to work as an important part of low back rehabilitation.
Some day we may be able to prevent low back pain, or at least
substantially. reduce it. Until the.n, our best approach is to learn
how to work with backache- and this book will tell you how to do
it.
Stover H. Snook, Ph.D.
Project Director - Ergonomics
Liberty Mutual Insurance Company

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PREFACE

Shortly after Dr. Rowe's important book, Backache at Work,
was published in 1983, he presented a summary of his thoughts at
an Occupational Safety Council meeting at the Rochester, N.Y.
Chamber of Commerce. Although we had worked together at the
Eastman Kodak Company for several years, I had not heard this
encapsulated version of his thoughts on the low back pain
problem in industry before, and I found his approach fascinating.
It also fit with my own experience studying the occurrence and
patterns of low back problems in the workplace associated with
manual handling activities. In embracing Dr. Rowe's philosophy
of the need to manage low back disability in industry, I began
thinking about putting together a "how to" book relating ways to
reduce job- and workplace design-related factors that might
contribute to low back disability or time lost from work during low
back pain episodes. Working With Backache is the result of those
thoughts.
This book is written primarily for medical, safety, personnel,
industrial hygiene, and engineering specialists who have to make
decisions regarding occupational low back pain problems or
who, through their design of the workplace and job, can influence
factors that may contribute to low back pain symptoms. People
with low back problems, including the author, have provided
much of the pragmatic information contained herein, and future
studies should give more attention to their approaches to limit
the severity of repeat attacks.
Information from work physiology, manual handling, and
biomechanics specialists has been simplified and generalized to
make it fairly easy to use in evaluating existing workplaces or

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jobs. This simplification necessarily reduces accuracy in specific

applications, so the reader is encouraged to learn the concepts

but not be too strict in applying them to work situations. A
universal rule in ergonomics is to try out an idea before you try to
sell it, even if it looks good on paper. The guidelines included in
this book are generally well-tested in the workplace, but in­
expensive simulation of a new workplace or task design is the
most effective way of "tweaking" it to assure that all factors have
been considered. The most important concept in Working With
Backache is that there are several ways to reduce low back
disability and the symptoms of low back pain at work. The
worker, management, and the designers of jobs can all contribute
to an improved picture for people with low back pain. Through
cooperative approaches to the problem, it should be possible to
reduce time lost from work, improve productivity, and increase
the comfort of people who are susceptible to repeated low back
pain episodes.
Suzanne H. Rodgers, Ph.D.
Rochester, N.Y.
February, 1985

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ACKNOWLEDGMENTS

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I am grateful to many people for their encouragement and
helpful suggestions for ways to improve this book. Special thanks
go to E. Carol Stein, M.D., Assistant Professor of Preventive,
Family, and Rehabilitative Medicine and Director of Occupational
Health Planning, University Health Service at the University of
Rochester, for her careful review of the manuscript and sug­
gestions for clarification of the text. Appreciation is also extended
to David M. Kiser, Ph.D., Group Leader of the Ergonomics Group
in Eastman Kodak's Health and Environment Laboratories, M.
Laurens Rowe M.D., Consultant in Orthopaedic Surgery to
Eastman Kodak Company (retired), Alice Rowe of Perinton
Press, and to my father, John A. Rodgers for their critiques of the
manuscript and helpful suggestions. The Foreword has been
contributed by Stover Snook, Ph. D., Ergonomics Director of
Liberty Mutual Insurance Company, to whom I am also grateful.
For their patience and enthusiasm for this project, Jim and
Alice Rowe of Perinton Press deserve special thanks, as does the
book's illustrator, Leigh Ann Smith of Albany, New York. I am
also indebted to Shari Revell and Leslie Norton for typing the
manuscript and doing other secretarial work.
For his encouragement and for educating me about low back
problems prior to developing my own internal education system,
I owe an additional big thank you to M. Laurens Rowe, M.D. My
appreciation also goes to Robert H. Jones, M.D., Rehabilitation
Consultant to Eastman Kodak Company, for teaching me about
return-to-work problems and for many discussions about low
back problems over the years. Thanks also to Harry L. Davis and
Charles I. Miller, M.D., co-founders of the Human Factors Group
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�Working With Backache

at Eastman Kodak Company, who first introduced me to

Ergonomics.

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�CONTENTS

Foreword .................................................v
Preface ................................................. vii
Acknowledgements ....................................... ix
Table of Contents ......................................... xi
List of Figures ........................................... xv
List of Tables ............................................ xvi
Section I: Low Back Pain at Work
Chapter 1: The Management of Low Back Pain at Work ..... 3
A. Low Back Pain ...................................... 4
1. Incidence......................................... 4
2. Diagnoses ........................................ 6
3. Natural History of Degenerative Disc Disease ....... 6
8. The Industrial Low Back Problem ..................... 9
1. Relationship to Work .............................. 9
2. Cost ............................................ 10
3. Approaches to Control Low Back Pain Disability ... 11
4. Return to Work Problems ......................... 12
Section II: What the Worker Can Do

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Chapter 2: Avoid Low Back Pain Aggravators ............. 19
A. Standing Workplaces - Postures ..................... 20
1. Bending Over .................................... 21

2. Hyperextension of the Back ....................... 22

3. Extended Forward Reaches ....................... 23
4. Crouching or Awkward Postures .................. 28
5. Constant Standing ............................... 26

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8. Seated Workplaces - Postures ....................... 28

1. Lack of Foot Support ............................. 28

2. Twisting - Low Supply Cupboard .................. 31
3. Extended Forward Reaches ....................... 32
4. Constant Sitting - Inadequate Support ............. 33
C. Manual Handling Tasks ............................. 34
1. Heavy Lifting .................................... 35
2. Twisting While Lifting or Pushing and Pulling ...... 36
3. Uneven Lifting or Carrying ....................... 39
4. Handling an Over-Sized Load ..... : ............... 41
5. Sustained Heavy Handling or Awkward Postures ... 43
Chapter 3: Keep Muscles Fit ............................. 45
A. Muscles That Support the Spine ..................... 45
B. Muscle Strength and Fatigue ........................ 47
C. Exercises to Keep These Muscles Fit ................. 48
1. Bent Knees Abdominal Curl ...................... 49
2. Leg Pull ......................................... 50
3. Cross-Over Stretch .............................. 50
4. Whole Body Stretch .............................. 50
5. Side Slides ...................................... 50
Chapter 4: Lift Safely ....................................
A. Safe Lifting and Low Back Pain ......................
B. General Lifting Guidelines ...........................
1. Do Not Twist While Lifting ........................
2. Plan the Lift .....................................
3. Determine the Best Lifting Technique .............
4. Take a Secure Grip on the Object Being Handled ..
5. Pull the Load in Close to Your Body ...............
6. Alternate Lifting Tasks With Lighter Work ..........
C. Other Manual Handling Techniques ..................
1. Two-Person Lifting ...............................
2. Sliding and Pushing ..............................

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Section Ill: How the Workplace Can Be Improved
Chapter 5: Work Location - Heights and Distances .........
A. Location and Body Mechanics .......................
B. Working Heights and Reaches .......................
C. Orientation of the Workplace ........................

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CONTENTS
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Foreword .................................................v
Preface ................................................. vii
Acknowledgements ....................................... ix
Table of Contents ......................................... xi
List of Figures ........................................... xv
List of Tables ............................................ xvi

..___)

Section I: Low Back Pain at Work
Chapter 1: The Management of Low Back Pain at Work ..... 3
A. Low Back Pain ...................................... 4
1. Incidence......................................... 4
2. Diagnoses ........................................ 6
3. Natural History of Degenerative Disc Disease ....... 6
B. The Industrial Low Back Problem ..................... 9
1. Relationship to Work .............................. 9
2. Cost ............................................ 10
3. Approaches to Control Low Back Pain Disability ... 11
4. Return to Work Problems ......................... 12

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Section II: What the Worker Can Do
'

Chapter 2: Avoid Low Back Pain Aggravators ............. 19
A. Standing Workplaces - Postures ..................... 20
1. Bending Over .................................... 21

2. Hyperextension of the Back ....................... 22

3. Extended Forward Reaches ....................... 23
4. Crouching or Awkward Postures .................. 28
5. Constant Standing ............................... 26

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Working With Backache

B. Seated Workplaces - Postures ....................... 28

1. Lack of Foot Support ............................. 28

2. Twisting - Low Supply Cupboard ..................
3. Extended Forward Reaches .......................
4. Constant Sitting - Inadequate Support .............
C. Manual Handling Tasks .............................
1. Heavy Lifting ....................................
2. Twisting While Lifting or Pushing and Pulling ......
3. Uneven Lifting or Carrying .......................
4. Handling an Over-Sized Load ..... : ...............
5. Sustained Heavy Handling or Awkward Postures ...

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Chapter 3: Keep Muscles Fit ............................. 45
A. Muscles That Support the Spine ..................... 45
8. Muscle Strength and Fatigue ........................ 47
C. Exercises to Keep These Muscles Fit ................. 48
1. Bent Knees Abdominal Curl ...................... 49
2. Leg Pull ......................................... 50
3. Cross-Over Stretch .............................. 50
4. Whole Body Stretch .............................. 50
5. Side Slides ...................................... 50
Chapter 4: Lift Safely ....................................
A. Safe Lifting and Low Back Pain ......................
B. General Lifting Guidelines ...........................
1. Do Not Twist While Lifting ........................
2. Plan the Lift .....................................
3. Determine the Best Lifting Technique .............
4. Take a Secure Grip on the Object Being Handled ..
5. Pull the Load in Close to Your Body ...............
6. Alternate Lifting Tasks With Lighter Work ..........
C. Other Manual Handling Techniques ..................
1. Two-Person Lifting ...............................
2. Sliding and Pushing ..............................

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Section 111: How the Workplace Can Be Improved
Chapter 5: Work Location - Heights and Distances.........
A. Location and Body Mechanics .......................
8. Working Heights and Reaches .......................
C. Orientation of the Workplace ........................

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Contents

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Chapter 6: Seating ......................................
A. Types of Workplaces - Standing, Sitting,
and Sit/Stand .......................................
8. Chair Design .......................................
1. Chair Seat Height Adjustability....................
2. Chair Seat Width .................................
3. Chair Seat Length or Depth .......................
4. Chair Seat Slope .................................
5. Chair Backrest ...................................
6. Other Characteristics - Swivel, Support, Covering ..
C. Footrests and Armrests .............................

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Chapter 7: Design of Manual Handling Tasks .............. 91
A. Association of Manual Handling and Low Back Pain .. 91
8. Handling Location .................................. 92
C. Lifting Guidelines to Reduce
Low Back Pain Aggravation ......................... 98
1. Occasional Lifts - The NIOSH
Manual Lifting Guidelines ........................ 98
2. Frequent Lifts ................................... 101
D. Force Exertion Guidelines .......................... 104
Chapter 8: Special Workplace Aids for People with Low
Back Pain ................................... 109
A. Workplace Postures ................................ 109
1. To Reduce Forward Bending and
Extended Reaches .............................. 109
2. To Reduce Hyperextension of the Back ........... 111
3. To Reduce Twisting ............................. 112
4. To Provide Postural Relief in Constant
Sitting or Standing Jobs ......................... 113
B. Manual Materials Handling Aids .................... 114
1. Improving Body Postures
During Handling Tasks .......................... 115
2. Reducing the Amount of Work in

Handling Objects ............................... 118

Section IV: How the Job Can Be Improved
Chapter 9: The Size and Design of
Objects to Be Handled ....................... 123

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A. Dimensions of the Load ................ , ........... 124

B. Configuration of the Load .......................... 127

C. Design of Handholds .............................. 129

II

Chapter 10: Providing Adequate Recovery Time .......... 131
A. Muscle Fatigue and Spinal Stability ................. 131
8. Postural Relief ..................................... 133
C. Manual Handling Tasks and Recovery Needs ........ 135
D. Examples of Recovery Time Calculations............ 137
1. Static Muscle Loading ........................... 137
2. Dynamic Work - Repetitive Manual Lifting ........ 138
Chapter 11: Work Patterns and Job Design ............... 143
A. Work and Recovery Patterns in Self-Paced Work ..... 143
8. Paced Work and Work Patterns ..................... 145
C. Job Design Guidelines ............................. 146
Section V: Summary and Addenda
Chapter 12: Summary .................................. 149
A. New Design ....................................... 150
8. Existing Workplaces ............................... 151
Appendix A: Surveying the Workplace ................... 155
1. Checklist to Identify Potential Low Back Pain
Aggravators in the Workplace .................... 155
2. Other Factors to Evaluate in the Workplace ....... 158
Appendix B: Selecting a Chair ........................... 161
1. Chair Characteristics as Selection Criteria ........ 161
2. The Process of Chair Selection .................. 161
References ............................................. 169
Index .................................................. 175

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Contents

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LIST OF FIGURES
Figure 1-1: Low Back Pain in Industry ...................... 5
Figure 1-2: The Natural History of
Degenerative Disc Disease ..................... 8
Figure 11-1: Bending ..................................... 21
Figure 11-2: Hyperextension of the Back ................... 22
Figure 11-3: Extended Forward Reaches ................... 24
Figure 11-4: Awkward Postures ........................... 25
Figure 11-5: Lack of Foot Support ......................... 28
Figure 11-6: Twisting in a Seated Workplace ............... 30
Figure 11-7: Twisting While Lifting ........................ 37
Figure 11-8: Uneven Load Carriage ........................ 40
Figure 11-9: Over-Sized Load Handling .................... 42
Figure 11-10: Muscles Supporting the Lower Spine ......... 46
Figure 11-11: Static Work Intensity
and Duration Relationship ................... 48
Figure 11-12: Bent-Knees Abdominal Curl ................. 49
Figure 11-13: Four Back Strengthening Exercises .......... 51
Figure 11-14: Guidelines for Lifting ..................... , .. 55
Figure 11-15: Bent Knees and Derrick Lifting Styles ........ 57
Figure 11-16: Position of the Feet in Low Lifting ............ 58
Figure 111-1: Load Location and
Forward Bending Moment .................... 68
Figure 111-2: Standing Anthropometric Measurements ...... 70
Figure 111-3: Seated Anthropometric Measurements ........ 71
Figure 111-4: Standing Forward Reach Capability ........... 73
Figure 111-5: Seated Forward Reach Capability ............. 74
Figure 111-6: Workplace Orientation in a Packing Task ...... 76
Figure 111-7: Recommended Seating Design ............... 82
Figure 111-8: Work Location and Backrest Utilization
in a Seated Workplace ....................... 85
Figure 111-9: Molded and Tubular Chair Design ............ 86
Figure 111-10: Good and Poor Handling Locations....•..... 93

Figure 111-11: Relative Static Pull Strength and Location -

Males ...................................... 95
Figure 111-12: Relative Static Pull Strength and Location Females ................................... 96
Figure 111-13: Lifting Height Design ...••.................. 97
Figure 111-14: NIOSH Manual Lifting Guidelines............ 99
Figure 111-15: Aerobic Work Intensity and
Duration Relationship ...................... fo3

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Figure 111-16:
Figure 111-17:
Figure 111-18:
Figure 111-19:
Figure 111-20:
Figure 111-21:
Figure 111-22:
Figure 111-23:
Figure 111-24:
Figure 111-25:

Guidelines for Repetitive Lifting ............ 105
Examples of Force Applications ............ 107
Reach Extenders .......................... 110
Height Adjustments for the Worker ......... 111
Use of Roller Bearing and Roller Conveyor
Sections to Reduce Handling Effort ......... 112
Back Support Aids for Seated Work ......... 114
Postural Relief Aids at a
Standing Work'place ....................... 115
A Special Aid for Large-Size
Sheet Handling ............................ 116
Aids to Support an Object's Weight During
Transfer Tasks ............................ 117
A Load Levelling Aid for Manual
Handling Tasks ............................ 118

Fi�ure IV-1: Effect of Object Length on Elbow Position .... 124
Figure IV-2: Object Width and Back and
Shoulder Posture ........................... 125
Figure IV-3: Object Depth and One-Handed
Carrying Postures .......................... 126
Figure IV-4: Load Configurations ........................ 128
Figure IV-5: Recovery Times as a Function of Work
Intensity and Duration ...................... 134
Figure IV-6: Lifting Patterns for People With and
Without Low Back Pain . ; ................... 144
Figure B-1: Selecting a Chair ............................ 164

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LIST OF TABLES
Table 1-1: Return to Work Considerations ................. 13
Table 111-1: Maximum Force
Application Recommendations ............... 106
Table IV-1: Heart Rate Elevations in Several
Occupational Tasks ......................... 139
Table 8-1: Recommended Chair and
Accessory Characteristics ••••..•....•........ 162
Table B-2: Chair Selection By Job Category .............. 165

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Section I: Low Back Pain at Work

Chapter 1: The Management of Low Back
Pain at Work

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Low Back Pain at Work

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CHAPTER 1:
THE MANAGEMENT OF LOW BACK
PAIN AT WORK

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Most industrial safety or loss control managers will acknow­
ledge that low back pain is the single most important factor in
Workers' Compensation costs. Despite long-standing attempts
to reduce the incidence of low back problems, first through lifting
programs taught by safety personnel, and more recently through
pre-placement strength testing, the low back problem has not
significantly abated. Experts in the field are rethinking the earlier
premise that low back pain can be "prevented" by teaching
people how to lift properly and by using only the strongest people
on heavy lifting jobs.

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In Backache at Work, Dr. M.L. Rowe suggests that a more
appropriate approach to low back pain in industry is to accept the
fact that 56% or more of the workers will report symptoms at
some time during their working careers. Hence, the institution of
programs to manage the disability associated with degenerative
disc disease, the most common cause of low back pain, should
do more to control low back compensation costs than either
lifting training or selection testing have done. In this chapter low
back pain is discussed, especially in relation to the natural ·
history of degenerative disc disease. It is viewed in the context of
how low back pain affects industry and what is being done to
control it. Finally, an introduction to the rest of the book reviews
ways in which the worker, workplace designers, and management
can help manage low back pain disability so the worker can

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continue to work, even with back pain.

A. LOW BACK PAIN
The studies by Dr. M.L. Rowe at Eastman Kodak Company
have been reported in several papers and in Backache at Work.
These longitudinal studies are unique in that one person was able
to follow over 1500 men during a 20-year period and observe the
pattern of low back pain events during that time. From data
gathered in Rowe's 8 studies, an understanding of the incidence,
diagnoses, and the natural history of degenerative disc disease
has been developed.
1. Incidence

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Statistics on the incidence of low back pain in industry vary
widely. The number of people who actually lose time from work
because of back pain will be less than the number of workers
reporting back pain to a company medical department over a
specific period; both will be considerably less than the number
who report it on a questionnaire in which people are asked if they
have ever had back pain.

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Three of the studies reported by Rowe (1983) can be used to
evaluate the incidence of low back pain in an industry with both
light and heavy work (Figure 1-1). In a review of all first visits to the
Medical Department in one year, 5.5% of the plant population was
seen for low back pain. This represented 5.8% of the male and
4.4% of the female workers in all jobs. Of these men and women,
68% could not identify a particular event that produced the low
back pain and 16% identified an event outside of the workplace.
The remaining 16% ascribed the back pain to some event at work.·
Only about 15% of these low back Workers' Compensation cases
resulted in extended absence or in disability due to low back
pain.

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In a review of 237 male retirees (ages 62-65) with a long work
history at the company, Rowe found that 56% had had low back
pain severe enough to report to the Medical Department during
their working years, and half of them had lost time from work
because of it. In a ten-year study of male workers in one

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Plant Workforce

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5.5% Report Low Back Pain in 1 Year

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Figure 1-1: Low Back Pain in Industry. The low back disability
picture shown is based on over 1600 first reports to a Medical
Department during one year. The breakdown by percent of reports
that were attributed to an injury either on the job or at home is
shown. Workers' Compensation reports indicate that 15% of the
people reporting work-related "injuries" to the back may develop
some disability.

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production division, 47% of the men in heavy jobs reported to the

Medical Department with low back pain and 22% lost time from

work. Thirty-five percent of the men in lighter jobs also reported
low back pain and 14% lost time.
Based on these studies, it appears that at least half of the
employees in a plant will experience low back pain sometime in
their working lives, and perhaps half of them will lose work time
because of it.
2. Diagnoses
Low back pain is a symptom that may result from many
causes. These include functional or developmental abnormalities,
degeneration of discs or spinal facet joints, injuries, and tumors
of the spine. It may be a referred pa_in from abdominal or pelvic
organs, such as the gastrointestinal tract and the genito-urinary
organs. In his study of over 1500 male employees over a 20-year
period, Rowe (1983) found the following clustering of diagnoses
to account for low back pain symptoms:
- 68%
Disc degeneration and sequellae
(including abnormal motion between the vertebrae, facet
joint subluxation, reactive bony productive changes, disc
protrusion, and degenerative spondylolisthesis).
- 20%
Inflammation
(including arthritis, prostatitis, and anklylosing spondylitis).
- 8%
Miscellaneious Causes
(including developmental spondylolisthesis and situational
causes where no disease can be detected).
True Injury

4%

A detailed analysis of these diagnoses and their presentation in a
patient with low back pain can be found in "Backache at Work."
3. Natural History of Degenerative Disc Disease
Because 68% of low back pain diagnoses in the Rowe study

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are attributed to degenerative disc disease, it is useful to describe
the natural history of this disease with the hope that activities that
exacerbate low back pain symptoms can be avoided.
In degenerative disc disease microscopic tears and ravelings
occur in the disc casing fibers, usually in the posterior third of
either the L4 or L5 disc (lumbar spine). Because the disc lacks a
blood supply, it cannot repair itself. These tears accumulate and
may eventually result in sufficient weakening of the disc casing to
allow fluid leakage from the pressurized gel that makes up the
disc. This "flattens" the disc somewhat and destablilizes the
coupling between the vertebrae on either side of the disc, making
it less rigid, or "sloppy." The vertebrae then can slide out of
alignment and may pinch the dorsal nerve root that passes
between the vertebrae (see Rowe, 1983 for illustrations and
discussion of the pathomechanics of degenerative disc disease).
Movements of the trunk that encourage movement in these less
rigid vertebral couplings further destabilize them; so for example,
twisting or leaning forward to pick up a load can further damage
the disc casing. Actual disc herniation probably occurs in less
than 5% of the cases of disc involvement. However, it may require
surgical intervention to relieve pressure on the nerve root.
The natural history of five decades of degenerative disc
disease symptoms is shown in Figure 1-2. The initial attacks may
occur when a person is in his or her 20's. These are usually mild
and diffuse but may represent early increments of damage to the
disc casing fibers. The attacks tend to be short and the symptoms
usually totally disappear between them. In the 30's and 40's, there
are more frequent attacks. These tend to be more severe,
resulting in more lost time and some disability. The pain becomes
more localized and lateralizes to one side. This is indicative of
pressure on a nerve root with abnormal sensations, numbness,
and pain usually following the distribution of the sciatic nerve.
Residual pain is often present between acute attacks. In the 50's,
the symptoms tend to settle into more of an arthritic pattern, one
exacerbated by temperature and humidity changes and relieved
by activity. By the time a person reaches his or her 60's,
connective tissue has stabilized the vertebrae around the
damaged disc and more activity may be tolerable than had been
during the previous three decades.

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20's
26%Workforce
120/oLT
Sudden, acute attacks
Diffuse pain
3-10days
Non-specific cause
Return to full activity
Infrequent attacks

23%Workforce
330/oLT

The Natural History of
Degenerative Disc Disease

Lateralized pain
More frequent attacks
More severe radiating
pain - more chronic

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60's
5%Workforce
4%LT
Mild chronic pain
or total relief
More periods without
pain, more flexibility

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Numbness, tingling in
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Little symptom-free time

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130/oLT
More arthritic
Less severe pain
but still constant
Better after early morning

Figure 1-2: The Natural History �f Degenerative Disc Disease. For
each decade between the 20's and the 60's, the symptoms of low
back problems are listed. The % of the workforce in those decades
and the% of lost time (%LT) from work due to low back pain is also
shown. The exposure risk data are taken from the studies of Dr.
Rowe (1983 ) over a 20-year period.

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B. THE INDUSTRIAL LOW BACK PROBLEM
From the previous section, it is clear that many employees
can be expected to experience low back pain during their
working years. One may not be able to prevent the occurrence of
degenerative disc disease, but it may be possible to lessen .its
clinical severity and to reduce the amount of disability experi­
enced by 15% of the workers who account for 80% of the total
compensation costs to industry (Rowe, 1983). This section
addresses the relationship between low back pain incidence and
job heaviness, the cost of low back pain to industry, methods
used in attempting to control the problem, and some of the
problems associated with returning a person with degenerative
disc disease to work.
1. Relationship to Work

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Rowe's analysis of one production divisions' medical records
(1983) suggests that people in heavy effort jobs report more low
back pain than do those in light effort jobs. Heavy effort in this
example is lifting objects weighing about 40-50 lb (18-22 kg) on a
fairly repetitive basis, usually 6 times per minute for 10 minutes
continuously, repeated about 6 times per shift. Other occasional
lifting of supplies or pushing and pulling of handcarts may also
occur between the more frequent lifting activities. Forty seven
percent of the male workers on the heavy effort jobs reported to
the Medical Department in a 10-year period with low back pain
symptoms, and 22% of them lost some time. This compared to
35% of the people in light effort jobs, 14% of whom lost time from
work for low back pain. This difference in low back pain
incidence between the workers in light and in heavy effort jobs is
less than might have been anticipated. Rowe (1983) attributed
the higher reporting and lost time for people in heavier jobs to a
"need to report" back pain. This theory was supported by the
observation that departments reporting more back pain also
report more upper respiratory infections, gastrointestinal dis­
turbances and all other diagnoses than are reported by the
general plant population.
In a study of 100 consecutive Workers' Compensation cases
for low back pain, Rowe (1983) found that 76% of the people were

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doing their accustomed work when the back pain occurred.
Twelve percent of the cases could be directly related to an injury;
8% were associated with an unguarded move, and only 4% were
associated with unaccustomed work. This contradicts the argu­
ment that low back injuries at work are often sustained when a
person is doing heavy work to which he or she is not accustomed.
Although these conditions doubtless contribute to the industrial
low back pain problem, they are probably not the decisive factor
in its etiology. Yet, it is the heavy job to which most of the efforts
to control back problems have heretofore been directed, through
teaching people how to lift, setting weight lifting limits, and using
strength testing to select people with enough strength to match
the measured job demands.
It appears that people who work in heavy effort jobs, in
workplaces where postural demands are heavy, or where sus­
tained awkward motions are required, are less able to continue
that work during an episode of low back pain. Conversely, people
in more sedentary jobs who can control their postures and
workloads are less likely to need relief from job demands when
they have low back pain. One way to reduce lost time associated
with back pain is, therefore, to provide workplace aids or designs
that lessen the likelihood of aggravating the vulnerable back and
that enable people to work with some backache. These "aggra­
vators" are discussed in Chapter 2.
2. Cost
The cost of low back pain to industry is often expressed in
terms of Workers' Compensation payments. This represents only
a fraction of the actual cost. Low back pain is variously described
as costing the industrial sector 1 to 7 billion dollars a year (White,
1983), even though the compensation costs are considerably
lower than that. About one-third of the Workers' Compensation
costs are related to low back pain, however, and, of those, about
15% of the people account for 80% of the cost (Rowe, 1983).
These low back disability cases are often people in their 30's and
40's who are unable to return to their jobs. Because of their youth,
they may be on disability for up to 35 years, representing a large
and continuing cost to industry. It is obviously to the advantage
of the individual with low back disability as well as to industry to

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attempt to reduce the incidence and severity of the disability and
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Like many other "costs" in industry, the actual cost of low
back pain is more than the compensation and disability dollars
and time lost from work. Personal productivity may be reduced
for a worker who is experiencing an episode of low back pain or
for a person who has the residual backache seen between
episodes in more advanced degenerative disc disease. This can
occur if the pain is distracting, requiring a worker to change
posture frequently, stretch, and take recovery breaks from heavy
lifting tasks or sustained postures. Additional costs incll.�de
training others to fill in for a person disabled with back pain, and
those of company medical, supervisory, and personnel time
spent trying to determine when the person can return to work and
what work restrictions will be needed.

17

Since about 75% of the people with low back pain have
repetitive episodes (Rowe, 1983), the opportunities for costs to
accrue are vast. The control of these costs by managing the
degree of disability of a person with backache is the focus of this
book.

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3. Approaches to Control Low Back Pain Disability

Over the past 50 years there have been a number of
approaches made to control the industrial low back pain problem.
These can be grouped into four categories: the selection of
workers for the heavier jobs; education on safe handling of
materials; the setting of weight limits along with workplace and
job design to accommodate workers with less strength; and the
development of exercise and behavior modification programs
("Back Schools") to help the worker with low back pain learn to
cope with any disability. Workplace modification may also be
part of the last program.
Recognizing that low back pain disability often cannot be
linked to a particular action, some medical departments report
back incidents in two ways: those where an "injury" is identified;
and those where there appears to be a "physical failure," not
attributable to any workplace condition or job demand. An

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Working With Backache

example of physical failure of the back is when a person bends
over to tie a shoe and cannot straighten up again. From Rowe's
studies (1983), it is possible that about 75% of the compensable
back problems can be classified as physical failures.
The above strategies to control low back disability are
discussed briefly in later sections of this book. Over the past ten
years the emphasis has been slowly evolving from one of
prevention of low back pain incidents through training, selection,
and enforcement of weight limits, to that of active intervention in
the low back pain case in order to prevent long-term disability;
this is the fourth strategy mentioned above.

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4. Return to Work Problems

The factors that need to be addressed in order to reduce low
back-related lost time in industry are grouped in Table 1-1
according to who can do something about them: the worker with
low back pain, supervision in the department of concern and
other management personnel, and the job and workplace design­
ers. Clearly, individuals with more severe degenerative disc
disease may find it more difficult to return to work.
For the worker, the following factors may influence his or her
return to work after a prolonged absence associated with low
back pain:
• degree of disability, including postural muscle weakness
resulting from the enforced inactivity during the attack
• financial incentives or disincentives
• alternative skills available for a job change
• job satisfaction before the incident
A worker who can make more money on disability than at work,
who has limited alternative job skills and needs to be restricted
from much of the work he or she has been doing, or who is not
particularly content with his or her job represents a poor risk for
prompt return to work.

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Table 1-1: Return to Work Considerations
Person(s) With Control

Worker

Degree of Disability
Other Medical Problems
Motivation/1 llness Behavior
Alternative Skills

Workplace and Job
Designers

Postures Required
Manual Handling Required
Durations of Heavy Tasks or
Awkward Postures
Job Pattern Control
by Worker
Accommodations Available

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Administrators/
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Worker's Previous Job
Performance
Flexibility in Job Methods
Availability of Other Jobs
Production Pressures
Training Programs
Benefits Structure

Table 1-1: Return to Work Considerations. Some factors are listed
that may influence the ease with which a person with degenerative
disc disease can return to work after an attack of low back pain.
These are factors that determine the size of the disability problem
from low back problems in industry. The workplace and job factors
are discussed in more detail in this book.

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The worker's supervision or other company management
can affect the worker's ability to return to work. For example, by:
• making available other jobs within the worker's skill-level and
not requiring extensive retraining or significant salary
reductions
• showing flexibility in looking for job accommodations to help
the worker back to his or her old job
• providing auxiliary help for occasional tasks that may be
difficult for the worker with back pain to perform alone
• providing training to help develop the worker's alternative job
skills
• providing a rehabilitation exercise program if absence from
work is longer than 3 weeks.
A supervisor who must generate a certain amount of product
per shift, day, or week may resist returning someone to work who
can do only part of the job, especially if there are many people
available in the outside labor force who can do the full job with a
minimum of training. Returning a person with significant degen­
erative disc disease to a physically demanding job that takes only
a few months to learn, such as loading tractor trailers with
shipping cases or handling supplies in a stockroom, can be
especially difficult. The job demands are more likely to aggravate
the worker's symptoms, and restrictions from heavy lifting will
most likely be requested by the worker's personal physician.
Both the availability of alternative jobs and the ways in which the
task can be altered to accommodate the worker with low back
disability may also be limited.
The worker who has been an excellent and valued team
member before the back problem occurred will be more likely to
be accommodated than one with a mediocre work record. If the
low back pain victim is considered to have "caused" hi_s or her
own problem by doing something careless ("didn't lift safely"),
supervision may deny that worker the opportunity to return to
work until the whole job can be performed. And although it is

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probably incorrect to say that the back problem was "caused" by
improper lifting, this is often said in heavy jobs.
The job and workplace designers can influence the cost of
low back disability by modifying the following factors:
• the postural demands of work - whether the worker has to
maintain awkward or fatiguing postures in order to operate the
machine, asemble the parts, or do the tasks required on the job
• the seating available - its design and appropriateness for a
person with low back problems (backrest, foot support, etc.)
• provision of recovery periods after heavy work or sustained
awkward postures
• inclusion of workplace accommodations such as support
stools, footrails, or adjustable height tables to permit the
person with low back disability to get postural relief during
sustained work
• provision of handling aids to reduce the lifting and carrying
demands of jobs
• reduction of unnecessary manual handling tasks through a
systems approach to materials handling that uses conveyors
and automated equipment, when appropriate.
All such design factors can make it easier for the person with
some low back disability to return to work. The reduction of job
effort demands should permit this worker to do much otthe job
when the back pain is not severe. Factors that aggravate the low
back pain symptoms are also reduced; hence there is a lessened
need to report them. Most of this job design work is best done
during initial facility layouts and job specifications. Designing

jobs and workplaces to accommodate a majority of the potential

work force wi II make them more suitable for people with low back
pain as well. If the job and workplace are already designed,
accommodations or aids may often be added at low cost, with
solutions limited only by the creativity of the designer and
workers in the area.

�16

Working With Backache

In the remainder of this book, the roles of the worker,

supervision, and designers are discussed in more detail. Specific

recommendations are given for workplace accommodations and
job design that will help the person with low back pain remain an
active member of the workforce for most of his or her career.

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Section II: What the Worker Can Do

Chapter 2: Avoid Low Back Pain
Aggravators
Chapter 3: Keep Muscles Fit
Chapter 4: Lift Safely

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There are actions that the worker can take to avoid aggra­
vating underlying degenerative disc disease. Most people with
chronic back problems know intuitively what these are, although
they may not be able to formally define them. These actions must
be avoided both at work and at home, and examples of each are
included in Chapter 2. Exercises to keep the trunk and limb
muscles fit are included in Chapter 3 as another means the
worker can take to reduce the frequency and severity of low back
pain. Chapter 4 includes information about techniques for
manual handling; these reduce the stress on the L4 and L5 discs
and make overexertion incidents less likely to occur.

17

CHAPTER 2: AVOID LOW BACK PAIN
AGGRAVATORS

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The characteristic symptoms of degenerative disc disease
have been described briefly in Chapter 1 and thoroughly in
Backache at Work by Dr. M.L. Rowe (1983). The microscopic
tears and ravelings in the L4 and L5 disc casing that can lead to
fluid leakage and the "sloppy" vertebral linkages in this area may
be increased by postures and manual handling activities that put
high compressive or shear forces on the disc, especially on the

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posterior one-third of the disc near the nerve roots. Once a

person is in the more advanced stages of degenerative disc
disease, certain motions or actions may trap the nerve root
between two vertebrae, or may stretch or tear the capsule or the
ligaments of the facet joints between the vertebrae. High forces
on the disc may cause it to rupture and press on the nerve root. All
19

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of these can result in severe pain. Some of these motions are
described and illustrated in this chapter. In addition to increasing
the compressive and shear forces on the disc and increasing the
instabi_lity of the vertebrae in the L4 or LS area, these motions
increase muscle fatigue, thereby reducing a person's ability to
"protect" the back. These factors are discussed under standing
and seated workplace postures and manual handling tasks. They
represent actions that the worker with chronic backache should
avoid. It is no doubt safer for the person without backache as well
to avoid continued exposure to these activities. Although the
worker has some control over the actions he or she takes when
away from work, the same options may not be available in the
workplace. Sections 111 and IV show how the workplace and job
can be designed or altered to reduce the tasks that can aggravate
low back pain symptoms.
A. Standing Workplaces - Postures

Although a great deal of emphasis has been placed on the
role of manual materials handling activities in the etiology or
aggravation of low back pain, postural factors are probably at
least equally important. In a standing workplace, there are many
factors to consider when looking for actions that may increase
back pain symptoms. These include:
• bending over, unsupported by the arms, as in work at a drafting
board
• hyperextending the back, as in high reaches
• extended forward reaches
• crouching or other awkward postures, such as leaning to one
side
• constant standing
They are discussed in the context of how they influence the
lumbar spine in a person with degenerative disc disease.

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1. Bending Over

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Figure 11-1 illustrates the posture of a person doing food
preparation in a kitchen. Because the work involves downward
forces, the counter is 36 inches (90 cm) high, although the visual
demands of the work would be better satisfied with a 43-inch (11O
cm) high work surface. The worker bends over to exert the
necessary force and to have good visual control of the task. This
statically loads the back and hip muscles. At the same time, the
weight of the upper body is now acting as a load on the spine
because it is no longer aligned over the feet. The back muscles
have a very short lever arm (2 inches or 5 cm) and are quite
heavily loaded in the bending posture (see Chapter 5 for further
discussion of biomechanical stresses on the back). This static
loading can fatigue the muscles that stabilize the back in
response to forward flexion of the trunk. The longer this posture
must be sustained, the more fatigue will accumulate. There is
then more opportunity for the back to be "unprotected" by these
fatigues muscles when a twisting motion, uneven weight distribu­
tion, or unexpected motion occurs.

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Figure 11-1: Bending. The height of the counter is low enough to

require the kitchen attendant to bend over from the hips while
preparing the turkey. This bending loads the hip extensors and the
erector spinae muscles that extend the trunk and will fatigue them if
it is sustained for a minute or more.

�22

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Working With Backache

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Besides work done on a low counter, bending over may be
required when a person has to work in an area with inadequate
head clearance. This situation may occur fairly frequently for
maintenance workers, caisson workers, coal miners, and people
who load and unload shelving units that are less than 6 feet (2
meters) high. These requirements for bending are more difficult
for the worker to avoid than a too-low counter Sl..!rface where, for
example, thickness may be added to the surface by using sheets
of plywood or other materials to build up the height for better
visual access. For too-low head clearance, the worker can only
avoid sustained work in the bent-over posture by taking small
sitting or lying down breaks to relieve the static back muscle
stress or by working from a kneeling posture, where appropriate.

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2. Hyperextension of the Back

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An example of an activity that produces hyperextension of
the back is illustrated in Figure 11-2. Hyperextension involves
moving the trunk past its normal erect position so that the upper
body is oriented behind its normal resting point. As the spine
extends backwards, the pelvis moves forward, and there is a

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Figure 11-2: Hyperextension of the Back. The need to reach or
handle materials from locations over shoulder height usually results
in arching, or hyperextension, of the back. This increases the load
on the posteriorthird of the lumbar discs and may result in back pain
symptoms in susceptible people.

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concentration of compressive force on the posterior one-third of
the L4 or L5 discs. This increased pressure can aggravate an
already damaged disc and may result in a pinched nerve root if
the lower vertebra's articular process slides forward and partially
closes off the nerve root's exit port. Even for persons with no
history of degenerative disc disease, repeated hyperextension of
the back, especially during manual handling tasks, is not recom­
mended since it may increase the rate of microscopic tear and
raveling damage to the normal disc casing.

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Activities that cause hyperextension are primarily those
involving tasks above shoulder height, i.e., about 52 inches (132
cm) above the floor. The task� include reading dials or displays
located above standing eye height, about 60 inches (150 cm)
above the floor. The person who is handling cases or products
with the back hyperextended is putting additional stress on the
lumbar discs. A person who sometimes works lying on the
stomach in order to access the task, such as the case of a low­
seam coal miner, a maintenance worker fixing a machine, or an
automobile mechanic, may also hyperextend the back when his
or her head is raised. Finally, many extended reaches (discussed
below) are accompanied by back hyperextension.

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The worker can control the amount of hyperextension in
many overhead tasks by using a step stool or platforms or by
avoiding the placement of materials over shoulder height where
there is a choice. Where the hyperextension is associated with
work on the stomach, frequent short recovery breaks are recom­
mended to rest the back and abdominal muscles between
exertions.
3. Extended Forward Reaches
Reaches that exceed the length of a person's arm and require
bending or stretching forward to accomplish a task can aggravate

low back pain in several ways: forward stretches can result in

hyperextension of the back to counteract the tendency to fall
forward; unequal loading of the spine can occur if only one hand
and arm are used in the activity; bending forward puts a
mechanical stress on the lower back; and the handling of any
weight or exertion of any force at full arm's extension can put

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high compressive and/or shear force on the lumbar intervertebral
discs because of the posture and long force arm (see Figure 11-3).

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Extended reaches with both arms or unequal stretching of
one arm forward in a task can occur in many occupational tasks.
Large-size objects may create extended reaches, as will be
discussed in Chapters 7 and 9. Activation of valves, reaches
across work stations to get supplies or to pull materials off of a
conveyor, and reaches into the far corner of a large shipping case
represent activities where extended reaches are often required.
At home, reaching to the upper shelf in a cupboard, trying to
remove the tire and jack from the trunk of a large car, and tree
trimming often involve extended and unbalanced reaches that
can aggravate low back symptoms.

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A worker can avoid some of these reaches by using handle
extenders on inaccessible valves (illustrated in Chapter 8), and
using aids to activate distant controls. To move an object closer
one can sometimes slide it forward using a "crook" or "hook."
Some reaches can be reduced by tilting the case or product
container upward by 15 to 30 degrees, the far side being uphill of

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Figure 11-3: Extended Forward Reach. Reaches that are more than
20 inches in front of the body or are below standing waist level will
require the worker to bend at the waist and put additional pressure
on the lower back. If part of the workplace or equipment makes it
difficult to bend the knees, the stress on the lumbar discs is greater.

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the near side at the workplace. Because the greatest arm reach is
at shoulder level, postural adjustments such as bending the
knees or using a step stool to keep the reach at shoulder level
comprise another strategy to reduce aggravation of low back
symptoms during extended reaches.
4. Crouching or Awkward Postures
Some occupational tasks require crouching, stooping, or
leaning over, all of which put a load on the low back and its
lumbar discs. Figure 11-4 illustrates a welder in a crouching
position; this can be a fairly acceptable posture for short periods
of time. Sustained work in this posture, with some shifting of the
body weight to maintain stability, can put strong shear and
compressive forces on the lumbar discs as the back muscles
stabilize the posture during forward bending of the trunk. When a
person stands up after an extended period in a crouched posture,
the muscles of the back may not support the spine as well (due to
fatigue), increasing the likelihood of a pinched nerve root.
Postures where one hip is higher than the other, or where a
load is not borne evenly across the trunk, leave room for

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Figure 11-4: Awkward Postures. Crouching to get to the proper
height for a welding task is illustrated. Although this posture can be
sustained for a short time without difficulty, sustained work will
result in leg and back muscle fatigue and may contribute to
instability in the lumbar area. Other awkward postures can result
from inadequate head clearance and from working at floor or ground
level.

�26

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destabilization of the vertebral column at the place where the disc
may have lost some fluid and the junction is unstable. Twisting of
the trunk may increase the vulnerability of the disc to rupture or
accelerate facet joint subluxation and may, again, lead to a
pinched nerve root.
Awkward postures often result from a designer's inadequate
attention to the maintenance needs of equipment or facilities.
Repair operations may have to be done under tanks or machines
at sites where other equipment is in the way, so awkward
postures are required to move out a motor or remove a part. In
some locations head clearance has not been provided, as at the
top of a production machine in a flat-roofed, low building. In
warehouses, the dimensions of storage shelves are usually less
than 55 inches (140 cm) high. This low head clearance is
particularly awkward for the transfer of heavy items from the
lowest of the shelves. Outside of work, a person may be exposed
to awkward postures during car maintenance, home-improvement
activities such as putting in a tile floor, and in outdoors activities
including planting and weeding.
The worker may not be able to avoid some awkward postures
in the workplace, but he or she should be aware of the need to
take frequent "postural relief" breaks. Provision of a small "dolly"
or stool to enable sitting close to the ground instead of having to
crouch, or the availability of either a floor covering with good
cushioning properties or a pair of knee pads for kneeling in some
tasks will also improve the conditions for people with a history of
backache. Unequal loads across the trunk can be counteracted
in some instances by providing a firm support against which the
worker can pull with the arm that is not supporting a load. This
can help to even out the load on the back muscles and reduces
the opportunity for a twisting motion to aggravate the unstable
lower lumbar disc areas.
5. Constant Standing
Jobs that require sustained standing, especially where the
standing is not broken up by periods of walking or sitting, can be
difficult for people with chronic low back pain. If bending or
extended reaches are also required, the problems may be

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insurmountable for some workers. Constant standing puts an
unremitting load on the lumbar discs, creates back muscle
fatigue from the sustained alignment of the upper and lower body
during the work activities (many of which involve forward
movement of the upper body), and results in orientation of the
pelvis in a posture that may increase the pressure on the
posterior one-third of the lumbar discs (L4 and L5, especially). If
the worker is slouched forward rather than upright (but not
hyperextended) the pressure on these discs will be greater.
Slumping forward in a chair results in high disc pressures.
The most important workplace modifications would allow an
alternation of standing and sitting during the course of the shift.
Walking is also desirable for short periods. Jobs with a large
amount of walking, however, may also aggravate back pain
symptoms, especially if the walking includes carrying a load in
only one hand. Examples of tasks where constant standing or
walking may be required include those of mail carriers, guards in
some institutions, kitchen cafeteria attendants, order expediters,
warehouse order pickers, lathe operators, and machine control
operators. Outside of work, extended periods of standing for
more than one hour at a time may be needed in meal preparation
and clean-up, lawn care, ironing and laundry activities, and
painting, plastering, or wall-papering.
For the worker to avoid constant standing, seating should be
available near the workplace such that it can be used as needed.
Provision of fold-away seating is desirable, such as a "jump seat"
or a seat that can be stored under the table or next to a wall until
needed. If it is not available, the worker with backache should
take frequent breaks to the nearest area with seating in order to
relieve the stressed postural muscles. For people who work in a
prescribed area and stand fairly still for much of the shift, a
footrail or a small footstool, from 4 to 8 inches (1 Oto 20 cm) high,
can retard the development of low back pain symptoms. Putting a
foot on the rail will tilt the pelvis forward and relieve the pressure
on the back third of the L4 and L5 discs. Rubber mats at the work
station or safety shoes with good soles that are appropriate for
the work and thick enough to give a cushioning effect may also
be used to reduce the strain of constant standing on the feet and
back.

�28

Working With Backache

B. SEATED WORKPLACES - POSTURES
Although many people with low back pain find relief from
symptoms when they can sit down, extended sitting can in itself
aggravate the symptoms. Long distance driving is an activity that
can be extremely uncomfortable for a person with low back pain
if the seat does not give good support to the lumbar spine. If the
seat is set back, requiring full leg extension for activation of the
gas, clutch, and brake pedals, back pain may result. In this
section, some seated workplace characteristics are described
that can aggravate low back pain symptoms by increasing the
stress on the L4 and LS discs and by decreasing the stability of
the spine at this level when the disc has "flattened."
1. Lack of Foot Support

Persons with inadequate support for the feet in a seated
workplace will relieve the pressure on the back of their thighs by
twisting the legs around the chair supports (Figure 11-5) or by
supporting the feet on some part of the workbench. Both of these
actions can aggravate low back pain symptoms. The leg twisting
also twists the trunk somewhat and can destabilize the lumbar

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Figure 11-5: Lack of Foot Support. Inadequate support for the feet
can occur when a person is seated at a workbench if the chair or
stool is of a fixed height and there is not enough room (height) to get
the upper legs under the work surface while using the chair's
footrest. The lack of foot support results in increased load on the
lower spine and fatigue of the back extensor muscles if the posture
must be sustained for several minutes at a time.

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spine if it is already weak due to disc flattening. Forward
extension of the legs in conjunction with leaning forward to work
on the workbench is somewhat like doing a straight leg sit-up.
Both of these activities put a high compressive force on the L4
and L5 discs and may result in further damage to the disc casing.
There are several workplace situations where foot support
can be inadequate. They include:
• A workbench surface more than 26 inches (66 cm), above the
floor without a footrest. This results in adjustment of a chair
beyond the point where the feet can rest comfortably on the
floor.
• A chair with good height adjustability but a fixed ring footrest.
When the chair seat is adjusted to 20 or 21 inches (51 or 53 cm)
above the floor, the footrest is too low to keep the thighs
parallel to the floor.
• A footrest in the workbench that is fixed and recessed more
than 17 inches (43 cm) from the front surface of the workbench
or is more than 9 inches (23 cm) above the floor, which restricts
leg clearance.
Lack of an adequate footrest is seen quite frequently in
offices where table or desk surfaces are 30 inches (76 cm) above
the floor and chairs are adjustable from 16 to 20 inches (41 to 57
cm) above the floor. To have the person working close to elbow
level on the desk, the seat would have to be at the top of its range.
This brings the feet about 4-5 inches above the floor unless a
footrest is available under the desk. A chair footrest is less
satisfactory in office work because the worker is usually leaning
forward to write or type on the desk surface. Leaning forward
from the chair with one's legs near the base of the chair usually
precludes use of the chair's back rest, again increasing the stress
on the lower lumbar discs of the spine.
The worker can overcome the lack of a footrest by fashioning
one out of an old shipping case, box, telephone books, or a pile of
building materials. If footrest height is fixed instead of adjustable,
a 5-inch (13 cm) height is usually preferred. The worker can also
make sure to adjust his or her chair to the most appropriate

�30

Working With Backache

height for the task being done. In general, the thighs should be

parallel to the floor, not sloping downward, in order to protect the
back from excessive disc pressures.

Figure 11-6: Twisting in a Seated Workplace. The design of a seated
workplace and the location of supplies and conveyors will affect the
amount of twisting required of the worker. Supplies that are stored
below the work surface can both interfere with leg clearance and
cause twisting or leaning to one side when they are procured.
Storage locations that are close to the work area but encourage.the
seated operator to get up and change posture are preferred. Too­
high storage results in hyperextension of the back and should be
avoided unless step stools are provided.

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2. Twisting - Low Supply Cupboard

Some twisting of the trunk can occur when a person has to
procure or dispose of supplies from the seated posture. The
design of the work station will determine how much twisting will
occur. Locating the supply and disposal sites at 90 or 180 degrees
away from the primary workplace assures some trunk twisting,
even if a swivel chair is made available. Locating supplies or
outgoing product storage areas at heights below 20 inches (51
cm) or recessed in from the front of the workplace by more than
10 inches (25 cm), results in the worker having to lean over to one
side (Figure 11-6). This can differentially load the spine and may
aggravate back pain symptoms in people with pre-existing
lumbar instability. Similarly, high shelves and ones more than 15
inches (38 cm) to the right or left of center of the worker are also
likely to increase the opportunities for a worker to twist the trunk
and aggravate low back pain symptoms. Two-handed lifts or
force exertions in these situations are particularly difficult to do
without twisting the trunk and loading the spine unevenly.
Situations where twisting of the trunk may occur while in a
seated posture include the following:
• At a desk, a person turning to throw something into a
wastebasket behind or to the side of the chair.
• A person accessing files at the side of the desk or reaching for a
source book or paper work at the far corner of the desk or in a
bookcase above the desk.
• At a seated assembly workbench, a person with stacks of trays
of incoming product on the floor next to her or him; also with a
stack of outgoing product for the next work station that starts
on the floor.
• A person working at a seated workplace and using a pallet or
skid on the floor as the source of parts or as a place to dispose
of the part after this task.
• A person working at a seated workbench with supplies (like
empty corrugated cases and other packaging materials) over-

�32

Working With Backache

head in open bins. Occasional handling of these only, but they

are accessed by standing up on the chair's foot ring and
reaching forward and to one side.

• A two-handed lift from one side of the workbench to the other,
as might occur if product comes in or goes out of the station on
a conveyor that is oriented at 90 degrees to the workbench.
Similar twisting may occur where there is inadequate leg clear­
ance, as may be the case at a kitchen sink, next to some
machines, or in a standing workplace where a person is using a
stool. Inability to get the knees and legs under the counter or
work surface is accommodated by rotating the knees to the side
and twisting the upper trunk. A table that is too low to allow thigh
clearance with a fixed height chair also requires this type of trunk
twisting and can aggravate low back pain symptoms.
The worker can reduce the trunk twisting by standing up to
procure and dispose of supplies or parts instead of remaining
seated. If there is frequent handling required (less than 2 minutes
between lifts), the constant changes of posture may be annoying.
The worker may be able to reorganize the workplace to keep the
· 1ocations for procuring and disposing of product closer to
workbench height and nearer to the main work area. Some ways
of doing this include raising a pallet on 2 or 3 empty pallets, or
using a "hook" or "crook" to pull a tray or container from one side
closer to the workbench center. A swivel chair and/or chair with
casters will permit easy changes in worker orientation if a
workplace is U-shaped or requires 90 to 180 degree rotations
from the main workplace. If such chairs are not available, the
worker should stand up to change position. Where only oc­
casional lifts of materials from overhead or lateral shelving are
required, the worker should always stand up, since this is a way to
get postural relief from constant sitting.
3. Extended Forward Reaches
An extended reach to the side of a seated workplace may
result in twisting of the trunk or unequal loading of the spine that
could increase the risk for low back pain. Forward reaches that
are more than 15 inches (38 cm) in front of the body will require

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33

the worker to lean forward in the chair and thereby lose the
benefit of any available back support. Occasional reaches are not
likely to be a problem, but continuous work with extended
reaches or frequent reaches that are well out of the comfortable
working envelope (see Chapter 5) should be avoided. This
forward bending with extended reaches is similar to forward
slumping in that it puts a high compressive force on the lower
lumbar discs.
Activities that can result in extended reaches include work­
places where controls are located or supplies are stored on a
back panel or against a wall and the workbench is at least 24
inches (61 cm) deep. The extended reach may be to a low shelf or
to a pile of trays or parts at the side of the workbench, both of
which unevenly load the spine and may increase any instability at
the lumbar region. Reaches forward with two hands to procure a
tray, product, or part from a conveyor at the rear of a work station
reduce the effectiveness of a chair's lumbar support for the
person with low back pain.
The worker can avoid extended reaches by using aids to
extend the reach in some instances, by standing up for occasional
extended reaches; and by raising low supplies or products so that
low extended reaches are not necessary. A hook on a 12-inch (30
cm) long handle with a T-grip, similar to a dock worker's hook,
can be used to pull a tray off of a conveyor that runs at the same
height as the work surface and to move it nearer to the worker.
Provided that there is adequate leg room at the seated workplace,
the worker can also pull him-or herself as close as possible to the
front surface of the workbench in order to reduce the reach
distance. In some workplaces a semi-circular cut-out in the
workbench permits the worker to get closer to a conveyor
without sacrificing a large amount of workspace.
4. Constant Sitting - Inadequate Support

As is discussed in Chapter 6 under Seating, constant sitting
can aggravate low back pain symptoms as much as can constant
standing. This is particularly true where chairs are not designed
to give support to the lumbar spine. A person slouched forward in
a chair without backrest support will have more compressive

�34

Working With Backache

force on the lumbar discs than will the same person standing

comfortably upright. Over time this force may increase the

microinjuries to the disc casing and hence aggravate low back
pain symptoms.

Many assembly lines are designed to maintain the flow of
materials pasta person's workbench so that he or she does not
have to interrupt the assembly task by getting up to procure
supplies or dispose of product. This results in a 2- to 4-hour
period of uninterrupted sitting, which can be uncomfortable for a
person with back pain. Work stations along conveyors typically
tie the worker to one location and one type of posture, either
sitting or standing. Other constant sitting activities include
sewing machine use, word processing work, many in-process
inspection tasks, some control console monitoring tasks, switch­
board operation, crane operation, and long distance driving. Seat
design is as critical in the vehicular setting as it is in manufacturing
and office operations.
The worker can avoid aggravating back pain symptoms by
adding a cushion to a chair with poor back support, purchasing a
back support chair insert, or wearing an inflatable supportive
vest. He or she should find opportunities to change postures
frequently, and should work in the standing posture for short
periods if the task does not require much bending. Upright
posture is best, and slouching forward should be avoided. A brisk
walk would probably be preferable to sitting down over a hot
beverage during work breaks. It is also very important that the
worker adjust the backrest for optimum support when possible.

C. MANUAL HANDLING TASKS
Low back pain and heavy lifting have often been causally
linked, although it is more probable that they are linked primarily
by the need to report back pain in heavy jobs (Rowe, 1983). If 56%
of a workforce reports low back pain during their careers and 68%
of those have degenerative disc disease, then up to 38% of the
workforce may have repeated episodes of back pain. Those who
are working in jobs that require frequent manual handling of
materials will be more likely to lose time from work during these
episodes than those who can control their workload and alter

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their posture. Some handling activities that can aggravate low
back pain are discussed below along with suggestions for their
modification.
1. Heavy Lifting
The handling of a heavy load, one that weighs more than 40
lb (18 kg) for instance, will increase the compressive force on the
lower lumbar discs even if it is lifted in the most optimal manner.
This compressive force is determined by the horizontal distance
from the center of mass of the upper body and the load in the
hands to the L4 or LS spinal segment. The farther the person is
bent forward or the load is held in front_of the body, the greater is
this distance, and the more work the back and hip extensor
muscles must do to counteract the tendency of the body to fall
forward. The heavier the load, the more work these back muscles
must do to stabilize the posture, even when the object is held
directly next to the body (see Chapters 5 and 7).

4

There are many occupational tasks that involve heavy lifting;
some are easier to modify than others. For example, many foods
and chemicals are packaged in 50 or 100 lb (23 or 45 kg) bags,
which must be handled on and off pallets or skids. Shipping
cases weighing from SO to 75 lb (23 and 34 kg) are not unusual in
industry. Seventy pounds (32 kg) is a suggested upper weight
limit for some package delivery companies. Wooden pallets must
be handled in some jobs, and they often weigh more than 60 lb
(27 kg). In construction and maintenance tasks, a person may
have to routinely lift building supplies weighing more than 50 lb
(23 kg). Stock rolls or trays or bins of parts may have to be lifted
into position in a machine loading task, and waste bins may have
to be unloaded with similar efforts. These often weigh more than
40 lb (18 kg) each and may also be bulky.
The principal response of the worker with low back pain to
these lifting tasks does not have to be a job restriction, except
perhaps where heavy lifting occurs for a majority of the shift and
is not easy to avoid. The use of sliding rather than lifting to move
heavy objects is the best way to avoid high compressive forces on
the lumbar discs. For bag handling from pallets or to machine
supply hoppers, for example, a forklift truck or an adjustable-

�36

Working With Backache

height table (levelator) can be used to bring the bag to a little
above the level of the place to which it must be moved. It can then
be slid off of the pallet and dropped onto the table or hopper
without the full weight being lifted by the worker. In some
workplaces it may be possible to provide a hoist or block and
tackle to accomplish the heavier lifts; the worker with low back
pain should use these. In other jobs it may not be necessary to lift
the whole container if only part of its contents are needed. This
would be possible in a large scale food preparation operation
where only part of a bag of flour might be used to make a bread
dough. Use of a scoop or smaller container to remove only the
necessary material would reduce the need for lifting the heavy
bag.
2. Twisting While Lifting or Pushing and Pulling

Although all manual handling training programs caution
against twisting while lifting or exerting forces, people still do it
because it is faster or may be the only way to accomplish the task
in some workp.laces. When materials have to be transferred
between two locations that are oriented at 90 degrees to one
another, they are often moved from one side to the other by
turning the upper trunk and keeping the feetstfll-(F-igure 11-7): If
the object weight and size is not very great, the distance between
locations is only a few feet, and if the handling frequency is low,
this is probably not an activity to be concerned about in terms of
low back pain aggravation. Heavier items, more frequent lifting,
and more pronounced twisting can destabilize the lumbar disc
area in people with degenerative disc disease. The shear forces
on the L4 and L5 discs may result in subluxation of the facet
joints. This can result in narrowing of the channel through which.
the dorsal nerve root passes, pinching it and causing very severe
pain. In addition, when the trunk is twisted, the abdominal and
chest muscles are not in their optimal orientation for exerting
force, and they do not offer effective support and protection for
the back.
Situations that result in twisting of the trunk during manual
handling tasks include:
• moving an item horizontally with arms extended across a

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workplace, as in moving a stack of materials from left to right at
the far side of the workbench.
• pulling a hand cart or truck through a corridor, using one hand
and facing forward.
• working in an area where there is inadequate foot room to use a
step turn. This may happen when pallets are lined up around
the end of a conveyor on a fast production line (requiring the

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Figure 11-7: Twisting While Lifting. The orientation of the workplace
will affect the amount of trunk twisting done in a handling task.
Removing items from a high conveyor line or shelf to a workplace
located at 90 degrees to the side will often be done with a twist,
especially if the frequency of lifting is high. It is preferable to design
the workplace so that the lift is made totally in front of the body.

�38

Working With Backache

handler to lift at a frequency of 9 or more times per minute).
The pallets are brought close to the conveyor in order to
reduce movement time. There may not be enough space to
turn the feet as product is removed to the pallets, which are
usually placed at either 90 or 180 degrees to the conveyor. The
handler, therefore, twists at the knees to accomplish the task.
• swinging bags or cans up from a lower level to a higher one in a
warehousing or trailer unloading task. By swinging instead of
lifting the bag or can, a more ballistic lift can be made and less
sustained effort is required. But such a movement is made
across the body rather than in front of it, and the trunk is
thereby usually twisted at least 90 degrees.
• getting one's body behind an object to push it when it is being
moved laterally around an obstruction. Construction tasks
may require the worker to take a fixed and stable posture while
exerting force with the upper trunk to locate a beam among
other supports in a building frame. It is often not appropriate
to make a step turn in this situation since the footing area
may be limited.
• handling tasks where the terrain is rough and footing is
precarious, such as on littered floors. It may be preferable to
maintain a stable posture than to risk stepping and losing one's
balance.
The worker with low back pain is wise to avoid trunk twisting
whenever possible. The use of a step turn instead of a twist is
recommended whenever stepping is appropriate. Except where it
cannot be done for safety reasons, hand carts and trucks should
be pushed instead of pulled through corridors in order to reduce
the trunk twist associated with one-handed pulling. At conveyor
palletizing stations, marks on the floor should identify the best
locations for pallets so that adequate foot room for a step turn is
provided. The conveyor rates should be controllable by the
handler so that pace pressure doesn't make step turns too time­
consuming to use. One other approach to reduce the amount of
twisting in a handling task is to train the worker to pull the object
to the point nearest its destination instead of picking it up earlier,
where it first comes into the workplace or work site. In this way

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twisting can be minimized, and a footing halfway between the
optimum position for either procuring or disposing of the
product can be taken.
3. Uneven Lifting or Carrying

Because a person with degenerative disc disease often has
instability in the lower lumbar spine, any activity that unevenly
loads the spine may aggravate low back pain symptoms. A major
activity in which such uneven loading may occur is one-handed
carrying, especially if the object being carried is quite heavy and
bulky. The weight of the object is counteracted by bending to the
contralateral side, which loads the back, abdominal, and chest
muscles. The shear forces on the lower lumbar discs will increase
and the potential for pinching the dorsal nerve root between the
bony processes of the vertebrae is greater. A similar unbalance
can occur if the object being handled is not symmetrical
and has more weight on one side than the other. This requires the
trunk muscles to develop differential forces to keep the body in
balance. Any instability of the load, as occurs if a liquid in an open
container is handled, may require the trunk muscles to alter their
tension suddenly in order to counteract the motion, and this too
may result in instability in the lumbar region.
Occupational tasks that result in uneven loading of the spine
include carrying pails of water or other liquid (Figure 11-8) and
carrying a heavy suitcase or bulky item with a handle_ at the top,
such as a "portable" TV set. Furniture moving exposes handlers
to many unevenly balanced loads, either because the object itself
is asymmetrically weighted (as in a refrigerator and most appli­
ances) or because the lifting and carrying task requires one hand
to be higher than the other (as in taking a couch down a narrow
flight of stairs with a landing). Lifting patients in a medical facility
or handling pumps and other heavy equipment in a maintenance
operation are other examples of uneven loading of the spine.
Awkward postural requirements, such as crouching, leaning to
one side, or kneeling, can also result in uneven loading of the
spine as the weight is shifted from one side of the body to the
other searching for a stable posture. Standing with the feet on
different levels will also unevenly load the spine during a lifting
task, as can two-person lifting where the handlers are not well
matched in size or strength.

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Figure 11-8: Uneven Load Carriage. The cleaner is carrying a heavy
bucket of water on one side of the body that is not balanced by the
mop in the other hand. To keep from being pulled to the left side, she
has to stabilize her posture with the back and hip extensors and with
the abdominal and buttock muscles. This uneven loading of the
spine increases the risk of a nerve root pinch in people with
degenerative disc disease.

The person with an unstable lower back usually learns
through experience that uneven loading of the s pine is often
associated with sharp pain. Toa.void this he orshe usually makes
certain that loads do not become concentrated on only one side.
If a suitcase is carried, it is balanced by a second suitcase or bag

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in the other hand; this helps to load the spine more equitably. If a
force has to be exerted on one side only, the handler can stabilize
his or her posture by holding on to a fixed structure with the
opposite arm. In two-handed carrying tasks, the handler should
try to keep the hands even and to share the load as equally as is
possible. Th.e use of straps, hand trucks, dollies, and other
handling aids that permit an uneven load to be lifted or transported
with both hands at the same height are also recommended (see
Chapter 9).
4. Handling an Over-Sized Load
The horizontal distance from the lumbar spine to the center
of a load being held in the hands will strongly influence the
lumbar disc compressive and shear forces. The heavier the load
and the farther its center of mass is from the spine, the more force
there will be on these discs, and the more opportunity there will
be for damage to them and for aggravation of low back pain
symptoms. This distance will be affected by the design of the
workplace or lifting task (see Extended Reaches) and by the
dimensions of the items to be lifted. Bulky objects, even if they
are not very heavy, extend the lever arm and put additional
demands on the back and hip extensor muscles to counteract the
body's tendency to fall forward. Objects that extend more than 20
inches (51 cm) in front of the body usually produce hyper­
extension of the back as the handler tries to reduce the load on
these muscles by bringing the load closer to the lumbar spine
(Figure 11-9).
Some objects that are over-sized and produce awkward
lifting or handling postures include:
• furniture
• trays more than 20 inches (51 cm)
long and wide
• sheet materials more than 20 inches (51 cm)

in length and width

• plywood sheeting
• large glass or metal plates
• bales of raw materials or waste more than
20 inches (51 cm) wide and long
• some wide stock rolls of paper, plastic, etc.

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Figure 11-9: Over-Sized Load Handling. Carrying a large-size tray (2

dimensions being more than 30 inches or 76 cm long) results in
hyperextension of the back. The handler tries to reduce the stress on
the erector spinae muscles by arching the back and moving the
center of mass of the load and upper body closer to the spine. Grip is
usually less stable as well because the arms have to be extended
rather than the elbows lying next to the side. This instability
increases the risk for losing control of the load.

Some long products (e.g., pipe) may be held in front of the body
on their long dimension while being placed on a machine or in a
rack. Even moderately narrow products may be over-sized in
these handling tasks.
The worker with low back pain who is confronted with an
oversized load often has a number of options. These include
sliding the load rather then lifting it onto a transfer cart or to a
pallet on a levelator in a production workplace. A rope or strap
may also be used to permit the load to be grasped closer to the
body if it does not have handholds. Other materials handling aids

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such as a dolly or hand truck may be used instead of carrying the
object manually. An overhead hoist, a transfer table, or a cart
could be used to support the weight of a supply roll being loaded
into a machine. When multiple separate items constitute the load,
such as sheets of paper, piping, metal plates, etc., the worker
should restrict each lift load to 25 lb (11 kg) in order to keep the
compressive and shear forces on the lumbar spin acceptable.

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Even under the best conditions for handling heavy objects,
sustained effort can produce fatigue of the back, hip, abdominal,
and arm muscles, resulting in less protection of the vulnerable
vertebrae in a person with degenerative disc disease. In the same
manner, sustained awkward postures will selectively load some
muscles, and their fatigue may make the person less able to
respond to a sudden change in posture or in the balance of a load.

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The unguarded move in a handling task is more likely to result in
aggravation of the low back pain symptoms, as it often is
accompanied by uneven loading of the spine and higher shear
forces on the lumbar discs.
Sustained heavy handling tasks can be found in many
warehouse and shipping areas, stockrooms, chemical or bulk
food packaging areas, pallet loading operations at the end of a
production machine, package delivery and bulk mail handling
businesses, and ditch digging operations. The people doing
these jobs spend the majority of the shift doing handling tasks,
and their muscles may show some fatigue. Their overall workload
can be considered heavy, requiring close to the recommended
upper limit of energy expenditure for a typical shift. Jobs or tasks
where sustained awkward postures may be required include
many low-seam coal mining operations, some tunnel or water
main construction work, some maintenance and construction
tasks where clearances are tight (for example, overhead duct
repairs), automobile mechanic work with extended reaches and
overhead work, and construction work such as pipe fitting, where
frequent bent-over postures, sustained holding, and crouching
may be required.

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The worker whose job requires him or her to sustain heavy

lifting or awkward postures for a large part of the shift is unlikely

to be able to perform that work during an attack of low back pain,
and job restrictions or time lost from work usually result. By
taking frequent, short breaks from the heavy work or awkward
postures, usually for 1 or 2 minutes every 15 minutes of work,
however, the potential for aggravating the symptoms between
attacks will be less. Most people will do this intuitively unless they
are paced externally by a machine, peer or supervisory pressure,
or a pay incentive. The worker with degenerative disc disease
should be made aware that the use of these mini-breaks will
actually increase productivity by reducing the back discomfort
and potential for lost time due to low back pain.

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CHAPTER 3: KEEP MUSCLES FIT

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A. MUSCLES THAT SUPPORT THE SPINE

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There are four major groups of muscles that protect the
lower spine by stablizing it and by counteracting high pressures
on the 4th and 5th lumbar discs. These are the back extensor
muscles, or erector spinae, that lie along either side of the spine,
the abdominal muscles that counteract lumbar disc pressure by
creating a positive pressure in the abdomen and by stabilizing the
spine during turning movements, and the hip extensors and
flexors, including those of the spine, buttock, and upper leg
(hamstring), that provide stability to the lower spine during
motions around the hips (Figure 11-10).

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These muscle groups act to increase the flexibility of the
spine by keeping it aligned during a variety of movements such as
bending forward, stretching backwards, reaching to the side, or
holding an object in front of the body. The back extensors
operate on very short lever arms (about 2 inches or 5 cm) and
have to develop high forces to counteract the tendency of the
body to fall forward when an object is lifted. The abdominal
muscles are particularly important in lifting tasks because they
stabilize the lower spine by fixing the trunk's posture. The
increased intrabdominal pressure is in the opposite direction to
the increased pressure on the L4 and L5 discs and, therefore,
relieves the discs of some of the force on them. Poorly toned
abdominal muscles provide less of a counteractive force and are
less able to protect the spine when motions to one side are made.
The hip flexors and extensors act like guy wires around the lower
spine and provide stability during the full range of movements. If

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Figure 11-10: Muscles Supporting the Lower Spine. The major

muscle groups that help support the lumbar spine are shown. The
erector spinae muscles extend the back, the hip flexor and extensor
muscles are used in forward, backward, and sideways bending, and
the abdominal muscles control trunk flexion, rotation, and lateral
bending.

the trunk is twisted to one side, these muscles are less able to
protect the spine because their force is not directly transmitted to
the spine. This means that more work is done by the muscles to
get the same effect of protecting the spine. As a person flexes
forward to lift up an object, the muscles of the hip extensors help
the back extensors keep the body from falling forward. If there is
a heavy weight to be carried on one side of the body or if an object

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is heavier on one side, the hip flexor and erector spinae muscles
work together to keep the spine balanced and stable.
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B. MUSCLE STRENGTH AND FATIGUE
If the muscles of the back, abdomen, buttock, and upper leg
are not kept fit they are less able to keep the spine stable as
various motions are made. This can sometimes result in high
compressive forces on the lumbar discs during a lifting task or
during an awkward posture. The primary concern with less fit
muscles, however, is not so much the peak forces required in
certain tasks but the muscles' inability to sustain moderate
workloads for extended periods. For example, a muscle with less
capacity because of a lack of exercise will fatigue faster at the
same workload than will a fit one. This is particularly important
for tasks where the required posture is leaning forward or to one
side or where an object has to be held or carried for more than a
few seconds.
Figure 11-11 shows the relationship between the percent of
muscle strength used (% MVC) and the length of time it can be
exerted continuously (in minutes). The higher the capacity
(MVC, or maximum voluntary contraction strength), the lower %
MVC any given task will be. Thus, if a person has a grip strength
of 100 pounds (or about 45 kg), a 50-pound (23 kg) object held in
that hand uses 50% of grip strength. If the grip capacity is only 75
pounds (34 kg), however, the same .object uses 67% of grip
strength. The 50% MVC load can be held for 1 minute contin­
uously, whereas the 67% MVC load can be held for only 45
seconds before muscle fatigue occurs. Thus, the person with less
capacity will have to take more frequent recovery breaks (see
Chapter 10), and this may affect his or her productivity in a heavy
job. A similar situation occurs for the back muscles. Their
capacity for a given task will depend on the biomechanics of the
posture or the lifting situation. The force exerted by the back

extensor muscles, for example, will be acting on a 2-inch (5 cm)

lever. That will have to counteract the object weight on a lever
from the spine to the center of mass of the body and the object
being lifted (see Chapter 5). The farther the body is from the
upright posture and the heavier the load, the higher the percent
of back extensor maximum strength required, and the sooner

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Working With Backache

fatigue will occur. Keeping the back muscles well-toned will

reduce the risk of overexertion by increasing their strength and
making each task a lower percent of that maximum value.

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amount of time, in minutes, that a given percentage of muscle
strength can be sustained is shown by this curve. The maximum
muscle strength will depend on which muscles are active, but the
relationship with time is similar across muscle groups. The longer a
posture has to be sustained the more likely it is that the active
muscles will reach the limits of this curve, and fatigue will result.

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C. EXERCISES TO KEEP THESE MUSCLES FIT

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There are a number of exercises that can be used to stretch,
tone, and strengthen the four groups of muscles that protect the
lower back. The ones summarized below are suggested because
they can be done equally well by people with healthy backs and
by people who have a history of low back pain.

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1. Bent-Knees Abdominal Curl (Figure 11-12) - Lie on your back
with your knees bent and heels flat on the floor. Clasp your hands
behind your head. Slowly raise your head, shoulders, and upper
trunk off of the floor on a count of 3. Then, slowly lower yourself
again on a count of 3. Breathe out as you come up. Repeat 5 to 10
times initially, increasing the number to 20 times later as you
become better conditioned.

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2. Leg Pull (Figure ll-13a) - Lie on your back with your knees
bent and your heels flat on the floor. Bring one knee up to your
chest and clasp it with your hands. Keep your head on the floor.
Hold the knee up for 10 seconds, then return the leg to its bent
knee position and repeat the stretch with the other leg. Repeat
the cycle 3 times for each leg initially and increase to 5 times later.
Then raise both knees to the chest at once and hold for a count of
10 before relaxing again. Repeat this 3 times.
3. Cross Over Stretch (Figure ll-13b) - Lie on your back with
straight legs. Bend your right knee and cross it over your left leg.
Put your left hand on your right knee and stretch your right arm to
the side. Turn your head to look at your right arm, keeping your
shoulder and head on the ground. Pull down on your right knee
and hold it for a count of 10. Then relax and repeat it again.
Change legs and do the same stretch twice on the left leg.
4. Whole Body Stretch (Figure ll-13c) - While standing, clasp
your hands over your head and turn your palms upward. Your
feet should be a shoulders' breadth apart. Slowly stretch your
arms over your head looking straight ahead and keeping your
hands together. Do not hold your breath or go up on your toes.
Repeat 5 times initially and up to 10 times later on.
5. Side Slides (Figure ll-13d) - Standing with your feet a
shoulders' breadth apart, press your right hand against the
outside of your right thigh and slowly slide it down, leaning to the
right with your trunk. Come back to an upright posture and then
repeat the slide with the left arm and leg. Repeat the cycle 5 times
initially and up to 1 O times later on.
If these exercises are done every other day and at a moderate
level, the back, buttocks, hamstring, and abdominal muscles will
be toned. The suggested number of repetitions should not be
exceeded, especially during the initial conditioning stages.
Muscle spasm is a common outcome when a nerve root is
pinched in the lower spine. The pinched nerve causes increased
activity of the motor neurons which increase back muscle
contraction strength, and this further increases the pain in a
positive feedback loop. One has to break the cycle by stretching
out the muscle or by reducing the pinch on the nerve root to stop

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muscles ("b" and "d"), and the trunk extensor muscles ("c") are
illustrated. See the text for instructions.

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the muscles from going into spasm. The best approach is to curl
the legs up to your chest to take the pressure off the nerve root by
opening up the space between the vertebrae. With the chin down
and yqur arms down at your sides, the stretch on the back
muscles should reduce the spasm as well as reduce the trigger
from the pinched nerve. Lying on the floor with the lower legs on
a chair seat usually gives relief if a nerve pinch/muscle spasm is
caught early enough.
Some recent research suggests that whole body exercises
may be preferable to specific exercises for the back as a way of
preventing low back pain episodes. Whole body muscle toning
can improve the way in which one works at any job since there is
less probability that any muscle will limit the performance of a
task. If the whole body exercise program includes back exercises,
then it may be preferable as long as exercises that may be difficult
for a person with low back instability (such as back arching and
some straight leg stretching exercises) are not required. Any
exercise is better than none, but too much exercise at high
intensity or of extended duration is not advisable, especially
when starting or resuming an exercise program.

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Manual handling tasks are associated with a high incidence
of occupational low back pain reports. One corrective approach
used for many years has been to train people how to lift safely so
that the risk of overexertion is reduced. Defining safe lifting then
becomes the challenge, since what people do in the workplace is
not always consistent with what is considered the best lifting
practice by safety and ergonomics specialists.

A. SAFE LIFTING AND LOW BACK PAIN
Despite a strong emphasis on training programs for at least
30 years, there has not been a concomitant decrease in the
incidence of reports of low back pain in industry. As Rowe (1983)
has suggested, the low back pain problem associated with
manual handling tasks may be related more to the need to report
the pain when doing heavy or repeated lifting or force exertion
than to a problem with the way the object is lifted. The person
with degenerative disc disease may benefit from learning safe
lifting techniques, but the application of those techniques may
not reduce the probability that he or she will have an episode of
low back pain on the job.
Safe lifting techniques can be expected to reduce overexertion

injuries of the arm and shoulder muscles. A reduction in strains
and sprains can be expected for a period of 3 to 6 months after a
lifting training program because people are more aware of good
body mechanics and how to use their muscles effectively during
handling tasks. As with most training programs, however, the
benefits will begin to "wear off" after six months. The major

53

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points will have to be reinforced at least once a year, preferably in

a new format, in order to maintain the lowered incidence of

reported strains and sprains.

Despite the difficulty of showing that low back pain problems
are significantly different before or after lifting training, information
about safe lifting techniques should be provided at the workplace.
Explanations of body mechanics, patterns of work that increase
or decrease the potential for muscle fatigue, and special tech­
niques developed by people who lift for a living (such as dock
workers, furniture movers, and shipping dock handlers) can help
others develop appropriate methods for their handling tasks.

B. GENERAL LIFTING GUIDELINES
There has been considerable discussion over the past 10-15
years about the appropriate way to teach lifting. The method
used for many years suggested stereotyped postures with the
legs always bent, back straight, chin in, and with the legs doing
the lifting. Several researchers have noted that few people when
left to their own devices use this technique - except when the
object to be lifted is very heavy. Many workers handle objects
weighing up to 30 pounds by using a modified derrick lift; the
knees are not used to do the lifting, but one leg is stretched out to
counterbalance the load on the spine as the object is raised from
the floor to a table. Other forms of dynamic or free-style lifting,
most of which involve a combination of knee and back bending,
have also been observed. Most researchers agree that the
stereotyped lifting technique may not be optimal for every
worker. The. guidelines given below (and in Figure 11-14) are
general ones that apply across different types of lifts, whether
they are done free-style or in a more stereotyped lifting posture.
1. Do Not Twist While Lifting

This is perhaps the most critical factor in the design of lifting
tasks and in their execution. The muscles that support the spine
and keep the discs and vertebrae aligned even if there has been
some loss offluid from the disc have been enumerated in Chapter
3. Twisting will reduce their effectiveness and increase the rate at
which they fatigue, especially if the object being lifted is heavy.

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a.

Plan the Lift

b.

Determine the Best Lifting
Technique

C.

Get a Secure Grip

d.

Pull the Load In Close To Your
Body

e.

Alternate Lifting and Light Work
Tasks

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manual lifting tasks are illustrated. See the text for further discussion.

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to twist as will the amount of foot clearance and the rate at which

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The orientation of the workplace will affect the person's tendency

the lifts must be made. Chapter 5 discusses design factors that
can influence the amount of twisting done during lifting tasks.

Sizing up the load and determining how it will be lifted and
where it will be placed is one way of avoiding overexertion
injuries. An unplanned lift may result in the handler having to
support the load longer than is necessary. This can produce local
muscle fatigue that may increase as the shift proceeds and limit
the worker's ability to sustain the work for a full 8 hours. The
closer the weight of the object is to the capacity of the weakest
muscle groups involved in the lift, the faster these muscle groups
will fatigue, and the more opportunity there is for a muscle
overexertion injury to occur. The relationship between duration
and intensity of effort shown in Figure 11-10 illustrates the impact
of extended holding times, as might occur in unplanned lifts, on
available strength.
One aspect of planning a lift is to determine if it is too heavy
or bulky for one person to handle. By assessing the situation first
instead of starting directly in on the lift, one can decide if a
handling aid, a cart, or another person is needed to move the
object.
3. Determine the Best Lifting Technique
The size, weight, and location of the lift, the frequency at
which it must be repeated, and the duration of continuous lifting
are all factors that will help determine the best lifting technique.
Compact objects (see Chapter 9) lend themselves to better lifting
postures than do bulky objects, and heavy objects require more
use of the legs for lifting then do light ones. Lifting frequency and
duration should be considered when deciding on the lifting
technique, because an awkward posture may become a limiting
factor in extended lifting tasks. Calisthenics associated with
lifting up the body every time an object is lifted may also limit a
person's capacity for a lifting task if the legs are bent for each lift.
However, a "derrick" (or stoop) lift (Figure 11-15} is not recom-

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mended for frequent lifts because of the high pressure it puts on
the lumbar discs.

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Figure 11-15: Bent Knees and Derrick Lifting Styles. Two handling
styles are shown, a bent knees (or squat) lift in "a" and a derrick (or
stoop) lift in "b". Bent knees lifting is recommended to reduce the
stress on the lumbar disc, especially in repetitive lifting tasks. It
requires more energy to lift this way, however, because the whole
body is lifted with each case. Some workers may lack the leg
strength needed to raise the body and load from the squat position
and, therefore, may choose to use stoop lift.

a

In addition to choosing the best technique for lifting, one
should plan how to avoid the awkward postures or calisthenics
by using aids (see Chapter 8).
In choosing the best lifting technique, the feet should be

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placed in a stable posture so that slips or awkwqrd postures

during the lift are not likely. Generally, this means that the feet

will be about 12 to 18 inches (30 to 46 cm) apart and one foot will
be somewhat behind the other one, rather than side by side
(Figure 11-16). At least one foot should be flat on the floor.

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Figure 11-16: Position of the Feet in Low Lifting. When the feet are
spread apart and the back can be kept straight during a low lift
("Good"), the pressure on the lumbar spine is lower than it is if the
feet are side by side and the back is flexed ("Poor").

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4. Take a Secure Grip on the Object Being Handled

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The hand is the interface between the object being lifted and
the person; how secure the grip is will determine how safe the lift
will be. If the object has handholds (see Chapter9), a good power
grip can be used and stability is less ofa problem. Many of the
objects to be lifted, however, are not equipped with handholds.
Examples of these include shipping cases, bulk materials in bags,
sheet materials such as plywood, and raw materials such as
metals. The grip type will depend on the configuration of the
load. Wherever possible, a power or ledge support grip (see
Figure 11-14 "c") should be used rather than a pinch grip, which
has only 25% of the strength of a power grip.

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If a handler's grip is not secure there are at least two potential
concerns relating to back problems. The first is that the person
may lose control of the load while handling it and may take an
awkward posture or lose his or her stable foot position while
trying to get the load back into control. This can result in a slip or
trip accident which may aggravate a back problem. The second
potential problem is if a pinch grip is used and the hand and arm
muscles fatigue before the lift is completed. The need to readjust
the load to use different muscles can resu It in overexertion of the
arm or shoulder muscles or twisting of the trunk providing there
is no place to set the object down first. Poor grip stability, then,
can contribute to low back pain symptoms if handholds are not
available and the duration of holding the object is more than a few
seconds.
5. Pull the Load in Close to Your Body
Lift location determines both the amount of compressive
force on the lower lumbar spine and the strength available (i.e.,
which muscles) for making the lift. The discussion of work
location in Chapter 5 explains why this factor is so important.

Every lifting-technique emphasizes the need to get the load close

to the body to prevent excessive stress on the back and to make
the strongest muscles of the arms available to hold the load. If the
load can be held close to the body, the grip is usually more stable
and the shoulder muscles do not limit the duration of holding. In
addition, a person can walk normally without having to hyper-

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extend the back in order to counteract the forward pull of the
load.
Some lifting situations make it difficult to keep the object
close to the body because the handler cannot bend his or her
knees due to an obstruction. Objects that are handled near the
floor and that are too large to fit comfortably between the legs
during lifting will cause the lift to occur at a greater horizontal
distance from the spine than is desirable. In some of these
situations a lifting aid or a second persori may be needed to
reduce the risk of overexerting the muscles or putting excessive
pressures on the lumbar discs.
6. Alternate Lifting Tasks with Lighter Work

Heavy lifting is not usually sustained because people recog­
nize thattheir muscles are fatiguing and find ways to take breaks
to rest the muscles. Sustained moderately heavy lifting tasks are
more common, often found at the ends of conveyor lines where
materials are loaded or unloaded at a fixed rate. These can
become problem tasks, especially if an awkward posture such as
leaning to one side, bending forward, or twisting is incorporated
in the way the lifting is done. The design of lifting tasks and the
need to provide adequate recovery time in repetitive lifting jobs
are discussed in Chapters 7 and 10, and some suggestions for
ways to structure jobs where repetitive lifting is done for a
majority of the shift are included in Chapter 11. The general
guideline for job design is to provide alternate tasks that do not
heavily stress the same muscles. These lighter tasks allow the
active muscles to recover and are alternated with the lifting tasks
throughout the shift.

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C. OTHER MANUAL HANDLING TECHNIQUES
Not all objects are "lifted" in the workplace; but in choosing
guidelines for handling materials manually one has to assume
that one person's "lower" may become another person's "lift."
Lowering takes less energy to perform but the general guidelines
given in "B" above are still appropriate for these tasks. Two other
types of handling are discussed below: two-person lifting and
sliding or pushing.

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1. Two-Person Lifting

There is a general assumption that if one person should not
be making a lift, two people can do it. Although this may be
appropriate for bulky loads that are not very heavy, it is not
necessarily appropriate for heavy lifting. Even if a team of
handlers is well-matched in terms of their body size, strengths,
and work capacities, they cannot always perfectly share a load
when handling it together. Thus, it is not true that two people can
lift twice as much weight as one person can. Some suggestions
for determining when two-person lifting is most appropriate are
given below:

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a) When an object to be handled has two dimensions that are
more than 30 inches (76 cm), even if it is very light, two people can
probably handle it more safely than can one.
b) If a lift is being done very infrequently and the object exceeds
the guidelines for one-person lifting but is not more than 50%
heavier than the one person lifting weight limit, it can probably be
safely handled by two people.
c) If the object to be handled is very long (pipe, conduit) and is
awkward for one person to balance without hyperextending the
back, a two-person lift is recommended.
d) If items, such as bags, are handled frequently and for
extended durations (more than one hour continuously), total
lifting time and local muscle fatigue can be reduced by having
two people handle them together.
2. Sliding and Pushing

Local muscle fatigue can become a problem when an object
is handled frequently for extended periods. Inadequate time for

the active muscles to recover between exertions will cause a

build-up of fatigue, and the opportunity for an overexertion injury
to occur will be greater. One approach to reduce this fatigue is to
reduce the amount of effort for each transfer of the product by
not actually lifting it. Designing the workplace so the object can
be transferred using a push, pull, or slide can reduce the muscle

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work and make the total workload more acceptable as well.

Guidelines for the amount of force to be exerted and for the

design of handling tasks to permit the use of sliding are included
in Chapters 7 and 8.

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Section Ill: How the Workplace Can
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Chapter 5: Work Location Heights and Distances
Chapter 6: Seating
Chapter 7: Design of Manual
Handling Tasks

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Chapter 8: Special Workplace Aids for
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Section Ill:
How the Workplace Can Be Improved

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Even if the worker tries to minimize over-exertion on the job,
workplace design factors can contribute to his or her low back
pain symptoms. These include work heights and reaches that are
inappropriate for sustained work, poor seating, and repetitive
lifting tasks done in workplaces where unnecessary effort is built
into the job. Identification of these workplace problems and
suggestions of ways to overcome them by better design and
worker accommodations are covered in this section.

CHAPTER 5: WORK LOCATION - HEIGHTS
AND DISTANCES
Where the hands are located when a task is performed and
how closely the body posture conforms to an upright alignment
of the spine will determine the stress on the lower back. Body
mechanics, or biomechanics, can be used to analyze the direct,
shear, and rotation (torque) forces on the lower spine and the
muscle work required to keep it aligned. The compressive, shear,
and rotation forces are important contributors to small tears in
the disc casing that can result in fluid loss from the disc and
instability in the L4-L5 (fourth and fifth lumbar) vertebral column.
The demands on the hip flexor and extensor, erector spinae, and
abdominal muscles to keep the spine aligned are greater when
this instability is present (see Chapter 3). The consequences of
their failure to keep the spine aligned can be a very painful
compressed nerve root. In this chapter some discussion of the

65

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biomechanical stresses on the back is presented, and guidelines

for the design of working heights, reach distances, and workplace·

orientation are given.

A. LOCATION AND BODY MECHANICS
The spinal column is designed to support the weight of the
body and forms curves at two locations, at the cervical region
(below the head) and at the lumbar region in the lower back.
These curves are towards the ventral (or belly) side. When a
person is standing upright the center of mass of the body is
centered over the skeleton and ankles so minimal muscle effort is
required. If the person reaches forward or to the side, the muscles
of the trunk have to do extra work in order to counteract the
tendency of the body to follow the arm in that direction.
Alternatively, the person has to realign other parts of the body,
such as one leg, to reverse the forward fall and to reestablish the
center of mass over the skeleton. A teeter-totter analogy simplifies
the mechanics. Assume that child #1 weighs 50 pounds (23 kg)
and child _#2 weighs 25 pounds (11.5 kg). The length of the
teeter-totter board is 20 feet (6 meters). If the board is pivoted
around its center, child #2 will never be able to get child #1 off of
the ground because the balance point requires an equation of
force times distance on each side. At the board's midpoint:
Child #1
(50 lb) (10 ft)
500

Child #2
vs
VS

(25 lb) (10 ft)
250

If the teeter-totter board is set so that child #1 is only 5 feet (1.5 m)
from the pivot point, child #2 will be 15 feet (4.6 m) from that point
and can lift and hold the heavier child off the ground.
Child #1
(50 lb) (5 ft)
250

Child #2
VS

vs

(25 lb) (15 ft)
375

If the two children are to be equally balanced, the distance from
child #1 to the pivot point should be 6.7 feet (2.0 m) and child #2
should be 13.3 feet (4.1 m) from this point.

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Work Location-Heights and Distances

67

The trunk extensor muscles, or erector spinae, are the
primary muscles involved in keeping the spine upright. If one
leans forward, the erector spinae are activated to pull back on the
trunk. The weight of the upper body becomes the equivalent of
one of the children on the teeter-totter. The work of the erector
spinae muscles to counteract the upper body motion is equivalent
to the other child, measured as force rather than weight. The
lever arms, or distances, on which the forces work are: the
distance from the spine to the body's center of mass when the
person leans forward, which is the force arm (upper body mass
that has to be counteracted); and the distance from the insertion
of the erector spinae muscles to the same point on the spine,
which is the resistance arm (muscle work to counteract the
forward lean). The resistance arm is about 2 inches (5 cm) long,
and is fixed by one's anatomy. Unlike the children on the teeter­
totter, then, the resistance lever arm can not change, so the work
of the erector spinae muscles is directly. proportional to the
horizontal distance from the spine to the center of mass of the
body or to the center of mass of the body plus the weight of an
object held in the hands or carried on the trunk. The farther that
weight is from the ankles, the more work the back extensor
muscles have to do and the faster they will fatigue. An example of
the impact of horizontal distance on compressive forces on the
spine is shown in Figure 111-1.
The forward bending moment has to be counteracted by
activity of the erector spinae muscles and this force is transmitted
to the lower spine. The posterior third of the fourth and fifth
lumbar discs (L4 and LS) are most "vulnerable" to these forces as
they form the "S-shaped" curve of the lower spine.
Shear and rotational forces on the lumbar discs will be
created if the upper body is moved to one side, as in bending to
one side or reaching across the body, or if the trunk is rotated to
one side even if the body is still upright. This unequal loading of

the spine puts the back and hip extensor musc_les at bio­

mechanical disadvantage. The forces they develop are not fully
transmitted to the spine because of the altered orientation of the
force arm due to the twist. This would be somewhat analogous to
putting a bend at one end of the teeter-totter. Because the force is
not in Iine with the pivot point, the board's stabi I ity wi11 be greatly

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Forward Bending Moment=
(20) (20) + (100) (8) = 1200 inch lbs.
or (90) (.51) + (445) (.20) = 135 N.m

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or (90) (.38) + (445) (.15) = 101 N.m

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FA,= 15 inches (38 cm)
FA2= 20 inches (51 cm)
FA3= 6 inches (15 cm)
FA4= 8 inches (20 cm)
Upper body weight= 100 lbm (445 Newtons)
Figure 111-1: Load Location and Forward Bending Moment. The
forward bending moment is a function of the weight of an object held
in front of the body and the weight of the body as the handler bends
forward. The moment is the s um of these weights times their force
arms or levers. FA, and FA2 are the distances from the spine to the
center of the load and FA3 and FA4 are the distances from the spine to
the center,of mass of the upper body.

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reduced. In the case of the spine, the trunk and hip flexor muscles
wil I have to work harder to apply the same force to the force arm,
and they will, therefor�. be more subject to fatigue.

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When an activity requires high reaches or overhead work, the
spine is arched backwards or hyperextended. This motion
mechanically compresses the posterior third of the L4 and L5
discs especially, and puts the erector spinae muscles at a
disadvantage because they are no longer stretched for optimal
tension development. Repeated hyperextension of the back may
increase the opportunities for disc flattening in persons with
degenerative disc disease, thereby reducing stability in the lower
spine.

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B. WORKING HEIGHTS AND REACHES

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Work surface height will determine the amount of stress on
the back and shoulder muscles for work that is done by people of
very different body sizes. The most comfortable working heights
are at or around elbow height. If forces are applied, the work
surface should be belpw elbow height. If fine visual attention is
needed, the surface should be higher. A too low work surface
results in static loading of the back extensor muscles or the legs
because the worker has to lean forward, bend over, or bend the
knees to get into the right posture for the work. A too high work
surface requires the worker to elevate the elbows to do the task;
this puts a static load on the shoulder muscles that can result in
their early fatigue.
Anthropometric data of the elbow heights of people standing
upright (Figure 111-2) suggest that a standing work surface should
be between 35 and 41 inches (89 and 104 cm) above the floor, the
lower value for tasks where force exertion is needed and the
upper value for visually-demanding work. For seated work the
elbow height is measured relative to seat height. It assumes that

the seat height can be adjusted ,o meet the work surface height

needs. Elbow heights range from 7 to 12 inches above the seat.
Seated work surface heights can be varied from 25 to 32 inches
(64 to 81 cm) above the floor providing a footrest is available for
people with shorter legs (see Figure 111-3).

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50/50 Population Percentiles, Inches (cm)
5th

50th

95th

56.8(144)

62.1(158)

67.8(172)

48.4(125)

54.4(137)

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38.0(96)
37.4(95)

42.0(107)
40.9(104)

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Waist Height

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17.2(44)

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Figure 111-2: Standing Anthropometric Measurements. Five sets of
values are shown for 5th (small), 50th (average), and 95th (large)
percentile heights for a mixed population (men and women). The
values are given in inches and centimeters. These are useful in
determining appropriate heights for the design of standing work­
places.

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5th

50th

27.4 (70)

29.9 (76)

21.4 (54)

23.6 (60)

95th
Eye Height, Seated
(measured from seat)

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Midshoulder Height
(measured from seat)

Elbow Height
(Measured from seat)
7.3 (18)

9.3 (24)

15.1 (39)

16.6 (43)

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Popliteal Height
(Back of knee to floor)

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Figure 111-3: Seated Anthropometric Measurements. Four sets of
anthropometric measurements that are useful for seated workplace
design are shown. The values are for the 5th, 50th and 95th
percentile hei�hts based on a mixed population of men and women.
All of the heights except popliteal height are measured from the seat
pan, not the floor.

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Standing forward reach capability is a function of arm length

and of the height at which the reach is made. The range of motion

of the shoulder in moving the arm up and down in front of the
body is in an arc with the greatest forward reach available at
shoulder level. As the arm moves above shoulder level it loses
forward reach capability, falling from 22 inches to 15 inches (56
to 38 cm) as it moves from 54 to 72 inches (137 to 183 cm) above
the floor. At 80 inches (203 cm) above the floor the forward reach
is less than 5 inches (13 cm). Below shoulder level the forward
reach is also less. Many tasks are done at these heights, and the
worker has to lean forward or bend down to get the additional
reach capability. At elbow height, for example, most people have
only about 15 to 18 inches (38 to 46 cm) of forward reach, and at
mid-thigh height (about 30 inches, or 76 cm) their forward reach
has decreased to 5 inches (13 cm).
If the reach is not directly in front of the body, but is done
more towards one side, an additional 3 to 5 inches (8 to 13 cm) of
forward reach may be lost. If two arms are needed instead of one
to reach an item, forward reach is about 2 inches (5 cm) less in
front of the body. It is even more severely reduced if the reach is
more than 25 inches (64 cm) to one side of the center of the body.
A general guideline based on the reach and height inter­
actions suggests that work surface heights should be kept
between 35 and 41 inches (89 and 104 cm) for standing tasks
whenever possible. Forward reach requirements should be kept
within about 15 inches (38 cm) of the front of the body in order to
reduce the need for bending to extend the reach (Figure 111-4).
Lower and higher work heights are commonly found and are
associated with either back or shoulder muscle fatigue in many
people. Overhead assembly or repair work, as in installing duct
work or working under a car in a repair shop, should recognize
that more than 5 inches (13 cm) of forward reach will be difficult
for smaller workers.

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For seated work the same forward reach arc applies; the
farther to the side or the higher the reach is, the closer the object
to be reached must be. Forward reaches of 15 inches (38 cm) at
the work surface (Figure 111-5) and no more than 10 inches (25
cm) forward at 25 inches (64 cm) above the work surface are

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Figure 111-4: Standing Forward Reach Capability. The forward reach
capability of a small person (5th percentile functional arm reach
from the front of the body) in a standing workplace is shown at 35
and 50 inches (89 and 127 cm) above the floor. The guideline of
keeping forward reaches within 15 inches (38 cm) of the front of the
body is developed from this anthropometric data.

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recommended. If the reaches exceed these values, the worker

will have to lean forward and may lose backrest support. This

could result in an aggravation of symptoms for a person with
back pain who has to sit for a majority of the shift.

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Figure 111-5: Seated Forward Reach Capability. Forward reach
capability at heights between 25 and 40 inches above the floor in a
seated workplace is shown for a small person (5th percentile
functional arm reach from the front of the body). The 15 inches (38
cm) forward reach guideline for design of seated work tasks is based
on this anthropometric data.

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Reaches below the work surface at a seated workplace are of
concern because forward reach is very limited (to a few inches).
The worker will often have to twist to reach an object that has to
be handled or operated. Repeated movements below the work
surface may also result in rubbing the trunk on the chair's
backrest and can produce local skin abrasions. In general,
materials, items, or equipment that have to be reached or
activated frequently should be located near the work surface and
within the recommended forward reach dimensions given above.
Materials that have to be accessed infrequently might better be
placed where the operator has to get up to obtain them. This
would assure some postural adjustment in an otherwise pre­
dominantly seated task.

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C. ORIENTATION OF THE WORKPLACE
The way the workplace is designed will influence how much
turning or twisting a person has to do to accomplish the work.
The illustration at the beginning of Section 111 illustrates two
designs, one where the work is done in a 180-degree arc and
other where the work is kept within a 90-degree arc. In the first
example, the operator has to turn 180 degrees from the conveyor
to the pallet for each cycle. This 180-degree rotation in each
direction can increase the shear and rotational forces on the
lower lumbar discs and will reduce the effectiveness of the
abdominal and hip flexor muscles in supporting the lower spine.
Orienting the workplace to keep the movement pattern
within a 90-degree arc reduces the opportunities for extreme
twisting and reduces the movement time as well; this makes it
possible to complete more assemblies per shift if the operation is
self-paced. In the example in Figure 111-6, the 90-degree arc is
created by placing the packing work surface perpendicular to the
supply table. The worker can reach the incoming product better
and load it directly into the packing boxes, which can be at a

lower level. The packed boxes can be placed on the pallet in

another, separate, 90 degree turn. The supply table can be used
as temporary on-line storage to relieve the time pressure of the
conveyor's delivery of product.

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These changes in the orientation of the workplace relative to

the conveyor line and the pallet are intended to make it more

difficult for the worker to twist and put shear forces on the lower
spine. Other designs reduce extended reaches by making a cut­
out (semi-circular) in the work surface so the worker can access
materials that would otherwise be outside of a comfortable reach.
These designs can be used both in standing and sitting work­
places. This approach reduces the potential for fatigue of the
extensor muscles of the back by keeping the body more upright
during work.

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Figure 111-6: Workplace Orientation in a Packing Task. An example
is shown of a workplace design that permits two 90 degree turns to
be made in a packing cycle. The product arrives via a conveyor to a
supply table, is packed at a second, lower table. The cases are then
transferred to the pallet after severai have been filled. This reduces
the need for twisting a full 180 degrees as could occur if the packing
is done on the supply table.

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When materials, such as boxes or parts, have to be stored in
and around the workplace, the guidelines for height, distance,
and weight in lifting tasks (see Chapter 7) should be followed.
The orientation of the supplies or parts should be such that they
can be moved without twisting or hyperextending the back and
are not so low that the legs interfere with lifting them. These
limitations suggest that storage areas should be from 20 to 55
inches (51 to 140 cm) above the floor, whenever possible.

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How the Workplace Can Be Improved
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There is a common policy of taking people who have low
back pain out of standing jobs and putting them in jobs where
they can sit for the majority of the shift. This policy is probably
based on the observation that if one stands all day, backache
often results. However, sitting all day can be equally hard on the
back, especially if the chair being used is not well designed or if
there are not supplementary aids such as footrest available. In
this chapter some information about chairs and how they
influence the stability of the low back is presented. An approach
to selecting a chair for the workplace is presented in Appendix B.

A. TYPES OF WORKPLACES- STANDING, SITTING,
AND SIT/STAND
The decision about whether a job will be a seated or a
standing one is made primarily on the basis of the type of work to
be done. Although it is considered preferable to provide seating,
if possible, many tasks make it necessary to keep the worker on
his or her feet for a majority of the shift. Some of the job demands
that make a standing workplace more suitable than a sitting one
are:
1) When work has to be done over distances that exceed the
comfortable arm reach envelope (about 15 inches or 38 cm on
either side of the body).
2) When work is done on a moving part or conveyor and the
worker has to move along with the part.
79

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Working With Backache

3) When the work is spread out over several parts of a machine or

in a storage area.

4) When the height of the work above the floor is variable and
some of it cannot be easily reached from a seated posture.
5) When heavy weights are handled or large forces must be
exerted.
6) When the visual needs make a seated posture inappropriate,
either because of difficulty in seeing something on the line or
because one has to move around to get the best angle to view a
display.
In the above job conditions a standing workplace will be
preferable to a seated one; but during periods when the worker is
waiting for others or monitoring the equipment, a chair or
support stool could be used for postural relief of the back. The
opportunity to sit even for short periods should reduce the stress
on the back from continuous standing and should, therefore,
reduce the complaints from those with recurrent low back pain.
Sitting workplaces are more often observed in light assembly
tasks, inspection stations, and in other tasks done primarily with
the arms and hands, including typing, data entry and retrieval on
computer terminals, and other record keeping. If a person is in a
job where he or she is kept sitting for the majority of the shift, the
chair provided in the workplace should be carefully chosen to
give good postural support to the back. These chair character­
istics are detailed below. Jobs that do not give a person the
chance to get up and walk around fairly regularly are often found
to be associated with complaints of low back pain from people
who already have symptoms. Examples of these types of tasks
include work where everything is delivered to the seated work­
place and finished product is removed by someone else or by a
conveyor. The worker does not have to get up to procure new
supplies or dispose of the completed work, so he or she remains
seated for 2 hours continuously. Workplaces at conveyors where
assemblies, inspection, or other tasks are done on a part as it
comes past the worker in the seated station may also make the
worker "captive" to the chair. This is especially true if the

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conveyor heights are most appropriate for seated work and the
tasks are not easy to perform in a standing posture.
Sit/stand workplaces have been recommended for many
years by ergonomics and human factors specialists because the
option for either sitting or standing provides postural relief for the
back. Designing a good sit/stand workplace is not very easy,
however, because a work height that is good for a standing
workplace is too high for a seated workplace. Simply adjusting
the chair upwards to get the worker's elbows up above the work
surface is not satisfactory because it is difficult to get on and off
of a chair when its seat is adjusted to more than 21inches (53 cm)
above the floor. In view of this difficulty, special supports or
sit-stools have been recommended. In general, these provide a
seat that the worker can lean against while the legs remain in a
mostly standing posture. The support provides some relief for the
back; the feet can be rested, too, if there is a standby break in the
work. These support stools are not as readily available as are
chairs, but they have appeared in production furniture adver­
tisements more frequently over the past few years. Many of the
designs first came from Scandinavian countries.

B. CHAIR DESIGN

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The design of chairs for use in offices or production areas
should incorporate several common features (Figure 111-7). For
production or office workers who are seated for a large part of the
shift, well-designed chairs are necessary to avoid back pain, to
provide good support for the trunk and legs, and to reduce forms
of discomfort, such as result from pressure on the back of the
thigh, that might contribute to reduced individual productivity.
1. Chair Seat Height Adjustability
A good chair must be adjustable in height so it can optimize
the working height for a person's hands. The lower limit of
adjustability should be low enough so that people with short
lower legs can place their feet on the floor and still keep their
thighs parallel to the floor while seated. The upper height
adjustment should be to at least a level where people with very
long lower legs can sit without having their knees well above their
hips. For this reason, chairs that adjust between 15and 22 (38and

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a. Seat Height Adjustability

From 15 to 22 inches
(38 to 56 cm)

b. Seat Width

17 to 19 inches
(43 to 48 cm)

c. Seat Depth (or Length)

17 inches (43 cm)

d. Seat Slope

5-1 O degrees up
(towards the front)

Chair Backrest
e. Size

6-9 inches (15-23 cm) high
12-14 inches (3o-36 cm) wide

f. Movement Up and Down

7 to 10 inches (18-25 cm)
above the seat

g. Movement In and Out

12 to 17 inches (3Q-43 cm)
from the front of the seat

Figure 111-7: Recommended Seating Design. The recommended
chair height adjustability, seat dimensions, and backrest design are
summarized. See the text for discussions of the recommendations.

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56 cm) inches above the floor (seat pan to floor distance) are
recommended. Higher adjustability may be useful for situations
where footrests are built into the workplace and where work
surface heights are fixed at greater than 30 inches (76 cm) above
the floor in a seated workplace.
2. Chair Seat Width
If a chair is to be used comfortably by a large proportion of
the workforce, it should be wide enough to give good support to
the buttocks but not so wide that sliding on and off is difficult. If
the chair has arms, the inside distance betwee,n the arm rests will
have to be wide enough to accommodate a large person's hip
breadth plus any winter clothing worn. This would be about 19
inches (48 cm). If there are no arm rests or lateral limits of comfort
(see below), then a width of 17 inches (43 cm) should be
adequate.
Chair design that produces an "edge" at the limits of the
seat's width causes discomfort because the force per unit area on
the buttocks is considerably greater on the edge than on the seat
pan. This can limit lateral mobility and postural adjustments in
the chair and increase back discomfort because of the restriction.
Such edges are more commonly seen in molded plastic chairs
than in fabric-covered seating. They should be avoided in making
selections of cafeteria, conference room, or auditorium chairs
whose chief virture is that they stack well.
3. Chair Seat Length or Depth
Recent surveys of home and office chairs indicate that the
chair seat depth (front to back of the seat) is often greater than
the distance between the back and the back of the knee (buttocks
to popliteal distance) of many people. If this is true, then people
sitting on those chairs often have to slide forward in order to be
able to put their feet on the floor. By sliding forward they may not
be able to get the benefit of the backrest (discussed below), so
there is a greater possibility of developing back pain symptoms
during extended sitting. To accommodate the upper leg length of
most people, chair seat depth should not exceed 17 inches (43
cm). If the depth is much less than this, however, people with very

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Working With Backache

long upper legs will have inadequate leg support. Thus, a seat
depth of 17 inches (43 cm) is probably optimal. This dimension
interacts with the height adjustment characteristics of the chair.
A chair that does not adjust below 18 inches (46cm):for instance,
should have a seat depth of not more than 17 inches. The drag on
the back and upper leg will become excessively fatiguing and
painfu I if the person with shorter legs cannot reach the floor with
his or her feet and also cannot use the chair's back support. A
footrest will relieve this discomfort somewhat, but seat depth
should also be specified to improve seated comfort.
4. Chair Seat Slope
Recent discussions of chair seat slope have provided rec­
ommendations to slope it 5 to 15 degrees up or to design it 45
degrees down and have the worker sit and kneel simultaneously
to relieve the back. The usual recommendation is to slope the
seat pan up slightly (about 5-1 O degrees) so the front of the seat is
about 1 inch (2.5 cm) higher than its back. The seat height
adjustability is measured from the seat's front surface. Too much
upward slope of the seat restricts leg movements forward for
postural relief; the edge of the chair becomes a pressure point for
the underside of the upper leg. A rounded edge with padding is
preferable to a plastic or metal edge. A continuation of the chair's
seat beyond the turned edge assures that a sharp edge will not
produce discomfort when the legs are brought back alongside
the chair base during activities where the worker has to lean
forward.
The recent introduction of seating that angles the seat
forward and provides rest points for the knees and ankles is
based on the theory that tilting the pelvis forward will reduce the
stress on the lower spine and provide more comfortable seating
over long periods. Such seating appears to be bestin tasks where
the worker does not have to lean forward to write or to do a task
requiring force exertion. The weight must be evenly spread
between the buttocks, knees, and ankles to avoid symptoms of
"housemaid's knee" or sore ankles in extended sitting on these
chairs.
5. Chair Backrest

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The backrest of a chair should be large enough to give
support to the spine without interfering with sideways motions. It
should be adjustable up and down and in and out, or it should be
formed to provide lumbar (lower spine) and upper thoracic
(below the shoulders) support. The usual recommendation for
the size of an adjustable height backrest is from 6 to 9 inches
(15-23 cm) high and 12 to 14 inches (30-36 cm) wide. It should be
able to move from 7 to 10 inches (18-25 cm) above the seat height
in order to fit most people's need for lumbar support. It should
also be able to adjust in and out from 12 to 17 inches (30-43 cm)
from the front of the seat. This will provide support to the back
when a person is leaning forward about 5 inches (13 cm). Without
such horizontal adjustability, the worker who performs a job with
extended forward reaches at a seated workplace gets little
benefit from a backrest (Figure 111-8).

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Figure 111-8: Work Location and Backrest Utilization in a Seated
Workplace. A seated workplace job involving a wrapping task

requires the worker to l ean forward. He or she loses back support
because the backrest does not easily move forward. If this task is
done for several minutes continuously, symptoms can occur in
people with recurrent low back pain.

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More recently chairs are available that are molded or covered

with fabric to support the whole back, and they are adjustable as

a unit (Figure 111-9). Either the back follows the worker as he or
she leans forward because it is springloaded, or the worker uses a
push button adjust to bring the backrest forward as needed. The
design of the backrest in these chairs wi"II determine how
effective they are in reducing back stress during prolonged
seating. If the major support for the spine is near the shoulder
blades, the pressure on the L5 (fifth lumbar) disc will not be
reduced as much as it will if there is support both there and in the
lumbar region. If the backrest is sloped backward about 15
degrees, the compressive force on the lumbar disc will be less
than if it is upright. The backrest in a molded chair or in an "office
chair" must be designed in view of the need for support at two
places on the spine. Adjustability that allows the worker to
benefit from the backrest when he or she is leaning forward in the
chair (Figure 111-9) is also desirable.

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molded office chair with fabric covering ("a") and of two inexpensive
molded ("b") and tubular ("c") chairs that are typically used in
production or assembly areas are illustrated. Selection of these
types of chairs should emphasize the backrest design characteristics
shown here.

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6. Other Characteristics - Swivel, Support, Covering
Chairs that are used in workplaces where workers do not
have opportunities to get up or to change posture should be
stable, should move easily to the side so twisting is not required
of the worker, and should be covered with a material that
"breathes" so that localized sweating does not occur. Most
industrial chairs have 4 or 5 legs to provide stability against
tipping. The 5-legged version is recommended if the seated
worker has to reach for objects that are outside of his or her
comfortable reach distance (usually more than 15 inches, or 38
cm, away). As body weight is shifted to one side, upwards or
downwards, the 5 legs provide a stable base and reduce the
chance that the chair will tilt with the worker.
Since it is likely that a person working at a seated workplace
will occasionally, if not frequently, have to get supplies, parts, or
tools at locations to one side of the body or the other, it is
important to provide swivel capability in the workplace chair. If
the chair will swivel, and if there is adequate leg clearance, then
the needed items can be procured without twisting the upper
body. Such twisting is a major aggravator of low back pain
symptoms and should be avoided.
The fabrics used to cover a workplace chair are often chosen
according to aesthetic, cost, or durability considerations. Al­
though these factors are important, one should also consider the
worker's comfort. How well the material breathes and whether
prolonged sitting will result in stickiness and sweating has a
significant effect on worker comfort. The choice of a molded
chair with or without additional padding may be best resolved by
considering how long the worker has to stay in it. Plastic,
unperforated coverings, and other fabrics that do not breathe
should not be used in workplaces where extended sitting is
required and where seasonal temperatures may exceed the
upper comfort zone level of 78 degrees F (25 degrees C).
The decision about which chair should be used at a seated
place is influenced by the cost, durability, appearance, and
perceived importance of the chair. The design factors described
above will influence how comfortable the chair is for the worker

�88

Working With Backache

and whether low back pain symptoms are more likely to be

aggravated with extended sitting. Using the guidelines for chair

selection found in Appendix B, one can try to optimize the chair
for the workplace and job in order to reduce the potential for back
pain problems.

C. FOOTRESTS AND ARMRESTS
To provide optimal comfort in a seated workplace it is
advisable to provide an adjustable footrest as wel I as an adjustable
chair. The footrest will give the worker more options for adjusting
his or her height relative to the work surface. If the work surface is
high, the chair can be adjusted to a higher part of its range so the
work is near elbow height. As long as the footrest is available to
support the feet of people with shorter legs, the higher workplace
can be used comfortably by most workers.
Footrests are available as plates that can be adjusted in
height and in degree of tilt. A surface that is at least 16 by 12
inches (41 by 30 cm) in length and width should hold both feet
comfortably, and it should tilt up from the horizontal surface no
more than 30 degrees (see Figure 111-5). Height adjustability in
2-inch (5 cm) increments is recommended. Styrofoam packaging
material, phone books, and shipping cases have been used as
makeshift footrests in some places. These are better than no
footrest, but they do not tilt to provide the best comfort for the
ankles in the seated posture.
A footrest can also be built into the workplace station, either
as part of the bench structure or as part of the chair (see Figure
111-3). The main disadvantage of chair or workbench footrests is
that they tend to be in fixed locations and do not offer the
possibility of postural adjustments. Footrest rings on chairs are
sometimes not adjustable in height, so the ring can only be used
when the chair is in the low part of its height range. As the chair
goes up, the footrest no longer keeps the thighs parallel to the
floor, and discomfort in the low back area is more likely to result.
Armrests are useful aids in jobs involving, for example,
prolonged assembly or inspection tasks. The armrests may be on
the chair when monitoring or light work is done while the worker

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sits back in the chair. They should not run the full depth of the
seat, however, because they may make it difficult to pull the chair
up to the workplace. If the arms do not fit under the work surface
when the chair is near the top of its height adjustment, the worker
may not be able to get close enough to read the video display or
paperwork at the workplace. Then he or she may have to lean
forward, losing the chair's back support and potentially incurring
back muscle fatigue and pain.
Armrests that are attached to the work surface and can be
adjusted in many directions have been used in some fine
dexterity assembly work or in other work done primarily with the
hands and fingers. These armrests reduce the static muscle
loading of the shoulder and arm muscles and reduce the
potential for tremor to occur in the hands. The most important
attributes to look for in armrests are:
1. Adjustability- including distance, angle, and tilt.
2. Padding for comfort - using fabric or materials that breathe
and don't cause heat accumulation and sweating.
3. No sharp edges - so there is no discomfort caused by high
force per unit area on the skin on the inside of the forearm as it
lies on the armrest.
4. Ease of adjustment - an abilit y to change the direction of the
arm rest by exerting additional force on it or using a simple
fastener, like a wing nut, to reset the orientation.
For further information on chair, footrest, and armrest
design, see Appendix B.

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Section Ill:
How the Workplace Can Be Improved

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CHAPTER 7: DESIGN OF MANUAL
HANDLING TASKS

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Work involving lifting, lowering, pushing, and pulling of
materials is often associated with reports of low back pain in
industry. Some possible reasons for that association are dis­
cussed in this section. Guidelines for the design of occasional
and frequent lifting tasks and force exertions are also given.

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A. ASSOCIATION OF MANUAL HANDLING AND
LOW BACK PAIN

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Studies of the incidence of low back pain are complicated by
the variety of ways in which the data are collected. A questionnaire
that asks if people "have ever had" low back pain gets quite
different information than a search of medical records to see if
the same people "have ever reported" low back pain. If the
question is further refined to "Have you ever lost time from work
for low back pain?" the numbers become still lower. A similar
problem occurs in trying to define the relationship between
manual lifting and low back pain. One has to classify the lifting or
handling requirements in a way that identifies the potential risk to
the lumbar discs or to back, arm, or shoulder muscles. At extreme
lift locations or heavy weights, for example, this risk is reasonably
easy to define. In the center of the continuum, however, the
definition is less clear, and this makes it difficult to attribute the
incidence of back proplems to specific lifting conditions.
Studies from Eastman Kodak Company, the University of
Michigan, and Liberty Mutual have identified the following
relationships between manual handling and low back pain:
91

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Working With Backache

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1) People who work in heavy jobs have more need to report low
back pain symptoms than do people in lighter jobs (Rowe).

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2) Lifting that puts high compressive forces on the L4 and L5
discs (more than 650 kg) is associated with twice the average
number of low back pain reports (Chaffin and Park).

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3) People who perform lifting tasks requiring muscle strengths
that are above the acceptable levels for 75% of the working
population report three times more low back pain (Snook).

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On the basis of this evidence, it is advisable to examine the
design of manual handling tasks and to try to design them so the
disc compressive forces are not too high, the strengths required
will accommodate of least 75% of the potential workforce in
terms of "acceptable" lifting conditions, and the postures do not
further aggravate low back problems because of twisting or
uneven loading of the spine.

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B. HANDLING LOCATION
The biomechanics of postures and loads on the lumbar spine
have been discussed in Chapter 5. When an object is lifted, the
center of mass of the body and the load is pulled forward (longer
force arm) and the back extensor muscles have to do additional
work to keep the body from falling forward. In the teeter-totter
analogy, adding the load to one child's end means that the other
child has either to increase the load on the opposite end or to
lengthen the lever in order to balance the board. The back's
muscle lever is fixed, so this option is not available; the only way
the increased load can be counteracted is to change the amount
of force exerted by the extensor muscles. This analysis assumes
that body postural adjustments, such as moving one leg to help
stabilize the load, cannot be done. Such a situation may exist, for
example, if a load is lifted from a low position or over an
obstruction (Figure 111-10).
The amount of strength available to lift an object will depend
on where it has to be handled from, where it is going, and how one
has to get it there. Figures 111-11 and 111-12 show the relative
isometric (static) pull strengths available at 12 locations above

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Figure 111-10: Good and Poor Handling Locations.The best handling
of a load is close to the front of the body and at about waist level
("a"). Lifting to the center of a pallet ("b") or over an obstruction,
such as into a water tank ("c"), results in high compressive forces on
the lumbar discs and is not recommended for people with a history
of low back pain.

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the floor and in front of the ankles for men and women. Although
dynamic lifting strength is less than static pull strength, the
relationships between the amount of strength that can be made
available at each location should be similar. The table shows the
most static pull strength at the point where the load is 13 inches
(33 cm) above the floor and within 7 inches (17 cm) in front of the
ankles (horizontal distance). As the tray is pulled upward at 32,
52, 72, or 74 inches (81, 132, 180, or 185 cm) above the floor,
muscle strength is reduced significantly. This reduction is
related to the dropping out of the leg, back, and upper arm
muscles and increased reliance on the weaker forearm and
shoulder muscles. At each height, there is an additional decre-

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Working With Backache

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ment in strength if the tray is located farther in front of the ankles.

This is a lengthening of the force arm, increasing the load on the

back. It also results in more the force being generated by
shoulder instead of upper arm, trunk, and leg muscles.

The loss of strength with location is greater for the females
than for the males. This is probably related to the average
differences in body size and, therefore, lever lengths for the
extended horizontal pulls; it is also explained by the available
muscle groups dropping out faster at each of the vertical
distances. Average knee, waist, and shoulder heights for males
and females are indicated on the drawings to the right of the
relative strength tables in Figures 111-11 and 111-12.
The reduction in strength as an object is handled higher or
farther in front of the body means that any weight becomes a
greater percentage of strength in these positions. A 20-pound (9
kg) box may represent 20% of maximum voluntary lift strength at
13 inches (33 cm) above the ground and 7 inches (18 cm) in front
of the ankles. If it has to be lifted to a shelf that is 52 inches (183
cm) above the floor and can still be kept as close to the body, it
can take up to 80% of the strength available at that level. The short
time the load has to be held will probably make that lift
acceptable, but repeated lifts at frequencies above 6 per minute
could result in muscle fatigue and a further reduction in lifting
capacity.
Although the lower heights for lifting are where more
muscles are available, the stress on the lower back at these
heights is usually greater. The person with degenerative disc
disease will be most comfortable lifting in a range from 32 to 50
inches (81 to 127 cm) above the floor. This is the range where the
lift can be made by the upper arm muscles, aided by slightly
bending the knees at the lower end and without having to
hyperextend the back at the upper end. Figure 111-13 illustrates
the poor and good ranges for the design of lifting tasks for the
majority of the workforce. Lifts that are less than 10 inches (25
cm) or more than 50 inches (127 cm) above the floor are not
recommended, especially in repetitive lifting tasks. In all circum­
stances, the load should be carried as close to the body as is
possible, preferably within 10 inches (25 cm) of the ankles (as
measured horizontally).

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Strength and Location-Males.
The maximum static pull strength
on a tray held at 12 different
locations in front of the body is
shown as a percent of the strong­
est point at 13 inches (33 cm)
above the floor and 7 inches (17
cm) in front of the ankles. The
average values for males are
given.

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Average Males - 2-Handed Static Lifting Strength

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Figure 111-11. The average values
for females are given.

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Design of Manual Handling Tasks

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Figure 111-13: Lifting Height Design. Three lifting heights are illus­
trated. Frequent lifts above 50 inches (127 cm) and below 1 O inches
(25 cm) in "a" and "c" are not recommended for people with
degenerative disc disease. Lifts around waist or elbow ("b") are best
tolerated for sustained work periods.

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Location of the lift should also consider the need to avoid
unequal loading of the spine and twisting. If the object to be lifted
is located behind an obstruction, or if the handler has to take an
awkward posture because of limited foot clearance at the
workplace, twisting or uneven handling may result and increase
the shear and rotational forces on the lower back. The design of
large storage containers, for example, makes awkward lifts likely
when trying to remove parts from the bottom. Unless a side can
be broken down or a walk-in side is provided to allow easier
access to the bin, the handler ends up doing a "derrick lift" to
procure the lowest part. This type of lifting is particularly difficult
and inappropriate for people with degenerative disc disease.

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Working With Backache

C. LIFTING GUIDELINES TO REDUCE LOW BACK

PAIN AGGRAVATION

There are three major factors to consider when choosing
appropriate lifting guidelines for people with a history of low
back problems. Lift location is cine of these and has been
discussed above. The second factor is the amount of weight that
can be lifted. This will be determined by mu·scle strength and is
highly influenced by lift location and the load's configuration.
The weight also will influence the amount of force on the lumbar
discs, so biomechanical considerations as well as strength
measures are of interest. The third factor relates to workload and
local muscle fatigue, both of which are influenced by the rate of
lifting and the duration of continuous work. In this section
guidelines for occasional and frequent lifting are presented.
1. Occasional Lifts -The NIOSH Manual Lifting Guidelines

Figure 111-14 illustrates the guidelines for lifting that have
been developed by a committee for the National Institute for
Occupational Safety and Health. This graph is applicable only for
lifts done less frequently than one lift every 2 to 5 minutes and
where the lifting range is between 20 to 40 inches above the floor.
They assume 2-handed lifts in the sagittal plane (in front of
body), a compact load, good handholds, good posture, and
smooth lifting in a temperate environment. The weight of the
object to be lifted is shown on the vertical axis and the horizontal
distance from the ankles (or spine) is given on the horizontal axis.
Two curves are shown. One marks the upper limit of the zone of
recommended lifting task design and is called the Action Limit
(AL). The other marks the upper limit of weight considered safe
for people to lift even if they have been specially trained and
selected and is called the Maximum Permissible Limit (MPL).
The design of lifting tasks in the Acceptable Lifting Con­
ditions zone wi II assure that at least 75% of the women and 99% of
the men will have the strength needed to make the lifts. At the
MPL, only 25% of the males and 1% of the females have the
required strengths. The recommendation of the NIOSH Guideline
is to train or select people for jobs including lifts in the

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(lb.)

(Kg)
Body Interference
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HORIZONTAL LOCATION OF LOAD

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Figure 111-14: NIOSH Manual Lifting Guidelines. The weights that
can be lifted at different horizontal locations in front of the ankles are
shown by three zones. The Acceptable Lifting Conditions Zone is
where manual handling tasks should be designed to be suitable for
most people. The guidelines were developed by a committee for the
National Institute for Occupational Safety and Health. See the text
for further explanation of the use of these guidelines.

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Administrative Controls Required Zone because many people
will find the lifts difficult.
The graph in Figure 111-14 can be used in several ways. If one
knows the weight of the load, it is possible to estimate what
percentage of the workforce may find a given lift acceptable or
possible. By defining the horizontal location of the load when it is
lifted and finding the intersection point between that value and
the weight, a point is obtained that can be evaluated relative to
the AL and MPL lines. If the point falls below the AL, then more
than 75% of the women and 99% of the men are accommodated. If
it falls above the MPL, less than 25% of the men and 1% of the
women are accommodated. Between these two curves the point
can be related to the distance it is from either extreme. The
percentage of the population accommodated can then be inter­
polated. If the point falls halfway between the 2 curves, for
instance, then 99 - (0.5) (99-25), or 62% will determine what
percent of the men will be able to do the job safely. For the women
the calculation is 75 - (0.5) (75-1) or 38% who can do it safely.
A second way to use the guidelines is to take a given location
of a lift and figure out the heaviest object that can be handled by
most people (AL or below) at the workplace. The point of interest
is fixed by the AL curve as it intersects the horizontal distance
value. The weight is read off of the vertical axis at that point.
Similarly, one can specify the object weight and use the guideline
to decide when a handling aid would be advisable because of an
awkward horizontal lift requirement.
Since not all lifts are done at 20-40 inches above the floor, the
NIOSH Manual Lifting Guide also includes formulae for calcu­
lating the AL and MPL weight limits for other lift locations. These
are as follows:
English Units:
Al(lb) = 90(6/H) (1 - .01 I V-30 I ) (0.7 + 3/D)
Metric Units:
Al(kg) = 40(15/H) (1- .0041 V-751) (0.7 +7.5/D)

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H is the horizontal distance factor when the load is
picked up. It is in inches or centimeters.

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V is the vertical height factor or the height at which the
load is picked up, and is also in inches or centimeters.
The difference between 30 inches (76 cm) and the
actual height is treated as an absolute value ("IV-30I").
This means that the sign is disregarded and 20 inches
(51 cm) up is considered equivalent to 20 inches (51
cm) down as a factor influencing lifting task design.

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D is the vertical lift distance from beginning to end of
the lift. If it is less than 10 inches (25 cm), it is assumed
equal to 10 inches. It should generally be the difference
between the starting and ending V values.

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The MPL values are obtained by multiplying the AL
value by 3.

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The NIOSH guidelines are primarily useful for determining
how to design lifting tasks and whether a specific task is difficult
for a large percent of the workforce. There are situations when
the weights calculated for the AL do not make sense. These most
often occur when the occasional lifts do not meet the assumptions
mentioned above and some other factor, such as pinch grip
strength or pressure on a joint, is more limiting than the back,
arm, and shoulder muscle strengths. Whenever a handling task is
being evaluated, one should look carefully to see if there is a
limiting muscle group or a condition that makes the task difficult
to perform. With that situation in mind, one can calculate an AL
and MPL, but those values should not be used for design until the
task is simulated to see if they are appropriate.
2. Frequent Lifts
If lifting is done more than once every 2 to 5 minutes there is
potential for build-up in local muscle fatigue and for the total
workload to limit the acceptable weight to be handled. Repeated
exertions, even if they only last a few seconds, need recovery
time to restore the energy supply of the muscles. The amount of
strength required to do a task and the number of muscle groups
that can be applied to the work will determine the percent of
capacity used by any one muscle group. The higher that value,

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the longer it will take to regenerate the energy supplies for the

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next effort. The closer those efforts follow one another, the more

opportunity there is for the energy supply to fall below its optimal
level and, with time, the more potential there is for the heavily
loaded muscles to fatigue.

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Lifting frequencies that exceed 6 per minute appear to have
increased potential for local muscle fatigue to develop. Since
many lifts take only 2-3 seconds to perform, the recovery time
after each lift is about 7 seconds. For high strength requirement
tasks, the ratio of work to recovery time should be at least 1 to 3to
avoid cumulative fatigue. While 6 lifts per minute will be within
this guideline for short duration lifts, higher lifting frequencies
will not be. Because fatigue builds with time, frequent breaks in
the lifting task to do some other, less physically-demanding,
work will permit some additional recovery to occur. The duration
of lifting tasks that are done more than once every 2 minutes
shou Id be chosen to reduce the chances for significant fatigue to
develop in the active muscles.
The work of repetitive lifting puts demands on the cardio­
vascular system (heart and blood vessels) to deliver enough
oxygen and nutrients to keep the muscles working. The longer
that activity level has to be sustained, the more stress there is on
the cardiovascular system. Acceptable levels of aerobic work
vary according to the number of minutes or hours they have to be
sustained before a lighter activity or recovery period is provided.
Figure 111-15 illustrates the relationship between intensity and
duration for aerobic work. By definition, maximum aerobic work
capacity for the task can be sustained for 6 minutes before
exhaustion sets in. One hour of continuous lifting would be the
upper limit for a task that takes 50% of aerobic capacity, but it
would take at least an hour to recover from the hour of work. If a
repetitive lifting task is done for a full 8-hour shift, the work
should take no more than one-third of the aerobic work capacity
for these muscles.
Figure 111-16 shows the relationship between weight handled
and lifting frequency based on data from psychophysical and
physiological studies. The psychophysical studies ask the
workers to adjust weight to a value that would be"acceptable" to

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Figure 111-15: Aerobic Work Intensity vs Duration Relationship. The
relationship is shown between the intensity of work done (percentage
of oxygen usage or aerobic capacity) and the length of time (in
hours) it can be sustained.

lift at the frequency indicated. These studies were based on 40
minutes of lifting and extrapolated by the worker involved to an
8-hourda y. The physiological studiesare based onmeasurements
of the heart rate and energy demands of the lifting tasks; they
determine the guideline values for sustained work. These com­
bined data suggest that at frequencies from 1 to 6 lifts per minute,
the total energy requirements of the job are within most people's
capabilities providing the loads are kept below 40 lb (18 kg). The
higher the frequency of lifting, the lower the weight should be to

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Working With Backache

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reduce the potential for local muscle fatigue or for excessive

workload in terms of energy requirements. To simplify, one can

generalize as follows:

a. At lifting rates below 1 per minute the psychophysical study
data best describe the potential stress of the job. The NIOSH
Manual Lifting Guide graph and formula can be used to calculate
the AL (Action Limit) for these jobs.
b. At lifting rates from 1 per minute to 6 per minute the
acceptable weights are affected by the length of time the effort
has to be sustained in each lift and the amount of recovery time
left before the next lift. The psychophysical data shown in Figure
111-16 can generally be used to determine the acceptable lifting
weights in this range.
c. At lifting rates above6 per minute, total workload must also be
considered. Data from studies of the metabolic and cardiovascular
demands of lifting tasks can help to determine what the acceptable
weights and frequencies will be. Total workload can be controlled
by limiting the time of continuous lifting to 20 minutes or less, the
higher frequency lifting being done for very short continuous
periods. In self-paced operations these limitations are often
worked into the job. In machine-paced operations, the design of
the line may make it difficult to limit the periods of continuous
lifting; it is those jobs where overexertion injuries are more
frequently seen.
d. Objects that weigh more than 33 lb (15 kg) should be handled
by sliding rather than lifting at rates of 6 per minute or more.

D. FORCE EXERTION GUIDELINES
It has been recommended that sliding rather than lifting is
preferable for repetitive handling tasks in order to reduce the
potential for local muscle fatigue; The amount of force that can
be exerted depends on the location of the object, how accessible
it is and whether one can get behind or in front of it, and on one's
posture during the push or pull. Relative muscle strengths
available for pulling up on a tray at several locations in front of the

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Object Weight in Pounds (Kilograms)

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Figure 111-16: Guidelines for Repetitive Lifting. The maximum weight limits for lifting at different
frequencies are shown. For lifts less than 1 per minute the NIOSH guidelines for occasional lifts
can be used (Figure 111-14). For one hour or less of continuous lifting, frequencies above 7 per
minute can be handled providing the objects are not too heavy. The Recommended Design zone
will be suitable for at least 50% of the women and 75% of the men. Lifts in the Not Recommended
zone are suitable for less than half of the workforce and are likely to be difficult for people with low
back pain.

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Maximum Force for Design
Force Conditions

Pounds

Newtons

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Forward Push, Truck Handling
Initial Force
Sustained for 1 Minute
Emergency Stop
Pull In, Waist Level
Pull Up from Floor Level
Pull Up from 20 Inches (51 cm) Height
Kneeling

50
25
80

220
110
355

55

245

125

555

70

310

40

180

55

245

Upper Body, Standing
Pull Up, Waist Height
Pull Up, Shoulder Height,
Arms Extended

30

135

Boost Up, Shoulder Height

60

265

Pull Down from Overhead

100

445

Push Down, Waist Level

75

335

Lateral Push Across Body

15

65

Forward Push, Waist Height
Near
Arms Extended

30
25

135
110

Pull Upward, Elbow Height

25

110

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Lateral or Transverse Push
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Foot Pedal Activation

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Table 111-1: Maximum Force Application Recommendations. Data

on the maximum static force levels for design of handling tasks is
summarized for different muscle groups. The values shown accom­
modate half of the female workforce and most of the male workforce.
It is assumed that these forces will be exerted for only a few seconds
unless otherwise noted.

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body have been given in Figures 111-11 and 111-12 and are
discussed in Chapter 5. Table 111-1 summarizes some data on
recommended upper limits for force exertion tasks done while
standing or sitting and when having the whole body strength or
just a few muscles to apply to the object.

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Figure 111-17: Examples of Force Appllcations. Three examples of
forces applied by different muscle groups are given. In "a" the foot
pedal force is developed primarily by the lower leg, whereas the cart
handling task in "b" involves whole body pulling where the most
strength is available. In task "c" the assembler pushes the product
onto the conveyor and often has to raise the load slightly at full arm's
extension to get it over the conveyor's edge. Most of the work is done
by the weaker muscles of grip and the shoulders.

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In many situations it is not possible to push or pull the load
directly in front of the body. Instead it is moved across the front of
the body using a lateral push. The amount of strength available
for pushing an object across the body is very small, limited
primarily to the weaker shoulder muscles (pectoralis, especially).
Forces exceeding 15 lbs (67 Newtons) in this direction are
difficult for many people to exert. This value is not the weight of
the object to be moved but, rather, is the force to slide it across
the work surface. Anything that can reduce the frictional resis­
tance of the object and the surface should make the task more
acceptable.
In a seated workplace it is often necessary to move a tray, a
part, or the product from one side of the workplace to the other. It
is generally recommended that objects weighing more than 10
lbs (4.5 kg) should be handled while standing. To improve
handling efficiency, these workplaces are often designed to
permit the worker to slide the object or tray on and off of a
conveyor at the rear of the workplace. This sliding force should
be kept below 30 lbs (134 Newtons).
In the design of tasks where force exertion is used to slide
objects rather than having to lift them, it is important to avoid
workspace confinement (such as inadequate foot room) that
might result in twisting. Lateral motions are more likely to
unevenly load the spine and result in twisting than are straight­
forward motions. Forward pushes from a seated workplace may
put some additional strain on the back if the worker leans forward
in his or her chair and cannot use a footrest effectively (Figure
lll-17c). Low sliding resistance and whole body forward pushes
are preferable.

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Section 111:
How the Workplace Can Be Improved

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CHAPTER 8: SPECIAL WORKPLACE AIDS FOR
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Some of the work activities and workplace design factors
that may bring out back pain symptoms in people with de­
generative disc disease have been reviewed in Chapter 2. Some
equipment and workplace design accommodations to reduce
these problems are reviewed in this chapter. They are classified
under either workplace postures or manual materials handling
aids.

A. WORKPLACE POSTURES
There are workplace aids that can help relieve excessive
pressures on the lumbar discs by reducing the amount of
bending forward, hyperextension, extended reach, or twisting.
There are also ways of obtaining postural relief when doing a job
that requires constant standing or sitting all day.
1. To Reduce Forward Bending and Extended Reaches
Workplace height adjustments can reduce the need for a
person to bend forward over a work surface that is too low. The
adjustments can be made with an adjustable table, such as a
drafting table, or by using wooden platforms on the work surface
to raise the work. If the latter approach is used, the platforms
should be easy to remove if the next worker at the work surface
prefers the fixed work height.
Extended reaches can be reduced by using tool or control
extenders or aids to move objects closer. Examples of these are
adapters for power tools that increase the distance from the
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"chuck" of the driver to the screw driver bit or socket wrench.

This makes it easier for an assembler or repair operator to reach

points that would require awkward and extended reaches were a
standard tool used. Valves or other controls may also be difficult
to access in some fluid control systems, so handle extenders
have also been used on them. The handle is placed at the end of a
shaft that is welded to the stem of the valve (Figure lll-18a).
Another type of reach extender is like a shepherd's crook but with
less bend in its neck. It can be fabricated from pipe and helps the
worker slide an object closer to the body without having to reach
far forward (Figure 11I-1 Bb). Use of such an aid requires that the
object can slide on its storage surface.

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Figure 111-18: Reach Extenders. Valve handle extenders are shown
in "a". These are welded onto the valve stem and permit the worker to
open the valve without leaning over and fully extending the arm. Use
of a "crook" is shown in "b". A piece of pipe or a light, rigid, tubular
material is bent to permit a case to be slid forward before it is picked
up.

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Special Workplace Aids for People with Low Back Pain 111

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Bending forward will also occur if a person is working at too
low a height. Aids that will raise the work height, such as an
adjustable overhead conveyor mechanism for the part, or stools
or dollies that the worker can sit on during the low work will give
relief to the person with low back pain. Use of the stool or dolly
depends on having leg clearance. They should not be used if
hyperextension of the back or leg interference will result in more
awkward postures.
2. To Reduce Hyperextension of the Back
Back hyperextension is most commonly seen when a person
is working at high locations, as in overhead work, or when a bulky
load is being handled. The latter category will be discussed under
"Manual Materials Handling Aids" below. The primary way to
reduce back hyperextension caused by too-high work levels is to
raise the worker above the floor using either a platform, a step
stool, or a vehicle such as a platform truck (Figure 111-19). Some
hyperextension is inevitable in overhead work where clearances
limit how much the worker can be raised. So, regular breaks from
these tasks to ones that do not require hyperextension are

recommended.

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Figure 111-19: Height Adjustments for the Worker. A step stool ("a")
and a low platform ("b") are shown as portable aids to alter working
heights and reduce stress on the back from hyperextension in too­
high work.

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Working With Backache

3. To Reduce Twisting

A job that requires frequent twisting movements, even
without objects being handled, is likely to bring out low back pain
symptoms in people with degenerative disc disease. The reasons
behind this are discussed in Chapter 3. A workplace that requires
an operator to make 180-degree turns to pick up parts or product
and then dispose of them is more likely to encourage trunk
twisting than is one where supplies are stored adjacent to the
.primary work area. For assembly tasks, then, provision of storage
bins or holders within a comfortable arm reach (15-20 in. or 38-51
cm) for a seated or standing operator is•an approach to reduce
twisting. If this is not feasible because of the nature of the task, it
is important to orient the workplace so materials are as close to
the main work surface as is possible. Use of roller conveyor
sections to transfer parts from one area to another, especially if
the parts are heavy (more than 40 pounds or 18 kgm), can also
reduce the potential stress of twisting on the back (Figure 111-20).

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Figure 111-20: Use of Roller Bearing and Roller Conveyor Sections to
Reduce Handling Effort. Three examples are shown of the use of
roller bearing ("a" and "c") or conveyor sections ("b") to reduce the
work of transferring a product or case in the workplace. Although
the worker in "b" is twisted, which is not recommended, his lower
back is not experiencing as high loads because the weight of the
case is carried by the conveyor.

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Special Workplace Aids for People with Low Back Pain 113

Use of a swivel chair in a seated workplace will reduce the
opportunities for trunk twisting when parts are procured or
disposed of. This assumes that the feet are free to move with the
chair as it swivels and are not tied to a foot pedal or restricted
because of a barrier below the work surface.
4. To Provide Postural Relief in Constant Sitting or Constant
Standing Jobs

Postural flexibility is a useful technique for reducing the
potential for low back pain when standing or sitting is required
during most of the shift. It is recommended that some seating be
provided for people who mostly stand (see Figure 111-22 later),
and that brief standing tasks be provided for people who
generally sit. In addition, the seated worker should have a
footrest and good lumbar support in the chair (Figure lll-21a).
Footrests have been discussed in Chapter 6 as has lumbar
support as a design feature of chairs. If the chair being used in the
workplace does not have good lumbar support, there are a
• number of products available that can be placed in.chairs or worn
by the worker with back pain to provide that support. They
include inflatable cushions that conform to the buttocks and
back as one sits in a chair, rectangular foam cushions sculpted to
fit the curve of the lower back (Figure 111-21b), and an inflatable
vest that provides a cushion for the back when one sits in a
high-backed chair (Figure 111-21c). Plastic supports that can be
inserted in chairs and are not compressible have also been
developed. The purpose of all of these aids is to support the
lumbar spine and provide an alternative to a less-than-optimal
chair design. Although these aids are a compromise for a well­
designed chair or seat, they are portable and do offer some relief
for workers with back pain who have to sit for extended periods.
For people who have to stand for the majority of the shift and
do not alternate their standing with regular walking activities, a
foot rail is recommended for postural relief (Figure 111-22). The
constant load of standing often includes some leaning forward to
work on a bench, conveyor, or piece of equipment. Additional
compressive force is then placed on the lumbar discs and can
result in symptoms especially for people with a history of back
pain. The footrail allows the worker to tilt the pelvis back and up,

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Figure 111-21: Back Support Aids for Seated Work. Three forms of
back support are shown. A standard chair with an adjustable
backrest ("a") is preferable. However, addition of a wedge-shaped
pillow ("b") to the existing chair or use of an inflatable vest that
provides back support in a chair that lacks good support ("c") are
ways for the .back pain sufferers to overcome poor seating.

taking some of the pressure off the lumbar discs. An appropriate
footrail for a standing workplace should be not more than 8
inches (20 cm) above the floor and should run the width of the
work station. It should have a flat or curved surface that is at least
4 inches (10 cm) wide. If a box or portable foot support is used, it
should follow the dimensions given in Chapter 6 for footrests.

B. MANUAL MATERIALS HANDLING AIDS
The lifting, holding, and carrying of objects can put high

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Figure 111-22: Postural Relief Aids at a Standing Workplace. A
footrail and a swing stool attached to the workplace are shown.
These can each be used to give the worker's back some relief from
constant standing.

compressive and shear forces on the lumbar discs. This may
increase the reporting of low back pain, especially in people with
a history of degenerative disc disease. Techniques to reduce
those forces by changing the way objects are handled or moved
and by reducing awkward lifts are discussed below.
1. Improving Body Postures During Handling Tasks

Bulky objects are usually handled in the workplace on an
infrequent basis. These may be large in several dimensions, such
as a roll of insulation material, or may be sheet materials where it
is difficult to reach across two of the dimensions. In handling
such objects, the worker often hyperextends the back to reduce
the stress on his or her hand, arm and shoulder muscles. One
approach to reduce this hyperextension is to provide straps or

�116

Working With Backache

special holders that permit the worker to support the load closer
to the body and with a power grip. A sheet material handling aid
uses a triangular holder with a D-type handle and two hooks
about 18 inches (46 cm) apart that fit under the sheet. The
handler carries the sheet using one hand to steady it and the
other to pull up on the D-type hanc;lle with a power grip (Figure
111-23).

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Figure 111-23: A Special Aid for Large-Size Sheet Handling. A sheet
supporter is shown with two hooks spaced about 18 inches (46 cm)
apart and a single D-handle on which a power grip can be taken. This
eliminates the need for extended reaches and pinch grip handling of
the sheets and reduces the opportunities for fatigue of the forearm
and shoulder muscles during sheet carrying.

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�Special Workplace Aids for People with Low Back Pain 117
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If an object has to be transported for more than a few
seconds a hand cart or truck is preferred, especially if the item is
bulky. A sheet material cart with swivel wheels and handles at
each end can be used on floors to transport several sheets at a
time, for instance. Carts with one, two, or three shelves are often
useful for transporting smaller items between workplaces. Wheels
or dollies that are strapped to larger items such as trunks,
suitcases, or business equipment reduce the need for holding
and carrying materials and, thus, spare the back, arm, hand, and
shoulder muscles (Figure lll-24a).

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Figure 111-24: Aids to Support an Object's Weight During Transfer
Tasks. A hand truck is shown in "a", and a small overhead hoist is
depicted in "b." Both of these aids reduce the load on the muscles by
supporting the weight of the object while it is transferred from one
location to another. They are recommended especially for the
handling of bulky and/or heavy items or when the transfer distance
is more than a few feet.

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2. Reducing the Amount of Work in Handling Objects

Objects that are heavy (more than 40 lbs. or 18 kg) and have
to be moved in a workplace can be a problem for people with
degenerative disc disease. Handling aids such as hoists may be
useful in supporting the object during transfer.so the worker only
has to direct the load, not lift and hold it (Figure lll-24b). If a hoist
is not available, equipment that will raise the load so it can be
transferred at about waist level to the next location is recom­
mended: examples are levelators, lowerators, and scissors lifts.
The levelators and scissors lifts have powered adjustment cap­
ability and can be moved by each worker to the best height for
handling (Figure 111-25). They are often placed under pallets or
skids and the levels are changed as the product is put on or taken
off. The lowerator is spring-loaded, and the weight of objects
placed on it pushes the spring down, keeping the loading level
constant. Storage carts for plates in many cafeterias use this
principle. Low lifts are avoided and less bending forward is
needed when a levelator, scissors table, or lowerator is available.

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Figure 111-25: A Load Levelling Aid for Manual Handling Tasks. A
scissors lift table is illustrated (the guard at its base has been
removed to illustrate the scissors mechanism) as it is being used in a
final aseembly work station. The product is assembled, packed into
a case and transferred horizontally to the pallet on the scissor lift. As
the pallet is loaded, the lift table is lowered to that horizontal
transfers are possible throughout the handling activity.

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Special Workplace Aids for People with Low Back Pain 119

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When highly repetitive lifting is required, adjustable height
aids like levelators are also recommended because they reduce
the total workload. Each time an item is lifted from a low height,
as when pallets are unloaded near floor level, the body is also
lifted. The work of raising the body makes up a substantial part of
the job workload, and this effort is not contributing to productivity.
In repetitive lifting tasks it is also recommended that ways be
found to slide the object rather than lifting it. The use of a section
of roller conveyor to transfer a part or product from one part of
the workplace to another has already been mentioned. An air
table or a roller bearing table surface can also be used to aid in
sliding an item so it does not have to be lifted. These are
particularly helpful for workplaces where bulky loads are moved.
The air table contains compressed air in small metal jets that are
mounted in the work surface. The sheet materials or cases move
over the surface with little frictional resistance and can be
directed to the next location. Roller bearing tables are particularly
useful for case or carton handling tasks as they reduce the
frictional resistance for sliding. Highly polished (waxed) maple
surfaces and the additional ,of "slides" made of Teflon or other
materials have also been used to aid in sliding items across work
surfaces so that lifting is not required.
Where it is difficult to justify the purchase of a levelator or
scissors table, use of additional pallets or of a fixed platform is
recommended to raise the height of a supply or outgoing pallet­
load of parts. Placing 2 pallets under the pallet being unloaded
will raise the lower tier to at least 16 inches above the floor instead
of having it 5-6 inches above the floor during lifting. This reduces
compressive force on the lumbar discs during lifting and reduces
leg interference during the initial procurement of the item. If the
parts arrive in a large bin (more than 30 inches (76 cm) to a side),
use of a fixture that can tilt the bin forward about 45 degrees
reduces the horizontal location of the lifts at the far side of the bin
and the extended reaches to the bin's bottom.
The choice of aids or workplace modifications to reduce
stress on the back for persons with low back pain will depend on
the frequency of handling, duration of the tasks, and the weight
and dimensions of the objects handled. The above techniques
are examples of an approach intended to reduce the compressive

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and shear forces on the lower spine and to prevent fatigue of the
trunk muscles that support it. Self-paced, well-designed lifting
tasks are not out of the question for a person with degenerative
disc disease.

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Section IV: How the Job Can
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Chapter 9: The Size and Design of Objects
to Be Handled
Chapter 10: Providing Adequate
Recovery Time
Chapter 11: Work Patterns and Job Design

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In addition to activities by the workers and workplace
modifications, administrative and job design approaches can be
used to improve the work situation for a person with low back
pain. These approaches are widely .appropriate because they
reduce the opportunities for muscle fatigue to develop. Included
in this section is a discussion of the design of items to be handled,
including load size, configuration, and handhold characteristics.
The rest of the section addresses job design, providing adequate
recovery time in more demanding physical or postural work, and
structuring the job to allow a person with low back pain to
regulate the work pattern in accordance with his or her capacity
for physical effort.

CHAPTER 9: THE SIZE AND DESIGN OF
OBJECTS TO BE HANDLED
The size of an object that has to be lifted or carried and
whether it has good handholds will determine the amount of
stress on the lower back. Bulky objects are more difficult to
handle and often result in strong hyperextension of the back. The
handler arches back to bring the load closer to the center of the
body so as to enhance the postural stability. As a result, the
compressive forces on the posterior third of the L5 (fifth lumbar)
disc are increased, and there is an increased risk of damage to the
disc. If an object does not have handholds, the handler has to find
the most stable location to grip it. The strength available for
gripping will depend on the dimensions over which the grip is
taken and on other characteristics of the surface and object size.
If a grip is not stable or fatigues quickly, there is a risk of losing

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control of the load and having to either shift it to other muscles or
drop it. These shifts or drops may be accompanied by awkward
postures, uneven loading of the spine, or sudden, unguarded
movements that may aggravate back pain symptoms in people
with degenerative disc disease. In this chapter some suggestions
for object size and handhold design are included both for
packaging and container designers to use in developing their
designs and for back pain sufferers to use in determining when
they should look for alternate ways of handling the object

A. DIMENSIONS OF THE LOAD

The dimensions of an object that has to be manually handled
will determine which muscle groups are most heavily stressed
and what posture is assumed. Objects that are compact, i.e., less
than 10 inches (25 cm) to a side, can be held close to the body
without requiring the elbows to be abducted (held away from the
sides) and without overloading the shoulder muscles. When the
length of an object exceeds 18 inches (46 cm), the handler's
elbows will be abducted and the shoulders will be loaded,
because 18 inches is wider than the usual shoulder breadth. If the
object is handled across its length, the elbows cannot be kept flat
against the body and must be elevated (Figure IV-1 ).

�18 Inches

&gt;24 Inches

(!:&gt;46 cm}

(&gt;61 cm)

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Figure IV-1: Effect of Object Length on Elbow Position During
Handling. Objects that are 18 inches (46 cm} long or less permit the
handler's elbows to remain next to the body. When object length
exceeds 18 inches, and especially at values above 24 inches (61 cm),
the elbows are abducted and the shoulder muscles can fatigue and
limit handling times.

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The Size and Design of Objects to be Handled

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As the widths of objects increase from 1Oto 20 inches (25-51
cm), the location of the load's center of mass is moved forward,
and this puts more stress on the lower back (Figure IV-2). The
biomechanics of this have been presented in Chapter 5. In
addition, the wider the load, the more it has to be supported by
shoulder muscles and the less effective are the stronger upper
arm muscles (biceps and triceps). At an object width of 36 inches
when the weight has to be supported 18 inches ( 46 cm) or more in
front of the body, shoulder strength is the primary limiter of the
weight that can be safely lifted. In general, it is recommended that
object width be kept near 10 inches (25 cm) when there is a
choice.

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Figure IV-2: Object Width and Back and Shoulder Posture. Compact
objects that are not more than 10 inches (25 cm) wide can be held
close to the body and do not put an additional postural load on the
back and shoulders. Objects that are wider than this, especially at
widths of more than 20 inches (51 cm), put heavy forces on the
lumbar discs and often cause hyperextension of the worker's back
during handling.

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The depth of an object will determine where it is carried and
how stable it is as it is lifted. If it does not have good handholds
and has to be lifted from the bottom;the depth of the object will
strongly influence the height of the hands and the posture of the
trunk during the lift. If the object has to be carried, its depth may
interfere with walking and will require the carrier to hold it out
farther in front of the body. This increases the pressure on the
lumbar discs and cannot be sustained for very long. A depth of
about 6 inches (15 cm) is optimal to avoid interference with
walking and to provide stability. Since many parts and products
are deeper than this, a guideline of 12 inches (30 cm) in depth or
less for the design of packages may be more practical. If
handholds are provided, the depth may be greater and still
provide stable handling, but then interference with the legs must
be evaluated in relation to handhold positions.

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Figure IV-3: Object Depth and One-Handed Carrying Postures. The
arm, shoulder, and trunk postures are shown for a person carrying a
compact (less than 4 inches or 10 cm deep) briefcase ("a") and for a
person carrying an item with a handhold at the top that is both wide
and deep ("b"). The bulky item causes shoulder fatigue and unequal
loading of the spine; this can result in low back pain for people with
recurrent symptoms.

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�The Size and Design of Objects to be Handled

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If the object is carried in one hand, e.g., a suitcase, its width
or depth is even more important. The deeper it is, the greater is
the load on the shoulder muscles to keep it away from the legs
during walking (Figure IV-3). The handler also leans to the
opposite side in order to reduce arm stress, and this motion
unevenly loads the spine. The shoulder work results in rapid
fatigue of these muscles. If the object's width is 4 inches (1 O cm)
or less, the arm can support the load without shoulder abduction
being required.

B. CONFIGURATION OF THE LOAD
If the object to be moved is within the size guidelines given
above, it still may be difficult to handle because of its con­
figuration. If its weight is not distributed equally but is con­
centrated on one side (Figure IV-4a), the handler has to adjust
posture to balance the load during its transfer. In some situations
the balancing may be done by unequally loading the trunk,
thereby reducing the stability of the spine. A person with a history
of low back pain will usually avoid unequal weighting of the spine
as would occur if a heavy suitcase is carried in one hand and
nothing is held to counteract it in the other hand. Handling a
piece of equipment with a motor in one end, for instance, may put
shear forces on the lower discs that could aggravate back pain
symptoms in these workers.
If the object to be lifted contains liquid or powder that can
shift as it is moved, additional stress is placed on the back, hand,
arm, and shoulder muscles (Figure IV-4b). The unstable load
may result in compensatory movements of the trunk to counteract
a sudden shift in the load. These unguarded movements can be
associated with increased risk of low back pain.
Because poorly configured objects may still have to be
handled, there are some techniques that can be used to reduce
the effects mentioned above. Powders, grains, and pellets or
other chemicals that can shift when handled should be placed in
bags that match their volume, wherever possible, so weight
shifting is less severe. Some of these substances are handled in
bulk containers such as fiber drums and large boxes; these do not
need to be lifted but can be rolled ("chimed") or transported by a

�128

Working With Backache

forklift or pallet truck to their destinations. Objects with unequal

weight distribution that may not be apparent when one looks at

them should be marked to indicate the heavier side. Suggested
handling locations can also be marked if the items do not have
built-in handholds.

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Figure IV-4: Load Configurations. Three loads are shown. An object
with uneven weight distribution is shown in "a", a woman carrying a
kettle of liquid is shown in "b", and a person carrying a compact load
is shown in "c". The uneven load puts additional stress on the back
and abdominal muscles to stabilize the spine. The shifting liquid has
to be held out from the body. It can cause a sudden shift of the center
of mass of the upper body and the load that the back or abdominal
muscles will have to counteract.

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The Size and Design of Objects to be Handled

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C. DESIGN OF HANDHOLDS
Objects that are manually handled should have handholds to
improve the stability of the interface between the handler a_nd the
load. Shipping cases usually do not have handholds unless the
load is very heavy or bulky (Figure IV-3c). The cost of adding
extra inserts to a case to form a handhold is the primary reason
why handholds are not routinely incorporated into cases. Other
containers such as trays, bags, and cans may not have designed
handholds, but they do have places where they can be lifted.
Such grip locations may have sharp edges or inadequate clear­
ances for the fingers so that the grip is not very stable. If pinch
grip is required to control a load, the duration of holding can
become critical. Pinch grip is only 25% of power grip strength.
Pinch grip control of an item weighing more than 15 pounds (7
kg) must be completed in 3-4 seconds (if at all) or fatigue can
occur.
General guidelines for the design of handholds on objects
that have to be lifted manually are:
1) Allow the handler to use a power grip or a ledge grip with the
fingers curled (see Figure ll-14c earlier).
2) Provide at least 1 inch of depth between the handle and side of
the object b�ing lifted or carried.
3) Avoid sharp or narrow edges on weight-bearing surfaces of
the handle. Round off edges and try to make the thickness at least
0.25 inches at the load-bearing surface.
4) Mark the handle locations on molded containers.
5) For cut-out handholds allow at least 4.5 inches of length and 2
inches of depth for the hand to clear the opening.
6) Locate the handhold just above the center of mass of the
object being lifted.
Handholds influence low back pain symptoms indirectly by
increasing the stability of handling a load and, thus, reducing the
potential for the handler to make a sudden, unguarded move to

�130

Working With Backache

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respond to an uncontrolled lift. They also influence back muscle
fatigue in repetitive lifting tasks by bringing the object closer to
waist level if it is lifted off of a pallet on the floor, for example. If a
case or object can be lifted with handholds at a location that is
about two thirds of the way up its height (or depth), then less
upper body weight will be lifted· with each case. The back
muscles will not be likely to fatigue as rapidly during extended
lifting tasks if low lifts are thus avoided.

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Section IV:
How the Job Can Be Improved

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CHAPTER 10: PROVIDING ADEQUATE
RECOVERY TIME

Earlier chapters have discussed the relationship between the
intensity of muscle work and the time it can be sustained before
some recovery time must be provided. More intense, or harder,
muscle work results in some build-up of lactic acid and temporary
depletion of the muscle energy supplies. These have to be "paid
back" between muscle efforts. Thus, the distribution of lighter
effort tasks within a job that includes heavy effort tasks can
influence the build-up of fatigue and the ability of the worker to
continue the work for a full shift. In this chapter, the implications
of fatigue in the muscles that stabilize the spine and the need for
postural relief and proper design of manual handling tasks is
discussed.

A. MUSCLE FATIGUE AND SPINAL STABILITY
The importance of fitness of the back was described in
Chapter 3. The more fit these muscles are, the higher their
strength capacity, and the lower the percentage of strength a
given task will take. Lower %MVC (maximum voluntary con­
traction of muscle) activities can be sustained for longer times
before fatigue occurs (see Figure 11-11 in Chapter 3)·.
As a muscle fatigues, the same amount of load will become a
greater part of its capacity. This continues until the load and the
capacity are identical and the effort can only be sustained for a
few seconds more. Good job design tries to reduce the probability
that muscles will fatigue to this point by giving the most heavily
loaded muscles in a task some relaxation time in order to restore

131

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Working With Backache

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their energy supplies. Intermittent work is the alternation of
heavy and light work (or rest) in such a way as to limit the
build-up of lactic acid over time.
The muscles that support and align the lower spine are active
in maintaining upright posture and in performing manual handling
tasks. An awkward posture, such as bending forward to work on a
too-low surface or leaning to one side to make an extended reach
with one hand, will require work of the back, hip, and abdominal
muscles. The longer the posture has to be maintained, the more
chance there is for these muscle groups to fatigue. When they are
fatigued, they are less able to stabilize the spine in a subsequent
task, e.g., in handling product or exerting forces on one side of
the body. To assess the stress on the back in a job, therefore, one
has to look at not only the required lifts and postures but also at
the length of time when a non-optimal posture is taken before
making a lift or taking a more extreme posture. This possible
fatigue of the important spine stabilizers during a job may help to
explain why some jobs with only moderately heavy handling
tasks show higher low back pain incidence reporting than jobs
with heavier loads.

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If tr"'=!, -..r.cor spinae and hip extensor muscles are fatigued
from constant bending, a twist of the trunk or high compressive
forces on the lower lumbar discs produced by a heavy lift may
result in misalignment of the spine. The person with degenerative
disc disease who already has some instability in his or her lower
spine due to fluid loss from the L4 or L5 disc will be particularly
vulnerable to fatigue of these muscles. The misalignment may
trap the nerve root between the vertebral processes and cause
irritation and pain. Irritation of the nerve root may set up a reflex
increase in the strength of contraction of the back muscles and
can create a muscle spasm that is very painful. To relieve the
spasm, the person has to stretch out the muscle right away by
curling the trunk forward and trying to mechanically realign the
vertebrae to take the pressure off of the nerve root. Ice packs and,
later, hot packs are sometimes used to temporarily relieve the
spasm. The less fit the back muscles are, or the more fatigued
they are from an awkward posture or inadequate recovery time
between exertions, the greater the opportunity for improper
alignment of the spine and a subsequent nerve root pinch.

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B. POSTURAL RELIEF

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Extended periods of work in one posture can result in static
muscle fatigue even when heavy work is not required. The
muscle loading would have to be less than 15% of maximum
strength to avoid fatigue after 5 minutes of continuous work (see
Chapter 3, Figure 11-11). Even in jobs where one's posture is
relatively restricted, as in long-distance truck driving, there is a
natural adjustment of posture every few minutes. This movement
relieves the static load from some muscles and brings in other
muscles to do the task.

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The importance of chair and seat design to allow a person to
adjust posture laterally as well as vertically and horizontally has
been discussed in Chapter 6. Provision of an adjustable backrest
that will move in as the worker leans forward on the work surface,
for instance, is a recommended chair design feature for jobs
requiring continuous sitting. Footrest availability, especially a
portable design, is also recommended as it gives the worker more
options for height adjustment in the workplace. For a continuous
standing job, provision of a footrail or a support stool has been
recommended to offer some relief for the leg, buttock, and back
muscles.
If options for changing posture are provided, most people
will not require additional recovery time in constant standing or
constant sitting jobs. When awkward postures such as leaning to
one side, bending forward, squatting, crouching, or twisting the
trunk are required, however, additional recovery time is needed
to prevent loss of strength in the trunk and buttock muscles over
time. Figure IV-5 illustrates the recovery time needed (vertical
axis) after muscle exertions of different intensities (curves) for
several durations (horizontal axis) of continuous work. A person
working in a bent-over posture that loads the erector spinae
muscles to 40% of their maximum capacity, therefore, will need
more recovery time the longer he or she remains in that posture
(i.e., 5 minutes of recovery time after 1 minute of bending) in
order to avoid fatigue of those muscles. Bending for more than 1
minute at a time at this work intensity will fatigue the muscles and
may require up to 45 minutes of recovery time if the muscles are
exhausted.

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axis, that is needed to recover from a muscle effort of a given
duration, in minutes on the horizontal axis, is shown for different
muscle work intensitites (% of maximum voluntary contraction
strength) by a series of curves. Use of these curves is illustrated in
the text later in this chapter. Light muscle effort is represented by the
20% and 30% curves, moderate effort by the 40% and 50% curves,
and heavy effort by the 70% and 90% curves.

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In methods analyses of job demands it has been common to
award a 10-15% fatigue factor for people who are required to
work in awkward postures. This provides about one hour of
recovery time per shift and should be adequate in a self-paced
job where the work and recovery pattern can be regulated by the
worker. It is probably a less satisfactory approach in externally­
paced operations. There the worker has less control over work
and recovery patterns and may get the fatigue factor time
allowance in 10-15 minute blocks at the end of about an hour of
continuous work in the awkward posture. Short work periods
broken up by short recovery periods or by work that uses the
muscles less heavily are preferable to intensive, long-duration
work and long recovery breaks as a way of reducing the
opportunity for muscles to fatigue over the shift.

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When determining adequate recovery times for a manual
handling task, one has to identify the frequency of lifting or
applying force, the intensity of the work either in terms of the
weight lifted or the force exerted, and the maximum duration of
continuous work before a recovery break is needed. Chapter 7
includes a discussion of the interactions of these factors in the
design of handling tasks. When determining how much recovery
time is needed and how the work should be structured to avoid
accumulating fatigue in the active muscles, one has to consider
both local muscle and whole body fatigue potentials of the job.
The former can be estimated from a calculation of the intensity
and duration of effort of the involved muscle groups. The
potential for fatigue will be related to the time of exertion and the
percent of maximum muscle strength used in the postures. If the
work is quite dynamic but the lifting or force exertions exceed 6
per minute, local muscle fatigue can occur unless the recovery
times are adequate for moderately heavy work. Even if the static
work curve (Figure 11-11) suggests that the task is appropriate,
the short continous muscle contraction times followed by short
recovery times can still result in the build-up of some fatigue
products in the muscles.
Whole body fatigue can become the limiting factor in

�136

Working With Backache
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repetitive lifting tasks, and it is associated with demands on the
heart and blood vessels (the cardiovascular system). To deliver
enough oxygen to the muscles to allow them to form the energy
compounds needed for muscle work, the heart rate is increased
and the heart muscle has to work harder. The acceptability of
working at elevated heart rates is related to the percent of
maximum aerobic work capacity a person must use and the
duration of the work. Figure 111-15 in Chapter 7 illustrates the
relationship between the percent of aerobic capacity used and
time. The aerobic capacity value is specific to the type of work
being done. If the work uses the whole body, as would be true in a
repetitive lifting job that is done from floor to waist level, then
whole body aerobic capacity as measured on a treadmill can be
used to determine the individual's maximum aerobic capacity for
the work. If the job involves standing quite stationary and using
primarily arm, shoulder, and upper trunk muscles, then an arm
capacity test, such as lifting or cranking, would be needed to
assess the person's maximum aerobic capacity.
To determine the appropriate recovery periods for repetitive
lifting tasks that may result in whole body fatigue, it is necessary
to measure the heart rates of people during work. Enough light
activities or recovery can be inserted to assure that the heart rate
elevation averages no more than 33% of heart rate range
(predicted maximum heart rate minus resting heart rate) for an
8-hour shift. Predicted maximum heart rates are determined by
subtracting age from 220 beats per minute. With this admittedly
rough estimate of aerobic work intensity, one can also look at
peak work loads and be sure that they meet the guidelines for
duration that Figure 111-15 recommends. To bring the over-all job
demands down, light activities or recovery time must be made
available during the repetitive handling tasks. If oxygen usage is
measured, a maximum workload of 12 ml of oxygen per minute
per kilogram of body weight averaged over the 8-hour shift is
recommended.
These recommendations for provision of adequate recovery
time relate to low back pain in the workplace in several ways. If
the posture during work is such that the back muscles are loaded
not only by the weight of the object being lifted but also by the
way it has to be handled, their rate of fatigue will be greater. Then

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Providing Adequate Recovery Time

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they may not be able to keep the spine aligned during a postural
change or a sudden movement because they may not have the
strength needed. As a result, there is more potential for the
vertebrae to slide on one another and to pinch the nerve root
during a lift or postural change, producing low back pain
symptoms. If the work is very demanding and whole body fatigue
occurs, the worker may be less attentive to postural changes and
may slip or put an excessive load on one part of the spine. Whole
body fatigue will show up as reduced endurance for work, and
the worker wil I need longer recovery times as the shift progresses.
It is better to incorporate the recovery periods into the work
periods and reduce the over-all load throughout the shift than to
try to make up for the heavy work with extended break times.

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D. EXAMPLES OF RECOVERY TIME
CALCULATIONS

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static work and for dynamic handling tasks are given below.

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If a person is doing a task that requires bending forward
while working on a bench, the back muscles are likely to be
loaded to about 40-50% of their capacity in order to keep the
upper body from falling forward. Taking the 50% MVC value, one
can find from figure 11-11 that this effort can be sustained for one
minute continuously. The muscle is then fatigued. If the task
takes 15 seconds to complete in the bending posture, there will
be slight back muscle fatigue. A recovery time of an additional 15
seconds should restore the energy supplies of the back muscles.
If the static muscle load is greater, for example, 75% of maximum
force, the recovery time will have to be lengthened in proportion
to the work time. Fifteen seconds of bending work at 75% of the
maximum strength of the back extensors will need 150 seconds

of recovery time. Figure IV-5 illustrates the relationship between

workload intensity, duration, and the needed recovery period to
prevent accumulating fatigue. To find the proportionate recovery
time after a static effort, one finds the intersection between the
intensity of that effort (percent of maximum voluntary muscle
strength) and the duration (or holding time in minutes). The

�138

Working With Backache

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vertical axis value at this point indicates the percent recovery
time needed to restore the muscles.

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2. Dynamic Work - Repetitive Manual Lifting

There are both local muscle and whole body fatigue reasons
to provide adequate recovery time in these tasks. So, the first
consideration is to identify the intensity and duration of the lifts
and to determine the necessary recovery time using Figure IV-5,
as discussed above. If the lifts are more than 6 times per minute
and the object being lifted weighs more than 20 lbs (9 kg), one
can calculate the additional need for recovery time by determining
what the appropriate work/recovery cycle shou Id be. For example,
a 40 lb (18 kg) case may represent 75% of strength for less strong
workers. The lift may only take 3 seconds, so at a steady 6 per
minute lift rate, every 3 seconds of lifting is followed by 7 seconds
of recovery, giving a work/recovery ratio of 1 :2.5. The suggested
recovery time for this task would be about 8 seconds, one more
th,an is available at this lifting rate. An additional one second of
recovery time per lift would be recommended to prevent ac­
cumulated muscle fatigue. At higher lifting frequencies additional
recovery time at the end of the task would have to be given to
make up for the inadequate recovery time between lifts.
To keep the total workload within acceptable levels, it is also
necessary to estimate the cardiovascular load of the work. As a
general guideline, one can assume a heart rate range of 100
(between resting and predicted maximum values). A heart rate
elevation of 33 beats per minute above resting levels averaged
over the shift is the maximum recommended workload. The
heavier the handling task (more weight, higher frequency), the
more light work recovery time is needed in order to reduce the
total load. From a list of the energy expenditure and heart rate
elevations of job activities (Table IV-1), one can determine the
average and peak workloads and assure that they stay within the
guidelines in Figure 111-15 (Chapter 7) by adding light work as
needed. For example, if a job requires a worker to lift heavy boxes
at 6 per minute for 4 hours a shift, and the average heart rate
elevation is 50 beats per minute, that represents a 50/100 or 50%
of aerobic capacity (represented by % of heart rate range)
workload. To reduce the total workload to 33% of maximum for

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Effort Level

Light

Moderate

Heavy

HR Elevation
Whole Body

10-20

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46-75

&gt;75

Upper Body

10-15

16- 30

31 -50

&gt;50

Typing, Data
Entry (U)

Packing,
Small (U)

Industrial
Cleaning

Landscaping

Record
Keeping (U)

Punch Press
Operation

Carpentry

Loading
Coal

Small Parts
Assembly (U)

Metal
Working (U)

Plastering

Handling
Cases,
&gt;25Ibm
&gt; 4/min.

Drill Press
Operation (U)

Painting

Sweeping/
Mopping
Floors

Cement
Mixing

Sitting,
Reading

Driving a
Truck/Car

Gardening

Stone
Masonry

Monitoring

Sewing (U)

Packing,
Large (U)

Smelting
Work

Standing

Ironing (U)

Sheet Metal
Work

Agricultural
Work

Drafting

Washing
Windows

Laundry Operations (U)

Bench Work

Truck and
Auto Repair

Sorting Scrap

Road Paving

Walking

Metal Casting

Tasks

Inspecting

Very Heavy

Crane Operation (U)
Cafeteria
Work (U)
Machine
Tending

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Table IV-1: Heart Rate Elevations In Several Occupatlonal Tasks.
Estimates of heart rate elevations (beats/min above the resting
value) for work tasks are given in four effort categories from light to
very heavy work. These can be used to design jobs so that the total
workload does not exceed the aerobic capacity guidelines presented
in Figure 111-15 (Chapter 7). For upper body work (U), local muscle
fatigue should also be evaluated for moderately heavy or heavier
tasks.

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the whole shift, the 50% would have to be balanced by a very low
workload. That value can be calculated by solving the following

equation:

(50) (240 min.)+ (x) (240) =
12,000 + 240x =
240x =
X=

(33) ( 480)
15840
3840
16.0

A 16% of aerobic capacity workload is not much more than light
assembly or paper work. This suggests that if the heavy lifting is
done for the first four hours of the shift, the workers can only do
light work during the second half.
This example illustrates why short duration intensive effort is
preferable to long duration effort with added rest break time. If
the above task were to be broken up into 10 minute segments with
5 minutes of lighter activity alternating for the full 8 hours, the
lifting frequency could be reduced from 6 per minute to 4.5 per
minute, the heart rate elevation would be reduced from 50 to
about 38 beats per minute (a 25% drop in workload), and the light
activity could be about 23% of maximum aerobic capacity in
order to average out at 33% for the shift. The calculation is as
follows:
38(320) + x(160) = 33(480)
12160+ 160X = 15840
160 X= 3680
x = 23% moderate activity level
A number of moderately demanding jobs can be done using 23%
of aerobic work capacity, including wrapping and packing tasks,
some cleaning operations, moderate effort assemblies, and
many inspection and monitoring tasks.
By altering the pattern of work in this example, one also
reduces the stress on local muscle groups by giving more
recovery time between lifts. Total output per shift is not reduced,
although it is taking more of the shift to complete the work. There
may be jobs where this abi I ity to restructure the pattern of work is
not possible. Those jobs will also probably require some "natural

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selection" of workers because they will be too difficult for people
with lower work capacity to perform. When a second worker is
available, the heavier work can often be shared. Thus, more
recovery time is provided by cutting the lifting frequency in half
for each worker.

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How the Job Can Be Improved

TITI

CHAPTER 11: WORK PATTERNS AND
JOB DESIGN

The previous chapter discussed ways of alternating light and
strenuous tasks to reduce the local muscle stress and the whole
body demands of repetitive tasks and awkward postures. In this
chapter the implications of self-paced and externally-paced jobs
for the person with low back pain are discussed. In addition,
some guidelines are included for the choice of job activities and
the design of jobs to reduce the opportunities for muscle or
whole body fatigue.

A. WORK AND RECOVERY PATTERNS IN SELF­
PACED WORK
Determination of the job effort level that is acceptable to
most workers will depend on the strengths and postures required,
the total energy required over the shift, the environmental
stressors present, and the amount of control the worker has over
the way the work is done. Physiological and psychological
"behaviors" modify the way a job is done, sometimes greatly
different from its initial design. For example, if a person (not a
machine) is pacing a handling job, he or she may cluster the
lifting into a short, intensive period and then do lighter and less
strenuous tasks for longer periods between the lifting tasks. This
strategy is in lieu of doing fewer lifts over a longer time period. If

the person has low back pain, however, it may be more suitable to

intersperse the lighter activities more frequently within the lifting
periods. Figure IV-6 illustrates some of these potential work
patterns. The person with backache is responding to the ac­
cumulating fatigue in the back muscles caused by the repetitive
lifting; he or she is protecting the back by reducing the continuous

143

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lifting time to a level where fatigue is not significant. The person
with no backache is lifting to "get it over with" and to have a
longer period to do other tasks or relax before the next lifting
period occurs.
Well-designed jobs will permit the work to be accomplished
during the shift by any one of a number of job patterns. The
appropriateness of an intensive lifting period will be determined
by the nature of the materials being handled and by the fitness of
the handler. Such a work pattern should not be required since
many people of less strength or less endurance capacity will not
be able to follow such a pattern without fatigue.

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Figure IV-6: Lifting Patterns for People With and Without Low Back
Pain. Examples are shown of possible self-paced lifting patterns for
workers without ("a") and with ("b") low back pain on a job where
frequent moderately heavy lifting is required. The theoretical job
requirement is unloading 24 cases weighing 20 pounds (9 kg) each
from a pallet every 15 minutes throughout the shift.

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Even if a handling task is not required or is well within most
people's capabilities, postural requirements may put the person
with back pain at a disadvantage in some jobs. If the job is
self-paced, he or she can usually find a way to get postural relief
by alternating activities frequently. A repair bench worker, for
instance, can work for several minutes while seated on a stool at
the bench. He or she can get up and procure a new product or
dispose of the old one, do paper work, or do another test in the
standing posture at a higher work bench in order to get postural
relief. Conversations with fellow workers, a search for a better
tool, trips to the drinking fountain or restrooms, and other
legitimate activities also serve as breaks from the primary task. If
the job has been structured to make it unnecessary for the worker
to leave his or her workbench or station, these secondary work
activities and arbitrary work breaks often increase in order to
provide the postural adjustments that most people need.

B. PACED WORK AND WORK PATTERNS
There are many types of paced work. Some of these are
paced by the worker and include a desire to meet a particular
goal, conscientiousness, and a desire to excel or "be the best."
Some are paced by supervision and relate to production goals,
incentive pay, deadlines, and standards of performance. Others
are a function of the workplace and job characteristics, such as
conveyor pacing, emergency responses, service needs, and
rapid response computer systems. Work that is paced by the
worker, by supervision, or by the job goals (such as rapid service)
can be structured to fit the capabilities of many workers unless
the time constraints are unreasonably tight. Work that is machine­
paced or that requires emergency responses cannot be organized
as well by the worker. The way such work is designed will
determine how many people will be able to do it.
Chapter 10 includes a discussion of the importance of

providing adequate recovery time in a job where moderately

heavy or heavy effort tasks are done or where awkward postures
are required. In an externally-paced task the recovery time is
fixed; if it is not adequate, the worker has to find ways to get away
from the machine in order to recover fully. Some of the arbitrary
and secondary work breaks mentioned above, such as getting a

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Working With Backache

drink of water, going to the restroom, or getting a new tool are
used to get away from the pace pressure. Since no piece of
machinery is routinely 100% efficient, occasional breakdowns in
the line will also provide work breaks from the pace pressure. If
the work is on a reasonably short line (6-12 people on a work
team), the line may be stopped infrequently by the lead operator
in order to give the worker a break while some maintenance or a
new set-up is done. Occasionally a line is stopped just to allow
people to "catch up."
A person with chronic low back pain is at a disadvantage in
externally-paced operations because there are fewer options for
organizing the work pattern to reduce back stress. If the product
is moving in and out of the workplace at a fixed rate, it is harder to
take frequent short breaks, to readjust posture, or to rest the
muscles involved in a lifting task. Because the worker cannot
control these factors as well in machine-paced operations, it is
important to include a variety of activities and postures in the
tasks done at each station. One should also consider the option
of moving people between stations in order to spread out the
heavier tasks and to make the jobs suitable for more people.

C. JOB DESIGN GUIDELINES
The guidelines for job design given below focus on two
primary needs of the person with backache, providing postural
relief and permitting the person to vary his or her work pattern in
physically demanding jobs.
1. Do not confine a worker to one location for the full shift,
but provide alternatives for moving to other places in order to get
supplies, do record keeping tasks, or do quality checks, for
example.
2. Provide for postural adjustments during the work. Have
some type of seating available for predominantly standing
activities and include some activities that require standing or
walking in a job that is done at a seated workplace.
3. For self-paced jobs with frequent moderately heavy to
heavy lifting tasks (see Chapter 7), provide ways to break the
lifting tasks into 5- to 15-minute periods with less demanding

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Work Patterns and Job Design

147

tasks alternating for equal lengths of time. Ideally, the structuring
of these tasks should be loose enough to allow each person to
develop his or her own best work pattern. The job designer has to
define some light work activities that are integral to the job and
can be used as recovery periods between the heavier tasks.
4. For externally-paced jobs such as conveyor assembly
lines, decisions about the time needed to do the task and which
activities go into each job should consider the need for adequate
recovery time in moderately heavy or heavy handling tasks (see
Chapter 10). Line balancing should consider both the time to
accomplish the task and the time needed to recover before the
next task is done. Enough light activities to provide adequate
recovery time should be scheduled in the heavier jobs.
5. In machine-paced operations where materials are coming
in and out of a workplace by conveyor, the worker should be able
to work in places other than directly at his or her work station. It
should be possible to work down the line a little in order to permit
more variability in performance when parts do not fit properly or
when distractions, such as visitors, are present. When a supplying
activity is scheduled to occur and the worker needs to get a little
ahead on the line, he or she should be able to work up the line,
too.
6. If an object weighs more than 40 lbs (18 kg), find a way to
slide it rather than requiring it to be lifted. This is especially true if
the handling is done more than once a minute for much of the
shift.

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Section V:
Summary and Addenda

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CHAPTER 12: SUMMARY

In looking at the low back pain problem in industry, one
should recognize that there are ways that the lost time and
disability can be reduced through actions of the worker, the
workplace and job design engineers, and supervision. The
worker who has repeated low back pain episodes can learn good
body mechanics, avoid actions that may trigger the attacks
("aggravators"), follow safe work practices in lifting and handling
materials, and do regular exercises to keep the body muscles
toned, especially those of the back, hips and abdomen. The
design engineers can help the person with low back pain by
assuring that reaches are within most people's capabilities
without having to stretch or twist, that working heights do not
result in static loading of the back, that handling requirements
are resonable, and that postural flexibility is provided. Supervision
can improve the low back problem in industry by supporting
improvements in workplaces or jobs where static loading or
twisting of the back may aggravate symptoms in people with
degenerative disc disease. They can also learn to recognize job
and environmental pressures that make it more necessary for a
worker to report low back pain episodes. These include externally­
paced operations and tight time lines, jobs where the worker has
little control over the way the work is done, and situations where
postural relief is difficult to obtain. In addition, managers can
encourage the establishment of worker fitness programs, es­
pecially for people who work in jobs that require moderately
heavy to heavy effort or awkward p�stures.

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A. NEW DESIGN

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A long-term approach to reducing low back pain disability is
to design the workplace so there is less opportunity for the
"aggravators" of symptoms to occur. A summary of design
guidelines that should make it less necessary to report low back
pain symptoms is given below.

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1. Keep working heights around elbow height for most
people. For standing work this is in a height range from about 35
to 41 inches (89 to 104 cm) above the floor. For seated work it is
from 7 to 11 inches (18to 28cm) above the seat pan of the chair or
stool.

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2. Keep forward reaches within 15 inches (38cm) of the front
of the body and between elbow and head height, roughly from 38
to 55 inches ( 97 to 140 cm) above the floor when standing. Higher
and lower forward reaches are not recommended, especially on a
repetitive basis. If they occur, forward reaches of more than 10
inches require bending and stretching and increase the dis­
comfort for people with low back pain.
3. Avoid lifting items above 50 inches (127 cm) or below 20
inches when standing, where possible. Use sliding for low lifts or
use levelators to raise the load above 20 inches for handling
tasks.
4. Design force exertion tasks so they can be approached
directly in front of the body and at 40 to 50 inches (102 to 127 cm)
above the floor.
5. If a compact object weighs more than 40 lb (18 kg), look
for ways to handle it other than lifting. Use conveyors or sliding
surfaces, for example.
6. Provide workplace aids for postural relief, such as foot
supports, chairs or support stools, armrests, and backrest cus­
hions, as appropriate to the work. Design jobs so the seated
operator can get up and walk and the standing operator can sit
down occasionally.
7. Design packaging so the dimensions do not exceed the

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Summary

151

reach and grip capabilities of most people and so the package
does not interfere with the legs during walking and carrying.
Objects that have more than two dimensions that exceed 20
inches (57 cm), even if they weigh less than 25 lbs (11 kg), may be
difficult for less strong workers to handle repetitively.
8. Orient the workplace so that twisting of the upper body is
not likely to occur. Keep the work within a 90-degree movement
pattern where possible. Store supplies so they can be accessed
without the worker having to take awkward postures, preferably
between 20 and 55 inches (51 and 140 cm) above the floor in a
standing workplace. Storage at or up to 25 inches (64 cm) above
the work surface in a seated workplace is also preferred. Supplies
that are only occasionally needed can be placed far enough to
one side to require the worker to stand up and get some postural
relief.
9. Select a chair according to the type of work being done
and the time of continuous sitting. The longer a person has to
remain seated before he or she can get up to walk or stand for a
while, the more important it is to have a chair with good back and
foot support and with adjustability to improve the workplace "fit"
for the individual worker.
10. Provide aids for handling materials that are not compact
or are heavier than 40 lbs (18 kg). Small hoists, straps, carts, and
transfer tables with roller bearings are examples of such aids.
11. Include height adjustability in standing workplace work
surfaces, where feasible.

B. EXISTING WORKPLACES
Workplace problems can often be identified by looking at
accident and medical reports for low back pain incidents. Jobs

that involve· heavy lifting, awkward postures, or high time

pressure demands that make work organization difficult for the
individual worker may show higher low back pain reporting than
do lighter, more sedentary jobs. The need for a person to report
symptoms when a low back pain episode occurs is much greater
if the job activities put fairly high pressures on the lumbar discs or
contribute to fatigue of the spinal musculature.

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It may sometimes be difficult to alter the workplace to fit the
recommended guidelines for working heights, reaches, orienta­
tion, etc. Accommodation of individuals according to their back
problems may be a more feasible approach in some instances to
help get a person back to work or to reduce the potential for
aggravating his or her symptoms on the job. Most of these
accommodations will be usefu I for people without back problems,
too, as they reduce static loading of muscles that can limit self­
paced productivity levels. Some accommodations are described
below.

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1. Use a scissors lift, levelator, platform, or 2 or 3 extra
pallets to raise items to about 20 inches (51 cm) above the floor in
frequent handling tasks.
2. Use tool or reach extenders to reduce the need to stretch
or twist in long reaches.
3. Provide chair inserts or inflatable cushions for additional
lumbar support at a seated workplace if the chair is not designed
according to ergonomic guidelines.
4. Use an adjustable footrest, or use a block of wood,
styrofoam, or a telephone book as a footrest for standing or
sitting workplaces to give postural relief:
5. Use small light platforms on a too-low work surface to
raise the work height enough to reduce bending for the taller
worker.
6. Use sections of roller conveyor, ball bearings mounted on
the work surface, or slides to permit heavy items to be moved
across the work surface without having to be lifted.
7. Include lighter activities as part of the job requirements
and allow the workers to structure the way the job is performed,
alternating light and heavier activities according to their best
work pattern.
8. Release the person on a conveyor-paced job from the
pace pressure by moving materials on and off of the conveyor
line to another work surface. He or she can then keep some

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Summary

153

control and work at an appropriate rate for the back discomfort.
9. Provide hand carts or hoists to support the weight of
objects that are difficult to handle either because of their weight
or their confi-guration.
Since about two-thirds of the workforce might experience
low back pain at some point in their working careers, it is wise to
take the long term approach of designing or redesigning the
workplace and job so most people can work without aggravating
their low back. Accommodations are appropriate as short term
"fixes" and do improve the job for many people. However,
integrating the ergonomic principles into the whole job will have
greater benefits than simply those related to low back problems.
Well-designed jobs and workplaces can improve productivity by
reducing fatigue from awkward postures or too-heavy work, by
providing more management flexibility in placing people in jobs
and covering changing production demands, and by better using
the talents and capabilities of the workers.

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Low back pain symptoms in the workplace may not be easily
prevented because of the recurrent nature of the disease.
However, workplace and job situations may exacerbate symptoms
by requiring the worker to use postures or handle materials that
aggravate the back. This Appendix includes a checklist that can
be used to help identify changes to facilitate the low back pain
patient's return to the workplace. If the conditi_ons indicated in
the checklist are avoided in workplace and job design, the
opportunities for extended lost time from low back pain should
be reduced significantly. Other factors relating to supervisory
style and conditions that may increase the risk of slip and trip
accidents are also discussed.
I. Checklist to Identify Potential Low Back Pain Aggravators in
the Workplace

In surveying the workplace, one should place a check by the
appropriate descriptions of low back pain �ggravators.
___ 1. Constant standing with little opportunity to sit down.
___ 2. Constant sitting with little opportunity to stand up or
move around.
___ 3. Low working heights requiring the worker to bend
over frequently.
___ 4. Extended reaches requiring the worker to bend
forward to perform a task for at least a minute continuously.

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___ 5. Activities that require the worker to take an awkward

posture, such as crouching, while doing a task lasting longer

than one minute.

___ 6. Repeated and sustained work over shoulder level
(about 50 inches above the floor).
___ 7. Activities that require the worker to twist the upper
trunk in order to reach or see something.
___ 8. Activities that result in uneven distribution of body
weight on the feet, especially where one foot is lower then the
other and manual force exertion or lifting and lowering is being
done.
___ 9. Inadequate clearances for moving the feet while
doing a task that will result either in uneven balance or twisting of
the trunk.
___ 10. Seating that has inadequate support for the back
(no adjustable lumbar support).
___ 11. Lack of an appropriate footrest at a seated work­
place (unless working height is about 26 inches above the floor or
lower).
___ 12. A fixed workplace where it is not possible to adjust
the location or heights of equipment being used, therefore
possibly resulting in awkward postures for some workers (e.g., a
visual display terminal that is too high or too low for some
workers and cannot be tilted).
___ 13. Occasional lifting or lowering of objects weighing
more than 40 pounds at heights below 35 and above 45 inches.
___ 14. Frequent lifting (1 per minute or more) or lowering
of objects weighing more than 25 pounds.
___ 15. Handling of large-size loads (more than 20 inches
in any dimension for boxes or cases).

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Appendix A-Surveying the Workplace

157

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___ 16. Handling of sheet materials without straps, special
holders, or a second person.
17. Handling of awkward loads that can shift suddenly
.
(such as liquids in cans or bags of loose material) when they
weigh more than 25 pounds.

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___ 18. Handling of materials where the load is not shared
equally between the hands, so that the load on the spine is
imbalanced.

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___ 19. Sustained (more than 30 seconds) pushing or
pulling of heavy loads in trucks or across flat surfaces. Forces
exceeding 40 pounds (or 180 Newtons).
___ 20. Activities that require lateral force exertion, as in
pulling or pushing an object across the front of the body, where
more than 15 pounds of force (70 Newtons) is required.

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___ 21. Lifting or lowering any objects when the hands are
less than 10 inches above the floor, unless the knees are bent and
the load is compact.

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___ 22. Externally-paced jobs where the worker cannot go
"off-line" easily to take a recovery break. Examples are conveyors
or production machines where the worker must keep pace or
shut down the line. This is especially of concern for handling
tasks.
___ 23. Manual handling tasks that require the worker to
bend to one side to exert a force or lift an object, resulting in a
trunk twist or uneven loading of the spine.
___ 24. Moderately heavy workloads that are sustained for
more than 1 hour continuously, especially if a sustained awkward

posture or if frequent moderately heavy to heavy lifting is

required in the job.

___ 25. Work in a cold environment (such as a food storage
warehouse) where repetitive lifting or awkward postures are
required.

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2. Other Factors to Evaluate in the Workplace

In addition to the workplace and job factors indicated in the
checklist, the work environment should be evaluated in terms of
supervisory style and the potential for slip and trip accidents. The
"style" factor can influence the reporting of low back pain
symptoms and the ease with which a person gets back to work
after an episode of low back pain. Slip and trip accidents are
associated with development of or exacerbation of low back pain
and may be related to either workplace or job factors.
To survey an area for its supervisory style, one has to
interview the workers and supervisors and be sensitive to factors
that can influence the worker's time pressure or job control. The
less control or the more external pacing present, the more
potential there is for a person with back problems to run into
difficulties in performing the job during low back pain episodes.
The difficulties arise when the person is less able to organize his
or her work pattern in order to reduce back discomfort, as when
he or she is constrained from taking frequent short work breaks,
changing postures, using aids, or altering the methods used to
accomplish the task. If a supervisor exerts close control over the
way the work is done and does not tolerate work pattern
adjustments, and if the person with low back pain is unable to do
the work in the usual manner, then he or she will have to report
the back problem and get a medical restriction. Some questions
that can be used to elicit information about supervisory style are:

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a. Are there any jobs in your area that might be difficult for a
person with a back problem to perform?

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b. How do you handle a person with a medical restriction for
moderately heavy lifting (or continuous standing) in your area?

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c. Are there aids available in the workplace to help in manual
handling activities? Are they used?
d. Are there periods of increased production pressure when
it is difficult to meet your schedule?

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e. What is the scheduled break time on the jobs in your area?
If a person completes the work early, can he or she go on break
for longer periods?

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An evaluation of the workplace for potential slip/trip ac­
cidents would include looking for housekeeping problems. This
includes such things as: parts, liquids, or oils on the floors;
crowded aisles; equipment left in walkways; and other hazards
that might contribute to a tripping or slipping accident. Job
factors that result in hurrying, such as too tight a timeline in a
paced operation or high production pressure, are also more
likely to result in slip/trip accidents. Workplaces where there is a
change in the walking or standing surface height, whether it is a
small flight of stairs, a stair ladder, a step stool, or a platform may
also increase the risk of a slip or loss of balance because of a
misstep.

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This section has addressed the identification of workplace,
job, and environmental factors that may contribute to low back
pain problems on the job. Guidelines for designing workplaces
and jobs to reduce the opportunities for aggravating backache
symptoms are given in Chapters 5 through 11.

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The choice of a chair for a workplace will determine how
comfortable the worker is and, indirectly, how productively he or
she works. This Appendix gives general guidelines for chair
selection that are based on population size. It also includes
information for deciding which type of chair is best as a function
of the type of work being done.

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1. Chair Characteristics as Selection Criteria
Table B-1 summarizes the height, width, and depth of a
chair's seat, characterisitics of its back rest, and suggested
dimensions for the footrest and armrests. These guidelines for
selection are based on anthropometric (body size) data of the
U.S. population and are intended to make it possible for the
greater part of the workforce to be comfortably accommodated
by the chair design. If a chair is being chosen for a personalized
work station at home, the purchaser shou Id choose one that best
satisfies his or her body size.
If the height and depth recommendations for the seat are not
met by available chairs, an adjustable footrest should be pur­
chased with the chair that comes closest to the guidelines. The
footrest will reduce discomfort in the back that may be caused by
inadequate foot support or by an inability to use the backrest and
still keep one's feet on the floor.
2. The Process of Chair Selection
The recommendations given above for selecting a chair can
be used for any applications. Other decisions must be made
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Table B-1: Recommeded Chair and Accessory Characteristics
Characteristic

Measurement or Feature

1. Seat Height Adjustability

From 15 to 22 inches
(38 to 56 cm)
17 to 19 inches (43 to 48 cm)
17 inches (43 cm)
5-10 degrees up
(towards the front)
Lumbar and Thoracic Support
6-9 inches (15-23 cm) high
12-14 inches (30-36 cm) wide
7 to 1 O inches (18-25 cm)
above· the seat
12 to 17 inches (30-43 cm) from
the front of the seat
5-legged; castered, if needed
At least 180 degrees of swivel,
if needed
A "breathing" fabric that does
not trap heat and cause
stickiness.
Easy to adjust without tools;
pneumatic cylinder adjustment
where possible.
Portable and adjustable
16 inches (41 cm) iong,
12 inches (30 cm) wide
Easy to adjust in 2-inch
(5-cm) increments
Adjustable with seat height

2. Seat Width
3. Seat Depth (or Length)
4. Seat Slope
5. Chair Back Rest
Size
Movement Up and Down
Movement In and Out
6. Support
7. Swivel
8. Fabric or Chair Covering
9. Adjustability
10. Footrests
Size
Adjustability
Chair Footrests
11. Armrests
Size

Adjustability

12 inches (30 cm) long,
3 inches (9 cm) wide on chairs
so chair can fit urider
work surface
Up and down about 5 inches
(13 cm) on chairs. Wider
motion capability if armrests
are on a work bench

Table B-1: Recommended Chair and Accessory Characteristics.

Recommended dimensions and characteristics of chairs, footrests,
and armrests are given in inches and centimeters. Few chairs will be
found that possess all of the characteristics recommended; the ones
that come closest are preferred.

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Appendix B-Selecting a Chair

-,

163

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about the type of chair and the kind of work that is done in the
seated posture, however. Figure B-1 summarizes some of the
decisions that should be made before the final chair is selected.
Following this process should lead one to a chair that is best
suited to the job and that takes account of the usual job postures
as well as the population's physical size range.

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Table B-2 indicates important selection features for chairs
and accessories to be used in workplaces where assembly, word
processing, inspection tasks, and intermittent seated jobs are
done. These tasks are described below. Each job will have its
unique combination of tasks, so the chair selection process
suggested in this table should be used only as a guide to how to
analyze the needs.

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Assembly tasks often require the worker to lean forward on
the work surface in order to hold or put pressure on a part, use a
tool, or attach a part to the main assembly. The operations cannot
be performed while sitting back in the chair, so the backrest must
be able to move forward with the worker as the work is done.
Provision of workplace armrests to help steady the hands may
also be desirable.

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A word processing job may involve sitting back in the chair
and entering text on the keyboard. There is little need to lean
forward during text entry, but the word processor operator may
have to go to another location to pick up the printed output. Chair
height adjustability is important especially if the video display
unit's keyboard is not separate from the screen. Sustained
awkward head and neck postures can bring out low back pain
complaints.

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An inspector may remove product from the manufacturing
process at some point and test it, then either return it to the line or
dispose of it in a waste bin. In any case, the inspector may have to

move objects around the workplace; this can include a need for

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frequent extended reaches, twisting of the trunk, and reaches up,
down, and to the side of the primary work area.. In addition, the
worker may lean forward to be able to see the defects for which
the inspection is being done.

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Working With Backache

164

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Seated or Sit/Stand Workplace?

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4-8 Hours or Less Than 4 Hours

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Most Important Features

Most Important Features

Good Back Support
Easy to Adjust Height
and Depth of Seat
"Breathing" Fabrics
Good Padding

I

+

• Seat Needs to Adjust
up to 25 inches (102 cm)
• Must Have Footrest
• Look at Stools or Other
Props

Seat Height Less than 23 Inches
(58 cm) - Ease of Getting On and Off

l

• Need Backrest to Move
Forward at Least 5
Inches (12 cm)

+

Leans Forward to Write
or Assemble on Work Surface
• Need Good Back Support
• Provide Good Foot Support
Either Through Portable or
Built-In Footrest

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What Does the Worker Do?

Extended Reaches - Forward

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Reaches to Side or Up and Down
• Need to Limit Size of Backrest
to Reduce Abrasions
• Need Swivel Capability
• Stable Base (5 Legs)

1

Operates Foot Pedal
• Need Good Backrest
• Movable Foot Pedal Desirable
• Adjustability in Height

Figure 8-1: Selecting a Chair. A decision tree is shown for selecting
a chair according to the activities required by the job. The most
important chair characteristics are indicated according to the
reaches and work locations, especially.

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�Appendix B-Selecting a Chair

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Table B-2: Chair Selection by Job Category
Most Important Characteristics (marked by an "X")

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Job Type
Chair and
Accessory
Characteristics

Assembly

Word
Processing

Inspection

Seated TasksIntermittent

Seat Height

X

X

X

X

Seat Depth

X

X

X

X

Seat Width

X

X

5-Legged
Support

X

X

X

X

Backrest Size
Backrest
Adjustment
Up and Down

X

In and Out

X

X

X

X

X

X

X

X

X

Fabric Covering

X

X

X

Footrest

X

X

X

Armrest

X

Padding

X

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Table B-2: Chair Selection by Job Category. Chair and accessory
characteristics are shown in column one. Four job types are
indicated across the top of the table. The most important character­
istics in chair or accessory selection are marked with an "X" under
each job type.

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Working With Backache

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These three tasks are often done for more than 4 hours a shift

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and are often sustained for two hours continuously without a

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break. Other jobs may provide seating for people who are doing
certain tasks such as paperwork, record keeping, repair work, or
some testing. These intermittent seated tasks are evaluated in the
last column of Table B-2.

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REFERENCES

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Caillet, R. 1981. Low Back Pain Syndrome. Edition 3. Phila­
delphia: F.A. Davis Company, 230 pages.

I I

Rowe, M.L. 1965. Disc surgery and chronic low back pain.
Journal of Occupational Medicine 7: 196-202.

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Chapter 1:

Kapandji, I.A.1974. ThePhysiology of theJoints. Volume 3: The
Trunk and Vertebral Column. Translated by L.H. Honore. New
York. Churchill Livingstone, 251 pages.

Rowe, M.L. 1969. Low back pain in industry.Journal of Occupa­
tional Medicine 11: 161-169.
Rowe, M.L. 1971. Low back disability in industry. Updated
position.Journal of Occupational Medicine 13: 476-478.
Rowe, M.L. 1983. Backache at Work. Fairport, N.Y.: Perinton
Press, 122 pages.
White, A.H. 1983. Back Structure, Incidence and Causative
Factors of Back Injuries and Pain (Psychological, Biomechanical,
and Psychophysical). Paper presented at the National Safety
Council's Back Injury Prevention and Rehabilitation Satellite
Video Teleconference, May 18, 1983. Chicago: National Safety
Council, pages 7-11 of syllabus.

169

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170

Working With Backache

Chapter 2:
Chaffin, D.B. and K.S. Park. 1973. A longitudinal study of low­
back pain as associated with occupational weight lifting factors.
American Industrial Hygiene Association Journal 34: 513-525.
Kodak Human Factors. 1983. Ergonomic Design for People at
Work, Volume 1. Belmont, Calif.: Lifetime Learning, 406 pages.
Nachemson, A. 1975. Towards a better understanding of low­
back pain: A review of the mechanics of the lumbar disc.
Rheumatology and Rehabilitation 14: 129-143.
Tichauer, E.R. 1978. The Biomechanical Basis of Ergonomics:
Anatomy Applied to the Design of Work Situations. New York:
Wiley lnterscience, 99 pages.
Chapter 3:
Imrie, D. with C. Dimson. 1983. Goodbye Backache. New
York: Arco Publishing, Inc., 159 pages.
Pfeiffer, G.J. 1983. Self Starter. A Self Help Guide to Back Care.
Rochester, N.Y.: Xerox Corporation, 25 pages.
Rohmert, W. 1960. Zur Theorie der Erholungspausen bei dyna­
mischer Arbeit. Internationale Zeitschrift fur Angewandte Physio­
logie 18: 191-212.
Scherrer, J. and H. Monod. 1960. Le Travail musculaire et la
fatigue chez l'homme. Journal de Physiologie (Paris) 52: 419-501.
Chapter 4:
Brown, J.R. 1975. Factors contributing to the development of
back pain in industrial workers. American Industrial Hygiene
Association Journal 36: 26-31.
Himbury, S. 1967. Kinetic Methods of Manual Handling in
Industry. I.LO.: Occupational Safety and Health Series No. 10.
Geneva, Switzerland: International Labour Office, 38 pages.

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□
□

References

171

Chapter 5:
Chaffin, D.B. and G.B. Andersson. 1984. Occupational Bio­
mechanics. New York: John Wiley &amp; Sons, 454 pages.
Frankel, V.H. and M. Nordin. 1980. Basic Biomechanics of the
Skeletal System. Philadelphia: Lea &amp; Febiger, 303 pages.
Kapandji, I.A. 1974, op. cit. (Chapter 1).

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Kodak Human Factors. 1983, op. cit. (Chapter 2).
NASA. 1978. Anthropometric Source Book. Volume II: A Hand­
book of Anthropometric Data. Yellow Springs, Ohio: NASA
Scientific and Technical Information Office, 424 pages.
Chapter 6 and Appendix B:
Grandjean, E. 1980. Fitting the Task to the Man: An Ergonomic
Approach. 3rd Edition. London: Taylor &amp;. Francis, Ltd., 50-62.
Grandjean, E., W. Hunting, G. Wotzka, and R. Schaerer.1973. An
ergonomic investigation of multipurpose chairs. Human Factors
15: 247-255.
Kodak Human Factors. 1983, op. cit. (Chapter 2).
Konz, S. 1979. Work Design. Columbus, Ohio: Grid Publishing
Company, 592 pages.
Mandal, A.C. 1981. The seated man (Homo Sedens), .the seated
work position -Theory and practice. Applied Ergonomics 12(1):
19-26.
Roebuck, J.A. Jr., K.H.E. Kroemer, and W.G. Thomson. 1975.
Engineering Anthropometry Methods. New York: John Wiley &amp; .
Sons, 459 pages.

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Chapter 1:
Astrand, P.-O. and K. Rodah I. 1977. Textbook of Work Physiology,
Second Edition. New York: McGraw-Hill, Inc., 681 pages.

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Ciriello, V. 1984. Paper presented on lifting frequency and
acceptable work load at the 1984 Brouha Work Physiology
Symposium in Rochester, N.Y., September, 1984.
Damon, A., H.W. Stoudt, and A.A. McFarland. 1966. The Human
Body in Equipment Design. Cambridge, Mass.: Harvard Univer­
sity Press, 360 pages.
Drury, C., Editor. 1978. Safety in Manual Materials Handling.
DHEW/NIOSH Publication No. 78-185. Cincinnati, Ohio: De­
partment of Health, Education and Welfare/National Institute for
Occupational Safety and Health, 209 pages.
Keyserling, W.M., G. Herrin, D.S. Chaffin, T.J. Armstrong, and
M.L. Foss. 1980. Establishing an industrial strength testing
program. American Industrial Hygiene Association Journal41:
730-736.
Kroemer, K.H.E. 1970. Horizontal Static Forces Exerted by Men
Standing in Common Working Postures on Surfaces with Various
Tractions. AMRL-TR-70-114. Wright-Patterson AFB, Ohio:
Aerospace Medical Research L,aboratory, 36 pages.
NIOSH. 1981. Work Practices Guide for Manual Lifting.
DHHS/NIOSH (National Institute for Occupational Safety and
Health) Publication No. 81-122. Washington, D.C.: Government
Printing Office, 183 pages.
Petrofsky, J.S. and A.A. Lind. 1978a. Comparison of metabolic,
circulatory and ventilatory responses of man to various lifting
tasks and to bicycle ergometry. Journal ofApplied Physiology
(REEP) 45(1 ): 60-63.
Petrofsky, J.S. and A.A. Lind. 1978b. Metabolic, cardiovascular
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Rehmert, W. and J. Rutenfranz. 1983. PraktischeArbeitsphysiol­
ogie, 3rd Edition. New York: Thieme Publishers, 440 pages.

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�References

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Rowe, M.L. 1983. op. cit. (Chapter 1).
Snook, S.H. 1978. The design of manual handling tasks. Ergon­
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Snook, S.H., R.A. Campanelli, and J.W. Hart. 1978. A study of
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Yates, J.W. 1984. Paper on research of handling frequency and
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Reliability of the psychophysical approach to manual lifting of
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Yates, J.W., E. Kamon, S.H. Rodgers, and P.C. Champney. 1980.
Static lifting strength and maximum isometric voluntary con­
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Himbury, S. 1967, op. cit. (Chapter 4).

'7

Chapter 9:

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Chapter 8:

Jacobsen, C. and L. Sperling. 1976. Classification of hand grip. A
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Napier, S. 1956. The prehensile movements of the human hand.
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6(9): 16-19.

Tichauer, E.R. 1978, op. cit. (Chapter 2).

�Lind, A.R. and J.S. Petrofsky. 1978. Cardiovascular and Res­
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Rodgers, S.H. 1978. Metabolic Indices in Manual Materials
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Working With Backache

Chapter 10:
Astrand and Rodahl. 1977, op. cit. (Chapter 7).

Rehmert, W. 1973a. Problems in determining rest allowances.
Part 1: Use of modern methods to evaluate stress and strain in
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Rohmert, W. 1973b. Problems in determining rest allowances.
Part 2: Determining rest allowances in different human tasks.
Applied Ergonomics 4(2): 158-162.
Rohmert and Rutenfranz. 1983, op. cit. (Chapter 7).
Scherrer, J., H. Monod, A. Wisner, P. Andlauer, A. Baisset, S.
Bouisset, H. Desoille, J.M. Faverge, A. Dubois-Poulsen, E.
Grandjean, B. Metz, P. Montastruc, S. Pascaud, M. Pottier, and D.
Rohr. 1967. Physiologie du Travail (Ergonomie). Travail Physique
Energetique. Volume 1. Paris: Masson Cie., 387 pages.
Simonson, E., Compiler and Editor. 1971. Physiology of Work
Capacity and Fatigue. Springfield, 111.,: C.C. Thomas, 571 pages.
Chapter 11:
Salvendy, G. and M.J. Smith, Editors. 1981. Machine Pacing and
Occupational Stress. London: Taylor &amp; Francis Ltd., 374 pages.

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INDEX

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A
Action Limit (AL}, NIOSH
Lifting Guidelines, 98
Adjustability, Workplace
Height, 118,150
Aggravators, of Low Back
Pain (LBP}, 15,19,149,155
Aids, to Reduce LBP,

Capacity, Muscle, 47,92,131
Carrying, Uneven Loading,
39,126

Carts, for Materials Handling,
117
Chairs
Adjustability, 81,162
Back Supports, 33,84,162
Covering, 87,162
118,150
Design of, 81,151,162
Anthropometric Measurements
Lack of Foot Support, 28
Seated, 71
Seat Dimensions, 83,162
Standing, 70
Seat Slope, 84,162
Armrests, 88,162
Selection Criteria, 151,161
Assembly Tasks, and Chair
Swivel, 31,162
Selection, 161
Checklist, for Workplace
Survey, 155
B
Cost, of Low Back Pain, 10
·sack Supports, 33,84.
113,162

D
Backache at Work, by
M.L. Rowe, 3,6, 19, vii
Degenerative Disc Disease,
3,149
Bending Over, 21,66,133
and Age, 8
Biomechanical Stress, on Back,
Natural History of, 8
21,23,66,92
Depth, of Object Handled, 126
Body Mechanics, 66, 92
Dimensions, of Object Handled,
C

Capacity, Aerobic Work,
101,135

124,150

Disability, Management of
in LBP, 11,153

175

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Working With Backache

Disc (L5), Compressive

Forces on, 19, 65, 92

Dynamic Work, Lifting,138
E
Effort Levels, Heart Rate
Elevations,139
Exercises,for Back and Trunk
Muscles,48
F
Fatigue, Muscle,20,69,131
Fitness,Back and Trunk
Muscles,48
Footrail,for Back Relief,113
Footrests,28,88,162
Foot Room, Inadequate,37
Forces,
Exerted, Maximum Static
Pull,95
on L5 Disc,19,65,95
Maximum Push and Pull,
106
Frequency,Lifting,105

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Inspection Tasks, and

Chair Selection, 163
Intensity-Duration
Relationship,
Aerobic Work,101,138
MuscleWork,48,131,138

J

Job Design, Guidelines,
143,146

L

Length,of Object Handled,124
Lifting,
Guidelines,54,98
and Low Back Pain,53,91
Patterns to Reduce Fatigue,
143
Repetitive or Sustained,
43,101,135,143
Tasks,34,123,135,143,152
Techniques,54,118
Training and LBP,3,14
Two-Person,61
Lifts,and Levelators for
G
Grip,59,129
Handling,118
Load,
H
Oversized,42,124
Handholds,Design of,129
Size and Configuration,
Handling Aids,
124,127
15,33,41,114,117
Location,of Work,65,92,151
Heart Rate Elevation,
and Backrest Use,85
and Work,139
Low Back Pain,
Heavy Lifting {see Lifting)
Aggravators,15,19,149,155
Heavy Work,and LBP,9
Diagnoses,6
Hoists,for Materials Handling,
and Effort Level,9
117
Incidence,4,153
Industrial Studies,4
Hyperextension of Back,
and Lifting Patterns,53,143
22,41,115,125

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177

Index

Management of,11,149
Need to Report,9,151

M

Manual Handling Tasks
(see Lifting),34,43,92,
118,123,135,143
Muscles,for Spinal Support,
45,65,131

Secondary Work,
Breaks,143
from Static Work,134
References,169
Restrictions,Job,44
Return to Work
Considerations,12

s

Seated Work,
N
Constant,33,113
Nerve Root Pinch,7,25,
Postures,28
52,131,137
Twisting,30
Seating,79,161
NIOSH Occasional Lift
Guidelines,98
Sheet Materials,
Handling Aids,116
Sliding,
p
Instead of Lifting,
Paced Work,
42,60,112
and Recovery Time,
Surfaces,Air Table,
133,143,152
Roller Bearings,112,11 E
andSlip/TripAccidents,159
Pallets,for Height Adjustments, Slip and Trip Accidents,
Evaluation,159
119
Spasm,Muscle,50,132
Patterns,of Lifting,143
Spine, Instability,
%MVC (Maximum Voluntary
6,25,39,131
Contraction),47,131,137
Standing Work,
Platforms,to Adjust
Constant,26,113
Working Height,111
Postures,20,
Postures,
Static Muscle Loading,
Awkward,25,39,43
21,92,131,137
Flexibility,27,113,133,146
Strength, Relative Static
Push and Pull Forces,95,106
Pull,95
Push and Pull,106
R

Reach Extenders, 109, 152
Reaches,
Seated,32,74,150
Standing,23,73,150
Recovery Time,
Calculations of,137

Supervisory Style,

Evaluation of,158
Survey of Workplaces,155
Twisting,

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�Working With Backache

178

Seated,30

While Handling Materials,
36,76,97,112

w

Width,of Object Handled,124
Word Processing,and
Chair Selection,163
Work-Recovery Cycles,
Workload Adjustment,
43,60,133,135,143
Workers' Cc;&gt;mpensation,
and LBP,3,9,10
Workplace Design,
Aecom modations,
15,65,109
Heights,21,69,92,111,150
Orientation,30,75,112,151
Seated,28,80,150,161
Sit/Stand,79
Standing,15,79

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WORKING
WITH
BACKACHE.

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SUZANNE H. RODGERS, Ph. D.

Dr. Rodgers is an internationally known
consultant in occupational ergonomics
involved in research, problem solving, and
training of others to understand and find
solutions for job and workplace prob­
lems. She combines academic strength in
physiology with 13 years of industrial field
experience and with a curiosity and interest
in learning from the people who best
understand job and workplace problems,
the workers themselves. In Working With
Backache, she brings ergonomic and phys­
iological theory together with workplace
observations to-help clarify how workers,
engineers, health and safety specialists,
and management can work together to
reduce low back disability on the job. The
pragmatic and readable style of Working
With Backache makes it a useful resource
for people with chronic back problems by
showing them what types of motions and
postures to avoid and how they can reduce
the opportunities for discomfort through
work pattern adjustments and work design
both at home and on the job.

PERINTON PRESS
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POST OFICE BOX 1105
FAIRPORT, NEW YORK 14450
U.S.A.

ISBN 0-931157-01-3

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�WORKING
WITH
BACKACHE
SUZANNE H. RODGERS, Ph. D.

Dr. Rodgers is an internationally known
consultant in occupational ergonomics
involved in research, problem solving, and
training of others to understand and find
solutions for job and workplace prob­
lems. She combines academic strength in
physiology with 13 years of industrial field
experience and with a curiosity and interest
in learning from the people who best
understand job and workplace problems,
the workers themselves. In Working With
Backache, she brings ergonomic and phys­
iological theory together with workplace
observations to help clarify how workers,
engineers, health and safety specialists,
and management can work together to
reduce low back disability on the job. The
pragmatic and readable style of Working
With Backache makes it a useful resource
for people with chronic back problems by
showing them what types of motions and
postures to avoid and how they can reduce
the opportunities for discomfort through
work patterri-adjustments and work design
both at home arid on the job.

PERINTON PRESS
POST OFICE BOX 1105
FAIRPORT, NEWYORK 14450
U.S.A.

ISBN 0-931157-01-3

�</text>
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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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                  <text>University at Buffalo. Department of Industrial and Systems Engineering.</text>
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                  <text>IN COPYRIGHT - EDUCATIONAL USE PERMITTED &#13;
&#13;
This Item is protected by copyright and/or related rights. You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. In addition, no permission is required from the rights-holder(s) for educational uses. For other uses, you need to obtain permission from the rights-holder(s). http://rightsstatements.org/vocab/InC-EDU/1.0/  </text>
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                <text>A book written by Dr. Rodgers that provides a practical approach to employee training, workplace design and job design to reduce low back pain.  </text>
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                <text>1905-06-06</text>
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                    <text>Dr. Rodgers provided trainings internationally. The following pages are a compilation of cover pages,
syllabi, and schedules for several trainings she provided from 1984 to 2005 which are listed below.

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January 1984: Repetitive Motions, Total Work Load and Temperature Stress. Training Seminar in
Occupational Ergonomics for the United States Post Office
August 20-22, 1984: 3-Day Training Program in Ergonomics/Human Factors. Rochester Products
Engineers.
August 1984: Ergonomics Training Course for Rochester Products, GMC.
September 20, 1984: 2-Hour Ergonomics Awareness Course. Central Engineering, Mobil Chemical
Films Division.
September 27, 1984: 4-Hour Awareness Course in Human Factors/Ergonomics. Oldsmobile Engine
Plant, Lansing, Michigan
September 28, 1984: 8-Hour Engineers’ Course in Human Factors/Ergonomics. Oldsmobile Engine
Plant.
September 1984: 3-Day Training Program for In-Plant Ergonomics/Human Factors Team at General
Motors Assembly Plants
October 9-11, 1984: 3-Day Human Factors Training Course for Fairfax Assembly Plant, GMC
November 27-29, 1984: Human Factors Engineering at General Motors Corporation, BuickOldsmobile-Cadillac Group
February 4-6, 1985: 3-Day Human Factors Training Course for the Chevrolet Engine Assembly Plant,
GMC.
May 28-30, 1985: 3-Day Human Factors Training Course. General Motors Corporation, Oklahoma
City Assembly Plant.
July 1985: Ergonomics Training Course. Ergonomics Committee, Delco Moraine
July 8-9, 1985: 2-Day Ergonomics Training Program. Delco Moraine Ergonomics Committee
July/August 1985: Ergonomics Training Course. Designers, Engineers, Tooling, Materials, Delco
Moraine
July/August 1985:1-Day Ergonomics Awareness Program. Delco Moraine First-Line Supervisors,
Health, Safety, and Placement.
October 9-11, 1985: The Ergonomics of Manufacturing Systems Design Ergonomics Training Course.
B-O-C Industrial Engineering
October 23-25, 1985: 3-Day Ergonomics Training Program. General Motors Corporation, C-P-C
Pontiac Assembly Plant.
November 12, 1985: Bausch and Lomb Ergonomics Awareness Seminar
February 4-6, 1986: 3-Day Ergonomics/Human Factors Engineering Training Program. General
Motors Lordstown Fabrication Plant.
October 1-2, 1986: Ergonomic Principles in New Design. BOC Lake Orion Assembly Plant, GMC.
October 3, 1986: Ergonomics Awareness Course. B.O.C. Orion Assembly Plant, GMC.
October 29-31, 1986: 3-Day Ergonomics Training Course. C.P.C Van Nuys Assembly Plant
November 1986: Meeting and Presentation Skills- 2 Day Training Program. GM/UAW Joint Training
Committee.
December 1986: Ergonomics, A Five Day Training Program. GM/UAW Training Committee C.P.C. Van
Nuys Assembly Plant.

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January and February 1987: 3-Day Ergonomics Training Course. B O C Lansing Operations Project on
Disability Management and Workers’ Compensation Cost Control
April 23-24, 1987: Reducing Work Injuries and Illness Through Ergonomics, 2-Day Ergonomics
Course. University of Iowa Physical Therapy Programs and College of Nursing.
August 4-6, 1987: Ergonomics Training Course. St. Mary’s Goodyear
August 4-6, 1987: 3-Day Ergonomics Training Program. Goodyear Tire and Rubber Company, St.
Mary’s, Ohio.
November 16-18, 1987: 3-Day Ergonomics Training Course. B O C Lansing Operations Project on
Disability Management and Workers’ Compensation Cost Control.
December 4, 1987: Ergonomics Awareness and Problem Solving Course for Northeast Packaging,
Plastics Packaging Division, Mobil Chemical Co.
January to March 1988: Goodyear Tire and Rubber Company Ergonomics Training General Products
and Textile Divisions
March 11, 1988: AIIE Chapter Meeting
June 21, 1988: Ergonomics- Practical Approaches for Reducing Occupational Illness, Injury and
Disability While Improving Quality Performance.
July 18-21, 1988: Ergonomics Training Course. The Goodyear Tire and Rubber Company, Asia/Pacific
Regions. Singapore.
September 22-25, 1988: Industrial Medicine – An Introductory Course for Therapists. Meeting
Planners, Inc.
September 26-29, 1988: 4-Day Ergonomics Training Course. Delco Products Rochester Division
General Motors Corporation
October 11, 1988: 1-Day Ergonomics Awareness and Problem Solving Course. Mobil Macedon
Design Products.
October 21, 1988: Postural Demands, Workplace and Equipment Design. Work Re-Entry Program,
University of Rochester.
October 27, 1988: Ergonomic Job Analysis Techniques, a 4-Hour Training Course for Members of the
St. Mary’s Medical Center Workers’ Evaluation &amp; Rehabilitation Center Staff.
October 27, 1988: Ergonomics in the Workplace “Higher Productivity Through Job Design”. A
RAMAC/SMMC Seminar for St. Mary’s Medical Center.
August 3, 1988: Ergonomic Guidelines for Manual Handling Tasks Seminar and Problem Solving
Workshop.
November 8-10, 1988: 3-Day Ergonomics Training Course. Health and Environment Laboratories,
Eastman Kodak Company.
November 21, 1988: Ergonomics-Prevention of Occupational Overexertion Injuries. Center for
Occupational Rehabilitation and Ergonomics, University of Rochester Medical Center.
November 22, 1988: Ergonomics in Dietary Jobs. Dietetics Department, University of Rochester
Medical Center.
December 1988: Ergonomics Awareness Course. Eastman Kodak Company, Colorado Division.
December 14-15, 1988: 2-Day Ergonomics Training Course for Central Engineering Based on the
Pigment Weigh Room and Banbury Loading Area Designs for the Napanee Plant. Goodyear Tire and
Rubber Company.
December 27, 1988: Occupational Rehabilitation and Ergonomics Clinic Seminars, Total Work Load
and Aerobic Capacity Evaluations. University of Rochester Medical Center.

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January 5, 1989: Problem Solving with Job Examples for Total Job Demands. Seminar for
Occupational Rehabilitation and Ergonomics Team, University of Rochester Medicine.
January 10-12, 1989: 3-Day Ergonomics Training Course. Eastman Chemicals Division.
January 30-February 1, 1989: 3-Day Ergonomics Training Course. General Electric Bridgeport.
February 9, 1989: Applied Ergonomics from the Industrial Perspective. Presentation to the
Organization Resources Counselors Meeting.
March 9, 1989: Ergonomics Awareness Course. International Paper Company.
March 30, 1989: Ergonomics Awareness Course: Amoco Corporation.
April 3-7 and 26-28, 1989: Ergonomic Training, Work Smarter Not Harder, an 8-Day Ergonomics
Training Program. BOC General Motors Plant.
April 17-20, 1989: 4-Day Ergonomics Training Course. Eastman Kodak Company.
June 1, 1989: 4-Hour Ergonomics Awareness Seminar. Supervisory, Support, and Manufacturing
Engineers at GE’s Erie Transportation Systems.
June 14-15, 1989: Ergonomics Training Course for Engineering Staff. International Paper Corporate
Engineering.
July 25-25, 1989: Ergonomics Update and Awareness Training. Lansing Body Plant of General
Motors Corporation.
September 16, 1989: Overexertion Injury Risk Factors
September 30, 1989: Basic Schedule for 2-Day Ergonomics Course
October 4-6, 1989: 3-Day Ergonomics Training Course. Goodyear Hose and Belt Plant.
November 14, 1989: One-Day Ergonomics Awareness Course for Engineers. DuPont Fibers Plants.
November 20-21, 1989: 1.5 Day Ergonomics Training Course. Xerox Corporation.
January 1990: Ergonomic Awareness Training. 911 Emergency Communications Center Employees
January 11-12, 1990: 2-Day Ergonomics Training Course. General Electric Medical Systems
Engineers.
February 13-15, 1990: 3-Day Ergonomics Training Based on Topeka’s Earthmover Band Building
Operation. Central Engineering and Topeka Plant Personnel, The Goodyear Tire and Rubber
Company.
March 7, 1990: 4-Hour Ergonomics Awareness and Problem Solving Session. GE Transportation
Systems Supervisory and Production Personnel
March 8, 1990: Ergonomics Design Guidelines and Their Applications, a 4-Hour Seminar. GE
Transportation Systems.
March 26-29, 1990: 4-Day Ergonomics Training Course. Amoco Foam Plants.
April 8-9, 1990: Ergonomics and Occupational Health, a 1.5 Day Training Course. General Electric
Occupational Health Nurses and Human Relations Managers.
April 9-11, 1990: 1990 General Electric Occupational Nurse Education Seminar.
May 22-25 and September 25-28, 1990: 4-Day Ergonomic Training Course. Goodyear Tire and
Rubber Company Plants.
June 11-13, 1990: 1990 General Electric Occupational Nurse Education Seminar
June 13-15, 1990: 3-Day Ergonomics Training Program. General Electric Aircraft Engine.
June 18-22, 1990: 4-Day Ergonomics Training Course Based on New Design Problems. Central
Engineering Personnel.
June 22, 1990: Ergonomics Awareness. Goodyear Luxembourg Plant Personnel.
July 10-13, 1990: Ergonomics Training Course. John Deere Waterloo Works.

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July 23, 1990: Ergonomics Awareness. Rohm and Haas.
July 20, 1990: 1-Hour Ergonomics Awareness Presentation. Midwest Electronics Products Staff.
September 10-11, 1990: Ergonomics and Occupational Health, a 1.5 Day Training Course. General
Electric Occupational Health Nurses and Human Relations Managers.
October 15-17, 1990: Ergonomics Awareness Course for Supervisors and Engineers. John Deer
Harvester Works.
October 18-19, 1990: Ergonomics Training Course for Trainers. John Deere Harvester Works.
November 6-9, 1990: 4-Day Ergonomics Training Program. General Electric Motors Plants.
November 15, 1990: Ergonomic Approaches to Managing Cumulative Trauma Injuries in the
Workplace. Owens Corning Fiberglass Safety Managers.
January 11, 1991: 4-Hour Ergonomics Awareness Course. GE Aerospace.
January 11, 1991: 1.5 Day Ergonomics Training Course
January 22-25, 1991: 1.5 Day Ergonomics Course. John Deere Waterloo Works.
January 25, 1991: Ergonomic/Human Factors Design of Controls and Displays, 2-Hour Awareness
Course. John Deer Engineers.
March 26-28, 1991: 3-Day Ergonomics Course. GE Appliances Louisville.
April 4-5, 1991: Problem Solving: Using Ergonomics and Physiology for Lifting Tasks
April 16-19, 1991: 3.5 Day Ergonomics Training Course. Amoco Foam Products.
April 22-24, 1991: 2-Day Ergonomics Course. GE Aerospace
April 29 – 30, May 1 – 2, 1991: 2 Day Ergonomics Training Course. General Electric Medical Systems.
May 6, 1991: Occupational Medicine Seminar for Supervisors/Managers. City of Rochester Bureau
of Employee Relations/Employee Safety.
May 7-8, 1991: 2-Day Ergonomics Training Course. Photochemicals, Polymer, and Recovery
Departments
May 30, 1991: Ergonomics Awareness Training. Astro-Valcour Inc.
July 1, 1991: 1.5 Hour Ergonomics Awareness Course for Teams. GE Hooksett Aircraft Engine Plant.
July 9, 1991: Ergonomics Coordinating Committee Training. GE Aircraft Engine Plants.
July 9-12, 1991: Ergonomics Awareness for Supervisors. GE Aircraft Engine Plants.
September 3-6, 1991: Ergonomics Training Program. General Electric Aircraft Engine Plants.
September 10-12, 1991: 3-Day Ergonomics Training Course for GE Appliances, Louisville.
September 3-6, 1991: 3.5 Day Ergonomics Training Program. General Electric Aircraft Engine Plants.
September 17-20, 1991: 3.5 Day Ergonomics Training Course. Amoco Chemical Plants
October 3-6, 1991: Applied Ergonomics: Controlling Overexertion Injuries at Work
October 28-30, 30-November 1, 1991: 2-Day Ergonomics Course for Engineers. Bloomington,
Indiana General Electric Appliance Plant.
November 5-8, 1991: 4-Day Ergonomics Training Course. Eastman Kodak Company.
November 25, 1991: 1 Day Ergonomics Seminar for Managers and Engineers. Sara Lee Meatcutting
Plants.
December 3, 1991: Ergonomics Awareness Seminar. Vermont Employers and VOSHA
January 27-28, 1992: 3-Hour Ergonomic Awareness Session for People on the Ham Bone Lines.
February 10-13, 1992: 3.5 Day Ergonomics Training Course. GE Appliances Dishwasher Plant.
March 1, 1992: Regulatory Agencies: Standards that Impact Industry and Healthcare. Polinsky
Advantage.

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March 1, 1992: Job Analysis and Placement – The Ergonomics Viewpoint Lecture/Problem Solving.
Polinsky Advantage.
March 12, 1992: Ergonomic Job Analyses and Design Guidelines. Astro Valcour.
March 31, 1992
April 6-8, 1992: 2-Hour Ergonomic Awareness Session for Supervisors, Planners and Engineers.
General Electric’s Dishwasher Plant.
April 7, 1992: 4-Hour Ergonomics Training for Departmental Teams. GE Appliances.
April 8-9, 1992: 6-Hour Ergonomics Course for Engineers. General Electric Appliances.
April 14-16, 1992: 3-Day Ergonomics Training Course. Amoco of Canada Fabrics and Fibers Plants.
April 20-21, 1992: Resource Manual for the Ergonomics Core Team. General Electric Aircraft Engine
Plants.
May 4-7, 1992: 4-Day Ergonomics Training Course for General Electric Aircraft Engine Plants
June 1-4, 1992: 4-Day Ergonomics Training Program. GE Appliances Plant.
June 10, 1992: 1-Day Seminar on Applied Ergonomics. Clients of The Therapy Source.
September 30, 1992: 1-Day Ergonomics Seminar. VA Medical Center.
October 1992 – proposed schedule for March
November 23-24, 1992: Ergonomics – 2-Day Seminar on Practical and Cost-Effective Approaches to
Improve Health, Safety and Performance at Work.
December 11, 1992: Ergonomics and the ADA. Riccardi and Burton Physical Therapy, P.C.
January 19-21, 1993: 3-Day Ergonomics Courses for Engineers and Plant Production Specialists.
Goodyear Tire and Rubber Company.
March 4, 1993: Ergonomics and Safety. Harris Corporation Safety Committee.
Winter 1993: Ergonomic Approaches to Improve Working Comfort in OEC.
April 5, 1993: Ergonomic Workplace Analysis. Seminar for Rochester Council on
May 10-11, 1993: 2-Day Ergonomics Team Training Course. Optics Center of Bausch and Lomb.
June 1993: 2-Day Ergonomics Training Course. GE Plastics Mt Vernon Plant
August 2, 1993: Ergonomics Awareness. Mack Molding Company.
August 26-27, 1993: Ergonomics Problem Solving. GE Transportation Teams.
September 20-22, 1993: Designing for People, 2.5 Day Engineers’ Training Course in Ergonomics.
Amoco Foam Products Technical Center.
November 18-19, 1993: Ergonomic Workplace Analysis, Ergonomic Refresher Course. Amoco
Fabrics and Fibers.
January 4-7, 1994: 3.5 Day Ergonomics Training Course. GE Aircraft Engine Plant.
March 24-26, 1994: Ergonomics Problem Solving Course. SmithKline Beecham, Cidra, Puerto Rico.
April 6, 1994: Office Ergonomics Training Session. ARCO Chemical Beaver Valley Plant.
May 3, 1994: Office Ergonomics Training Session. City of Rochester.
May 4, 1993: 1-Day Ergonomics Course for Engineers. SmithKline Beecham Clinical Laboratories.
July 19-21, 1994: Ergonomics Course. SmithKline Beecham Clinical Labs.
October 18-21, 1994: Ergonomics Training Course. General Electric Aircraft Engines.
October 24-26, 1994: 2.5 Day Engineers’ Training Course in Ergonomics. Amoco Foam Products
Technical Center.
October 27, 1994: Ergonomics Team Training and Problem Solving. Amoco Foam Products.
November 15-17, 1994: Ergonomic Training. SmithKline Beecham Clinical Labs.
November 29-30: 2-Day Ergonomics Training Course. Amoco Fabrics and Fibers Ergonomics Team.

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o
o
o
o
o
o
o
o
o
o

o
o
o
o

December 9, 1994: Ergonomic Job Analysis Technique Review Fatigue Model Training. Xerox
Ergonomics Team Members and Engineers.
March 13, 1995: Office Ergonomics Training Session. Rochester Police Department.
May 10-11, 1995: 2.5 Day Ergonomics Training. GE Aircraft Engines.
May 24-26, 1995: 3 Day Ergonomics Team Training Course. SmithKline Beecham Clinical Lab.
June 12, 13, 15, 1995: Ergonomics Training Course. Thomson Professional Publishing Ergonomics
Teams.
November 3, 1995: Ergonomics and the Computer Workplace. Amoco Corporation Personnel.
December 7-8, 1995: Ergonomic Principles for Design, a 2-Day Course. Engineers at Bausch and
Lomb Contact Lens Division.
June 1997: Ergonomics Training and Awareness Courses.
July 28-August 1, 1997: Entrenamiento En Ergonomia. SmithKline Beecham Argentina.
August 19, 1997: Ergonomics Training for New Employees. Office of Emergency Communications.
September 1997: Applied Ergonomics: An Evidence Based Approach. Professional Training
Seminars.
September 30, 1997: A Guide to the Understanding of Work-Related Musculoskeletal Discomfort,
Illness, and Injury in Repetitive Work. General Electric Aircraft Engines.
December 1997: Ergonomics Training for New Employees. Office of Emergency Communications.
June 18, 1998: Ergonomics Training for New Employees. Office of Emergency Communications.
July 1998: Ergonomic Job Analysis and Problem Solving Review Course.
July 20-23, 1998: Ergonomics Team Training. General Electric Aircraft Engines.
February 9 and 16, April 20 and 27, 1999: Reducing Accidents Through Ergonomics. City of
Rochester.
March 18-19, 1999: 2-Day Ergonomics Training Course for Engineers. USCS, IBS, Cabledata.
May 4-6, 1999: Ergonomics Problem Solving Course. Cal/OSHA.
May 18 and 25, 1999: Reducing Accidents Through Ergonomics. City of Rochester Training Program.
November 1999: Treinamento de Ergonomia para. GE Celme e GE Varig.
April 13, 2000: Department Wellness Program. City of Rochester Parks Department.
June 6-9, 2000: Ergonomics Team Training Course. GE Superabrasives.
October 9-13, 2000: Ergonomics Team Training Course. GEAE Evendale.
October 13, 2000: Office Ergonomics – Evaluating Workplaces. GEAE Evendale.
February 1-2, 2001: 2-Day Ergonomics Team Training Course. GEES Miami Power Systems.
March 2001: Ergonomics Job Analysis and Applications in the Field – A Course for Loss Control
Specialists and Others. California State Compensation Insurance Fund.
February 19, 2003: Ergonomics Seminar on Muscular Fatigue Evaluation and Problem Solving to
Develop Strategies to Decrease Risk of Occupational MSDs. Lawrence Livermore National
Laboratory.
September 16-17, 2003: Ergonomics Training Course for Health and Safety Consultants. University
of Alabama at Tuscaloosa College of Continuing Studies.
February 18 and March 10, 2005: Ergonomics Awareness Course. City of Rochester.
May 17, 2005: Follow-Up Ergonomics Training and Awareness. B.G. Sulzle.
September 26, 2005: Ergonomics Awareness for Ne Emergency Communications Specialists.
Emergency Communications Department.

�Repetitive Motions, Total Work Load, and Temperature Stress
Training Seminar in Occupational Ergonomics for the
United States Post Office
January, 198'4
Suzanne H. Rodgers, Ph.D.
Dept. of Industrial Engineering
State Univ. of N.Y. at Buffalo

Table of Contents
Pages

\

2-7

I. Repetitive Motions
Grip Type and Strength
Static Load and Endurance
Grip Span and Wrist Angle Effects
Gloves Effect

3-5
6-7
7

II. Total Work Load
work Load and Endurance
Demands of Occupational Tasks

8-13
8-12
13

III. Temperature Stress
Heat Balance
Thermal Comfort
Windchill

14-18
15
16-17
18

2

�/~

)

3-Day Training Program in Ergonomics/Human Factors
For Rochester Products Engineers - August 20-22, 1984
Outline
DAY 1:

Industrial Ergonomics - General Background Material

7:30 - 9:00 AM
9:00 -

('\,

9:30 AM

Slide Talk:

Overview of Ergonomics - Scope, Value

Discussion: How does ergonomics relate to other
company units and service groups? When should
you "plug in" ergonomics in the design of a new
facility? What sources of information are available in an existing plant to help identify potential ergonomics problems?

10:00 - 11:00 AM

Slide Talk and Discussion:

11:00 - 11:30 AM

Case Studies on Who to Design For

12:30 - 1:45 PM

~-)

Who Do We Design For?

Slide Talk and Demonstrations: People's Behaviors Psychological and Physiological

1:45 - 2:45 PM

Discussion: What are the implications of these
behaviors for the design of jobs and workplaces?
What are the implications of these behaviors on
productivity?

3:15 - 4:30 PM

Slide Talk and Demonstrations: Techniques for
for Studying Jobs or Surveying Workplaces

Homework Assignment: Spend at least one hour observing
someone at work. Analyze the job demands, postures,
patterns of work; interview {if possible) the person
to learn the subjective difficulty of specific tasks.

DAY 2:

Workplace and Equipment Design

7:30 - 9:00 AM

Slide Talk and Problem Solving:
Clearances, and Layout

Heights, Reaches,

�9:00 -

9:30 AM

Discussion: How does workplace and equipment
design influence productivity?

10:00 - 10:30 AM

Seating; Visual

Slide Talk and Demonstration:
Comfort

10:30 - 11:30 noon

Illustrated Lecture: Environmental Factors Noise, Vibration, Lighting, Temperature

12:30 -

2:00 PM

Slide Talk: Information Transfer, Person-toPerson (Signs, Displays), Person-to-Machine
(Controls, Keyboards), Product-to-Person
(Inspection)

2:00 -

2:30 PM

Discussion: What workplace factors increase the
potential for human error or information overload to occur?

3:00 -

3:45 PM

Slide Talk and Demonstration: Design and
Selection of Hand Tools - Grasp, Wrist Motions

3:45 -

4:30 PM

Problem Solving Session: Use of Anthropometric
and Strength Data in the Design or Evaluation
of Industrial Workplaces or Equipment.

DAY 3:

Job Design

7:30 -

9:00 AM

Slide Talk:
Evaluation

9:00 -

9:30 AM

Discussion: Is there a relationship between low
back pain and the weight and size of an object
being handled?

10:00 - 10:30 AM

Case Studies:
Guidelines

10:30 - 11:30 noon

12:30 - 1:30 PM
1:30 -

2:00 PM

2:00 - 2:30 PM

Manual Handling Task Design and

Using the NIOSH Manual Lifting

Slide Talk and Demonstration:
Motions Tasks

Slide Talk and Demonstration:
Pressure
Illustrated Lecture:

Repetitive

Paced Work/Time

Shift Work and Overtime

Discussion: What factors determine acceptable
workloads on overtime or late night shift schedules?

3'

�"/:t

\

3:00 - 3:30 PM

Review of GM Resource People and Materials
Available to Engineers

3:30 - 4:30 PM

Discussion:

How do you cost justify plant ergo-

arnica studies or initiate involvement in
workplace, equipment, or job design?

;

6/16/84 SHR

~nitial

�ERGONOMICS TRAINING COURSE FOR ROCHESTER PRODUCTS, GMC

Course Outline and Syllabus
August, 1984

The material in this syllabus is for use within Rochester
Products, GMC.
Rights of reproduction of unpublished
material must be obtained from Dr. Rodgers.
The other
sources are indicated at the end of the syllabus.

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

I
---./

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y.14622

�Oldsmobile Engine Plant, Lansing, Michigan
4-Hour Awareness Course in Human Factors/Ergonomics
September 27, 1984

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

The material on pages 2 and 5-8 is reproduced courtesy
of Eastman Kodak Company from Ergonomic Design for People
at Work, Volume 1. Rights to reproduce the unpublished
material in this handout must be obtained from Dr. Rodgers.

'&gt;

�Oldsmobile Engine Plant, Lansing, Michigan
8-Hour Engineers' Course in Human Factors/Ergonomics
September 28, 1984
Syllabus

/

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

The material on pages 7, 9-13, 43-44, and 50-51 is reproduced courtesy of Eastman Kodak Company from Ergonomic Design for
People at Work, Volume 1. The material on pages 6, 32-35, and
45-46 has been reproduced from Ergonomics: An Approach to Productivity and Effectiveness prepared by the GM Asembly Division Centra! Office Industrial Engineering Department in 1983. Rights
to reproduce other unpublished material in this syllabus must be
obtained from Dr. Rodgers.

__./

\,

�3-Day Training Program for In-Plant Ergonomics/Human Factors
Team at General Motors Assembly Plants
Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics/Human Factors
Outline
DAY 1:

General Background Material, Hand Tools, Repetitive
t-1otions

7:00 - 7:30

AM

Slide Talk: Overview of Ergonomics - Scope, Value

7:30 - 8:30

AM

Slide Talk and Discussion:

8:45- 9:30

AM

Problems on Who Do We Design For?

9:30 - 10:15 AM

Who Do We Design For?

Slide Talk and Demonstrations: People's Behaviors - Psychological and Physiological

10:30 - 11:00 AM

Slide Talk:
Person

Information Transfer- Person-to-

11:00 - 11:45 AM

Lunch

11:45 - 12:45 PM

Repetitive Motions Problems

1:00 - 2:00

PM

Hand Tool Design

2:15 - 3:45

PM

Problems in Hand Tool Design

Homework Assignment: Spend at least one hour ,observing
someone at work. Analyze the job demands, postures,
patterns of work; interview (if possible) the person
to learn the subjective difficulty of specific tasks.

DAY 2:

Workplace and Equipment Design, Environment, Inspection

7:00 - 8:30AM

Slide Talk and Problem Solving:
Clearances, and Layout

Heights, Reaches

J.

�8:45 - 9:15 AM
9:15 - 10:00 AM

Slide Talk and Demonstration:
Patterns of work

Static Loading and

Equipment Design- Controls and Displays,
CRT workplaces

10:15 - 11:00 AM

Workplace and Equipment Design Evaluations

11:00 - 11:45 AM

Lunch

11:45 - 12:15 PM

Problem Identification

12:15 - 1:45

PM

Problem Discussion

2:00 - 2:30

PM

Environment -Lighting, Noise, Temperature

2:30 - 3:00

PM

Inspection

3:15 - 3:45

PM

Problems in workplace Design

DAY 3:

Job Design

7:00 - 7:45 AM

Slide Talk: Low Back Pain - What It Is, What It
Means In the Workplace

8:00 -9:15AM

Slide Talk:
Evaluation

9:30- 11:00 AM Case Studies:
Guidelines
11:00 - 11:45 AM

Manual Handling Task Design and
Using the NIOSH Manual Lifting

Lunch

11:45 - 12:45 PM Slide Talk and Demonstration:
Pressure

Paced Work/Time

1:00 - 2:15 PM

Illustrated Lecture: Total Work Load- How
Much Is Too Much? Includes Shift Work and
Overtime.

2:30 - 3:15PM

Survey Techniques

3:15 -3:45PM

Review of GM Resource People and Materials
Available to Trainees

9/29/84 s:HR

3,

�3-Day Ergonomics/Human Factors Training Course
Table of Contents
Page

Topic
Table of Contents
Course Outline
Course Purpose and Goals

1
2
4

Day 1
Overview of Ergonomics/Human Factors
Who Do We Design For?
People's Behaviors - Psychological and Physiological
Information Transfer - Signs, Codes, Structure
Repetitive Motions Problems
Hand Tool Design
Problem in Hand Tool Design
Homework Assignment - Observing a Person at Work

5

8
17
24
34
42
46
49

Day 2
Heights, Reaches, Clearances, and Layout
Static Loading and Patterns of work
Equipment Design - Controls and Displays
Problem Identification
Environment
Inspection
Problems in Workplace Design
Anthropometric Data

51
56

60
66
69
74
75

80

Day 3
Low Back Pain
Manual Materials Handling
NIOSH Manual Lifting Guidelines - Case Studies
Paced Work/Time Pressure
Total Work Load, Shift Work, Overtime

84
91
101
108
113

Resources
Survey Techniques
Checklist for Ergonomics Input to New Design
Partial List of GM Resource Materials
Bibliography
Topics in Ergonomic Design for People at Work,
Volume 1
9/29/84

121
135
140
141
148

SHR

Jr

�3-DAY HUMAN FACTORS TRAINING COURSE FOR FAIRFAX ASSEMBLY PLANT,

GMC

Course Outline and Syllabus
October 9-11, 1984

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
''HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS

2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14S22

The material on pages 11, 19, 20, 26, 54, 61, 62, 80-83,
118 and 126-131 of this syllabus is reproduced courtesy of
Eastman Kodak Company from Ergonomic Design for People at
Work, Volume 1. The material on pages 10, 41, 43-45, 59,
73, 94, 95, and 144 has been taken from Ergonomics: An
Approach to Productivity and Effectiveness, published by ·
the GM Assembly Division's IE Central Office.
Rights
to reproduce the other unpublished materials in this
syllabus must be obtained from Dr. Rodgers.

\

.

\

'J

.

�3-Day Ergonomics/Human Factors Training Course
Table of Contents
Page

Topic
Table of Contents
Course Outline
Course Purpose and Goals

1
2
4

Day 1
Overview of Ergonomics/Human Factors
Who Do We Design For?
People's Behaviors - Psychological and Physiological
Information Transfer - Signs, Codes, Structure
Repetitive Motions Problems
Hand Tool Design
Problem in Hand Tool Design
Homework Assignment - Observing a Person at Work

5
8

17
24
34
42
46
49

Day 2
Heights, Reaches, Clearances, and Layout
Static Loading and Patterns of Work
Equipment Design - Controls and Displays
Problem Identification
Environment
Inspection
Problems in Workplace Design
Anthropometric Data

51
56
60
66
69
74
75
80

Day 3
Low Back Pain
Manual Materials Handling
NIOSH Manual Lifting Guidelines - Case Studies
Paced Work/Time Pressure
Total Work Load, Shift Work, Overtime

84
91
101
108
113

Resources
Survey Techniques
Checklist for Ergonomics Input to New Design
Partial List of GM Resource Materials
Bibliography
Topics in Ergonomic Design for People at Work,
Volume 1
~

9/29/84

121
135
140
141
148

SHR

/ r

�~
~

[!J
.

·-

Gene('al Motors Corporatign

.

Bui~·Otd•motlile·Cadlllt~ Qroup

-

HUMAN
FACTORS
ENGINEERING
Suzanne

H.

Rodgers,

PhD.

November 27-29, 1984

�3-Day Ergonomics/Human Factors Training Course
Table of Contents
Page

Topic
Table of Contents
Course Outline
Course Purpose and Goals

1
2
4

Day 1
Overview of Ergonomics/Human Factors
Who Do We Design For?
People's Behaviors- Psychological and Physiological
Information Transfer - Signs, Codes, Structure
Repetitive Motions Problems
Hand Tool Design
Problem in Hand Tool Design
Observing a Person at Work

5
8
17
24
34
42
46
49

Day 2
Heights, Reaches, Clearances, and Layout
Static Loading and Pat.terns of Work
Equipment Design - Controls and Displays
Problem Identification
Environment
Inspection
Problems in Workplace Design
Anthropometric Data

51
56

60
66
69
74

75
80

Day 3
Low Back Pain
Manual Materials Handling
NIOSH Manual Lifting Guidelines - Case Studies
Paced Work
Total. Work Load

84

91
101
108
113

Resources
Survey Techniques
Checklist for Ergonomics Input. to New Design
Partial List of GM Resource Materials
Bibliography
Topics in Ergonomic Design for People at Work,
Volume 1
9/29/84

SHR

121
135
140
141

148

�i\
3-DAY HUMAN FACTORS TRAINING COURSE FOR THE CHEVROLET
ENGINE ASSEMBLY PLANT, GMC

Course Outline and Syllabus
February 4-6, 1985

/------\
. \.__)

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS

2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN

J. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

The material on pages 11, 19, 20, 26, 54, 61, 62, 80-83,
118 and 126-131 of this syllabus is reproduced courtesy of
Eastman Kodak Company from Ergonomic Design for People at
Work, Volume 1. The material on pages 10, 41, 43-45, 59,
73, 94, 95, and 144 has been taken from Ergonomics: An
Approach to Productivity and Effectiveness, published by
the GM Assembly Division's IE Central Office. Rights
to reproduce the other unpublished materials in this
syllabus must be obtained from Dr. Rodgers.

�~

J

3-DAY HUMAN FACTORS TRAINING COURSE
GENERAL MOTORS CORPORATION, OKLAHOMA CITY ASSEMBLY PLANT

Course Outline and Syllabus
May 28-30, 1985

()
'._/

Suzanne H. Rodgers, Ph.D

,

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

rhe material on pages 11, 19, 20, 26, 54, 61, 62, 80-81,
118 and 126-131 of this syllabus is reproduced courtesy of
Eastman Kodak Company from Ergonomic Design for People at
~ork, Volume 1.
The material on pages 10, 41, 43-45, 59,
73, 94, 95, and 144 has been taken from Ergonomics:
An
Approach to Productivity and Effectiveness, published by
the GM Assembly Division's IE Central Office. Riqhts
to reproduce the other unpublished materials in this
syllabus must be obtained from Dr. Rodgers.

�2-Day Ergonomics Training Course
Ergonomics Committee, Delco Moraine
July, 1985
Schedule
Day 1:
8:00AM
8:45
9:15
9:30
10:15
11:00
11:15
12:00
1:00 PM
2:00
2:30
2:45
3:45
4:00
4:30
5:00

Overview of Ergonomics
Who Do We Design For?
Break
Exercise in the Use of Anthropometric Data
Physiological and Psychological Behaviors
Break
Reducing Unnecessary Effort - Static Muscle Work
Lunch
Workplace Design Problem Solving
Reach and Height Interaction
Break
Reducing Unnecessary Effort - Manual Lifting
Break
Information Display
Lighting
End of Session - Evaluation of Day 1

Day 2:
8:00 AM
9:15
9:30
10:30
11:00
11:15
12:00
1:00 PM
2:00
2:30
2:45
3:15
4:00
4:15
4:45
5:00
7/1/85

Providing Control Over the Job - Pace Pressure and
Patterns of Work
Break
Job.Analyses Using Ergonomics Principles
Repetitive Motions Disorders
Break
Tool and Job Design and Repetitive Motions Disorders
Lunch
Learning and Pace Pressure Exercise
Low Back Pain and Work
Break
Return to Work and Placement of People With Low Back
Pain or Repetitive Motions Disorders
Job Analyses Using Ergonomics Principles
Break
Cost-Benefit Approaches to Making Ergonomics Changes
in Existing Workplaces
Resources and the Organization of Ergonomics Programs
in Industry
End of Course - Evaluation of Day 2

SHR

,
J....

�2-Day Ergonomics Training Course - Delco Moraine
Ergonomics Committee
Table of Contents

Syllabus Page

Overview of Ergonomics
Who Do We Design For?
Anthropometric and Strength Data
Guidelines for Using Anthropometric
Data
Problem Solving - Anthropometric Data
Psychological and Physiological
Behaviors

2

EDFPAW Page
3
8

4
5

285, 294

6
8

311
289., 342

9

90, 107, 179

Static Loading and Patterns of Work
Problem Solving - Workplace Design
Heights, Reaches, Clearances
Height and Reach Interaction
Recommended Chair and Accessory
Characteristics

11
14
15
17

342
14
24

18

57

Manual Handling Task Design
Strength and Location
Pull Strength and Strength/Endurance
NIOSH Manual Lifting Guidelines
NIOSH Lifting Formula
Repetitive Lifting Guidelines
Maximum Force Applications

19
22
23
24
27
28
29

Information Transfer - Dispatcher

30

90, 93, 101,
112, 168, 175

Environment - Lighting
Paced Work/Time Pressure

33
36

225' 234

Repetitive Motions Problems
Grip Strength and Factors That
Affect It
Workplace Interventions - Repetitive
Motions Problems
Hand Tool Selection and Design

40

43
44

Low Back Pain
Low Back Pain and Manual Lifting

46
48

Survey Techniques
Equipment for Ergonomics Work

51
53

Cost-Benefit Analysis of Ergonomic
Problem Solutions
Ergonomics Programs in Industry

55
59

41
140

313
320, 333

5

'·

�2-DAY ERGONOMICS TRAINING PROGRAM - DELCO MORAINE

ERGONOMICS COMMITTEE

JULY 8-9, 1985

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

Permission to reproduce unpublished material in this
syllabus must be obtained from s. H. Rodgers.

�----···

\....
2-DAY ERGONOMICS TRAINING PROGRAM - DELCO MORAINE

DESIGNERS, ENGINEERS, TOOLING, MATERIALS

JULY AND AUGUST, 1985

Suzanne H. Rodgers, Ph.o·
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS

2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 5&lt;'4·3587 • 189 HUNTINGTON HILLS • ROCHESTER, N.Y. 1-1622

Permission to reproduce unpublished material in this
syllabus must be obtained from s. H. Rodgers.

�?.-Day Ergonomics Training Course
Designers, Engineers, Tooling, Materials
Delco Moraine, July/August, 1985
Schedule
Day 1:
8:00 AM
8:45
9:15
9:30
10:15
10:45
11:00
11:45
12:00
1:00 PM
2:00
2:30
2:45
3:15
4:00
4:15
5:00

Overview of Ergonomics
Job Analysis - Current Approach
Break
Who Do We Design For?
Exercise in Using Anthropometric Data
Break
Eliminating Unnecessary Work - Static Muscle Work
Height and Reach Interaction
Lunch
Job Analysis - Ergonomic Approach
Repetitive Motions Disorders
Break
Tool Design and Repetitive Motions Disorders
Low Back Pain and Workplace Design
Break
Job Analyses - Working Heights
End of Session - Evaluation Day 1

Day 2:
8:00 AM
9:00
9:45
10:00
10:45
11:00
12:00
1:00 PM
2:30
2:45
3:30
4:00
4:15
5:00
7/1/85

SHR

Factors Affecting Quality - Information Transfer
and Reducing Errors
Lighting and Environmental Factors
Break
Giving Person Control Over the Job - Pace Pressure
and Patterns of Work
Break
Manual Handling and Workload
Lunch
Job Analyses - Manual Handling Tasks
Break
Techniques to Survey the Workplace and Guidelines
for New Design
Cost-Benefit Analyses for Implementation of Ergonomic
Designs
Break
Problem Solving - Selling an Ergonomic Solution to a
Workplace Problem
End of Course - Evaluation Day 2

�2-Day Ergonomics Training Course - Delco Moraine
Designers Course
Table of Contents

Syllabus Page

Overview of Ergonomics

2

Workplace Design Problem
Who Do We Design For?
Anthropometric and Strength Data
Guidelines for Using Anthropometric
Data
Problem Solving - Anthropometric Data

4

EDFPAW Page
3

5

8

6

285,

7
9

311
289, 342

Static Loading and Patterns of work
Heights, Reaches, Clearances
Height and Reach Interaction
Recommended Chair and Accessory
Characteristics

10
13
15

14
24

16

57

Repetitive Motions Problems
Grip Strength and Factors That
Affect It
Workplace Interventions - Repetitive
Motions Problems
Hand Tool Selection and Design

17

20
21

Low Back Pain
Low Back Pain and Manual Lifting
Problem Solving - Workplace Design

23
25
27

Information Control - Dispatcher

28

Environment - Lighting
Paced Work/Time Pressure

31
34

Manual Handling Task Design
Strength and Location
Pull Strength and Strength/Endurance
Static Work Recovery Curves
NIOSH Manual Lifting Guidelines
NIOSH Lifting Formula
Repetitive Lifting Guidelines
Maximum Force Applications
Problem Solving ~ Job Design

38
41
42
43
46
49
50
51
52

Survey Techniques
Ergonomics Checklist for New Design
Cost-Benefit Analysis of Ergonomic
Problem Solutions

53
55

294

18

60

140

90, 93, 101,
112, 168, 175
225, 234

313

�;ff)

ERGONOMICS AWARENESS PROGRAM

DELCO MORAINE

FIRST-LINE SUPERVISORS, HEALTH, SAFETY, AND PLACEMENT

JULY AND AUGUST; 1985

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS ·SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PROOUCT OESIGN
3. HEALTH ANO SAfETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 1&gt;4622

Permission to reproduce unpublished materi~l in this
syllabus must be obtained from S. H. Rodgers.

�1-Day Ergonomics Awareness Course
First Line Supervisors, Health and Safety People, Placement People
Delco Moraine, Summer/Fall, 1985
Schedule
What i~ Ergonomics? Why Do It?
People's Size- Anthropometries
Workplace Design Using Body Size Information
Break
People's Strength and Endurance
Job Design Using Muscle Strength Information
Break
People's Performance Capabilities- Seeing, Understanding
Equipment and Lighting Design Using Performance
Capability Information
Lunch
Working Under Pace Pressure - Simulated Job
Influence of Workplace and Equipment Design on
Performance Under Pace Pressure
Break
Repetitive Motions Disorders and Tool Design
Break
Low Back Pain, Manual Lifting, and Job Placement
Cost Justifying Ergonomics Changes in the workplace
End of Course - Evaluation

8:00 AM
8:30
9:00
9:30
9:45
10:15
10:45
11:00
11:30
12:00
1:00 PM
2:00
2:30
2:45
3:45
4:00
4:45
5:00
7/l/85

SHR

�·~.

\
J
I

THE ERGONOMICS OF MANUFACTURING SYSTEMS DESIGN
ERGONOMICS TRAINING COURSE
B-0-C INDUSTRIAL ENGINEERING
OCTOBER 9 - 11, 1985

PURPOSE:
TO DEVELOP BASIC HUMAN FACTORS ENGINEERING SKILLS AT CENTRAL OFFICE THAT
WILL HELP ENSURE PROJECTS DEVELOPED HERE ARE ERGONOMICALLY SOUND.
TO· INCREASE AWARENESS. AND RECOGNITION OF RESOURC~ P.EOPLE. AND MATERIALS
AVAILABLE TO ASSIST IN ERGONOMIC ASSESSMENT OF C.O. PROJECIS.
.

'

TO EMPHASIZE THE CRITICAL ROLE OF HUMAN FACTORS ENGINEERING IN NEW
TECHNOLOGY AND ROBOTIC SYSTEMS,
TO INCREASE AWARENESS OF OFFICE ERGONOMICS AND ITS ROLE IN PRODUCTIVITY.

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

,.
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�3-DAY ERGONOMICS TRAINING PROGRAM
GENERAL MOTORS CORPORATION,

C-P-C PONTIAC ASSEMBLY PLANT

OCTOBER 23 - 25, 1985

SYLLABUS

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

-.....__/

�3-Day Ergonomics Training Program for General Motors
Assembly Plants- Suzanne H. Rodgers, Ph.D.,
Consultant in Ergonomics/Human Factors
Schedule
Day 1:

Background Material, Human Variability, Repetitive
Motions, and Tool Design

7:30

-

8:00 AM

Introductions, Review of Course Content, Goals

8:00

-

8:30

Overview of Ergonomics/Human Factors Engineering

8:30

-

9:15

Who Do We Design For?

9:15 - 9:30

Anthropometric Data

Break

9:30

-

10:15

Problem Solving Using Anthropometric Data

10:15

-

10:45

Who Do We Design For?
Capacities.

10:45

-

11:15

Information Transfer - Person-to-Person

12:00

Lunch

11:15

Strength and Other

12:00 - 12:30 PM People's Behaviors - Psychological and ,
Physiological
12:30

-

1:15

1:15 - 1:45

-

2:00

Break

2:00

2:30

Hand Tool Design and Repetitive Motions Problems

2:30

-

3:15

Problem Solving: Tools and Workplace Design

3:15

-

3:45

Discussion of Tool Problems, Repetitive Motions
Problems Management

Day 2:
I

Repetitive Motions Problems - Tendonitis,
Carpal Tunnel Syndrome

1:45

3:45 - 4:00

'--_..-/

Grip Strength and Factors Affecting It

Reveiw of P+inciples, Evaluations

workplace and Equipment Design, Environment, Inspection

7:30 - 8:00 AM

Static Loading and Patterns of Work

J

t.

�i,

8:00 - 8:45

Heights, Reaches, and Clearances

8:45 - 9:00

Break

9:00 - 10:00

Problem Solving:

Workplace Design

10:00 - 10:30

Environmental Factors - Lighting and Inspection

10:30 - 11:00

VDT Workplaces, Equipment Design and Human/Robot
Interactions

11:15 - 12:00

Lunch

12:00 - 1:00 PM

Identification of Ergonomics Problems in the Plant

1:00 - 2:00

Discussion of Problems Identified

2:00 - 2:15

Break

2:15 - 3:30

Discussion of Problems Identified

3:30 - 4:00

Review of Principles, Evaluations

Day 3:

Job Design

7:30

-

8:15 AM

Low Back Pain

8:15

-

9:15

Manual Materials Handling

9:15

-

9:30

Break

9:30

-

10:00

Using the NIOSH Manual Lifting Guidelines

10:00

-

11:15

Problem Solving: Manual Materials Handling

11:15

-

12:00

Lunch

12:00

-

1:00 PM

Paced Work - Exercise on Factors Affecting
Quality Performance

1:00

-

1:45

Techniques to Identify Ergonomics Problems

2:00

Break

1:45

.,

2:00

-

3:00

Problem Solving: Job, Environment and Workplace
Design

3:00

-

3:30

Cost/Benefi~

-

4:00

10/15/85

SHR

3:30

Analyses of Ergonomics Problem

Solutions
GM Resources, Evaluations, Summary

LL

�'
\

BAUSCH AND LOMB ERGONOMICS AWARENESS SEMINAR
NOVEMBER 12, 1985

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PROOUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

The material on pages 9-12, 25, 32, and 38-39 in this
syllabus is taken from Ergonomic Design for People at
Work, Volume 1 by the Eastman Kodak Human Factors
Section.
Other materials have been developed by Dr.
Rodgers; permission t9 reproduce that material must
be obtained from her.

�Table of Contents
Section

Page

Table of Contents

1

A. Overview of Ergonomics

2

B. Problem Solving - Workplace Design

4

c.

6
8

Who Do We Design For?

1. Anthropometric Distributions
Anthropometric Data
3. Strength Data
4. Strength vs Location
5. Static Strength vs Duration
2

0

9
13
14
15

D. Exercise Using Anthropometric Data

16

E. Posture and Productivity
1. Static Work
2. Static Work Recovery Curves
3. Workplace Design - Heights and Reaches
4~ Interaction of Height and Reach
5. Seated Workplace Design
6. Characteristics of Chairs and Accessories

17
18
20
23
25
26

F. Environmental Factors
1. General
2. Lighting

28
29
32

G. Factors Affecting Quality Performance
1. Information Transfer
2. Man vs Machine
3. Displays and Controls
4. Time Pressure
5. Fatigue - Total Workload

35
38
39
40
43

H. Problem Solving: Machine Design and Paced Work

47

I. Occupational Injury and Illness Prevention
1. Low Back Pain
2. Manual Materials Handling
3. Relationship Between Low. Back Pain and Weight
Handled
4. NIOSH Lifting Guidelines
5. Tool Design and Repetitive Motions Problems
6. Factors Affecting Grip Strength
7. Jobs Where Repetitive Motions Problems May
Be Seen

48

27

34

49

51
53
55
59
61
63

�J. Resources
1. Costs of Poor Design
2. Engineer's Checklist
3. Bibliography

11/4/85

SHR

64

65
70

�\
3-DAY ERGONOMICS/HUMAN FACTORS ENGINEERING TRAINING PROGRAM
LORDSTOWN FABRICATION PLANT,

GENERAL MOTORS CORPORATION

FEBRUARY 4 - 6, 1986

SYLLABUS

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

\
·~

�Ergonomic Principles in New Design
soc Lake Orion Assembly Plant GMC, October 1 &amp; 2, 1986

~--......._,,

\

)

\

Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics

Topics
Overview of Ergonomics,
Goals of Course

Page Locat1ons
Syllabus EDFPAWI EDFPAWII
3~

5-6,

3-11

2-16

73
8-10
285-312

Who Do We Design For?

7-9 '
12-15

Height and Reach Interaction
in Workplace Design

10-11

20,24,25

Posture and Productivity Static Work

16-20

52-87,
140

Static Work/Recovery Curves

21-24

Stat1c Work Problems

25-27

Information Transfer and Displays

28-37

Problem Solving: Maintenance
Dispatch Job

38

Environmental Factors: Lighting, " 39-42
Noise, Heat

I

13-14

24-29
217-219
218-219

50-52,
90-106,
107-133,
162-178

209-281

220-222

179-197

222-229

Inspection Tasks

43

Job Design and Overexertion
Injuries

44-51

135-151
203-213
266,
338-347.

Design Limit for Forces

52

384

Use of Lifting Gu1de11nes to Reduce 53-62
the Risk for Low Back Pain

337-445

4Q,

�Manual Handling Problem Solving

63

551-554

Repetitive Task Design and Tool
Design to Reduce Carpal Tunnel
and Tendonitis Symptoms

64-68

244-259
545-547

Risk Factors for Repetitive
Motions Problems

69

247-252

Hand Tool Design

70-72

~,

\

)

140-159

Work Pace and Quality Performance 74-78
Survey Techniques and Checklist

79-85

Cost/Benefit Analyses of
Ergonomic Prob 1em Solutions

86-93

Evaluations, Resources

94-97

256

230-243
313-319

98-121

365, 388

559-590

9/23/86 SHR

Yb.

�Ergonomics Awareness Course
B.O.C. Orion Assembly Plant. GMC

October 3, 1986

=-:'11 ·-=

--

IlL:

-

~
~=
---::
=Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN''

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY i'RCGAAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • Fi'OCHESTER, N.Y. 14li22

�Ergonom1cs Awareness Program - B.O.C. Or1on
Assembly Plant, GMC, October 3, 1986

7:00 -8:00AM Why Ergonomics? Concepts and Potential Benefits
8:00 -8:30AM Minimizing Fatiguing Postures- Static Muscle Effort
8:30 - 8:45 AM Break
8:45- 9:15AM Static Work/Recovery Curves- Use in Job Analysis
9:15- 9:45AM Factors Associated With Static Work and Techniques
To Reduce Them
9:45 - 10:30 AM Problem Solving- Postural Fatigue
I 0:30- II :00 AM Keep It Simple- Information Transfer
11:00- 11:45 AM Lunch
11:45- 12:30 PM Problem Solving: Maintenance Dispatch Job
12:30 - 1:00 PM Use Big Muscles for Handling Jobs
I :00 - 1:30 PM Low Back Pain and L1fting

1:30- 2:00PM Repetitive Work
2:00 - 2: 15 PM Break
2:15- 2:45 PM Give People Control of Their Work Patterns
2:45- 3:30 PM Cost Justifying Ergonomic Changes
------------,

'--_/

9/23/86 SHR

�3-Day Ergonomics Training Course
C.P.C Van Nuys Assembly Plant
October 29-31 , 1986

CJ

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

The material in this syllabus is meant to supplement the 2-volume
sourcebook in industrial ergonomics by the Eastman Kodak Human
Factors and Ergonomics Sections~ Ergonomic Design for People at
Work, published by van Nostrand Reinhold. The illustrations on pages
16 1 37 1 and 38 are from these volumes with permission of Kodak. The
material on pages 71 and 28-31 is from Working With Backache by
S.H. Rodgers and published by Perinton Press. The table on page 18
was developed by Dr. Inger Williams. Permission to reproduce other
material in this syllabus must be obtained from Dr. Rodgers.

�MEETING &amp; PRESENT AT ION SKILLS
A Two Day Training Program
Developed for the
GM/UAW JOINT TRAINING COMMITTEE
Van Nuys
by the
lnstttute of Industrial Relations
UCLA

November 1986

f--

~---

'I

\,

_

_/

�ERGONOMICS
A Five-Day Training Program

()

Developed tor the GM/UAW Training Committee
C.P.C. Van Nuys Assembly Plant

by Suzanne H. Rodgers, Ph.D.
Consultant in Ergonomics

December, 1986

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�ERGONOMICS
A Five-Day Training Program

Developed for the GM/UAW Training Committee
C.P.C. Van Nuys Assembly Plant

by Suzanne H. Rodgers, Ph.D.
Consultant in Ergonomics

December, 1986

&amp;::
. ~·=~
=~·-==

--=
-

--

-=

Suzanne, H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
W.ORKPLACE, EQUIPMENT AND PRODUCT DESIGN
'FOALTH AND SAFETY PROGRAMS

1587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�(

8 0 C Lansing Operations Project on
Disability Management and Workers'
Compensation Cost Control

3-Day Ergonomics Training Course

January and February, 1987

Suzanne H. Rodgers, Ph.D.
Inger M. Williams, Ph.D.

=:fla-=
Db:
·=
=
==
-

~=-:;

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�_,
...~t.;""'-~·---.\
I

Schedule for Ergonomics Training- January 27-29, 1987

Day 1:

7:30AM
8:00

8:45
9:00

10:30
11:30

,~,

Introductions/Goals of Course
Workers' Compensation Costs at BOC Lansing
Operations - A Statement of the Concern Sally Carlson
Break
A Review of Low Back Pain and Repetitive Motions
Injuries - How They Develop and What Approaches
Can Be Used to Manage Them.
Class Discussion About "Managing" Overexertion
Injuries
Lunch

;!}''-...___....-·.,_)

12:30 PM
1:15
2:15
2:30
3:15
4:00

Day 2:

7:30AM
8:30AM
9:15AM
9:30AM
10:30 AM
11:30 AM

Exercise on What is Ergonomics?
Identifying Stressors in the Return-to-Work
Process- Inger Williams
Break
Factors That Increase Stress at Work - Physical
Factors, Communication Failures, Lack of Control
Problem Solving: Identifying Ways to Reduce
Stress on a Job
End

Physical Job Stressors - Postures and Static
Work, Height and Reach Interaction
Work/Recovery Needs of Muscles
Break
Problem Solving: Evaluating Jobs With Postural
Stress
Review of Problems and Possible Solutions
Lunch

�12:30 PM
1:45PM
2:45PM
3:00PM
4:00PM

Day 3:

7:30AM
8:30

9:30
9:45
10:45

11:30
12:30 PM
1:15
1:45
2:15
2:30
3:30
3:45
4:00

1/12/87 SHR

Manual Handling Tasks- How to Evaluate Them
Problem Solving: Techniques to Reduce Stress
During Manual Handling Tasks
Break
Environmental Factors That Add to Job Stress and
Ways to Modify Them
End.

Job Control and Job Stress - Puzzle Assembly Task
Demonstration
Factors Influencing Job Control - Work Pacing,
Skills Level, Accountability, Automation,
Complexity, Flexibility in Job Patterns
Break
Techniques to Provide More Control Over Work Class Exercise
Communications and Job Stress - Feedback,
Instructions, Understanding Overexertion Injuries
and Illness, Peer Pressure, Supervisory Style,
Company Policies
Lunch
Problem Solving: Communications and Job Control
Using Accident and Illness Data to Identify
Ergonomics Problems
Cost Justifying Job Design, Workplace or Tooling
Changes in Existing Jobs
Break
Problem Solving: Return-to-Work Evaluations and
Job AcCommodations or Redesign
Summary of Course Highlights
Evaluation of Course
End of Course.

�..

·

··-

'·

'·

....

i

Unjversity of Iowa
Physical Therapy Programs and College of Nursing

2 - Day Ergonomics -Course, April 23-24, 1987

Reducing Work lqjuries and Illness Through Ergonomics

Suzanne H. Rodgers, Ph.D.
lngerM. Williams, Ph.D.

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS·
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON. USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT ANO ·P!\OOUCT DESIGN
3. HEALTH ·AND SAFETY PROGRAMS

(716) 54'4-3587 • 169 HUN;TINGTON HilLS • ROCHESTER, N.Y. •14622

(716) 381-4983

Inger M. Williams, Ph.D.
CONSULTANT IN ERGONOMICS/HUMAN FACTORS

214 WOODlAND ROAD
PtnsFoRo, NEw vdRk 14534

�Ergonomics Training Course - St. Mary's Goodyear
August 4 - 6, 1987 7:30 AM - 4:00 PM
Table of Contents
Starting Page Location
S)lllabus
EDFPAW 1
Topic
i-ii
Schedule
Table of Contents
1
Acknowledgements
3
Introduction and Course Goals
4
Overview of Ergonomics
5
Ergonomics Goals
8
3
Capacities for Work
9
11
Factors That Increase Stress
"
r

The Variability of People
Exercise- Designing for People
Using Anthropometric Data
Postural Demands and Job
Performance
Static Work- Postural Effort
Static Work Recovery Time
Needs
Height and Reach Interactions
Posture and Vision and
Productivity

14
16
17
19
20

8,285,290
8
285

.

52
112' 140 '150

EDFPAW2

2
210,446,496
237
13,446
13

4,142,217
24,217

22
27

20,30

217
218,255

29

17,30,50

223,282

What is Wrong With This Job?
Ergonomic Job Analysis

31
34

Ergonomics and Quality
Puzzle Exercise
Total Work Load, Shift Work,
Overtime
Environmental Factors
Lighting and Visibility
VDT Workplaces
Chair Characteristics
VDTs and Visual Discomfort
Paced Work/Time Pressure

36
38
39
45
48
49
52
53
54

210,276
21 0,242,320
172,225,234,241
28,101 '179
57
28,101,179

223
142
230
1.

�Information Transfer
Displays and Controls
Population Stereotypes Quiz
Job Control and Task
Complexity
Ergonomic Job Analysis
Low Back Pain and Repetitive
Motions Injuries
Risk Factors for Carpal
Tunnel Syndrome
Factors Affecting Grip
Strength
Techniques to Reduce Risk
Factors
Ergonomics Problem Solving
Hand Tool Selection and Design
Ergonomic Job Analysis
Low Back Pain
Risk Factors for Low Back Pain
Manual Materials Handling
Biomechanical Analysis of Lifts
Strength and Location
Maximum Force Applications
Kodak Lifting Guidelines
General Guidelines/Lifting/
Repetitive Work
Ergonomic Job Analysis
Ergonomics and Return to Work
Communications and Job Stress
CosVBenefit Analyses
The Costs of Poor Design
Problem Solving - Cost
Justifying Changes
How to Do An Ergonomics
Survey
Ergonomics Checklist
Ergonomics Equipment.
Bibliography

7187 SHR

57
61
62

162,181
90,107
107

237

64
66

162,181

237

68

135,340

71

151,244

74

151

75
77
79
83

254
"

140

85
90
92
96
97
98
99

15,122,151

135,340
135,340
360
135
135,338
384,446
403

101
102
106
112
113
117

9

119

122
124
130
132

313
313
320
365

98
161,497
534
2.

�Acknowledgements

The illustrations on pages 27, 28, 99, and 100 are used with
permission from Eastman Kodak's Ergonomic Design for People at
Work, Volumes 1 and 2 . The tables and illustrations on pages 52, 86
to 89, and 96 to 98 are from Working With Backache by S. H. Rodgers.
Material on pages 11 to 13, 29 to 30, 48 to 51, 53, and 108 to 112 has
been developed in conjunction with Dr. Inger Williams. All other
material in this syllabus is by Dr. S.H. Rodgers. Permission to
reproduce material from this syllabus must be obtained from her.

3.

�Goodyear Tire and Rubber Company, StMary's, Ohio
3-Day Ergonomics Training Program, August 4-6, 1987

Syllabus

Suzanne H. Rodgers, Ph.D.
Consultant in Ergonomics
169Huntington Hills
Rochester, New York 14622
(716) 544-3587

�Ergonomics Training Course- St. Mary's Goodyear
August 4 • 6, 1987 7:30AM· 4:00PM
Schedule
Tuesday. August 4th: Ergonomics and Productivity
7:30 - 8:00 AM

9:30-9:45

Introductions, Review of Course Goals,
Content
Overview of Ergonomics
Work Capacities and Stress Sensitizers
Human Variability - Who Do We Design
For?
Break

9:45-10:15
10:15-11:00
11 :00 - 11 :30
11:30- 12:00

Posture and Productivity
Static Muscle Work and Recovery Needs
Height and Reach Interaction
Posture, Vision, and Productivity

12:00- 1:00PM

Lunch

1:00- 2:30
2:30-2:45

What Is Wrong With This Job? Problem
Analysis
Break

2:45- 3:15
3:15-4:00

Workplace Design Guidelines
Review Videotaped Jobs from St Mary's

8:00-8:30
8:30-9:00
9:00-9:30

---"".,
" -__ j

Wednesday. August 5th: Ergonomics and Quality Performance.
Repetitive Motions Injuries
7:30-8:00 AM
8:00-9:00
9:00-9:30
9:30-9:45

Ergonomics and Quality Performance
Puzzle Exercise
Total Workload and Hours of Work
Break

9:45-10:15
10:15-10:30

Environmental Factors
Visibility and Quality Performance

·"·'·

�i.
·.\
I

I

10:30 - 11 :00
11:00- 12:00
12:00 - 1:00 PM

VDT Workplace Design
Displays and Controls- Information
Transfer
Lunch

1:45-2:15
2:15-2:30

Problem Solving: Factors Affecting
Quality
Overexertion Injuries - Repetitive Work
Break

2:30-3:00
3:00-4:00

Hand Tool Selection and Design
Problem Solving - Repetitive Jobs

1:00- 1:45

Thursday, August 6th: Ergonomics and Injury/Illness
Reduction, Low Back Pain and Manual Handling. Cost/
Benefit Analyses
7:30 - 8:15 AM
8:15- 9:30
9:30-9:45

Low Back Pain
Manual Lifting and Handling Guidelines
Break

9:45- !0:15
!0:15- 12:00
12:00-1:00 PM

Repetitive Lifting
Problem Solving - Manual Handling
Lunch

1:00- 1:45

Factors Affecting Return-to-Work After
Injury or Illness
Cost/Benefit Analyses
Break

1:45-2:15
2:15-2:30
2:30- 3:15
3:15-3:30
3:30-4:00

Problem Solving Using Cost/Benefit
Analysis Techniques
Surveys and Checklists
Summary of Main Points, Resources in
Ergonomics, Evaluations

7/28/87 SHR

ii.

�i

B 0 C Lansing Operations Project on
Disability Management and Workers'
Compensation Cost Control

3-Day Ergonomics Training Course

November 16 - 18, 1987

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�Ergonomics Awareness and Problem Solving Course for
Northeast Packaging, Plastics Packaging Division,
Mobil Chemical Co., Thursday, December 4, 1987
Syllabus*

10:00-10:35 AM Overview- What Is Ergonomics?- Work
Capacities, Who Do We Design For ?
10:35-11:15

Posture and Productivity - Static Work, Work and
Recovery Times, Reaches, Work Heights

11 :15 - 12:00

Job Design and Overexertion Injuries- Low Back
Pain and Manual Handling, Repetitive Motions
Problems

12:00 - 1 :00 PM Lunch
!:00- 2:00

*

Problem Solving - L 138/139 "Hand Wrap" Packer

1:00- 2:30

Problem Solving - L 138/139 "Rotary Stretch Film"
Packer

2:30-3:00

Selling Ergonomics Changes - Cost!Benefit

Permission to reproduce unpublished materials should be obtained from Dr. Rodgers.

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Goodyear Tire and Rubber Company Ergonomics Training
General Products and Textile Divisions
January to March, 1988
Schedule
Monday:
8:30- 9:00AM
9:00-10:00
10:00-10:15
10:15-11:15
11 :15 - 11 :45
11:45- 12:30

Introductions and Course Goals
Overview of Ergonomics - The Costs of Poor Design
Break
Who Do We Design For ? - Work Capacities
Problem Solving: Who Do We Design For?
Lunch

12:30-1:30 PM Problem Solving: Designing a Standing Workplace
1:30- 2:15
Posture and Productivity: Static Work, Height
and Reach Interaction
2:15- 2:30
Break
2:30- 3:00
Posture and Visibility
3:00- 4:00
Problem Solving: Workplace Design

0

Tuesday:
8:30- 9:00AM
9:00- 10:00
10:00-10:15
10:15-10:45
10:45- 11 :45
11 :45- 12:30
12:30-1:30 PM
1:30- 2:15
2:15- 2:30
2:30- 3:00
3:00- 3:30
(

\

~

3:30- 4:00

Repetitive Motions Problems- Tendonitis, Carpal
Tunnel Syndrome, Tennis Elbow, etc.
Factors Affecting Hand Grip Strength
Break
The Selection and Design of Tools
Problem Solving: Repetitive Motions Problems
Lunch
Factors Affecting Quality Performance - Puzzle
Techniques to Reduce Complexity
Break
Paced Work- Techniques to Retain Control
Environmental Factors - Lighting, Noise,
Temperature, Humidity
Summary -Job Stress Sensitizers

�Wednesday:
8:30- 9:00AM
9:00- 10:00
10:00-10:15
10:15-11:00
11 :00 - 11 :45
11 :45 - 12:30
12:30-1:30 PM
1:30- 2:30
2:30- 2:45
2:45- 3:30
3:30- 4:00

Low Back Pain
Workplace and Job Factors Associated with Low
Back Pain
Break
Manual Handling Guidelines - Push/Pull,
Lift/Lower, Repetitive Lifting
Problem Solving: Manual Handling
Lunch
Discussion: implementing an Ergonomics Program
Cost-Benefit Analyses of Ergonomics Problem
Solutions
Break
Problem Solving: Cost-Benefit Justification of
Change
Hours of Work ,

~-,\

\_j

Thursday:
8:30 - 9:30 AM
9:30- 10:30
10:30- 10:45
10:45-11:45
11 :45 - 12:30

Problem Solving: Workplace Modifications
Problem Solving: New Workplace Design
Break
Problem Solving: Repetitive Tasks
Lunch

12:30 -1:30PM
1:30- 2:30

Problem Solving: Job Design
Ergonomics Resources/Audits, Course Evaluations

1/10/88 SHR

' , ___

_/

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•
...•
~

Goodyear

l
/

)

..

'

Divisions des produits generaux/textiles
Cours de formation en ergonomie

'\

Akron (Ohio)

Du 18 au 21 janvier 1988
Du 22 au 25 fevrier 1988
Du 21 au 24 mars 1988

Programme

S H R

Suzanne H. Rodgers, Ph.D
Experte-conseil en ergonomie/facteurs humains
"Productivite accrue par une meilleure conception du travail"
1. SEMINAIRES DE SENSIBILISATION
2. FORMATION RELATIVE A L'UTILISATION DES FACTEURS HUMAINS
LORS DE LA CONCEPTION DES STATIONS DE TRAVAIL, DE
L'EQUIPEMENT ET DES PRODUITS
3. PROGRAMMES DE SANTE ET DE SECURITE AU TRAVAIL
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�\

,Goodyear - Formation en ergonomie
Divisions des produits generaux et des textiles
~
De janvier a mars 1988

,.

Horaire

''

Lundi
De
De

8 h 30 a 9 h 00
9 h 00 a 10 h 00

De 10 h 00 a 10 h 15
De 10) h 15 a 11 h 15
De 11 h 15 a··11 h 45
De 11 h 45 a 12 h 30
De 12 h 30 a 13 h 30
De 13 h 30 a 14 h 15
De 14 h 15 a 14 h 30
De 14 h 30 a 15 h 00
De 15 h 00 a 16 h 00

Presentations et objectifs du cours
Survol de l'ergonomie - Les couts d'une conception
inappropriee
Pause
Pour qui se fait la conception ? - Capacite de
travail
Resolution de problemes : Pour qui se fait la
conception ?
Rep as
Resolution de problemes : Conception d'une station
de travail debout
Position et productivite : Travail statique,
interaction de la hauteur et de la portee
Pause
Position et visibilite
Resolution de problemes
Conception d'une station
de travail

Mardi
De

8 h 30 a

9 h 00

De

9 h 00 a 10 h 00

De 10 h 00 a 10 h 15
De 10 h 15 a 10 h 45
De 10 h 45 a 11 h 45
De 11 h 45 a 12 h 30
De 12 h 30 a 13 h 30
De 13 h 30 a 14 h 15
De 14 h 15 a 14 h 30
De 14 h 30 a 15 h 00
De 15 h 00 a 15 h 30
De 15 h 30 a 16 h 00

Problemes des gestes repetitifs - Tendinite,
syndrome du canal carpien, synovite du coude, etc.
Facteurs affectant la force de prehension de la
main
Pause
Le choix et la conception des outils
Resolution de problemes : Problemes des gestes
repetitifs
Rep as
Facteurs affectant la qualite du rendement Casse-tete
Techniques de facilitation
Pause
Travail cadence - Techniques pour garder le
controle
Facteurs environnementaux'- Eclairage, bruit,
temperature, humidite
Resume - Agents de sensibilisation a la tension au
travail
I

�Mercredi
De
De

8 h 30 a 9 h 00
9 h oo a 10 h 00

De 10 h 00 a 10 h 15
De 10 h 15 a 11 h 00
De 11 h 00 a 11 h 45
De 11 h 45 a 12 h 30
De 12 h 30 a 13 h 30
De 13 h 30 a 14 h 30
De 14 h 30 a 14 h 45
De 14 h 45 a 15 h 30

a

16 h 00

De

8 h 30 a

9 h 30

De

9 h 30 a 10 h 30

De 15 h 30

Douleurs dans le bas du dos
Station de travail et autres facteurs associes aux
douleurs dans le bas du dos
Pause
Lignes directrices relatives a la manutention
manuelle - Pousser/tirer, soulever/abaisser,
soulevement repetitif
Resolution de problemes : Manutention manuelle
Rep as
Discussion : Implantation d'un programme
d'ergonomie
Analyses des couts et des avantages pour les
solutions ergonomiques aux problemes
Pause
Resolution de problemes : Couts et avantages
justifiant des changements
Heures de travail

Jeudi

De 10 h 30 a 10 h 45
De 10 h 45 a 11 h 45
De 11 h 45 a 12 h 30
De 12 h 30 a 13 h 30
De 13 h 30 a 14 h 30

Resolution
station de
Resolution
station de
Pause
Resolution
Rep as

de problemes
travail
de problemes
travail

Modifications de la

de problemes

Taches repetitives

Conception d'une nouvelle

Resolution de problemes : Conception du travail
Ressources ergonomiques/verification, evaluation du
cours

1/10/88 SHR

II

�Goodyear Tire and Rubber Company - General Products/
Textiles Divisions - 4-Day Ergonomics Training Courses
January- March, 1988, 8:30 AM - 4:00 PM, Tallmadge Training Center

Table of Contents
Starting Page Location
Topic
Schedule
Table of Contents
Acknowledgements
Introduction and Course Goals
Ergonomics Goals - Overview
The Costs of Poor Design
Capacities for Work

()

j

iii
v
1
2
6
8

EOFPAW 1

3

EDFE8W2

2
9
210,446,496

The Variability of People
10
Using Anthropometries Data
12
Exercises -Who Do We Design For? 14

8,285,290
285
8

13,446

Static Work - Postural Effort
Static Work Recovery Time
Needs
Height and Reach Interactions
Posture and Vision and
Productivity
Design to Minimize Stress
Ergonomic Problem Solving

112,140,150

24,217

Repetitive Work and CTS
Risk Factors for Carpal
Tunnel Syndrome
Factors Affecting Grip
Strength
Evaluating Hand Tools
Ergonomic Job Analysis - Priority 39
Effort Scale
'
(

S~llabus

Puzzle Exercise
Ergonomics and Quality
Displays and Controls Population Stereotypes

17
21
26
27
28
29

20,30
17,30,50
52

31

223,282

135,151 ,244
254
151
140

42
43
44
46

217
218,255

135

32
35
37

13

90,107

�--~~-,

Paced Work/Time Pressure
Other Environmental Factors
Factors That Increase Stress

47
50
51

Low Back Pain
Risk Factors for Low Back Pain
Manual Materials Handling
Maximum Force Applications
Strength and Location
Kodak Lifting Guidelines
Ergonomic Job Analysis

52
57
59
61
62
63
65

Ergonomics Survey
67
CosVBenefit Analyses
69
Problem Solving: Cost Justifying 74
Ergonomics Checklist
77
Problem Solving Forms
Course Evaluation Form

1/11/88 SHR

(

83
88

230
210,242,320
237

15,122,151

313

313

135
135,340
338
384,446
135,338
360,403

98

�Acknowledgements

The illustrations on pages 26, 63, and 64 are used with
permission from Eastman Kodak's Ergonomic Design for People at
Work, Volumes 1 and 2. The tables and illustrations on pages 53 to
56, 61, and 62 are from Working With Backache by S. H. Rodgers.
Material on pages 27, 39 to 42, and 51 has been developed in
conjunction with Dr. Inger Williams. All other material in this
syllabus is by Dr. S.H. Rodgers. Permission to reproduce material
from this syllabus must be obtained from her.

"·

�The Goodyear Tire and Rubber Company
General Products/ Textile Division
Ergonomics Training Course
Akron, Ohio
January 18 - 21 , 1988
February 22 - 25, 1988
March 21 - 24, 1988
(~)

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

·~

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�~I

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I,

AilE Chapter Meeting, Pontiac, Michigan- March 11, 1988
Outline of Sue Rodgers' Presentations

Morning: (2 hours)

Posture and Productivity
Static Work and Recovery Time Needs
Reach and Height Interaction
Problem Solving Example

Afternoon: (2 hours)

Reducing Overexertion Injuries
Work Capacities
Factors Affecting% of Capacity Used on the Job
Repetition Rate- How Much Is Too Much ?
Duration of Work

Technique for Prioritizing the Need for Change and for
Identifying the Most Effective Changes in Jobs Where
Overexertion Injuries Are Seen

2/12/88 SHR

I

I

�AilE Chapter Meeting, Pontiac, Michigan- March 11, 1988
Outline of Sue Rodgers' Presentations

Morning: (2 hours)

Posture and Productivity
Static Work and Recovery Time Needs
Reach and Height Interaction
Problem Solving Example

Afternoon: (2 hours)

Reducing Overexertion Injuries
Work Capacities
Factors Affecting % of Capacity Used on the Job
Repetition Rate- How Much Is Too Much?
Duration of Work

Technique for Prioritizing the Need for Change and for
Identifying the Most Effective Changes in Jobs Where
Overexertion Injuries Are Seen

2/12/88 SHR

�Ergonomics- Practical Approaches for Reducing
Occupational Illness, Injury and Disability
While Improving Quality Performance
1-Day Seminar- Pendleton, Oregon, June 21, 1988
Outline

8:30 - 9:30 AM Work Capacity- Definition, Measurement, and
Use in Job Design and the Evaluation of Job Demands
9:30- 10:30

Posture and Productivity- Fatiguing Postures
and Ways to Reduce Them

10:30 - 10:45 Break
10:45- 11:30 Case Studies: Seated and Standing Workplaces
11 :30- 12:00 Highly Repetitive Tasks, Tendonitis, and
Carpal Tunnel Syndrome
12:00 - 1:00 PM

Lunch

1:00-2:00

Case Studies: Repetitive Tasks

2:00-3:00

Manual Materials Handling and Low Back Pain

3:00-3:15

Break

3:15-4:30

Case Studies: Manual Handling Tasks

4:30-5:00

Summary and Guidelines for Ergonomic Job
Design

5/6/88 S.H. Rodgers
Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�The Goodyear Tire and Rubber Company
Asia/Pacific Regions
Ergonomics Training Course
Singapore
July 18-21, 1988

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DES.IGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�INDUSTRIAL MEDICINE
AN INTRODUCTORY
COURSE
FOR THERAPISTS

FACULTY:
GREGORY W. BRICK, M.D.
ROWLAND G. HAZARD, M.D.
Z. ANNETTE IGLARSH, P.T., PH.D., M.B.A.
W. MONROE KEYSERLING, PH.D.
JERRY LAMPE, P.T., PH.D.
LEONARD N. MATHESON, PH.D.
MARGARETA NORDIN, MED. DR. SCI.
ROBERT RADWIN, PH.D.
JAN RICHARDSON, P.T., PH.D.
SUZANNE H. RODGERS, PH.D.
JON TALSNESS, M.D.
KATHLEEN VIOLA, P.T.

COURSE CHAIRMAN:
STEVE VANCE, P.T.

September 22-25, 1988
Boston, Massachusetts

SPONSORED BY MEETING PLANNERS, INC.

I

�Delco Products Rochester Division
General Motors Corporation

4-Day Ergonomics Training C_ourse

September 26-29, 1988

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Delco Products Rochester Division Ergonomics Training
September 26-29, 1988

0
\

I

Schedule
Monday:

8:008:309:009:45-

8:30AM
9:00
9:45
10:00

10:00 - 11 :00
11 :00 - 11 :30
11 :30 - 12:30

Introductions and Course Goals
Overview of Ergonomics - The Costs of Poor Design
Who Do We Design For ? - Work Capacities
Break
Problem Solving: Who Do We-Design For?
Reach and Height Interactions -Workplace Design
Lunch

12:30 -1:30PM Problem Solving: Designing a Standing Workplace
1:30- 2:15
Posture and Productivity: Static Work and
Recovery Time Needs
Break
2:15- 2:30
2:30- 3:00
3:00- 4:00

Posture and Visibility, Chairs
Problem Solving: VDT Workplace Design

Tuesday:

8:00- 8:30AM
8:309:009:30-

9:00
9:30
9:45

Repetitive Motions Problems - Tendonitis, Carpal
Tunnel Syndrome, Tennis Elbow, etc.
Factors Affecting Hand Grip Strength
The Selection and Design of Tools
Break

9:45- 11:30
11 :30 - 12:30

Problem Solving: Repetitive Motions Problems
Lunch

12:30 - 1:00 PM
1:00- 1:30

Low Back Pain
Workplace and Job Factors Associated with Low
Back Pain
Design of Manual Handling Tasks
Break

1:30- 2:00
2:00- 2:15
2:15- 2:45
2:45- 4:00

Manual Handling Guidelines - Push/Pull,
Lift/Lower, Repetitive Lifting
Problem Solving: Manual Handling

�2.
Wednesday:
8:00 - 9:00 PM
9:00- 9:45
9:45- 10:00
10:00 -10:30
10 :30 -11 :30
11:30- 12:30
12:30-1:30 PM
1:30- 2:30
2:30- 2:45
2:45- 3:30
3:30- 4:00

Factors Affecting Quality Performance- Puzzle
Techniques to Reduce Complexity- Information
Transfer, Controls/Displays, Stress Sensitizers
Break
Paced Work- Techniques to Retain Control
Environmental Factors- Lighting, Noise,
Temperature, Humidity
Lunch
Discussion: Implementing an Ergonomics Program,
Surveys, Checklists, Guidelines
Cost-Benefit Analyses of Ergonomics Problem
Solutions
Break
Problem Solving: Cost-Benefit Justification of
Change
Review of Thursday's Problem Presentation Goals

Thursday:
8:00- 3:00
Class Problem Presentations
(with usual breaks)
3:00- 3:30

Ergonomics Resources, Course Evaluations

9/17/88 SHR

I

It

;

�Mobil Macedon Design Products

1-Day Ergonomics Awareness and
Problem Solving Course

October 11, 1988, 8:30 AM to 4:30 PM
at The Farm Restaurant

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

'

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Work Re-Entry Program, University of Rochester
Ergonomics Seminar# 2- October 21, 1988
Postural Demands, Workplace and Equipment Design

A. Static Muscle Effort
1.
2.
3.
4.

Postures of Concern
Techniques to Reduce Static Load
Recovery Needs in Static Postural Work
Problem Solving Example

B. Using Anthropometric Data in Workplace and
Equipment Design
1.
2.
3.
4.

Available Data
Use in Determining Clearances
Use in Determining Heights and Reaches
Use in Evaluating Visual Needs of Worker

C. Workplace and Equipment Design - Layout
1. Orientation of Supplies or Out-Going Product to Line
2. Materials Flow

D. Office Ergonomics- Seated Workplace Design
1. Layout
2. Factors Affecting Posture
a. Clearances
b. Keying Height
c. Visual Considerations
3. Job Design
4. Self-Help Diagnosis of VDT Workplace Discomfort
Contributors

10/21/88 S.H. Rodgers

�"i

,

Ergonomic Job Analysis Techniques
A 4-Hour Training Course for Members
of the St. Mary's Medical Center Workers'
Evaluation &amp; Rehabilitation Center Staff
Given by Dr. Sue Rodgers, Ergonomics
Consultant from Rochester, New York
October 27, 1988, 8 AM to Noon

Outline
I. Evaluating Job Physical Effort Requirements
A. Evaluation of Effort Levels
B. Muscle Fatigue and Recovery Time Needs
C. Ergonomic Job Analysis for Repetitive Work
D. Using Force and Manual Handling Guidelines
E. Total Workload
II. Other Job and Workplace Factors
A. Visual Work
B. Environmental Conditions
C. Pacing
D. Communications
ill. Design Considerations
A. Heights and Reaches
B. Location of Lifts
C. Size of Objects Handled
D. Orientation of Workplace Elements
E. Pattern of Heavy and Light Effort Task Alternation
IV. Problem Solving Examples for Job Analysis
A. Light Assembly Work
B. Building Cleaning
C. Trash Collection
D. Office Work
V. Selling Job/Workplace/Equipment Changes
A. Costs of Poor Design
B. Information Sources- Surveys
C. Where Industry Is Coming From

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

Permission to reproduce material in this handout
should be obtained from Dr. Rodgers or the cited
reference.

�tj'r&gt;.~,

·. -~t

-~

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'

i
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r

!Ergonomics in the Workplace
f'Higher Productivity Through Job Design"

A RAMAC/SMMC Seminar
Given by Dr. Sue Rodgers, Consultant in Ergonomics
from Rochester, New York
October 27, 1988, 1-3 PM
St. Mary's Medical Center, Racine, Wisconsin

Outline
I. Review of Overexertion Injuries
A. Low Back Pain Risk Factors
B. Repetitive Work Risk Factors
C. Techniques to Manage Disability Associated With
Overexertion Injuries
II. Concepts for Ergonomic Design of Jobs and Workplaces
A. People at Work Should Be Comfortable
1. Upright or Neutral Posture
2. Work Close to Elbow Level
3. Good Task Visibility
4. Comfortable Working Environment
B. Avoid Excessive Forces or Loads
1. Design for Majority of Potential Workforce
2. Lifting Near Waist Height
3. Slide Rather Than Lift
C. Give Worker Control of Work Pattern
1. Pacing Should Permit Variability
2. Timeliness of Feedback and Feedforward Information

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

Permission to reproduce material in
this syllabus should be sought from
Dr. Rodgers or the referenced sources.

�.

Ergonomic Guidelines for Manual Handling Tasks
Delco Products- Rochester, N.Y.
August 3, 1988

Seminar and Problem Solving Workshop Led by
Sue Rodgers, Consultant in Ergonomics

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�3-Day Ergonomics Training Course
Health and Environment Laboratories
Eastman Kodak Company
November 8-10, 1988

Syllabus

,!:

Sue Rodgers, Ergonomics Consultant
Mark Johnson, Ergonomics
Dick Little, Ergonomics
Carol McCreary, Ergonomics
Bob Weneck, Ergonomics

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�·-!

Eastman Kodak Company 3-Day Ergonomics Training Course
November 8th through 10th, 1988, B-952

Tuesday, November 8th: Overview, Posture and Productivity
8:00 - 8:30 AM
8:30- 9:00
9:00- 10:00
10:00 - 10:15

Introductions and Overview
Work Capacity
Who Do We Design For ?
Break

10:15- 10:45

Posture and Productivity - Static Work,
Reach/Height Interactions
Work/RecOvery Curves
Problem Solving: Standing Workplace Design
Lunch

10:45 - 11 :15
11:15-12:00
12:00- 1:00PM

/----\
__/I

_

1:00- 2:00
2:00- 3:00
3:00- 3:15

Problem Solving: Seated Workplace Design
Office Ergonomics
Break

3:15- 4:45
4:45-5:00

Problem Solving: Design of a New Workplace
Summary of Workplace Design Guidelines

-*
.JII.

Wednesday, November 9th- Preventing Overexertion Injuries:
8:00 - 8:30 AM
8:30- 9:15
9:15- 10:00
10:00-10:15

Repetitive Motions Disorders
Risk Factors for Tendonitis, Carpal Tunnel, etc.
Ergonomic Job Analysis Form
Break

10:15-10:45
10:45- 12:00
12:00- 1:00PM

Tool Design {DiCk
Problem Solving: Repetitive Tasks
Lunch

1:00- 1:30
1:30- 2:00
2:00- 2:30
2:30- 2:45

uttl;)

JJf-

Low Back Pain and Job Risk Factors
Managing Upper Extremity and Low Back ~
Disability in the Workplace
Manual Handling Guidelines
Break

+

�2:45-4:15
4:15-4:45
4:45-5:00

Problem Solving: Manual Handling ~
Frequent Lifting/ Total Workload
Work Pace

Thursday, November 10th: Ergonomics and Quality Performance
8:00 - 8:30 AM
8:30- 9:00
9:00- 9:30
9:30 -10:00
10:00-10:15

Environment- Lighting- ob Weneck
Environment- Temperature/Humidity
Reducing Job Complexity- Information
Break

10:15-11:00
11:00 -12:00
12:00- 1:00

Controls/Displays/Automation
Human Error and Reliability €(k JohnSQD)
Lunch

1:00 - 2:00 PM
2:00-3:00
3:00-3:15

Problem Solving - Equipment and Environmental .;Design
Cost-Benefit Analyses of Solutions
Break

3:15-4:15
4:15-4:45
4:45-5:00

Problem Solving Using Cost-Benefit Approach
Surveys/Checklists/Resources k"
Course Evaluations

*"

Homework Suggestions:
1 Week Before Course: Videotape of Jobs to Ergonomics, B-320
Night Before Course: Review Syllabus Contents, Volume 1, Ch 2, App.
Tuesday Night: Review Volume 2, Work Patterns, Manual Handling
sections, esp.
Wednesday Night: Review Volume 1, Chs 3,4,5

10/10/88 SHR

�Ergonomics- Prevention of Occupational Overexertion Injuries
Seminar for the Center for Occupational Rehabilitation and
Ergonomics, U of R Med. Center, November 21, 1988, 3:30-5:30 PM

I. Ergonomics and Work Capacity
II. Repetitive Work and Carpal Tunnel Syndrome
Ill. Manual Handling Tasks and Low Back Pain
IV. Problem Solving Form and Job Effort Analysis Technique
V.

Ergonomics and Work Restrictions

Industrial Ergonomics Resource Material Written or Edited by S.H. Rodgers, Ph.D.
Eastman Kodak Company Human Factors and Ergonomics Groups, Ergonomic Design for People at Work. Volume
1 (ISBN #534-97962-9) Workplace, Equipment, Information Handling and Environment Design, 1983, about $50;
Volume 2 (ISBN #442-22103-7) Job Design, Methods to Measure Job Demands, Human Capacities, Work
Patterns, Shift Work, and Manual Materials Handling, 1986, about $75. Available from van Nostrand Reinhold,
Mail Order Service, 7625 Empire Drive, Florence, Kentucky 41042. Customer service number is (606) 525-6600.
For multiple purchases contact Rachel Grabowsky at (212) 254-3232. There should be a 2-volume set reduced price
of about $100. as of January, 1987.
Rodgers, S.H. Working With Backache (ISBN #931157-01-3), 1985, published by Perinton Press. $18.95 plus
handling. Review of occupational low back pain problems and techniques to manage and prevent disability from
them using ergonomics approaches. Sections on what the worker can do, what workplace and equipment designers
can do, and what management can do to reduce low back pain problems at work. Available through S.H. Rodgers,
Ph.D., P.O. Box 23446, Rochester, N.Y. 14692. Phone= (716) 544-3587.
Rodgers, S.H. (Editor). Repetitive Motions Injuries, March, 1987 issue of Seminars in Occupational Medicine.
published by Thieme Medical Publishers, Inc., Suite 1501,381 Park Avenue South, New York, N.Y. 10016.
Phone= (212) 683-5088 (Shari Carpenter).
Rodgers, S.H. "Job Evaluation in Worker Fitness Determination", a chapter in Comprehensive Approaches in
Worker Fitness Evaluations edited by Jay Himmelstein, MD and Glenn Pransky, MD, Occupational Medicine: State
of the Art Reviews, March, 1988, published by Hanley and Belfus, Inc., 210 S. 13th Street, Philadelphia, PA
19107, (215) 546-4995.
Rodgers, S.H. "Matching Worker and Work Site -Ergonomic Principles", a chapter in Work Injury. Management
and Prevention by Susan J. Isemhagen, PT, published in 1988 by Aspen Publishers, Inc., 1600 Research
Boulevard, Rockville, MD 20850, (301) 251-8500.

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

171Rl ""'·3.'iB7 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�'•

Ergonomics in Dietary Jobs
Lecture for the Dietetics Department, University of
Rochester Medical Center, November 22, 1988
Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics

I. What Is Ergonomics? Applications in Dietetics.
II. Case Study : Hospital Tray Assembly
A.
B.
C.
D.
E.
F.

Job Characteristics
Health and Safety Concerns
Quality Concerns
Information Transfer- Menu Design
Seating
Work Pace

Ill. General Ergonomics Guidelines for Job Design

Assignment in Preparation for Class: You have already observed
the tray assembly operation for at least 30 minutes during lunch
or dinner (or breakfast). We will discuss the working postures,
pace, errors made, and environmental factors (lighting,
temperature, noise) in this session.
General Ergonomic Guidelines
1. Avoid sustained, awkward postures. Provide for postural
variability.
2. Keep the wrists straight whenever possible.
3. Slide instead of lifting objects.
4. Give the worker control over the job pattern. Design
flexibility into the job.
5. Reduce unnecessary environmental distractors.
6. Structure information to reduce complexity and increase
legibility.

11 /21/88 SHR

�Ergon~mics

Awareness Course

Eastman Kodak Company - Colorado Division
Windsor, Colorado December, 1988

Outline
A. Overview of Ergonomics and Its Benefits
B. Posture and Productivity
1. Static Muscle Work
2. Height and Reach Guidelines
3. Ergonomic Job Analysis Technique
C. Preventing Overexertion Injuries
1. Highly Repetitive Work- Risk Factors and How To
Reduce Them
2. Manual Materials Handling - Lifting, Lowering,
Pushing, and Pulling Guidelines
·i.-·1·
'
;

D. Ergonomics and Quality Performance
1. Reducing Complexity
2. Inspection and Visual Capabilities
3. Determining Appropriate Pacing ofOperations Need for Control Over Work Pattern

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�2-Day Ergonomics Training Course for Central
Engineering Based on the Pigment Weigh Room and
Banbury Loading Area Designs for the Napanee Plant

Syllabus

Goodyear Hall, December 14 -15, 1988
The Goodyear Tire and Rubber Company, Akron, OH

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN''

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN

3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�·-~\(

2-Day Ergonomics Training Course for Central Engineering Based on the
Pigment Weigh Room and Banbury Loading Area Designs for the Napanee Plant
Goodyear Hall, December 14 -15, 1988
The Goodyear Tire and Rubber Company, Akron, OH
Schedule
I. Weds., Dec.14th Ergonomics Overview and Review of
Questions About Banbury and Weigh Room Jobs
8:15
8:30
9:25
9:35
10:30
10:35
11:30

-------....._,_
/

12:15
1:10
1:15
2:10
2:25
3:20
3:30

'

4:30
ll.

1:15
2:10
2:25
3:15

r--\

_________A

·~

'

Review Pigment Room Video
Break
Review Banbury Loading Video
Break
Questions for Compounder
Break
Review First Designs of Pigment Room and Banbury
Loading Area
Homework: Pigment Weigh Room Design

Thurs, Dec 15th, Application of Ergonomics Principles to the
Design of the Pigment Weigh Room and the Banbury Loading Area
8:15
9:00
9:50
10:00

.

Introduction
Ergonomic Workplace Design Guidelines
Break
Ergonomic Guidelines for Manual Handling Tasks and
Total Workload
Break
Ergonomics Guidelines for Equipment and
Environmental Design
Lunch

Review of Pigment Weigh Room Design
Further Work on Pigment Weigh Room Design
Break
Work on Banbury Loading Area Design and Lunch
Review Banbury Loading Area Design
Break
Wrap-Up on Designs and Ergonomics Approach
End, Evaluations, Resources

�Occupational Rehabilitation and Ergonomics Clinic Seminars
Total Work Load and Aerobic Capacity Evaluations
December 27, 1988, 3:00PM Anderson Room
University of Rochester Medical Center

I. Aerobic Capacity Determinations
2. Energy Expenditure on Jobs
3. Heart Rate Measurements of Job Demands
4. Hours of Work and Shiftwork

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Seminar for the Occupational Rehabilitation and Ergonomics
Team on Problem Solving with Job Examples for
Total Job Demands, January 5, 1989, U of R Med

I. Low Back Pain Patient for Work Re-Entry
Job Information from the Patient
Job Information from the Employer
Videotape of Job
Questions to Ask Patient
Questions to Ask Employer
Relevant Data to Collect
Capacities to Measure
Appropriate Exercise/Work Hardening Protocol
II. Carpal Tunnel Syndrome Patient for Work Re-Entry
same as above

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
''HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Eastman Chemicals Division 3-Day Ergonomics Training Course
January 1Oth through 12th, 1989, Kingsport, TN
Tuesday, January 10th: Overview, Posture and Productivity

8:00 - 8:30 AM
8:30- 9:00
9:00- 9:15
9:15-10:00
10:00-10:15

Introductions and Overview
Work Capacity
Who Do We Design For ?
Exercise- Using Anthropometric Data
Break

10:15-10:45

Posture and Productivity- Static Work,
Reach/Height Interactions
Work/Recovery Curves
Problem Solving: Standing Workplace Design
Lunch

10:45-11:15
11 :15 - 12:00
12:00 - 1:00 PM
1:00- 2:15
2:15- 3:00
3:00- 3:15

TEC Videotape Review - Postures
Problem Solving: Seated Workplace Design
Break

3:15-4:45
4:45-5:00

Problem Solving: Design of a New Workplace
Summary of Workplace Design Guidelines

Wednesday, January 11th- Preventing Overexertion Injuries
and Enhancing Human Reliability

8:00- 8:30AM
8:30- 9:15
9:15- 9:45
9:45- 10:00

Repetitive Motions Disorders
Risk Factors for Tendonitis, Carpal Tunnel, etc.
Ergonomic Job Analysis Form
Break

10:00- 10:30
10:30 - 11 :30
11 :30 - 12:00
12:00- 1:00PM

Tooling Guidelines- Dick Little
Problem Solving: Repetitive Tasks
Human Error and Reliability - Rodgers, Little
Lunch

1:001:302:302:45-

Reducing Job Complexity- Information
Problem Solving: Controls/Displays/Automation
Environment - Lighting
Break

1:30
2:30
2:45
3:00

3:00- 3:45
3:45- 4:45

Temperature/Humidity and Job Demands
Shiftwork - Dick Little

�Thursday, Jan. 12th: Manual Handling and Cost/Benefit Analyses

9:00- 9:30
9:30- 9:45

Low Back Pain and Job Risk Factors
Managing Upper Extremity and Low Back
Disability in the Workplace
Manual Handling Guidelines
Break

9:45- 10:30
10:30 -11 :00
11 :00 -11 :45
11:45-12:00
12:00 -1:00PM

Problem Solving: Manual Handling
Frequent Lifting/ Total Workload
Problem Solving: Total Workload
Work Pace
Lunch

1:00- 1:45
1:45 -2:00

Cost-Benefit Analyses of Solutions
Break

2:00-3:00
3:00-3:15
3:15-3:30

Problem Solving Using Cost-Benefit ,Approach
Surveys/Checklists/Resources
Course Evaluations

8:00- 8:30
8:30- 9:00

Homework Suggestions:
1 Week Before Course: Complete Videotapes of Jobs/ Descriptions
Night Before Course: Review Syllabus Contents, Volume 1, Ch 2, App.
Tuesday Night: Review Volume 2, Work Patterns, Manual Handling
sections, esp.
Wednesday Night: Review Volume 1, Chs 3,4,5

12/2/88 SHR

�3-Day Ergonomics Course for the Bridgeport Plant
General Electric Company
January 30 - February 1, 1989

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
''HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�..-/~'\
\

General Electric Bridgeport, 3-Day Ergonomics Training Course
January 30th through February 1st, 1989

/

Monday, January 30th: Overview, Posture and Productivity

I

\

8:00 - 8:30 AM
8:30- 9:00
9:00- 10:00
10:00-10:15

Introductions and Overview
Work Capacity
Who Do We Design For ?
Break

10:15-10:45
10:45 - 11 :15
11 :15- 12:00
12:00 - 12:45 PM

Posture and Productivity- Static Work,
Reach/Height Interactions
Work/Recovery Curves
Problem Solving: Standing Workplace Design
Lunch

12:451:151:302:30-

The Design of Seated Workplaces
Office Ergonomics
Problem Solving: Seated Workplace Design
Break

1:15
1 :30
2:30
2:45

c

...___

/

2:45 -·3:45
3:45-4:00

Problem Solving: Design of a New Workplace
Summary of Workplace Design Guidelines

Tuesday, January 31st- Preventing Overexertion Injuries
and Enhancing Human Reliability

8:00- 8:30AM
8:30- 9:15
9:15- 10:00
10:00-10:15

Repetitive Motions Disorders
Risk Factors for Tendonitis, Carpal Tunnel, etc.
Ergonomic Job Analysis Form
Break

10:15 - 11 :15
11:15-12:00
12:00 - 12:45 PM

Problem Solving: Repetitive Tasks
Human Error and Reliability
Lunch

12:45- 1:15
1:15- 1:45
1:45- 2:15
2:15- 2:30

Reducing Job Complexity- Information, Pacing
Controls/Displays/Automation
Environment- Lighting
Break

2:30- 3:00
3:00- 4:00

Environment- Temperature/Humidity
Problem Solving: Information and Environment

·~cj

I.

�Wednesday, Feb 1st: Manual Handling and Cost/Benefit Analyses

9:00- 9:30
9:30- 9:45

Low Back Pain and Job Risk Factors
Managing Upper Extremity and Low Back
Disability in the Workplace
Manual Handling Guidelines
Break

9:45- 11:00
11 :00 -11 :45
11:45-12:15
12:15-1:00

Problem Solving: Manual Handling
Frequent Lifting/ Total Workload
Hours of Work and Shiftwork
Lunch

1:00-2:00
2:00-3:00
3:00-3:15
3:15-3:45
3:45-4:00

Cost-Benefit Analyses of Solutions
Problem Solving Using Cost-Benefit Approach
Break
SuNeys/Checklists/Resources
Course Evaluations

8:00- 8:30
8:30- 9:00

Homework Suggestions:

Night Before Course: Review Volume 1, Ch 2, Appendix, Syllabus
Monday Night: Review Volume 1, Chs 3,4,5, Volume 2, Work Patterns
Tuesday Night: Review Volume 2, Manual Handling

1/17/89 SHR

�Ergonomics Training Course- General Electric
Bridgeport, CT Plant, January 30th to February 1st, 1989
/-~\
j

Table of Contents

J

Topic
Schedule
Table of Contents
Acknowledgements
Introduction and Course Goals
Ergonomics Goals
Capacities for Work
Factors That Increase Stress
The Variability of People
Using Anthropometric Data

---/

Starting Page Location
EDFPAW 1
S;x:llabus
1
3
5
6
7
8
10
11
12

3

8,285,290
285

2
210,446,496
237
13,446

4, 142,217
24,217
218,255
223,282

Postural Demands/Performance
Static Muscle Work
Height and Reach Interactions
Posture, Vision, Productivity
Design to Minimize Effort
Static Work Recovery Needs
Problem Analysis: Standing Work
Problem Analysis: Seated Work
Finding Best Solution to Problem
Chair Characteristics
Visual Aspects of VDT Work
Self-Help in VDT Workplace
Comfort

15
16
19
21
22
23
28
29
31
32
35
37

Risk Factors for Carpal
Tunnel Syndrome
Factors Affecting Grip Strength
Techniques to Reduce Risk
Job Analysis Form - Repetitive
Tasks
Effort Estimation Scale
Evaluating Hand Tools
Problem Analysis: Repetitive
Work

38

151' 244

41
42
43

151' 254
151

Human Reliability/Inspection

52
112,140,150
20,24,30
17,30,50
52

EDFPAW 2

217
23,50
18,28,50
57
28,101,179

46
47
49

338
140

52

181

142
142

3

f

�~~~)

Ergonomics and Quality
Puzzle Exercise
Job Control and Task Complexity
Information Transfer - Controls
and Displays
Environmental Factors
Problem Solving Form

53
55
56
58
62
66

Risk Factors for Low Back Pain
Strength and Location
Maximum Force Applications
~Kodak Lifting Guidelines
Problem Analysis: Manual
Handling
General Guidelines/Lifting/
Repetitive Work
Total Workload
Paced Work/Time Pressure

69
75
76
77
79

Summary - Applied Ergonomics

92

Cost/Benefit Analyses
The Costs of Poor Design
Problem Solving Form
Ergonomics in Old/New Design
How to Do An Ergonomics
Survey
Ergonomics Checklist
10 Ergonomics Guidelines
Resources

93
97
99
102
103
105
111
112

Course Evaluation Form

end

1/17/89 SHR

90,107,162
210,242,320

15,122,151

82
83
89

135,340
135,338
384,446
360,403

206,276,480
230

9

313
313

98

365

534

�Acknowledgements

The illustrations on pages 19, 20, 52, 77 and 78 are used with
permission from Eastman Kodak's Ergonomic Design for People at Work,
Volumes 1 and 2. The tables and illustrations on pages 33, 34, 75 and
76 are from Working With Backache by S. H. Rodgers. Material on pages
10, 32, 36, and 37 has been developed in conjunction with Dr. Inger
Williams. All other material in this syllabus is by Dr. S.H. Rodgers.
Permission to reproduce material from this syllabus must be obtained
from her.

10/17/88 SHR

�Suzanne H. Rodgers, PhD.
Consultant In Ergonomics/Human Factors
169 Huntington Hills
ROCHESTER, NEW YORK 14622

Presentation to the Organization Resources Counselors Meeting
on February 9, 1989 at the L'Enfant Plaza Hotel, Washimgton, D.C.

Applied Ergonomics From the Industrial Perspective
I. National Trends and Ergonomics Applications
II. Ergonomics Interventions to Reduce Overexertion Injuries
A. ReJ?etitive Motions Injuries - Carpal Tunnel Syndrome and Tendonitis
1. R1sk Factors in the Workplace
2. Job Design to Reduce the Risk
B. Low Back Pain
1. Risk Factors in the Workplace
2. Reducing Uncomfortable Working Postures
3. Manual Handling Task Design to Reduce the Risk
III. Disability Management and Ergonomics

Handout Table of Contents
National Trends in Ergonomics
Carpal Tunnel Risk Factors
Recovery Time Needs
Ergonomic Job Analysis
Low Back Risk Factors
Height and Reach Capabilities
Manual Lifting Guidelines
References - SHR

1
2

4
12
15
17
18

20

(716) 544·3587
/

�Ergonomics Awareness Course
International Paper Company
Cincinnati, Ohio March 9, 1989

Outline
A. Ergonomics Overview
1. Benefits
2. Work Capacities and Job Demands
B. Posture and Productivity
1. Static Muscle Work
2. Work/Recovery Time Needs
3. Height and Reach Guidelines
4. Problem Solving: Loading and Unloading Machines
C. Repetitive Work
1. Risk Factors for Repetitive Motions Injuries/Illness
2. Ergonomic Job Analysis Technique
3. Techniques to Reduce the Risk for Injuries/Illness
4. Problem Solving: Unloading Folding/Printing Machines
Inspecting Boxes and Packing Them
Using Air Hammer to Break Out Boxes
D. Manual Handling and Low Back Pain
1. Risk Factors for Low Back Pain
2. Lifting and Force Exertion Guidelines
3. Techniques to Reduce the Risk for Low Back Pain
4. Problem Solving: Loading Machines, Palletizing Cases
Pushing Master Rolls
E. Cost/Benefit for Ergonomics Problem Solutions

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

�Ergonomics Awareness Course, International Paper Company
Cincinnati, Ohio, March 9, 1989
Table of Contents
A. Ergonomics Overview
1. Benefits
2. Work Capacities and Job Demands
B. Posture and Productivity
1. Static Muscle Work
2. Work/Recovery Time Needs
3. Height and Reach Guidelines
4. Problem Solving: Loading and Unloading Machines
C. Repetitive Work
1. Risk Factors for Repetitive Motions Injuries/Illness
2. Ergonomic Job Analysis Technique
3. Techniques to Reduce the Risk for Injuries/Illness
4. Problem Solving: Unloading Folding/Printing Machines
Inspecting Boxes and Packing Them
Using Air Hammer to Break Out Boxes
D. Manual Handling and Low Back Pain
1. Risk Factors for Low Back Pain
2. Lifting and Force Exertion Guidelines
3. Techniques to Reduce the Risk for Low Back Pain
4. Problem Solving: Loading Machines, Palletizing Cases
Pushing Master Rolls

Page
1
2

5
10
17
18

22,28

25
23

30
· 32
30

E. Cost/Benefit for Ergonomics Problem Solutions

36

F.
G.
H.
I.

43
45
46
47

Ergonomics Surveys
10 Ergonomics Guidelines
Ergonomics Reference Material- Rodgers
Extra Problem Solving Forms

Acknowledgements

The material in this syllabus belongs to Dr. Rodgers and may not be reproduced without
acknowledgement and peimission. Permission to use the material on pages 5-9 from the
Polinsky Rehabilitation Institute, on pages 10-15 from Thieme Publishers, and on pages
17 and 34-35 from Eastman Kodak Company should be obtained directly from them.

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Ergonomics Awareness Course

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Amoco Corporation
Chicago, Illinois March 30, 1989

Outline/Schedule

8:30

A. Introductions and Overview of Awareness Course

9:00

B.

Ergonomics and Worker Comfort
1. Static Muscie Work
2. Height and Reach Guidelines
3. Seated Workplace Design - VDT Workplaces
a. Postural Concerns
b. Visual Concerns
c. Job Design

11:00

c.

Preventing Overexertion Injuries
t. Highly Repetitive Work
a. Risk Factors
b. Techniques to Reduce the Risk
c. Ergonomic Job Analysis Technique
2. Manual Materials Handling
a. Risk Factors for Low Back Pain
b. Techniques to Reduce the Risk
c. Lifting, Lowering, Pushing, and Pulling Guidelines

c.

Ergonomics Problem Solving - Videotaped Examples
1. Packing Containers
2. Others Brought by Attendees

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1:30

2:30

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. ~4022

�Ergonomics Awareness Course- Amoco Corporation
March 30, 1989
Chicago, Illinois
Syllabus Table of Contents
Starting Page
Subject
1
Capacity and Workload Determinants
Sensitizers to Stress
3
Static Work - Postural Effort
4
Ergonomic Approaches to Reduce Work-Related lnj.
5
Recovery Time Needs for Repetitive Work
7
Recovery Time Graphs
14
15
Ratings of Perceived Exertion
Standing Reach and Height Guidelines
18
Designing Jobs to Minimize Unnecessary Effort
19
VDT Workplace Design
20
Sitting Reach Capability
21
Chair Characteristics
22
Posture, Vision, and Productivity
24
Improving Worker Comfort .. Computer Workplaces
25
Office Ergonomics - Self-Help
28
Finding the Best Solution to an Ergonomics Problem
29
Risk Factors for Repetitive Motions Disorders
30
Ergonomic Job Analysis Form
33
Evaluating Hand Tools
35
Repetitive Job Characteristics for Work Re-Entry
37
Risk Factors for Low Back Pain
38
Low Back Pain Prevention
40
Pull Force and Location
45
Force Exertion Limits
46
Kodak Guidelines for Lifting
47
Ergonomics Problem Solving Form
49
The Costs of Poor Design
51
How to Do an Ergonomics Survey
53
10 Ergonomics Guidelines
55
Additional Analysis Forms
56
Publications By or Edited By S.H.Rodgers
59

;
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The graphs on pages 18, 21, 47 and 48 are from Ergonomic Design for People at Work, Volumes
1 and 2 by Eastman Kodak's Human Factors Section. The material on pages 5, 6, and 15-17 is
from Polinsky Rehabilitation's FCA Network Newsletter, that on pages 7-13 is from Seminars in
Occupational Medicine. and the article on pages 25-27 is from Modern Job Safety and Health.
The material on pages 22,23 and 40-46 is from Working With Backache by SH Rodgers and the
job analysis form on page 33 has been published in Occupational Medicine - State of the Art
Reviews. See the publications list for further details. All other material belongs to SH Rodgers
and should not be reproduced without her permission.

�April 3-7, 1989

April 26-28, 1989

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�An 8-D~ Ergonomics Training Program for the
B.O.C. General Motors Plant at Wentzville, Mo,
April3-7 and 26-28, 1989

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Schedule
Monday, April3, 1989: Overview, Work Capacities, Human
Variability, Who Do We Design For ?, Posture and
ProductiVIty
6:30 - 7:00 Overview of Ergonomics and Benefits of Using It
7:00 - 7:30 Worlc Ca:Qacities and Human Variability
7:30- 8:30 Exercise: Who Do We Design For?
8:30 - 8:45 Break
8:45- 9:30
9:30- 10:00
10:00 - 10:30
10:30-11:15

Static Muscle Work- Postures To Avoid
Work/Recovery Curves for Static Worlc
Problem Solvmg: Postural Worlc
Lunch

11:15 - 11:45 Working Height and Muscles Available, Wrist Postures
11:45 - 1:00 Problem Solvmg - Sub-Assembly Task Height
1:00- 1:15 Break
1:15- 2:30 Problem Solving- Line Height Impact in Assembly Tasks
'

Tuesday , April 4th: Workplace and Equipment Design,
·.
Environmental Factors, Office Ergonomics, Visual Demands
6:30 - 7:00 Review of Design Guidelines from Day 1
7:00- 8:00 Computer Wo*Place Design
8:00- 8:30 Visual DemandS of Work
8:30 - 8:45 Break
8:45- 10:30 Problem Solving- Postural Worlc
10:30-11:15 Lunch
11:15 -12:00 General Workplace Layout
12:00 - 12:30 Lighting
12:30 - 1:00 Temperature, Humidity, Air Flow
1:00 - 1:15 Break
1:15- 1:45 Work Pace
1:45 - 2:30 Problem Solving: Environmental Factors

)

'-----./

.

Wednesday, April 5th: Repetitive Work, Tooling Design
6:30 - 7:00 Repetitive Motions Injuries and illnesses
7:00 - 7:30 RiSk Factors for Repetitive Motions Problems
7:30- 8:15 Ergonomic Job Analysis Technique
8:15- 8:30 Break
I

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8:30- 9:30 Problem Solving: Repetitive Work
. 9:30 - 10:30 Design and Selection of Hand and Power Tools
10:30- 11:15 Lunch
11:15 - 12:15 Ergonomic Evaluation of Workplace Tools
12:15- 1:00 Problem Solving: Tool Use
1:00- 1:15 Break
1:15- 2:30 Problem Solving: Repetitive Tasks, Paced Work, Tools
Thursday, April 6th: Quality Performance and Error Reduction
6:30- 7:15 Work Factors Affecting Human Reliability
7:15- 8:15 Information Display and Transfer
8:15- 8:30 ·Break
·
8:30 - 9:00
9:00 - 10:00
10:00 - 10:30
10:30- 11:15

Controls and Displays - Control Panels
Automation - Humans vs Machines, Complexity
Inspection Tasks
Lunch

11:15-12:15 Puzzle Assembly Task
12:15- 1:15 In-Plant Identification of Error-Likely Situations,
Unnecessary Complexity, etc.
1:15- 1:30 Break
1:30 - 2:30 Discussion of Plant Obsetvations
Friday, April 7th: Manual Materials Handling, Low Back Pain,
Cost /Benefit Analyses of Ergonomic Problem Solutions
6:30 - 7:00 Low Back Pain
7:00- 7:30 Risk Factors .for Low Back Pain- Postural, Handling
7:30 - 8:00 Force Exertion Guidelines
8:00 - 8:15 Break
8:15 - 9:15 Occasional Lifting Guidelines
9:15- 10:30 Repetitive Lifting, Total Workload, Hours of Work
10:30- 11:15 Lunch
11:15- 12:15 Problem Solving: Lifting Tasks
12:15 - 1:00 Cost /Benefit Arialyses - Data Available to Detennine the
Cost of Not Makfug a Change
.
1:00 - 2:00 Problem Solving: Cost/Benefit Approach
2:00- 2:30 Summary of Week and Discussion of Next 3 Days' Focus
Wednesday, April 26th: Group Presentations of Ergonomics
Problems, Analyses, and Cost Justified Solutions
6:30 - 2:30 Presentations and Critiques
)

I

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�Thursday, AJ!ril27th: Ergonomics in New Design, Survey
Techn1q_ues, Worker Fitness, Return to Work
6:30 - 7:00 Building Ergonomics Into New Designs
7:00- 8:30 Problem Solving: New Job/Workplace Designs
8:30 - 8:45 Break

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8:45 - 10:30 Swvey Techniques, Return to Work, Job Placement, Fitness
10:30- 11:15 Lunch
11:15- 2:30 Plant Tour and Problem Solving Based on Participants Needs
Friday, April 28th: Presentations by Ergonomics Representatives of
4 Examples (Each) of Ergonomics Problems for Use in General
Awareness Training
6:30- 10:30 Posture and Repetitive Work Examples
10:30- 11:15 Lunch
·
11:15 - 2:00 Human Error and Manual Handling Examples
2:00- 2:30 Summary, Resources, Course Evaluation
3/18/89 SHRodgers

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�ERGONOMICS TRAINING
S. H. Rodgers, Ph.D.
Apri 1 3-7, 1989
April 26-28, 1989
Attendance_List
Work Phone No.

Name:

Dept:

Kay Gifford
Gary T. Bagsby
Phyllis Freetly
Linda Henry
.Jim Sherard
.Jim DeFriese
Mary Heitert
.Jeredean Styers
Jim Loftus
Bill Duncan
Tom Sullivan
Rich Joellenbeck
Robert Stowers
Zane Scott
Ted Kram
Ty Dwellingham
Jack B. Carpenter
Marilyn Rubin

FAD-2001 (I.E.)
83-08 Ergonomics
83-08 Ergono:mics
83-08 Ergonomics
80 Safety
81 Medical
81 Medical
81 Medical
40 Central Engrg.
40 Central Engrg.
30 Tooling
83-08 Ergonomics
83-08 Ergonomics
83 U.A.W.
40 Central Engrg.
40 Central Engrg.
40 Central Engrg.
81 Medical (P.T.)

Suzanne H. Rpd.gers/
Frank Mc Atee
Robert Boatwright

Ergonomics Consultant
40 Central Engrg.
83 U.A.W H&amp;S Rep.

Wentzville outside number (314)327-xxxx
Kay Gifford outside number (313)236-8101

8-446-8101
8-568-2132
8-568-2132
8-568-2132
8-568-2132
8-568-2155
8-568-2155
8-568-2155
• 8-568-2530
8-568-2542
8-568-2293
8-568-2132
8-568-2132
8-568-2318
8-568-2534
8-568-2215
8-568-2528
8-568-2928
716-544-3587
8-568-2541
8-568-2132

�Ergonomics Training Course

7
'

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Table of Contents
Topic
Schedule
Table of Contents

Starting Page Location
Syllabus
EDFPAWl
i
-iv
--

Acknowledgements
Introduction and Course Goals
Ergonomics Goals/Overview
Capacities for Work
Factors That Increase Stress
The Variability of People
Height and Reach Interactions
Using Anthropoqietric Data
Who Do We Design For?

1
2
3
7
9
10
12b
13
15

Static Muscle Work
Recovery Time/Static Work
Effort Estimation Scales
Design to Minimize Effort

16
20
28
32

Problem Analysis: Standing Work
Finding Best Solution to Problem
Ergonomics Problem Solving

33
34
35

Seated Work - VDT
Seated Arm Reach
Chair Characteristics
Visual Work, Lighting, Posture

39
42
43
45

Self-Help in VDT Workplace
Comfort
Problem Solving Form

48
49

Environmental Factors
Paced Work/l'ime Pressure
Problem Solving Form

52
56
59

Risk Factors for Carpal
Tunnel Syndrome
Factors Affecting Grip Strength

62

Job Analysis Form - Repetitive
Tasks
Evaluating Hand Tools
Problem Analysis: Repetitive
Work

66

---

69
71

--

Human Reliability
Ergonomics and Quality
Information Transfer - Controls
and Displays
Job Control and Task Complexity
Puzzle Exercise
Reliability Problems Form

65

76
77
79
86
88
89

-3

--

--· -

8,285,290
20,24,30
285
112,140,150

-338
52

23, 50

-18, 28,50
20
57
17,30,50
28,101,179

EDFPAW2

----

2
210,446,496
237
13,446
218,255
---

24,217
217

--

---

--

142

--

142
223,282

--

--

210, 242, 320

--

--

230
151,244
151,254

140

181

--

90,107,162

--1v,

�_,,7
C

135,340

Risk Factors for Low Back Pain
Natural History Degenerative Disc
Manual Materials Handling
Strength and Location
Maximum Force Applications
Kodak Lifting Guidelines
Guidelines to Reduce Back Risk

91
93
94
98
99
100
101

Total Workload
Repetitive Lifting Guidelines
General Guidelines/Lifting/
Repetitive Work
Problem Analysis: Manl Handling

105
111
112

Cost/Benefit Analyses
The Costs of Poor Design
Ergonomics in Old/New Design
Problem Solving Form

117
121
123
124

Ergonomics Problem Instruct.
Problem Solving Forms

127
128

10 Ergonomics Guidelines
Ergonomics Checklist
Ergonomics Design Form
How to - Ergonomics Survey
Ergonomics/Return to Work
Low Back/Repet Motions Rehab

137
138
147
148
150
152

313

Ergonomics Awareness Examples
Equipment
Resources
Videotape Guidelines
Course Evaluation Form

154
159
161
165
end

320
365

3/18/8 9 SHR

15,122,151

338
135,338
384,446
360,403
135, 340
206, 276,48 0
403

113

--

9
--

313

----

--

98

--

---

446
534

--

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Acknowledgements
The illustrations on pages 12b, 42, 100, and 111 are used with
permission from Eastman Kodak's Ergonomic Design for People at Work,
Volumes 1 and 2. The tables, text and illustrations on pages 43, 44, 98,
99 and 101 to 104 are from Working With Backache by S. H. Rodgers. The
article on pages 20-26 was published by Thieme Publishers in Seminars
in Occupational Medicine in March 1987. The article on Perceived
Exertion is from the Polinsky Rehabilitation Center's FCA (Functional
Capacities Assessment) Newsletter, and information in there and on
pages 45 to 48 has been developed in conjunction with Dr. Inger Williams.
All other material in this syllabus is by Dr. S.H. Rodgers and permission
to reproduce it must be obtained from her.

12/13/88 SHR

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4-Day Ergonomics Training Course
Eastman Kodak Company, Rochester
April 17th to 20th, 1989

I

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Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT ANO PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�}--

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4-Hour Ergonomics Awareness Seminar for
Supervisory, Support, and Manufacturing Engineers
at GE's Erie Transportation Sy$tems, June 1, 1989

Outline
What Is Ergonomics - Why Do It ?
Review of an Ergonomics Program in Coil Winding - Bill
Fatiguing Work and Risk Factors for Injury on the Job
Techniques to Reduce the Risk for Injury
Videotape Review and Problem Solving
Discussion and Questions

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
..HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EOUIPMENT ANO PRODUCT DESIGN
3. HEAL.TH ANO SAFETY PROGRAMS
(711) 5oM-3lll7 • 1911 HUNTINGTON HILLS • ROCHESTER, N.Y. 1�

�Topic: Ergonomics Goals
I.

Designing Jobs Within the Capacities of Most People

II.

Designing Jobs to Maximize Human Performance Capabilities
Without Adding Unnecessary Stress

111. Decreasing the Opportunity for Human Error By Reducing
Unnecessary Complexity
IV. Optimizing the Interaction of the Worker with the Workplace,
Environment and Equipment/Tools to avoid Unnecessary
Effort and Accidents or Illness
V.

Providing Flexibility in the Way the Job is Done in Order to
Accommodate Individual Differences in Capacities

111�8.7 SHA

.,

�NTERNATIONAL@PAPER

Ergonomics Training Course for Engineering Staff
International Paper Corporate Engineering
Mobile, AL, June 14-15, 1989, 8:00 to 4:00 PM

Table of Contents
Wednesday: Overview of Ergonomics Concepts, Scope
Presentation of First Design Project
Discussion of Ergonomics Implications
Presentation of Second Design Project
Discussion of Ergonomics :Implications
Presentation of Third Design Project
Discussion of Ergonomics Implications
Who Do We Design For? Population Work Capacities
Guidelines for Reaches, Work Heights, Visual Access
Repetitive Work Guidelines
Thursday: Design to Reduce the Risk of Overexertion Injuries
Manual Handling Guidelines
Design to Reduce Environmental Stressors -Temperature,
Humidity, Noise, Lighting, Work Pace
Design to Reduce Human Error Potential
Review of Projects Using Ergonomics Guidelines
Cost/Benefit Analyses of Ergonomics Problem Solutions

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS

�-j_

2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�1.5-Day Ergonomics Training Course
for Xerox Corporation
November 20-21, 1989, Schlegel Road School
Schedule
Monday, November 20th
12:30- 1:00 PM
1:00- 2:00
2:00- 2:15
2:15 - 3:00
3:00- 4:00
4:00- 5:00

Introductions and Overview
Work Capacities and Ergonomics Design Goals
Break
Quantifying Fatigue at Work -Work/Reeovery
Problem Solving-Posture and Productivity
Overexertion Injuries-Overview

Tuesday, November 21st
8:00- 9:00
Risk Factors for Repetitive Motions Disorders,
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks
9:00-10:00
Break
10:00-10:15
10:15-11:00
Manual Handling Guidelines-Lifting, Force
Exertion
Problem Solving: Manual Handling
11:00-12:00
Lunch
12:00- 1:00 PM
1:002:002:453:00 4:00-

2:00
2:45
3:00
-4:00
5:00

Human Reliability and Quality Performance
Cost/Benefit Analyses of Ergonomics Solutions
Break
Problem Solving: Cost Justifying Change
Surveys, Resources, Summary, Evaluations

Suzanne H. Rodgers, Ph.D

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CONSULTANT IN ERGONOMICS/HUMAN FACTORS
""HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

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1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Ergonomics Update and Awareness Training - Lansing Body
Plant - General Motors Corporation - July 24-25, 1989
Ergonomics Handout
Monday. Julv 24th PM: Posture and Productivitv - Work Capacitv Over Time: Benefits of
Ergonomics Design
Muscle WorkJR.ecovery Needs to Avoid Fatigue and Overexertion
Comfortable Reaches and Work Heights
Videotape Review of Jobs Where Postural Problems Have Been Seen; Before/After
Examples of Ergonomics Improvements - Ergo Reps
Ergonomics and Quality Performance - Work Pace, Environment
Tuesdav, Julv 25th: Reducing Overexertion Injuries and Illness - Repetitive Motions .Problems
and Low Back Pain
.,.

Repetitive Motions Problems/Carpal Tunnel Syndrome - Why Now?
Factors Affecting Grip Strength and Other Risk Factors
Approaches to Reduce Risk Factors for Repetitive Work Problems
Videotape Review of Repetitive Tasks; Before/After Examples of Ergonomics
Improvements - Ergo Reps
Low Back Pain - What Is It ? How Can We Manage the Problem ?
Lifting, Pushing, Pulling Guidelines
General Guidelines for Ergonomic Job, Workplace, Equipment, and Environmental
Design
Proactive and Reactive Ergonomics
- The Future
k
Ergonomics Teamwor in the Lansing Body Plant - Ergo Reps

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. _TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�Ergonomics Awareness Course
1.l

Table of Contents
Topic

Starting Page Location

Course Content - Ergonomics
Table of Contents
Acknowledgements
Ergonomics Goals/Overview
The Costs of Poor Design
Capacities for Work
Factors That Increase Stress
Anthropometric Data
Height and Reach Interactions
Problem Analysis: Standing Work

Syllabus
cover
i
1
2
3
5
7
8

9

10
11
19
20

Recovery Time/Static Work
Design to Minimize Effort
Job Analysis Form - Repetitive
Tasks
Problem Solving Form

23

Ergonomics and Quality
Job Control and Task Complexity
Reliability Problems Form

25
27
29

Risk Factors for Carpal
Tunnel Syndrome
Factors Affecting Grip Strength
Risk Factors for Low Back Pain
Strength and Location
Maximum Force Applications
Kodak Lifting Guidelines
Repetitive Lifting Guidelines

30
33
34
36
37
38
39

Cost/Benefit Analyses
Cost Benefit - New/Existing Design
Cost/Benefit Problem Solving Form

40
44
45

Additional Problem Solving Forms
· Resources - Bibliography

48
54

EDFPAWl

3

8,285,290
20,24,30
23, 50
112,140,150
52

EDFPAW2

2
210,446,496
237
13,446
218,255
24,217

181
151, 244
143,298
15,122,151

365

466,503
135,340
135,338
384,446
360, 403
403

559

7/22/89 SHR

i
£,

�Acknowledgements
The illustrations on pages 8, 9, 38, and 39 are used with
permission from Eastman Kodak's Ergonomic Design for People at Work,
Volumes 1 and 2. The tables, text and illustrations on pages 36 and 37
are from Working With Backache by S. H. Rodgers. The article on pages
11-17 was published by Thieme Publishers in Seminars in Occupational
Medicine in March 1987. All other material in this syllabus is by Dr. S.H.
Rodgers and permission to reproduce it must be obtained from her.

7/22/89 SHR

�ERGONOMICS TRAINING
LANSING B.0.C. BODY ASSEMBLY PLANT
July 24, 25t 1989
II

AGENDA

II

&lt;MONDAY JULY 24th)
7:00 A.M.

Introductions / Goals
of Course

Dr. Suzanne Rodgers

7: 3(J A.M.

Disability Management

Brenda Wibert

7:45 A.M.

Workplace Engineering

Bruce Vanden Berg

8:00 A.M.

Workers Comp. Cost

Henry Miller

8:15 A.M.

Placement Activity

Annie Baker
Denny Cox

8:30 A.M.

BREAK

8:45 A.M.

Comp. Injuries, &lt;Body
Plant&gt;, Avg. Corp. Cost

Ergonomics
Representatives

f/�

9: 00 A.M.

Relationship of Ergo to
Safety, Use of P.C. to
track recordable inj.

Ergonomics
Representatives

k1
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9:30 A. ,-1.

Review of operations
Before / After &lt;slides)

Ergonomics
Representatives

16:00 A.M.
1{:15

5"'1d.Y

BREAK

A.M.

Dr. Suzanne Rodgers

11: 15 A.M.

LUNCH

12:00 P.M.

Sue, please fill in the remainder of Monday
and for Tuesday per your schedule.

Each of the days will begin at 7:00 A.M and end at 3:30 P.M •

•

�Acknowledgements
The illustrations on pages 13, 42, 95, and 106 are used with
permission from Eastman Kodak's Ergonomic Design for People at Work,
Volumes 1 and 2 published by van Nostrand Reinhold. The tables, text
and illustrations on pages 20, 43, 44, 93, 94 and 96 to 99 are from
Working With Backache by S. H. Rodgers. The article on pages 21-26 was
published by Thieme Publishers in Seminars in Occupational Medicine in
March 1987. The article on Perceived Exertion is from the Polinsky
Rehabilitation Center's FCA (Functional Capacities Assessment)
Newsletter, and information in there and on pages 45-48 has been
developed in conjunction with Dr. Inger Williams. All other material in
this syllabus is by Dr. S.H. Rodgers and permission to reproduce it must
be obtained from her.

9/89 SHR

\"

�Basic Schedule for 2-Day Ergonomics Course
Day 1: Posture and Productivity; Repetitive Work
8:00- 8:30 AM
8:30- 9:00
9:00- 9:45
9:45- 10:00
10:00- 10:30
10:45- 11:15
11:15- 12:00
12:00- 1:00 PM
1:001:452:152:303:004:00-

1:45
2:15
2:30
3:00
4:00
4:30

Introductions
Work Capacity; Who Do We Design For ?
Posture and Productivity- Static Work, Reach/Height
Interactions; Visual Needs
Break
Work/Recovery Curves
Problem Solving: Static Work
Problem Solving: Standing Workplace Design
Lunch
Repetitive Motions Disorders
Risk Factors for Tendonitis, Carpal Tunnel, etc; Tool Design
Break
Ergonomic Job Analysis Form
Problem Solving: Repetitive Tasks
Summary of Workplace Design and Repetitive Work Guidelines

Day 2: Manual Handling and Cost/Benefit Analyses
8:00- 8:30
8:30- 9:00
9:00- 9:30
9:30- 9:45
9:45- 10:45
10:45-11:30
11:30-12:00
12:00- 1:00 PM
1:00- 1:30
1:30- 2:30
2:30- 2:45
2:45 - 3:30
3:30- 4:15
4:15 - 4:30
9/30/89 SHR

Low Back Pain and Job Risk Factors
Managing Upper Extremity and Low Back Disability at Work
Manual Handling Guidelines
Break
Problem Solving: Manual Handling
Frequent Lifting/ Total Workload/Hours of Work
Job Review: Handling Tasks
Lunch
Cost-Benefit Analyses of Solutions
Problem Solving Using Cost-Benefit Approach
Break
Problem Solving: Cost Benefit Approach
Surveys/Checklists/Resources
Course Evaluations

�GOODjfYEAR

3-Day Ergonomics Training Course for the
Goodyear Hose and Belt Plant in Lincoln, NE
on October 4-6, 1989

Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH ANO SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�Basic Schedule for 3-Day Ergonomics Course
Day 1: Ergonomics Oyerview, Posture and Productivity
8:00- 8:30 AM
8:30- 9:00
9:00- 9:45
9:45- 10:00
10:00- 10:45
10:45- 11:15
11:15- 12:00
12:00 - 1:00 PM
1:001:452:152:303:004:00-

1:45
2:15
2:30
3:00
4:00
4:30

Introductions and Overview
Work Capacity
Who Do We Design For?
Break
Posture and Productivity- Static Work, Reach/Height
Interactions
Work/Recovery Curves
Problem Solving: Static Work
Lunch
Problem Solving: Standing Workplace Design
Seated Workplace Design and Visual Work
Break
Problem Solving: Seated Workplace Design
Job Review- Postures
Summary of Workplace Design Guidelines

Day 2: Preventing Overexertion Injuries and Enhancing Human Reliability
8:00 - 8:30 AM
8:30 - 9:15
9:15 - 10:00
10:00- 10:15
10:15- 10:30
10:30- 11:30
11:30- 12:00
12:00- 1:00PM
1:001:452:152:453:30-

1:45
2:15
2:45
3:00
4:30.

Repetitive Motions Disorders
Risk Factors for Tendonitis, Carpal Tunnel, etc.
Ergonomic Job Analysis Form
Break
Tool Design and Selection
Problem Solving: Repetitive Tasks
Job Review- Repetitive Tasks
Lunch
Reducing Job Complexity- Information, Pacing
Human Reliability- Controls/Displays and Automation
Environmental Factors Influencing Performance
Break
Problem Solving: Information and Environment

Day 3: Manual Handling and Cost/Benefit Analyses
8:00- 8:30
8:30- 9:00
9:00- 9:30
9:30- 9:45
9:45- 10:45
10:45-11:30
11:30-12:00
12:00- 1:00 PM
1:00- 1:30
1:30- 2:30
2:30- 2:45
2:45- 3:30
3:30- 4:15
4:15- 4:30

Low Back Pain and Job Risk Factors
Managing Upper Extremity and Low Back Disability at Work
Manual Handling Guidelines
Break
Problem Solving: Manual Handling
Frequent Lifting/ Total Workload/Hours of Work
Job Review: Handling Tasks
Lunch
Cost-Benefit Analyses of Solutions
Problem Solving Using Cost-Benefit Approach
Break
Problem Solving: Cost Benefit Approach
Surveys/Checklists/Resources
Course Evaluations

9/4/89 SHR
I

L

�.(

r

·. . .

. ...

,

Nit.

,.
&lt;
l · -t . ·.
·01t.1·e-D�y Ergonomics Awareness Course for
;�

'-ic

\

!Engineers at the DuPont Fibers Plants,
·_cape Fear, NC, November 14, 1989

Table of Contents
Topic·
A. Capacity and Workload Determinants
B. Who Do We Design For? -Anthropometrics
C. 11 Ergonomics Guidelines for Design
1. Height and Reach Interaction
2. General Anthropometrics Guidelines
3. Recovery Time Needs for Repetitive Work
D. Problem Solving: Posture and Repetitive Work
E. 11 Ergonomics Guidelines for Design (contd)
1. Static Strength and Position
2. Maximum Forces for Design
3. Occasional Lifting Guidelines
4. Factors Affecting Quality Performance
5. What Men and Machines Do Best
F. Questions To Ask in the Field
G. Checklist for Ergonomics Input to New Design
H.. Bibliographies

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

Page
1
2
6
8
10
12
19
21
22
23
24
26
27
29
35

�I

1.5-Day Ergonomics Training Course
for Xerox Corporation
November20-21, 1989, Schlegel Road School
Schedule
Monday, November 20th
12:30- 1:00 PM
1:00- 2:00
2:00- 2:15
2:15 - 3:00
3:00- 4:00
4:00 - 5:00

Tuesday, November 21st
8:00- 9:00

9:00-10:00
10:00-10:15
10:15-11:00
11:00-12:00
12:00- 1 :00 PM
1:002:002:45 3:00 4:00 -

2:00
2:45
3:00
4:00
5:00

Introductions and Overview
Work Capacities and Ergonomics Design Goals
Break
Quantifying Fatigue at Work-Work/Recovery
Problem Solving - Posture and Productivity
Overexertion Injuries-Overview
Risk Factors for Repetitive Motions Disorders,
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks
Break
Manual Handling Guidelines-Lifting, Force
Exertion
Problem Solving: Manual Handling
Lunch
Human Reliability and Quality Performance
Cost/Benefit Analyses of Ergonomics Solutions
Break
Problem Solving: Cost Justifying Change
Surveys, Resources, Summary, Evaluations

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICSiHUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

;�'�ti(

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�2-Day Ergonomics Training Course for
General Electric Medical Systems Engineers,
Waukesha, WI, January 11-12, 1990

Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�General Electric Medical Systems - Milwaukee, WI
2-Day Ergonomics Training Course for Engineering Staff
January 11-12, 1990

-C�J

Schedule

January 11th:

Ergonomics Principles and Guidelines - Problem
Identification

8:00-8:30 AM
8:30-9:30

11:00-12:00
12:00-1:00 PM
1:00-1:45
1:45-2:45
2:45-3:00
3:00-4:00
4:00-5:00

Introductions, Review Course Goals
Ergonomics in the Design Process - What Information is
Available? Why Do It? When Does It Come In?
Break
Who Do We Design For? Reaches, Heights, Clearances,
Forces, Weights, Lighting, Pace, Complexity of
Information
Problem Solving - Who Do We Design For?
Lunch
Problem Solving - Analyzing an Existing Design
Risk Factors for Repetitive Motions and Back Problems
Break
Designing to Reduce Complexity/Design for Assembly
Review of Ergonomic Design Guidelines

January 12th:

Ergonomics Problem Analysis and Applications

9:30-9:45
9:45-11:00

8:00-8:30 AM
8:30-9:00
9:00-10:00

Presentation of a Layout Design Problem
Questions to Develop Needed Design Information
Problem Solving in Small Groups Using Ergonomics
Guidelines
10:00-10:15
Break
10: 15-11:15
Presentation by Groups of Suggested Design with
Justifications and Discussion
11:15-12:00
Presentation of Additional Design Problems (3-4)
12:00-1:00 PM Lunch
1:00-2:30
Problem Solving in Groups by Product Area
2:30-2:45
Break
2:45-4:15
Pres�ntation by Groups of New Designs
4:15-4:45
Building Ergonomics Into the Design Process/Available
Resources
4:45 - 5:00
Course Evaluations
12/28/89 SHR/bl

I.

�Ergonomics Training Course for GE Medical Systems Engineers

.o

()

&lt;_)

Table of Contents
Topic
Schedule
Table of Contents
Acknowledgements

Starting Page Location
EDFPAW 1
Syllabus

EDFPAW 2

2
3

Introduction and Course Goals
Ergonomics Goals/National Trends

4
5

Who Do We Design For? The Variability
of People, Anthropometric Data
Height and Reach Interactions
Using Anthropometric Data

7
12
14

Recovery Time/Static Muscle Work
Quality Factors - Vision, Lighting, Pace
VDT Workplace Comfort
Design to Minimize Effort

16
23
25
29

Problem Solving - Who Do We Design For?
Finding the Best Solution to a Problem
Ergonomics Problem Solving
Extra Problem Solving Form

30
31
32
34

Risk Factors for Carpal Tunnel
Syndrome and Low Back Pain
Strength and Location
Maximum Force Applications
Kodak Lifting Guidelines
Summary of Guidelines to Reduce Injury

36
42
43
44
45

Human Reliability - Man vs Machine
Reliability Problem, Analysis Form
Information Transfer - Controls &amp; Displays
Job Control and Task Complexity

46
47
48
52

12 Ergonomics Guidelines
Ergonomics Checklist
How To - Ergonomics Survey, Questions

54
56
62

Cost/Benefit Analyses
The Costs of Poor Design
Problem Solving Form - Cost/Benefit
Ergonomics in Old/New Design
Extra Problem Solving Forms

65
70
72
75
76

New Design ProblemAnalysis Forms

82

Resources - Bibliographies
Course Evaluation Form

85
end

3
8,285,290
20,24,30
285
112,140,150,338
17,30,50
28,101,179
52

2
13,446
218,255
24,217
223,282

135,151,244,254,340
15,122,151

135,338
384,446
360, 403

181
90,107,162
313
313

98
9

365

559

1/5/90 SHR

2.

�0

Acknowledgements
The illustrations on pages 9-13, and 44 are used with permission
from Eastman Kodak's Ergonomic Design for People at Work, Volumes 1
and 2 published by Van Nostrand Reinhold in 1983 and 1986. The tables,
text and illustrations on pages 27, 42, and 43 are from Working With
Backache by S. H. Rodgers (1985). The table on page 46 is from Human
Perfoprmance in Industry by H. Murrell, published by Van Nostrand
Reinhold in 1965. The article on pages 16-22 was published by Thieme
Publishers in Seminars in Occupational Medicine in March 1987.
Information on pages 25, 26, and 28 has been developed in conjunction
with Dr. Inger Williams. All other material in this syllabus is by Dr. S.H.
Rodgers and permission to reproduce it must be obtained from her.

9/89 SHR

�()

Introductions and Course Goals
I. Introductions of Class Members and Instructor
II. Course Goals
A. Become Familiar With the Field of Ergonomics
and Some Resource Books
1. Overview of the Field
2. Ergonomics in Manufacturing
3. Resource Materials - Review Contents of the Kodak
Books

B. Be Able to Identify and Analyze Ergonomics
Problems in the Plant

0

1. Develop "eyes" for ergonomics problems
2. Learn how to ask questions and look further to
determine the underlying problems

C. Be Able to Generate Multiple Approaches for
Solving the Problems
1. Participate with the workers, other engineers, plant
maintenance, and supervision in solving
problems.
2. Generate at least 3 solutions for every problem
identified.

D. Understand How to Go About Incorporating
Ergonomic Principles Into New Designs

(\___/}

1. Understand the differences between new design and
redesign in applying ergonomics principles.
2. Be able to justify the time and potential extra cost
of designing using ergonomics principles by
using data from existing jobs.
3. Identify processes for incorporating ergonomics into new
design on a routine basis.
1/6/90 SHR

�''

7

7

_J

3-Day Ergonomics Training Based on Topeka's
Earthmover Band Building Operation*
Central Engineering and Topeka Plant Personnel,
The Goodyear Tire and Rubber Company,
Akron, Ohio, February 13-15, 1990

Syllabus

Suzanne :H:. '.RofLJers,. Ph.fl.
Consultant i,n '.Er9onomi,cs
16 9 :H:unttn9ton :H:UJs
'.Rochester, New yor� 14622
l__j

(716) 544-3587

L,

,_.,

* Based on a concept by Ron Beahn, Safety and Ergonomics Liason,
Central Engineering

�3-Day Ergonomics Training Course for Goodyear Central Engineering and
Topeka Plant Personnel, Akron, Ohio, February 13-15, 1990
Table of Contents

Topic

�

Schedule
Table of Contents
Ergonomic Goals/Trends
Course Goals
EarthmoverBandBuilding Incidents
Blueprints ofBand Building Area- Topeka
5 Questions Form
Ergonomic Opportunities- Band Building
Ergonomic Principles for Layout/Flow
Anthropometric Data
Recovery Time Needs for Repetitive Work
Height/Reach Interaction- Standing Work
Determining theBest Height for a Standing Workplace
Paced Work, Job Complexity, Environment- Puzzle
Factors Affecting Quality Performance
Factors Affecting Human Reliability
Finding Best Solutions to Ergonomics Problems
Problem Solving Form
Risk Factors for Carpal Tunnel Syndrome
Ergonomic Job Analysis Form
Summary of EarthmoverBandBuilding Design
Job Control and Task Complexity
Checklist for Ergonomics Input to New Design
Risk Factors for LowBack Pain
Strength and Location
Maximum Permissible Forces for Design
Guidelines for Occasional Lifts
Overexertion Risk Factors Summary
General Design Guidelines for Manual Handling and
and Repetitive Tasks
Cost-Benefit Analyses of Ergonomic Problem Solutions
Costs of Poor Design
Cost Justifying Problem Solving Form
Summary of EarthmoverBandBuilding Design
Extra Problem Solving Forms
SHR References
Evaluation Form

1
3
4
6
7
9
14
15
16
18
22
29
30
32
33
35
37
38
41
43
46
48
50
56
58a
58b
59
60
61
62
66
68
71
73
80
end

EDFPAW Location

Volume1

Volume1
Volume 1
Volume2
Volume·l
Volume1
Volumes 1 &amp;2
Volumes 1 &amp;2
Volume1
Volumes1 &amp;2
Volume2
Volumes1 &amp;2
Volumes1 &amp;2
Volume2
Volume2
Volume2
Volume2
Volume2
Volume2
Volumes1 &amp;2

Acknowledgments
The illustrations and information on pages19-21,29, and59 are used with permission from
Eastman Kodak's Ergonomic Design for People at Work, Volumes 1 and 2 published by Van
Nostrand Reinhold. The illustration and table on pages 58a &amp; b are from Working With Backa.che
by S. H. Rodgers. The article on pages 22-27 was published by Thieme Publishers in Seminars in
Occupational Medicine in March 1987. The blueprints and incident data are from Goodyear
Central Engineering and the Topeka plant. All other material in this syllabus is by Dr. S.H.
Rodgers and permission to reproduce it must be obtained from her.

3,

�4-Hour Ergonomics Awareness and
Problem Solving Session
for GE Transportation Systems Supervisory
and Production Personnel
Erie, PA, March 7, 1990

Table of Contents

National Trends in Ergonomics
How To Do An Ergonomics Survey
Identifying Ergonomics Problems
Ergonomic Job Analysis
Manual Lifting Guidelines
Finding the Best Solution to an Ergonomics Problem
Problem Solving Form
Ergonomics Design Guidelines
Extra Problem Solving Forms

1
2
4
10
13
14
15
18
23

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�,&lt;J
Ergonomics Design Guidelines and Their Applications
A 4-Hour Seminar for GE Transportation Systems
Erie, PA, March 8th, 1990

Table of Contents

· .. ,�

- �

Topic
Ergonomics Goals
Design Guidelines
Anthropometric Data
Height/Reach Interaction
Work/Recovery Needs for Muscular Work
Problem Solving: Designing for Comfort
Pacing Stress
Maximum Force Exertion Guidelines
Lifting Guidelines
Problem Solving: Designing to Reduce
Overexertion Injuries
Engineer's Checklist for New Design
Cost-Benefit Analyses
Problem Solving: New Designs
Resources

Starting Page
1
2
7
10
12
19
22
25
26
27

30
36

43
44

Acknowledgments
The illustrations and information on pages 7 to l1 and 26 are used with permission from
Eastman Kodak's Ergonomic Designing for People at Work, Volumes 1 and 2 published by Van
Nostrand Reinhold. The table on page 25 is from Working With Backache by S. H. Rodgers.
The article on pages 12-17 was published by Thieme Publishers in Seminars in Occupational
Medicine in March 1987. All other material in this syllabus is by Dr. S.H. Rodgers and
permission to reproduce it must be obtained from her.

I/ \

,'-{

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�4-Day Ergonomics Training Course for
Amoco Foam Plants
Chippewa Falls, WI, March 26-29, 1990

Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�4-Day Ergonomics c,eurse Training for Amoco Foam Plants
... .-------,

\

\

i

Monday: Ergonomics Overview, Posture and Productivity
8:00- 8:30 AM
8:30 - 9:00
9:00- 9:45
9:45 -10:00

Introductions and Overview
Work Capacity
Who Do We Design For ?
Break

10:00-10:45
10:45-11 :15
11:15-12:00
12:00-12:45 PM

Posture and Productivity-Static Work,
Reach/Height Interactions
Work/Recovery Curves
Problem Solving: Static Work
Lunch

12:45- 1:45
1:45- 2:15
2:15- 2:30

Problem Solving: Standing Workplace Design
Seated Workplace Design and Yisual Work
Break

2:30- 3:00
3:00- 3:45
3:45- 4:00

Problem Solving: Seated Workplace Design
Videotape Review-Postures
Summary of Workplace Design Guidelines

Tuesday: - Preventing Overexertion Injuries
and Enhancing Human Reliability
8:00- 8:30 AM
8:30- 9:15
9:15- 10:00
10:00-10:15
10:15-10:30
10:30-11:30
11:30-12:00
12:00-12:45 PM

Repetitive Motions Disorders
Risk Factors for Tendonitis, Carpal Tunnel, etc.
Ergonomic Job Analysis Form
Break
Tool Design and Selection
Problem Solving: Repetitive Tasks
Videotape Review - Repetitive Tasks
Lunch

12:45-1:30
1:30- 2:15

Reducing Job Complexity -Information, Pacing
Human Reliability-Controls/Displays and
Automation
Environmental Factors Influencing Performance
Break
Problem Solving: Information and Environment

2:15- 2:45
2:45- 3:00
3:00- 4:00

�Wednesday: Manual Handling and Cost/Benefit

Analyses

./�

t
•.

·.
j

8:00 - 8:30
8:30 - 9:00
9:00 - 9:30
9:30 - 9:45

Low Back Pain and Job Risk Factors
Managing Upper Extremity and Low Back
Disability in the Workplace
Manual Handling Guidelines
Break

9:45- 10:45
10:45-11 :30
11:30 -12:00
12:00 -12:45

Problem Solving: Manual Handling
Frequent Lifting/ Total Workload/Hours of Work
Videotape Review: Handling Tasks
Lunch

12:45- 1:15
1:15- 2:30
2:30 - 2:45

Cost-Benefit Analyses of Solutions
Problem Solving Using Cost-Benefit Approach
,Break

2:45- 3:30

Problem Solving: Cost Benefit Approach

3:30 - 3:45
3:45- 4:00

Surveys/Checklists/Resources
Instructions for Presentations·

Thursday: Problem Solving and Presentations by Class Members
8:00 - 9:15
9:15- 10:00
10:00 - 10:15

Work on Presentations (with Oversight)
Case Study #1
Break

10:15-10:45
10:45- 11:15
11:15- 11:45
11:45- 12:30

Case Study #2
Case Study # 3
Case Study # 4
Lunch Break

12:30 - 2:00
2:00 - 2:30
2:30 - 2:45
2:45 - 3:15
3:15- 3:30

Discussion: Starting an Ergonomics Program
Case Study # 5
Break
Action Plan Discussion
Course Evaluations

3/12/90 SHR

�r

LL.

�Ergonomics and Occupational Health
A 1.5 Day Training Course for General Electric Occupational
Health Nurses and Human Relations Managers
Nashville, TN on April 8-9, 1990
Cincinnati, OH on June 11-12, 1990
Philadelphia, PA on September 10-11, 1990

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�1990 GENERAL ELEC'IRIC OCCUPATIONAL NURSE EDUCATION SEMINAR
OPRYLAND HOTEL
NASHVILLE, TN
APRIL 9-11

�4-Day Ergonomics Training Course for
Goodyear Tire and Rubber Company Plants
May 22-25 and September 25-28, 1990, Akron, Ohio

Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�1990 GENERAL ELEC1RIC OCCUPATIONAL NURSE EDUCATION SEMINAR
WESTIN HOTEL
CINCINNATI, OH
JUNE 11-13

�Ergonomics and Occupational Health
A 1.5 Day Training Course for General Electric Occupational
Health Nurses and Human Relations Managers
Nashville, TN on April 8-9, 1990
Cincinnati, OH on June 11-12, 1990
Philadelphia, PA on September 10-11, 1990

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�3-Day Ergonomics Training Program
for General Electric Aircraft Engine
Evandale, Ohio, June 13-15, 1990
Syllabus

\

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

1716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�3-Day Ergonomics Training Course for GE Aircraft Engine, Evandale
Wednesday, June 13, 1990: Ergonomics Overview, Posture and Productivity
8:00- 8:30 AM
8:30- 9:00
9:00- 9:45
9:45 - 10:00
10:00- 10:45
10:45 - 11:15
11:15 - 12:00
12:00- 1:00 PM
1:001:45 2:15 2:303:004:00-

1:45
2:15
2:30
3:00
4:00
4:30

Introductions and Overview
Work Capacity
Who Do We Design For?
Break
Posture and Productivity- Static Work, Reach/Height
Interactions
Work/Recovery Curves
Problem Solving: Layout and Workplace Design
Lunch
Problem Solving: S.tanding Workplace Design
Seated Workplace :Oesign and Visual Work
Break
Problem Solving: Seated Workplace Design
Job Review- Postures
Summary of W?rkplace Design Guidelines

Thursday, June 14, 1990: Preventing Overexertion Injuries and Enhancing
Human Reliability
8:00 - 8:30 AM
8:30 - 9:15
9:15 - 10:00
10:00- 10:15
10:15 - 10:30
10:30- 11:30
11:30- 12:00
12:00- 1:00 PM
1:001:45 2:15 2:45 3:30-

1:45
2:15
2:45
3:00
4:30

Repetitive Motions Disorders
Risk Factors for Tendonitis, Carpal Tunnel, etc.
Ergonomic Job Analysis Form
Break
Tool Design and Selection
Problem Solving': Repetitive Tasks
Job Review- Repetitive Tasks
Lunch
Reducing Job Complexity- Information, Pacing
Human Reliability- Controls/Displays and Automation
Environmental Factors Influencing Performance
Break
Problem Solving: Information and Environment

Friday, June 15, 1990: Manual Handling and Cost/Benefit Analyses
·,-�

I

8:00- 8:30
8:30- 9:00
9:00- 9:30
9:30- 9:45
9:45 - 10:45
10:45 -11:30
11:30-12:00
12:00- 1:00 PM
1:00- 1:30
1:30- 2:30
2:30- 2:45
2:45 - 3:30
3:30 - 4:15
4:15 - 4:30
6/7/90 SHR

Low Back Pain and Job Risk Factors
Managing Upper Extremity and Low Back Disability at Work
Manual Handling Guidelines
Break
Problem Solving: Manual Handling
Frequent Lifting/ Total Workload/Hours of Work
Job Review: Handling Tasks
Lunch
Cost-Benefit Analyses of Solutions
Problem Solving Using Cost-Benefit Approach
Break
Problem Solving: Cost Benefit Approach
Surveys/Checklists/Resources
Course Evaluations

,
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Schedule for a 4�Day Ergonomics Training Course Based on New
Design Problems for Central Engineering Personnel, Luxembourg,
Monday, June 18,1990: Specification, Layout and Workplace
Design
8:00- 8:30 AM
8:30- 9:00
9:00- 9:45

Introductions and Review of .Course Goals
Videotape Review of New Design Task
Development of 5 Questions to ask the Experts about the JobSmall Groups

11 :45 - 12:45 PM

Break
Presentation of Questions and Expert Responses
Review of the Ergonomic Design Opportunities- Automation
or Ergonomics
Lunch

12:45 - 1:00
1:00- 2:00
2:00- 2:15

Design to Minimize Repetitive Handling/Rehandling
Group Problem Solving: Layout and Workplace Design
Break

2:15- 3:00
2:45 - 3:30
3:30- 4:00

Presentation of Layout Designs and Discussion
Who Do We Design For? Using Anthropometric Data
Height and Reach Interactions, Visual Needs

9:45 - 10:00
10:00- 11:00
11:00- 11:45

Tuesday, June 19, 1990: Work Heights and Reaches,
Machine Pacin�, Environmental Factors, Human Reliability, and
Repetitive Motions Risk Reduction
8:00 - 9:00 AM Group Problem Solv.ing: Working Heights
9:00- 9:45
Discussion of Results of Height Assessment Exercise
Break
9:45 - 10:00
10:00- 11:00
11:00- 11:45
11 :45 - 12:45 PM
12:45 - 1:45
1:45- 2:45
2:45 - 3:00
3:00- 3:45
3:45 - 4:00

Pacing, Environment, and Reliability Factors in Equipment
and Workplace Design- Puzzle Exercise
Group Problem Solving: Designing for Quality PerformanceMachine/Operator Interfaces, Lighting, Precision
Requirements, etc.
Lunch
Presentation and Discussion of Design Approaches to Improve
Operator/Machine Interfaces and Enhance Quality
Performance
Repetitive Motions Disorders and Risk Factor Reduction
Break
Group Problem Solving: Reducing the Opportunities for
Repetitive Motions Disorders
Summary of the Design to Date

�Wednesday, June 20, 1990: Information Processing, Manual
Handling, Force Exertion, Cost Justifying Ergonomic Designs
8:45 AM
8:45 - 9:15
9:15 - 9:45
9:45 -10:00
8:00 -

10:00 -11:00
11:00 -11:45
11:45 -12:45 PM
12:45 - 1:15
1:15 - 2:15

Review of Designs to Minimize Repetitive Motions Disorders
Controls/Displays and Information Handling Requirements
Applications of Human Factors Principles in New Design
Break
Manual Handling and Force Exertion Guidelines
Group Problem Solving: Assessing the Existing Design's
Handling Requirements, Defining Reasonable Ranges for
Handling and-Force Exertion Tasks
Lunch

2:15 - 2:30

Cost Justifying Ergonomic Design
Group Problem Solving: Cost Justifying The New
Operation
Break

2:30 - 3:00
3:00 - 3:30
3:30 - 4:00

Discussion - Cost Justifications
Evaluating Impacts of Non-Ergonomic Design
Problem Selection for Thursday's Session

Thursday, June 21, 1990 : Problem Presentations by Attendees

r.O

8:00 -10:00
10:00 -10:15
10:15 -11:45
11:45 -12:45

Work in Teams on Problems
Break
2 Presentations by Groups
Lunch

12:45 - 1:30

General Discussion: Ergonomics, Design, and Production How Can We Improve the Interfaces ?
2 Presentations by Groups
Evaluations, Resources

1:30 - 2:45
2:45 - 3:00
6/7/90SHR

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Occupational
Ergonomics

Ergonomics Awareness for Goodyear
Luxembourg Plant Personnel
Colmar-Berg, Luxembourg
Friday, June 22 1990

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Outline
A. The Scope of Ergonomics - What ?, Why ?, How ?
B. Work Capacity and Job Perfonnance
C. Overexertion lnjuries
1. Repetitive Motions Disorders
a. Tendonitis and Carpal Tunnel Syndrome
b. Risk Factors - Force; Duration, Frequency, Susceptibility
c. Techniques to Reduce the Risk
2. Low Back Pain
a. Degenerative Disc Disease
b. Risk Factors - Postures, Manual Handling
c. Techniques to Reduce the Risk
D. Ergonomic Problem Analysis Techniques
a. Problem Solving - Repetitive Work
b. Problem Solving - Manual Handling
E. Ergonomics and Quality Perfonnance
a. Complexity Factors in Job Design
b. Pacing/Automation, Environment
F. Cost-Benefit of Ergonomics Problem Solutions

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HE�LTH AND SAFETY PROGRAMS

�-.�

.I

Ergonomics Training Course for
John Deere Waterloo Works
Waterloo, IA, July 10-13, 1990

Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS.
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEAL TH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

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Occupet ione 1.
Ergonomics

.

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Ergonomics Awareness for Rohm .&amp; Haas
Louisville Plant Personnel, July 23,1990

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Outline
A. The Scope of Ergonomics - What ?, Why ?, How ?
B. Work Capacity and Job Performance
C. Overexertion Injuries
1. Repetitive Motions Disorders
.
.
··. . .
a. Tendonitis and Carpal Tunnel Syndrome
.
· .
b. Risk Factors - Force, Duration, Frequency, Susceptibility .
c. Techniques to Reduce the Risk
2. Low Back Pain
a. Degenerative Disc Disease
b. Risk Factors - Postures, Manual Handling
c. Techniques to Reduce the Risk
D. Ergonomic -Problem Analysis Techniques
a. Problem Solving - Repetitive Work
b. Problem Solving - Manual Handling
E. Ergonomics and Quality Performance
a. Complexity Factors in Job Design
b. Pacing/Automation, Environment
F. Cost-Benefit of Ergonomics Problem Solutions

I

Suzanne H. Rodgers, Ph.Q

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CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUG/.i JOB DESIGN"
1. AWARENESS SEMINARS
�_
2. TRAINING ON USE OF HUMAN FACTORS IN.
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER·, N.Y. 14622.

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ELECTRIC PRODUCTS, INC.
� QUALITY WEATiiERPROOF
.._ ELECTRICAL EQUIPMENT

Ergonomics Training and Problem Solving for the
Midwest Electric Ergonomics Committee
Mankato, MN, July 20, 1990

Syllabus

Course Content
A. Overview of Ergonomics and Its Value To The Plant
B. Preventing Fatigue
1. Work Capacities
2. Work/Recovery Needs
3. Designing Reaches
4. Improving Comfort in Office VDT Workplaces
5. Ergonomics Problem Solving
C. Repetitive Motions Problems and Approaches to Reduce Them
1. Description of Repetitive Motions Problems
2. Risk Factors
. 3. Ergonomic Job Analysis Technique
4. Interventions
D. Manual Handling and Low Back Pain Risk Reduction
1. Low Back Pain Risk Factors
2. Guidelines for Manual Lifting
3. Interventions
E. Cost/Benefit Analyses of Ergonomic Solutions

Suzanne H. Rodgers, Ph.D

&gt;-!

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

' ....

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT ANO PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

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(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Midu.,t,l

ELECTRIC PRODUCTS, INC.
� QUALITY WEAlHERPROOF
.._ ELECTRICAL EQUIPMENT

1-Hour Ergonomics Awareness Presentation
to Midwest Electric Products Staff
. Mankato, MN, July 20, 1990
Table of Contents
Topic

National Trends in Ergonomics
The Costs of Poor Design
Capacity and Workload Determinants/Stressors
Work/Recovery Time Graphs
Working Heights and Reach Capabilities
Designing Jobs to Minimize Unnecessary Effort
Ergono1TI1cs Problem Solving
Risk Factors for Repetitive Motions Problems
Factors Affecting Grip Strength
Guidelines for· Occas10nal Lifts - Kodak
Overexertion Injury Risk Factors
Cost Benefit Analyses of Ergonomic Solutions
References - SH Rodgers

Pa�e#
1

2

4
7
8
10
11
13
14
15
16
17

22

Acknowledgement
The illustrations on pages 8, 9, and 15 are used with permission
from Eastman Kodak's Ergonomic Design for People at Work,
Volumes I and 2 published by Van Nostrand Reinhold. All other
material in this syllabus is by Dr. S.H. Rodgers and permission
to reproduce it must be obtained from her.

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
-----

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�National Trends in Ergonomics
Industrial Ergonomics Trends:
1. Focus on illness and injury reduction- reduce health care
costs through ergonomic interventions- upper extremity and
back disorders. Workers' Comp costs increasing 40 to 60% per
year in some plants. Actual cost is about 6 to 7 times more.
Ergonomic problems account for 60-65% of Workers' Comp
costs (strain, sprain, overexertion, esp.).
2. Citation activity by OSHA re Morrell, Iowa Beef, and Kroger
for upper extremity disorders has attracted interest of industry in
general � carpal tunnel syndrome. Lifting guidelines pressure
for standard setting.
3. More training of IEs and the medical community, and more
general public awareness about overexertion injuries and
ergonomics interventions.
4. Changing characteristics of the workforce re women and older
workers in the next 10 to 15 years; probable competition
between employers for workers could lead to increased
attention to job and workplace design.
5. Information handling concerns as more data are collected and
displayed in process control, production machinery, and
computer systems. Software human factors needs are being
identified and complexity issues addressed.
6. Interactions of ergonomics and quality/excellence goals; and
value of ergonomics used at business team level to improve
communications and effect needed change.
7. Recognition of importance of people in manufacturing- GM's
pioneering experience with automation.

Other Applications:
1. Hospital/medical ergonomics- cost containment.
2. Complexity reduction and performance improvement in
military systems.
12n/88 S.H. Rodgers

�The Costs of Poor Design
A. Accident Data
1.
2.
3.
4.
5.

Workers' Compensation costs
Time lost from work - replacement cost
Injury recurrence costs
Accident investigation time - supervisory, Safety
Medical Department time

B. Medical Data

1. Overexertion illnesses
a. Low back pain
b. Repetitive motions disorders

2. Stress-related illness
a. Headaches
b. Gastrointestinal disorders
c. Behavior problems
d. Drug and alcohol abuse
3. Medical restrictions
a. How many?
b. How long?
c. Success in return to work?
d. Repeat injuries or illness?

C. Absenteeism

1. By job title - days lost for all reasons
2. Patterns in relation to production schedules

D. Turnover

1. Usual length of service on the job
2. Number of people on the job in a 5- or 10-year period
3. Reasons for leaving job

�E. Training Time
1 . Time to reach productivity goal
2. Time to be fully trained for job or jobs in department
F. EEO Picture
1. Experience in getting women or older workers on the job
2. Characteristics of people on the job - how typical of workforce
pool?
G. Quality Control
1. Amount of waste
2. Amount of repair work
3. Missed defects - audit
4. Consumer complaints
5. Amount of good product rejected

1/8/86 SHA

3

�Ergonomics and Occupational Health
A 1.5 Day Training Course for General Electric Occupational
Health Nurses and Human Relations Managers
Nashville, TN on April 8-9, 1990
Cincinnati, OH on June 11-12, 1990
Philadelphia, PA on September 10-11, 1990

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Ergonomics Awareness Course for
Supervisors and Engineers ·
John Deere Harvester Works, East Moline, IL
October 1_5, 16, 17, 1990
Table of Contents*

·,v-----,\
I

· Work Capacity and Job Design
Stress Sensitizers
Identifying Ergonomic Problems
Ergonomics Problem Solving Form
Risk Factors for Carpal Tunnel
Factors Affecting Grip, Strength
Ergonomic Job Analysis Technique
Ergonomic Problem Solving Form
12 Ergonomics _Guidelines
Cost/Benefit Analyses
The Costs of Poor Design
Problem Solving: Cost Justifying
References - S.H. Rodgers

Page

1
3
4
10
12
14
15
19
21
26

:30
32
35

• The material in this syllabus has been developed by Dr. S.H. Rodgers, and
permission to reproduce it must be obtained from her.

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
.. HIGHER PRODUCTIVITY THROUGH JOB DESIGN""
1. AWARENESS SEMINARS
Z. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EOUIPMENT AND PRODUCT OESIGIII

3. HEAL.TH AND SAFETY PROGRAMS
,,.., ....__, o 1a WUNTlllff.TtiM WILLA.• RCICHl!STl!R. N.Y: ,_

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Capacity and Workload Determinants
Yh 1//////////,, Maximum
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Work

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Capacity

Usu a 1

----------------------------- 75% - 35 min

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1 hour
40% - 2.5 hrs
33% - 8 hrs
25% - &gt; 12 hrs

Basel

�Ergonomics Training Course for Trainers
John Deere Harvester Works, October 18-19, 1990

Outline

A. Review of Ergonomic Concepts
1. Posture - Reach/Height futeraction, Static Holding Fatigue
2. Office Ergonomics - VDT Workplaces
3. Repetitive Motions Problems - Grip Strength, Tools, Ergonomic
Job Analysis
4. Manual Handlin� Tasks
5. Paced Work/Envrronment - Puzzle Exercise
6. Human Reliability/Quality Performance/Automation

fl'

B. Use of Problem Solving Forms, Guidelines, Checklists,
The John Deere Ergonomics Handbook
1. Problem Solving Forms
2. Checklists and Survey Techniques
3. Guidelines for New Design
C. Resources
1. References
2. Videota_pes
3. Profess10nal Meetings/Courses
4. Universities/Colleges
5. Other Companies

Suzanne H. Rodgers, Ph.D

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CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILL$ • ROCHESTER, N.Y. 14622

�Ergonomics
Job Sati sf action
Productivity
Quality
Safety
... ...�

4-Day Erg.onomics Training Program for
General Electric Motors Plants
November 6-9, 1990, DeKalb, IL

Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

0

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�4-Day Ergonomics Training Course for General Electric
Motors Plants, DeKalb, IL, November 6-9, 1990
Tuesday: Ergonomics Overview, Posture and Productivity

0

8:00- 8:30 AM
8:30- 9:00
9:00- 9:45
9:45 -10:00

Introductions and Overview
Work Capacity
Who Do We Design For ?
Break

10:00-10:45
10:45-11:15
11:15-12:00
12:00-12:45 PM

Posture and Productivity-Static Work,
Reach/Height Interactions
Work/Recovery Curves
Problem Solving: Static Work
Lunch

12:45- 1 :45
1:45- 2:15
2:15- 2:30

Problem Solving: Standing Workplace Design
Seated Workplace Design and Visual Work
Break

2:30- 3:00
3:00- 3:45
3:45- 4:00

Problem Solving: Seated Workplace Design
Videotape Review-Postures
Summary of Workplace Design Guidelines

Wednesday: - Preventing Overexertion Injuries and Enhancing
Human Reliability

9:15- 9:45
9:45- 10:00
10:00-11:00
11:00-12:00
12:00-12:45 PM

Reducing Job Complexity- Information, Pacing
Human Reliability-Controls/Displays and
Automation
Environmental Factors Influencing Performance
Break
Problem Solving: Information and Environment
Repetitive Motions Disorders
Lunch

12:45 - 1:30
1:30- 2:15
2:15- 2:45
2:45- 3:00
3:00- 3:15
3:15- 4:00

Risk Factors for Tendonitis, Carpal Tunnel, etc.
Problem Identification-Videotape Review
Ergonomic Job Analysis Form
Break
Tool Design and Selection
Problem Solving: Repetitive Tasks

8:00- 8:45 AM
8:30- 9:15

�Thursday: Manual Handling and Cost/Benefit Analyses
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8:00 - 8:30
8:30 - 9:00
9:00 - 9:30
9:30 - 9:45

0

Low Back Pain and Job Risk Factors
Managing Upper Extremity and Low Back
Disability in the Workplace
Manual Handling Guidelines
Break

9:45-10:45
10:45-11:30
11 :30 -12:00
12:00 -12:45

Problem Solving: Manual Handling
Frequent Lifting/ Total Workload/Hours of Work
Videotape Review: Handling Tasks
Lunch

12:45- 1:15
1:15- 2:30
2:30 - 2:45

Cost-Benefit Analyses of Solutions
Problem Solving Using Cost-Benefit Approach
Break

2:45- 3:30

Problem Solving: Cost Benefit Approach

3:30 - 3:45
3:45- 4:00

Surveys/Checklists/Resources
Instructions for Presentations

Friday: Problem Solving and Presentations by Class Members
8:00 - 9:15
9:15- 10:00
10:00 - 10:15

Work on Presentations (with Oversight)
Case Study #1
Break

10:15- 10:45
10:45 - 11:15
11:15- 11:45
11:45- 12:30

Case Study #2
Case Study # 3
Case Study # 4
Lunch Break

12:30 - 2:00
2:00 - 2:30
2:30 - 2:45

Discussion: Starting an Ergonomics Program
Case Study # 5
Break

2:45 - 3:15
3:15- 3:30

Action Plan Discussion
Course Evaluations

10/90 SHR
t

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Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EOUiPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

Ergonomic Approaches to Managing Cumulative
Trauma Injuries in the Workplace
Talk to Owens Corning Fiberglas Safety Managers, San Antonio, TX
November 15, 1990
Outline of Talk
Ergonomics and Cumulative Trauma Injuries - OSHA Activity
Risk Factors for Repetitive Motions/Overexertion Injuries
Analytical Techniques to Identify Fatigue Potential of Tasks
Problem Solving Examples
Examples of Approaches to Reduce the Risk of Overexertion

Table of Contents
Pa2:e#
Outline and Table of Contents
1
2
Risk Factors for Carpal Tunnel
Work/Recovery Curves
5
Ergonomic Job Analysis
6
Examples of Muscle Effort Levels
9
Finding the Best Solutions to Ergonomic Problems 10
Problem Solving Form
11
References - SHR.odgers
14

�4-Hour Ergonomics Awareness Course
GE Aerospace, Pittsfield, MA, January 11,1991
A.
B.
C.
D.
E.
F.
G.

Outline
Overview of Ergonomics and Health and Safety Goals
Preventing Fatigue - Work Capacity, Work Patterns
Preventing Repetitive Motions Injuries - Risk Factors, Approaches
Designing Safe Lifting Tasks - Defining the Demands
Reducing the Opportunity for Human Error
Cost Benefit Analyses ofErgonomics Problem Solutions
General Guidelines, Resources

Tonk

Table of Contents

OSHA Ergonomics Guidelines Outline -Draft
Capacity and Workload Determinants
Identifying Ergonomics Problems
Work/Recovery Curves, Height and Reach Interaction
Risk Factors for Repetitive Motions Problems
Ergonomic Job Analysis Technique
Ergonomics Problem Solving Form
Risk Factors for Low Back Pain
Manual Lifting Guidelines
Overexertion Injury Risk Factors - Summary
Factors Affecting Quality Performance
Job Conttol and Task Complexity
The Costs of Non-Ergonomic Design
Cost-Benefit Analyses of Ergonomic Problem Solutions
Cost-Benefit Problem Solving Form
12 Ergonomics Guidelines - Equipment and Workplace Design
References - SH Rodgers

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Page#
1
2
3
9
10
12
16
18
19
20
21
23
25
26
28
31
36

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

�,)
'

1.5-Day Ergonomics Training Course Schedule
Schedule

/

Day 1: Overview, Fatigue, Reducing Overexertion Injuries
7:30 - 8:00
8:00 - 8:45
8:45- 9:15
9:15-10:00

Introductions, Goals
Overview of Ergonomics, Update on Ergonomics
Activities at the Waterloo Works
Work Capacity and Fatigue
Break

11 :30 -12:15

Reducing Postural Fatigue, Work/Recovery Needs
Problem Solving: Postural Fatigue and Workplace
Design
Lunch

12:15- 1 :00
1:00 - 1 :30
1:30 - 2:15
2:15- 2:30

Overexertion Injury Prevention: Repetitive Work
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks
Break

10:00 -10:45
10:45-11 :30

2:30 -3:30

. Low Back Pain and Manual Handling

Day 2: Cost-Benefit Analyses and Problem Solving
7:30 8:15 8:45 9:15 -

8:15
8:45
9:15
9:30

9:30 -10:45
10:45-11:30

Problem Solving: Manual Handling
Cost-Benefit Analyses
Cost-Benefit Problem Solving Approach
Break
Problem Solving: Cost-Benefit Analyses
Where From Here ? Summary of Ergonomic
Guidelines for Design

1/11/91 SHR

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0

1.5 Day Ergonomics Course for John Deere
Waterloo Works, Waterloo, Iowa, January 22-25, 1991

-0
'£-'
V._ :_ \

Syllabus
A. The Scope of Ergonomics - What ? Why ? How ?
B. Work Capacity and Fatigue
C. Preventing Overexertion Injuries
1. Repetitive Tasks - Tendonitis, Carpal Tunnel Syndrome Risk
Factors, Techniques to Reduce the Risk
2. Manual Handling Tasks, Postures - Low Back Pain Risk Factors,
Techniques to Reduce the Risk
D. Ergonomic Problem Analysis and Solving Techniques
E. Cost-Benefit of Ergonomic Problem Solutions
F. Problem Solving Forms

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(71fn �.d.-�i::.A7 • 1FiQ 1-11 INTIN�TnM 1-111 IC:: • onrucc::TJ:::C

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�1.5-Day Ergonomics Training Course Schedule
Schedule
Day 1 : Overview, Fatigue, Reducing Overexertion Injuries
7:30 - 8:00
8:00 - 8:45
8:45- 9:15
9:15-10:00

Introductions, Goals
Overview of Ergonomics, Update on Ergonomics
Activities at the Waterloo Works
Work Capacity and Fatigue
Break

11:30 -12:15

Reducing Postural Fatigue, Work/Recovery Needs
Problem Solving: Postural Fatigue and Workplace
Design
Lunch

12:15 - 1:00
1:00 - 1 :30
1 :30 - 2:15
2:15- 2:30

Overexertion Injury Prevention: Repetitive Work
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks
Break

10:00 -10:45
10:45-11:30

2:30 -3:30

Low Back Pain and Manual Handling

Day 2: Cost-Benefit Analyses and Problem Solving
7:30 - 8:15
8:15- 8:45
8:45- 9:15
9:15- 9:30

Problem Solving: Manual Handling
Cost-Benefit Analyses
Cost-Benefit Problem Solving Approach
Break

9:30 -10:45
10:45-11 :30

Problem Solving: Cost-Benefit Analyses
Where From Here ? Summary of Ergonomic
Guidelines for Design

1/11/91 SHR
/
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�Ergonomic/Human Factors Design of
Controls and Displays
A 2-Hour Awareness Course for John Deere Engineers,
Waterloo, IA, January 25, 1991
Syllabus Table of Contents

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Human Reliability
Performance Shaping Factors
Human-Machine Interface Issues
Human Reliability Problem Solving Form
General Layout and Flow Guidelines
Human Size and Reach Data
Information Transfer
Job Control and Task Complexity
Controls and Displays
Control Panel Design Problem
Design of Visual Displays
Design of Auditory Displays
Design of Controls
Information Processing/Decision Making
Control/Display Relationships
Maintainability
Design of VDT Workstations
Factors Affecting Quality Performance
Paced Work/ Time Pressure
References - SHR
References - General

Suzanne H. Rodgers, Ph.D

'

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CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

Pa2e #
1
3
6
10
11
13
15
19
21
24
30
37
39
45
48
48b
51
55
57
61
62

�Team\rlork
Quality
Job Satisfaction

Productivity
Health
Safety

3-Day Ergonomics Course
GE Appliances Louisville
March 26-28, 1991

0

Syllabus

Suzanne H. �odgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�3-Day Ergonomics Training Course for GE Applianmces, Louisville
Tuesday, March 26, 1991: Ergonomics Overview, Posture and Productivity,
Repetitive Motions Disorders
7:15 7:458:158:30-

7:45 AM
8:15
8:30
9:15

9:15- 9:30

Introductions and Overview
Work Capacity
Who Do We Design For?
Posture and Productivity- Static Work, Reach/Height
Interactions
Break

9:30- 10:00
10:00- 10:30
10:30- 11:30
11:30- 12:00

Work/Recovery Curves
Layout and Workplace Design
Problem Solving:. Postures and Workplace Design
Lunch

12:00 12:451:152:00-

Problem Solving: Standing Workplace Design
Seated Workplace Design and Visual Work
Repetitive Motions Disorders- Risk Factors
Break

12:45 PM
1:15
2:00
2:15

2:15- 2:45
2:45- 3:15

Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks

Wednesday, March 27, 1991: Preventing Overexertion Injuries and Enhancing
Human Reliability; Cost-Benefit Analyses

0

7:15 7:45 8:15 8:45 9:15 -

7:45 AM
8:15
8:45
9:15
9:30

Tool Design and Selection
Human Reliability- Preventing Human Error
Controls and Displays- Information Transfer
Problem Solving: Accident Investigation
Break

9:30 - · 10:30
10:30- 11:30
11:30- 12:00

Manual Materials Handling - Lifting and Force Guidelines
Problem Solving: Manual Handling Tasks
Lunch

12:001:002:002:152:45-

Puzzle Exercise - Pacing, Environment
Cost-Benefit Analyses of Solutions
Break
Problem Solving: Cost-Benefit Analysis
Problem Selection for Presentations on Thursday

1:00
2:00
2:15
2:45
3:15

Thursday, March 27, 1991: Problem Analyses and Presentations

l)

7:15 - 8:00 PM
8:00- 11:30
11:30- 12:00

Ergonomics Program Suggestions - Where From Here ?
Work on Problem Analyses with Supervision
Lunch

12:00- 1:00 PM
1:00 - 3:00
3:00 - 3:15

Practice Presentations
Presentations to Managers
Course Evaluations, Resources

3/11/91 SHR

�.

.

.Ergonomics Training Course
Table of Contents

(�
\, .

.

j

Topic
Schedule
Table of Contents
Acknowledgements

Starting Page Location
EDFPAWl
Sl'.llabus
i

Introduction and Course Goals
Plant Ergonomics Programs and
Organization
The Costs of Poor Design
Capacities for Work
Factors That Increase Stress

0

(J

V

EDFPAW 2

--

1
2

--

6
8
10

----

3 13

9
2 10,446,496
237
98

Identifying Ergonomics Problems
S Questions Form
Human Reliability - Man vs Machine
Ergonomic Opportunities
Ergonomic Principles for Layout/Flow
Who Do We Design For? The Variability
of People
Anthropometric Data
Height and Reach Interactions
Using Anthropometric Data
Recovery Time/Static Muscle Work
Effort Estimation Scales
Design to Minimize Effort

11
13
14
15
16
18

14
3,8, 285, 290

342
2, 13,446

19
23
24
26
33
36

285
20,24,30
285, 3 11
11 2,140,150,338
3 38
52

448
218,255

Problem Analysis: Standing Work
Finding Best Solution to Problem
Ergonomics Problem Solving
Extra Problem Solving Forms

37
39
40
42

Seated Work - VDT
Seated Arm Reach
Chair Characteristics
Visual Work,Lighting,Posture

44
45
46
47

Self-Help in VDT Workplace Comfort

50

Risk Factors for Carpal
Tunnel Syndrome
Factors Affecting Grip Strength
Ergonomic Job Analysis Form
Table 1: Examples of Muscle Effort Levels
Evaluating Hand Tools
Problem Analysis: Repetitive
Work

51

Human Reliability
Puzzle Exercise
Ergonomics and Quality
Information Transfer - Controls
and Displays
Job Control and Task Complexity
Reliability Problems Form

53
54
56b
57
59
62
63
64
66
71
73

18 1

24,217

23,50

--

-·-

--

18,28,50
20
57
17,30,50
28,101;179

14 2
142
2 23,282

--·-

151, 244
--

151, 254

---

--256
--

18 1

--

140

--

90,107,162

10,222,23 2
--

232

--

.

.

'
lll.

�=&gt;

�

Environmental Factors
Paced Work/fime Pressure
Problem Solving Form

74
77
80

Risk Factors for Low Back Pain
Natural History Degenerative Disc Disease
Strength and Location
Maximum Force Applications
Kodak Lifting Guidelines
Summary of Overexertion Risk Factors
Guidelines to Reduce Risk for Injuries

83
85
86
87
88
90
91

Cost/Benefit Analyses
Problem Solving Form - Cost/Benefit
Ergonomics in Old/New Design
Extra Problem Solving Forms
New Design Problem Analysis Forms
Design Summary Form

92
96
99
100
103
104

How To - Ergonomics Survey
Examples of Questions
12 Ergonomics Guidelines
Ergonomics Checklist

106
108
110
112

Ergonomics Programs and Processes
General Ergonomics Guidelines - OSHA
First Job Characteristics
Ergonomic Case Study Form
Videotaping Suggestions
Resources - Bibliographies
Problem Solving Forms
Course Evaluation Form

117b
117e
118a
118b
119
120
126
end

210, 242, 320

230
135,340

15,122,151

135,338
384,446
360, 403
135, 340

-313

98

313

--

365

559

-·-

11/90 SHR

{V

�...

Problem Solving: Using Ergonomics and Physiology for Lifting Tasks
Lifting and Low Back Pain Seminar, Richland, WA, A�ril 4-5, 1991

Outline
A. Occasional Lifts -Two-Handed
B. Frequent Lifts -Two-Handed
C. One-Handed Lifts
D. Carrying
E. Postural Factors Contributing to Low Back Pain

Sixth

Suzanne H. Rodgers, Ph.D

Annual

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

Medicine

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

in the

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

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•

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OCCUPATIONA.L- ttgAL,TH NO�THWf:ST

Workplace
Sen1inar

�Occupati anal
Ergonomics

3.5 Day Ergonomics Training Course for
Amoco Foam Products, Greensboro, NC
April 16 - 19, 1991

Syllabus

Suzanne H. Rodgers, Ph.D

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�3.5-Day Ergonomics Training Course
Day 1: Ergonomics Overview, Reducing Fatigue at Work,
Workplace and Equipment Design
8:00- 8:30AM
8:30- 9:00
9:00- 9:45
9:45- 10:00

Introductions and Overview
Work Capacities- Who Do We Design For?
Preventing Fatigue: Work/Recovery Curves
Break

10:00- 10:45
10:45 - 11:15
11:15- 12:00
12:00 - 12:45 PM

Problem Solving: Postural Fatigue
Using Body Size Data- Heights and Reaches,
Visual Needs
Problem Solving: Standing Workplace Heights
Lunch

12:45- 2:00
2:00- 2:30
2:30- 2:45

Workplace Layout: Design to Reduce Extra Effort
Seated Workplace Design
Break

2:45- 3:30
3:30- 4:00

0

Problem Solving: Seated Workplace Design
Videotape Review - Postures, s-ummary of
Workplace Design Guidelines

Day 2: Preventing Overexertion Injuries and Reducing Error

"'--_)

8:00- 8:45AM
8:30- 9:00
9:15 - 9:45
9:45- 10:00

Risk Factors for Tendonitis, CafJ?al Tunnel
Syndrome, and Other Overexert.Ion Injuries
Ergonomic Job Analysis Form
Factors Affecting Grip Strength, Level of Effort
Break

10:00- 11:15
11:15- 11:45
11:45- 12:30 PM

Problem Solving: Repetitive Tasks
Tool Design and Selection
Lunch

12:30- 1:15
1:15- 1:45
1:45- 2:15
2:15- 2:30

Ergonomics and Quality Performance - Puzzle
Improving Human Reliability - Reducing Job
Complexity and Providing Operator Control
Controls/Displays and Automation
Break

2:30- 3:15
3:15- 4:00

Problem Solving: Information and Complexity
Environmental Factors Influencing Performance

Day 3: Manual Handling and Cost/Benefit Analyses
\

__)

8:008:309:009:30-

8:30
9:00
9:30
9:45

Low Back Pain - Job Risk Factors
Designing Manual Handling Tasks
Manual Lifting Guidelines
Break

•

(,

�9:45 -10:45
10:45 -11:15
11:15-11:45
11:45 -12:30

Problem Solving: Manual Handling
Total Workload/Hours of Work
Cost-Benefit Analyses of Ergonomic Problems
Lunch

12:30- 1:30
1:30- 2:15
2:15- 2:30

Problem Solving Using Cost-Benefit Approach
Surveys/Checklists/Resources
Break

2:30- 3:15
3:15- 4:00

Ergonomics Programs: Where From Here ?
Problem Selection for Day 4, Instructions for
Presentations, Initial Analyses

Day 4: Problem Solving and Presentations by Class Members

~--"~
~I

8:00- 9:00
9:00- 9:30
9:30- 10:00
10:00- 10:15

Work on Presentations (with Oversight)
Case Study #1
Case Study #2
Break

10:15- 10:45
10:45- 11:15
11:15-11:45
11:45 - 12:15

Case Study# 3
Case Study# 4
Case Study # 5
Action Plan Discussion, Course Evaluations

3/91 SHR

'

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�0
0
0

2-Day Ergonomics Course for GE Aerospace
Moorestown, NJ, April 22-24, 1991
Syllabus
A. The Scope of Ergonomics- What? Why? How?
B. Work Capacity and Fatigue
C. Preventing Overexertion Injuries
1. Repetitive Tasks- Tendonitis, Carpal Tunnel Syndrome Risk
Factors, Techniques to Reduce the Risk
2. Manual Handling Tasks, Postures - Low Back Pain Risk Factors,
Techniques to Reduce the Risk
D. Ergonomic Problem Analysis and Solving Techniques
E. Cost-Benefit of Ergonomic Pro~lem Solutions
F. Problem Solving Forms

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Ergonomics
Job Satisfaction
Productivity
Quality
Safety

2-Day Ergonomics Training Course for
General Electric Medical Systems
Waukesha, WI, April 29-30, May 1-2, 1991

Capacity Data and Problem Solving Forms
(Supplement to the GE Ergonomics Process Manual)

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�2-Day Ergonomics Training Course
..

~\

1

Day 1: Ergonomics Overview, Reducing Fatigue, Workplace and
Equipment Design, Repetitive Tasks
8:00 - 9:00 AM
9:00- 9:45
9:45- 10:00

Introductions and Overview of Ergonomics Process
Preventing Fatigue: Work/Recovery Curves
Break

10:00- 10:45
10:45 - 11:30

Problem Solving: Postural Fatigue
Using Body Size Data- Heights and Reaches,
Visual Needs
Seated Workplace Design
Lunch

11:30- 12:00
12:00 - 12:45 PM

2:30- 2:45

Problem Solving: Standin~ Workplace Heights
Risk Factors for Tendonitis, CafJ?al Tunnel
Syndrome, and Other OverexertiOn Injuries
Break

2:45- 3:15
3:15- 4:00

Ergonomic Job Analysis Form
Problem Solving: Repetitive Tasks

12:45- 1:30
1:30- 2:30

Day 2: Manual Handling Task Design, Reducing Error, Cost/Benefit,
Problem Solving
8:00 - 9:00AM
9:00- 9:45
9:45- 10:00
10:00- 11:15

Lifting and Low Back Pain - Risk Factors and
Guidelines for Safe Lifting and Force Application
Problem Solving: Manual Handling Tasks
Break

11:15- 11:45
11:45- 12:30 PM

Human Reliability - Ergonomics in Accident
Investigation
Cost Benefit Analyses of Ergonomic Problems
Lunch

12:30- 1:15
1:15- 2:00
2:00- 2:15

Problem Solving: Cost/Benefit Analyses
Discussion: Bmlding Ergonomics Into Other Processes
Break

2:15- 3:45
3:45- 4:00

Problem Solving Projects
Course Evaluations; Final Thoughts

4/91 SHR

l

\

\...~/

r(

�Table of Contents
,----~

'

/~\

u

Topic

Page#

1
2
3

Schedule
Table of Contents
Costs of Poor Design
Work/Recovery Time Graphs
Evaluating Static Work Recovery Time Needs
Finding the Best Solution to Ergonomics Problems
Ergonomics Problem Solving

6
10
11

5 Questions About Workplace and Job Design
Ergonomic Principles for Layout/Materials Flow
Anthropometric Data
Height and Reach Interaction
VDT Workplace Design Kit

13
14
16
17
18

Risk Factors for Repetitive Motions Problems
Ergonomic Job Analysis- Rating Form

27
28

Strength as a Function of Location
Maximum Forces for Design
Kodak Lifting Guidelines

30
31
32

Problem Solving Form
Human Reliability Problem Solving Form
Cost Justifying Change Form
Ergonomic Case Study Form

34
37
39
42

References - SH Rodgers

43

4/91

5

�The Costs of Poor Design
A. Accident Data
1. Workers' Compensation costs
2. Time lost from work - replacement cost
3. Injury recurrence costs
4. Accident investigation time - supervisory, Safety
5. Medical Department time

B. Medical Data
1. Overexertion illnesses
a. Low back pain
b. Repetitive motions disorders
2. Stress-related illness
a. Headaches
b. Gastrointestinal disorders
c. Behavior problems
d. Drug and alcohol abuse
3. Medical restrictions
a. Howmany?
b. How long?
c. Success in return to work?
d. Repeat injuries or illness?

C. Absenteeism
1. By job title - days lost for all reasons
2. Patterns in relation to production schedules

D. Turnover
1. Usual length of service on the job
2. Number of people on the job in a 5- or 10-year period
3. Reasons for leaving job

�E. Training Time
1. Time to reach productivity goal
2. Time to be fully trarned for job or jobs in department
F. EEO Picture
1. Experience in getting women or older workers on the job
2. Characteristics of people on the job- how typical of workforce
pool?
G. Quality Control
1. Amount of waste
2. Amount of repair work
3. Missed defects- audit
4. Consumer complaints
5. Amount of good p~oduct rejected

1/8/86 SHR

�Occupational Medicine Seminar for Supervisors/Managers
City of Rochester Bureau of Employee Relations/Employee Safety .
May 6, 1991, Water Bureau Training Facility

Ergonomic Approaches to Repetitive Motions Problems
Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics, Rochester, NY

4. Evaluating the Workplace to Identify Risk Factors
A. Risk Factors for Hand and Wrist Repetitive Motions Problems
B. Preventing Fatigue on the Job - Work/Recovery Needs
C. Defining Heavy Effort Levels
D. Defining Work Patterns and Overall Workload
5. How to Respond to RMI From an Ergonomic View
A. Techniques to Reduce Effort Levels
B. Techniques to Reduce Continuous Duration of Muscle Effort
C. Techniques to Reduce Repetition Rate and Total Time of Effort
D. Techniques to Reduce Other Stresses on the Job

Table of Contents
Page#
Risk Factors for Carpal Tunnel
Work/Recovery Curves
Tables 2 and 3: Effort Levels
Examples of Work Patterns from Heart Rate Curves
Techniques to Reduce the Risk
Risk Factor Analysis Form
VDT Workplace Design- Self Help
Chair Characteristics
References - SHRodgers

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

·-.-·

1

3
8
10
11
12

13
15
16

�...

2-Day Ergonomics Training Course For The
Photochemicals, Polymer, and Recovery Departments
in Buildings 18/48,317, and 351/352, Kodak Park Division,
Eastman Kodak Company, Rochester, NY, May 7-8,1991

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�2-Day Ergonomics Training Course Schedule
Schedule
Day 1: Overview, Fatigue, Reducing Overexertion Injuries
8:008:459:009:30-

8:45
9:00
9:30
9:45

9:45-10:30
10:30 - 11:30

Introductions, Goals, Overview of Ergonomics
Work Capacity and Fatigue
Reducing Postural Fatigue, Work/Recovery Needs
Break

11:30- 12:15j

Identifying Fatiguing Work Activities
Problem Solving: Postural Fatigue and Workplace
Design - 2 Jobs
Lunch

12:15- 12:45
12:45- 1:30
1:30- 2:00
2:00- 2:15

Overexertion lnjury.Prevention: Repetitive Work
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks - 2 Jobs
Break

2:15- 2:45
2:45- 3:30
3:30- 4:00

Reports on Repetitive Tasks Problem Solving
Low Back Pain and Manual Handling; Lifting
Guidelines
Problem Solving: Manual Handling Tasks

Day 2: Human Reliability, Cost/Benefit Analyses, and Problem
Solving Projects
8:00- 8:30
8:30- 9:30
9:30- 9:45
9:45 -10:00
10:00 - 10:30
10:30 - 11 :30
11:30- 12:15
12:15- 2:15

Reports on Manual Handling Tasks Problem Solving
Human Reliability: Accident Investigation and
Ergonomic Problem Analyses
Cost/Benefit Analyses
Break
Cost/Benefit Problem Solving Approach
Review of Videotaped Jobs for Risk Factors and
Problem Solution Approaches; Choice of Jobs for
Projects
Lunch

2:15- 2:30

Work on Projects Using Techniques Presented in
Course
Break

2:30- 3:45
3:45- 4:00

Project Presentations
Course Evaluations, Resources

5/6/91 SHR

r

L

�Ergonomics Awareness Training for
Astro-Valc,our Inc., Glens Falls, NY, May 30, 1991

Outline
Factors Associated with Fatigue- Work/Recovery Curves
Risk Factors for Hand, Wrist, Arm, and Shoulder Overexertion Injuries
Ergonomic Job Analysis Technique for Identifying Cost Effective Solutions to
Overexertion Problems
Problem Solving Example
Risk Factors for Low Back Pain
Guidelines for Reducing Overexertion Risk in Manual Handling Tasks
Problem Solving - Manual Handling Problems
Cost/Benefit Analyses of Ergonomic Problem Solutions
Developing an Ergonomics Process - Why ? Who ? What ? How ?

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�:¥.~:ao~us_ .........

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1.5 Hour Ergonomics Awareness Course forTeams
at the GE Hooksett Aircraft Engine Plant, July 1, 1991
Syllabus

Table of Contents
Topic
Proposed General Industry Ergonomics Guideline July, 1990
Identifying Ergonomic Problems
Work/Recovery Curves
Designing Jobs to Minimize Effort
Findmg the Best Solution to an Ergonomic Problem
Ergonomic Problem Solving
Risk Factors for Repetitive Work
Techniques to Reduce the Risk for Injury and Illness
Ergonomic Job Analysis for Repetitive Work
Table 2: Muscle Effort Levels
Definitions of Heavy Effort in MMH
Risk Factor Analysis Form
Risk Factors for Low Back Pain and Ways to Reduce Them
Strength and Location
Maximum Forces for Design
Manual Handling Guidelines
Overexertion Injury Risk Factors
Cost/Benefit Analyses
Cost of Poor Design
Cost/Benefit Problem Solving Form
12 Guidelines for Ergonomic Design
Plant Ergonomics Programs and Organization
Thoughts on Ergonomics Programs
Recommended Videotapes on Ergonomics Topics
References - SHR
Extra Forms

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

Page#

1

2
8

15
16

17
19
21

22a
23
24
25

26
28

29
30

32
33
37
39
42
47
51
54
55
56ff.

�"Ergo:a.o-.i.cs ········· Pn:lutfnty ···~·····
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. .
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:

Ergonomics Coordinating Committee Training for the GE
Aircraft Engine Plants in Rutland, VT, July 9, 1991

Syllabus

Schedule

7:30- 8:30AM

Identifying Fatiguing Activities·- Techniques to Reduce
the Risk for Fatigue at Work

8:30- 9:15

Ergonomic Problem Solving

9:15- 9:30

Break

9:30- 10:30

Identifying and Reducing the Risk Factors for Repetitive
Motions Disorders

10:30- 11:00

Manual Handling Risk Factors and Their Resolution

11:00- 11:30

Selling Ergonomic Changes

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"'

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Table of Contents
Topic

Pa2e

Table of Contents I Acknowledgements
Identifying Ergonomics Problems
Work/Recovery Graphs
Height and Reach Interactions
Finding the Best Solutions
Ergonomics Problem Solving Form

1

2

8
13
14
15

Risk Factors for C~al Tunnel Syndrome
Factors Affecting Gnp Strength
Risk Factor Analysis Form
Ergonomic Job Anallsis Technique
Table 2: Examples o Muscle Effort Levels
Table 3: Definitions of Heavy Effort in MMH Tasks

25
26

Risk Factors for Low Back Pain
Analyzing Jobs for Low Back Risk Factors
Force and Location Relationship - Static Pull
Maximum Forces for Design
Kodak Guidelines for Occasional Lifts
Kodak Guidelines for Repetitive Lifting

27
29
31
32
33
34

Cost/Benefit Analyses of Ergonomic Solutions
The Costs of Poor Design
Cost/Benefit Problem Solving Form
12 Ergonomics Design Guidelines

35
39
41
44

OSHA Proposed General Industry Guidelines
Plant Ergonomics Programs and Organization
Thoughts on Ergonomics Programs and Processes
How To Do An Ergonomics Survey
First Job Charactenstics
Ergonomics Case Study Problem Solving Form
Recommended Videotapes on Ergonomics
References - SHR

49
50
54
57
59
60
61
62

Overexertion Injury Risk Factors
Extra Problem Solving Forms

63
64ff

18
20
21

22

Acknowledgements

The illustrations on pages13, 33, and 34 are used with permission from Eastman
Kodak's Ergonomic Design for People at Work, Volumes 1 &amp; 2 published by Van
Nostrand Reinhold in 1983 and 1986. The table and illustration on pages 31 and 32
are from Working With Backache by S. H. Rodgers. The table on l?age 20 was
published by Thieme Publishers in Seminars in Occupational Medicme in March
1987. The analytical technique on pages 22 and 65 has been published by Hanley anc
Belfuss in a 1988 Occupational Medicine: State of the Art Review edition on Worker
Fitness Evaluations. All other material in this syllabus is by Dr. S.H. Rodgers and
permission to reproduce it must be obtained from her.

�Ergonomics Awareness for Supervisors at the GE
Aircraft Engine Plants in Rutland, VT, July 9-12, 199i

-=~··~
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Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(n6) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Ergonomics Training Program for the
General Electric Aircraft Engine Plants in Rutland,VT.
Team Training, September 3-6, 1991

Syllabus- e--~\~4.M&amp;

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Teamwork
Quality
Job Satisfaction

Productivity
Health
Safety

3-Day Ergonomics Course

GE Appliances Louisville
September 10-12, 1991

Syllabus

Suzanne H. ~odgers; Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

}

1. AWARENESS SEMINARS
2. TRAINING 'ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(n6) 544-3S87 • 169 HUNTINGTON HILLS • ROCHESTER. N.Y. 14622

�3-Day Ergonomics Training Course for GE Applianmces, Louisville
i

Tuesday, September 10, 1991: Ergonomics Overview, Posture and
Productivity, Repetitive Motions Disorders
7:157:458:158:30-

7:45AM
8:15
8:30
9:15

9:15- 9:30

Introductions and Overview
Work Capacity
Who Do We Design For ?
Posture and Productivity- Static Work, Reach/Height
Interactions
Break

9:30- 10:00
10:00 - 10:30
10:30 - 11:30
11:30- 12:00

Work/Recovery Curves
Layout and Workplace Design
Problem Solving: Postures and Workplace Design
Lunch

12:00 - 12:45 PM
12:45- 1:15
1:15- 2:00
2:00- 2:15

Problem Solving: Standing Workplace Design
Seated Workplace Design and Visual Work
Repetitive Motions Disord~rs- Risk Factors
.
Break

2:152:45-

2:45
3:15

Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks

Wednesday, September 11, 1991: Preventing Overexertion Injuries and
Enhancing Human Reliability; Cost-Benefit Analyses
7:15
7:45
8:15
8:45
9:15

-

7:45AM
8:15
8:45
9:15
9:30

Tool Design and Selection
Human Reliability - Preventing Human Error
Controls and Displays - Information Transfer
Problem Solving: Accident Investigation
Break

9:30 - 10:30
10:30 - 11:30
11:30- 12:00

Manual Materials Handling - Lifting and Force Guidelines
Problem Solving: Manual Handling Tasks
Lunch

12:001:002:002:152:45-

Puzzle Exercise - Pacing, Environment
Cost-Benefit Analyses of Solutions
Break
Problem Solving: Cost-Benefit Analysis
Problem Selection for Presentations on Thursday

1:00
2:00
2:15
2:45
3:15

Thursday, September 12, 1991: Problem Analyses and Presentations
7:15- 8:00PM
8:00- 11:30
11:30- 12:00

Ergonomics Program Suggestions - Where From Here ?
Work on Problem Analyses with Supervision
Lunch

12:00 - 1:00 PM
1:00 - 3:00
3:00 - 3:15

Practice Presentations
Presentations to Managers
Course Evaluations, Resources

3/11/91 SHR

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3.5-Day Ergonomics Training Program for the
General Electric Aircraft Engine Plants in Rutland, VT
Team Training, September 3-6, 1991

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�3.5-Day Ergonomics Training Course
.·~

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Day 1: Ergonomics Overview, Reducing Fatigue at Work,
Workplace and Equipment Design

7:308:008:309:15-

8:00AM
8:30
9:15
9:45

9:45- 10:30
10:30- 11:00

Introductions and Overview
Work Capacities -Who Do We Design For ?
Preventing Fatigue: Work/Recovery Curves
Break

11:00- 11:30
11:30- 12:15 PM

Problem Solving: Postural Fatigue
Using Body Size Data - Heights and Reaches,
Visual Needs
Problem Solving: Standing Workplace Heights
Lunch

12:15 - 12:45
12:45- 1:30
1:30- 2:15
2:15- 2:30

Problem Solving (Complete Earlier Problem)
Workplace Layout: Design to Reduce Extra Effort
Seated Workplace Design
Break

2:30- 3:30

Problem Solving: Seated Workplace Design
)

Day 2: Preventing Overexertion Injuries and Reducing Error

7:30- 8:15AM
8:15- 9:00
9:00- 9:30
9:30- 9:45

Risk Factors for Tendonitis, CafJ?al Tunnel
Syndrome, and Other OverexertiOn Injuries
Ergonomic Job Analysis Form
Factors Affecting Grip Strength, Level of Effort
Break

9:45- 10:45
10:45 - 11:30
11:30- 12:15 PM

Problem Solving: Repetitive Tasks
Tool Design and Selection
Lunch
·

12:15- 1:00
1:00- 1:30
1:30- 2:00
2:00- 2:15

Ergonomics and Quality Performance - Puzzle
Improving Human Reliability - Reducing Job
Complexity and Providing Operator Control
Controls/Displays and Automation
Break

2:15- 2:45
2:45- 3:30

Environmental Factors Influencing Performance
Problem Solving: Information and Complexity

Day 3: Manual Handling and Cost/Benefit Analyses

7:308:008:309:15-

8:00
8:30
9:15
9:30

Low Back Pain- Job Risk Factors
Designing Manual Handling Tasks
Manual Lifting Guidelines
Break
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�9:30-10:15
10:15 -10:45
10:45 -11:30
11:30-12:15

Problem Solving: Manual Handling
Total Workload/Hours of Work
Cost-Benefit Analyses of Ergonomic Problems
Lunch

12:15- 1:15
1:15- 1:30
1:30- 2:15
2:15- 2:30

Problem Solving Using Cost-Benefit Approach
Surveys/Checklists/Resources
Ergonomics Programs: Where From Here ?
Break

2:30- 3:30

Problem Selection for Day 4, Instructions for
Presentations, Initial Analyses

Day 4: Problem Solving and Presentations by Class Members

c

7:30- 9:30
9:30- 9:45

Work on Presentations (with Oversight)
Break

9:45- 10:00
10:00- 10:15
10:15- 10:30
10:30- 10:45
10:45 - 11:00
11:00- 11:30

Case Study # 1
Case Study #2
Case Study # 3
Case Study # 4
Case Study # 5
Action Plan Discussion, Course Evaluations

7/91 SHR

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�3 . 5-Day Ergonomics Training Course for
Amoco Chemical Plants
Joliet, IL , September 17 • 20, 1991

Syllabus

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CONSULTANT IN ERGONOMICS/HUMAN FACro~
"HIGHER PRODUCTIVITY THROUGH JOS 0ESIGN~

1. AWARENESS SEMINARS

2. TRAINING ON USE _QF HUMAN FACTORs IN
WORKPLACE, EOUIPI\iENT AND PRODUCT DES
3. HEALTH AND SAFETY PROGRAMS
IGN

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3.5-Day Ergonomics Training Course

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Day 1: Ergonomics Overview, Reducing Fatigue,, Workplace and
Equipment Design, Repetitive Tasks

8:00 - 8:30 AM
8:30- 9:00
9:00- 10:00
10:00-10:15

Introductions, Course Goals
Ergonomics Overview
Designing Jobs to Reduce Fatigue
Break

10:15-11:15
11 :15 - 11 :45
11:45-12:30

Problem Solving: Fatigue Reduction/Posture
Heights and Reaches
Lunch Break

12:30-1:30 PM
1:30- 2:30
2:30- 2:45

Problem Solving: Working Heights
Design Guidelines for Comfortable Working Postures
Break

2:45- 3:30
3:30- 4:00

Risk Factors for Repetitive Motions Problems
Techniques to Reduce Repetitive Motions Injuries and
Illnesses

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Day 2: Ergonomic Job Analysis, Layout, Manual Materials
Handling

8:00- 9:00AM
9:00- 10:00
10:00-10:15

Ergonomic Job Analysis Technique
Problem Solving: Ergonomic Job Analysis
Break

10:15-10:45
10:45-11:15
11 :15 - 11 :45
11:45-12:30 PM

Workplace Layout - Materials Flow
Problem Solving: Layout
Risk Factors for Low Back Pain
Lunch Break

12:301:00 1:45 2:15 -

Guidelines for Manual Ha~dling Tasks
Problem Solving: Lifting and Lowering
Guidelines for Pushing and Pulling
Break

1:00
1:45
2:15
2:30

2:30 - 3:00
3:00 - 4:00

Frequent Lifting and Overall Workload Guidelines
Hours of Work and Shiftwork
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Day 3: Human Reliability/Error, Ergonomics and Quality
Performance, Environmental Factors, Cost/Benefit
Analyses
8:00 - 8:30 AM
8:30- 9:00
9:00- 10:00
10:00-10:15

Model of Human Reliability
Contributors to Human Error at Work
Problem Solving: Ergonomics and Accident Analysis
Break

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Ergonomics and Quality - Puzzle Exercise
Environmental Factors- Noise, Vibration, Heat, Cold,
'
Lighting
11 :45 - 12:30 PM Lunch Break

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12:30-1:30

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1:30- 2:15
2:15- 2:30

Discussion: Starting an Ergonomics Program in Your
Plant
Cost Benefit Analyses of Ergonomic Problem Solutions
Break

2:30- 3:30
3:30- 4:00

Problem Solving: Cost-Benefit Analyses
Selection of Project for Day 4-:Presentation

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11 :00 - 11 :45

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Day 4: Project, Presentations, Program Discussion, Resources
8:00- 10:00
10:00-10:15

Work on Projects, Prepare Presentations
Break

10:15 - 11 :30
11:30-12:00

Project Presentations
Resources, Program De~elopment, Evaluations

8/31/91 SHR

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3.5-Day Ergonomics Training Course

!

Table of Contents
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Topic
Schedule
Table of Contents
Acknowledgements

Starting Page Location
EDFPAWl
S~llabus
i
iii
v

OSHA General Ergonomics Program
General Ergonomics Goals
Introduction and Course Goals
. Plant Ergonomics Programs and
Organization
The Costs of Poor Design
Capacities for Work
Factors That Increase Stress

1'
2
3
4

3

8
10
12

EDFPAW2

4

9
210,446,496
237

. j

Static Work- Fatigue
Identifying Ergonomics Problems
Low Back Risk Factors
Recovery Time/Static Muscle Work
Design to Minimize Effort
Risk Factor Analysis Fo11Il
Summary of Overexertion Risk Factors
Finding Best Solution to Problem

13
15
21
22
27
28
29
30

Who Do We Design For? Human Variability
Anthropometric Data
Height and Reach Interactions
Distributions and Design
5 Questions Form
Problem Analysis: Standing Work

31
32
37
40
41
42

Risk Factors for Carpal
Tunnel Syndrome
Risk Analysis Form
Ergonomic Job Analysis Form
Factors Mfecting Grip Strength
Table 2: Examples of Muscle Effort Levels
Table 3: Heavy Effoit- Manual Handling
Effort Estimation Scales
ijtra Fo!m - Ergo Job Analysis
Evaluating Hand Tools
VDT Workplace Design
Posture, Vision, Productivity

44
46
47
50
51
52
53
56
57
61
70

lJ

Self-Help in VDT Workplace Comfort
Assist Devices for VDTs

71
72

l~

Ergonomic Principles for Layout/Flow
Ergonomic Opportuities - Auto/Human

74
76

Risk Factors for Low Back Pain
Natural History Degenerative Disc Disease
Design Guidelines to Reduce Back Pain
Manual Handling Task Design

78
79
80
84

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112
313
112,140,150,338.
52

217
98
135,340
24,217

-3,8,285,290
285,311
20,24,30

2, 13,446
448
218,255

23,50
151,244

151,254
338
140
18,28,50
17,30,50
28,101,179

256
142
223,282

-14

342

---

135,340
135,340
135,340

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�Strength and Location
Maximum Force Applications
NIOSH Lifting Guidelines - 1981
Kodak Lifting Guidelines - Occasional
Kodak Lifting Guidelines - Frequent
Handling Risk Factors
Extra Forms
Total Workload, Shift Work, Overtime
l

86
87
88
92
94
95
97
99

Human Reliability
Factors Mfecting Quality Performance
Puzzle Exercise
Information Transfer - Controls/Displays
Paced Work{fime Pressure
Environmental Factors
Job Control and Task Complexity
Human Reliability - Man vs Machine

104
106
108
109
115
118
121
123

Ergonomics Programs and Processes
First Job Characteristics
Ergonomic Case Study Form
Cost/Benefit Analyses
Problem Solving Form- Cost/Benefit

124
127
128
129
135

12 Ergonomics Guidelines
Ergonomics Checklist
How To- Ergonomics Survey
Examples of Questions
Equipment for Ergonomics Work
Ergonomics Videotapes - Commercial
Videotaping Suggestions
Ergonomics Problem Presentations
Extra Problem Solving Forms
Course Evaluation Form

138
143
149
151
153
155
156
157
158 ff
end

15,122,151

135,338
384,446
398
360,403
408

-210, 288, 332,
473
181
10,222,232
90,107,162
230
210, 242, 320
232
181

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313
320

-98
162

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9/91 SHR

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�Acknowledgements

The illustrations on pages 34-37, 92, and 94, are used with permission
from Eastman Kodak's Ergonomic Design for People at Work, Volumes 1
and 2 published by Van Nostrand Reinhold. The tables and illustrations
on pages 33, 79-82, 86, and 87 are from Working With Backache by S. H.
Rodgers. The articles on pages 13-14 and 53-54 were published by the
Polinsky Institute's Functional Capacities Network. Information on pages
12, 47, and 61-73 has been developed in conjunction with Dr. Inger
Williams. The analytical technique on pages 47 and 56 has been
published by Hanley and Belfuss in a 1988 Occupational Medicine: State
of the Art Review edition on Worker Fitness Evaluations. All other
material in this syllabus, unless it has a specific reference, is by Dr. S.H.
Rodgers and permission to reproduce it must be obtained from her.
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�APPLIED ERGONOMICS:
Controlling Overexertion Injuries at Work
October 3-6, 1991 * Philadelphia, Pennsylvania
FACULTY
ALAN R. BROWN, P.T.
Granite Hill Physical Therapy
Brunswick, Maine
THOMAS COOK, P.T., PH.D.
Associate Professor of Physical Therapy
University of Iowa
Iowa City, Iowa
DONALD E. DAY, M.S.
Consultant in Ergonomics
Longmont, Colorado
DIANNE M. PARROTTE, M.D.
Chief, Occupational Medicine
Bath Iron Works
'· '&lt;;:':~, J3;;~;pl!:j~}:~:~f,f.$.~J:41e · •· ·

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�Tltursday, October 3, 1991 8:30 ~9:00AM- S. Rodgers
OSHA, Industry, E\rgoJlomics, Medicine- Where Are 'Ve?

A. OSHA and Ergonomics Legislation
1.
2.
3.
4.

Red Meat Cutters Guidelines
General Industry Guidelines- Proposed July, 1990
ANSI Z-365 Standard on Repetitive Tasks
Other

B. Industrial/Occupational Ergonomics Activities
1. Pre-OSHA Activity
2. OSHA-Driven Activity- Citations or Concerns
3. Ergonomics/Human Factors/Product Design

C. Ergonomics Educational and Professional Activity
1.
2.
3.
4.
5.

Schools - Different Emphases
Continuing Education/Seminars
Professional Societies
Publications
Accreditation Activity

D. Medical and Allied Health Activity
1.
2.
3.
4.
5.
6.

Rehabilitation/Return-To-Work
Handicapp·ed/Disabled Legislation
Industrial Medicine
Proactive versus Reactive- Health Care vs Wellness
Job Accommodation/Placement
Assessment of Worker Capabilities

E. Need for Multidisciplinary Approaches To Keep People

On the Job
1. Demographics of Workforce
2. Investment in Skilled Workers
3. More Need to Accommodate Change

F. Review of the Objectives of this Semiri,ar

�Friday, October 4, 1991 3:45 - 5:00 - S. Rodgers
Manual Handling Guidelines - NIOSH, Snook, U of M, Kodak

A. Biomechanical Guidelines
B. Psychophysical Guidelines
C. Physiological Guidelines
D. NIOSH 1981 and 1991 (?) Guidelines
E. Kodak Problem Solving Guidelines

),

�2-Day Ergonomics Course for Engineers
at the Bloomington, Indiana General
Electric Appliance Plant, October, 1991

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

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2-Day Ergonomics Seminar for Engineers at the Bloomington, IN
General Electric Appliance Plant, October 28-30, Oct 30-Nov 1, 1991
Schedule

Session 1: Overview, Work Capacities, Workplace Design
OveNiew of Ergonomics/Human Factors
1:45PM
1:00
Work Capacities of an Industrial Population
1:45 - 2:45
Break
2:45 - 3:00
Problem Solving: Determining the Best Height of a
3:00 - 4:00
Standing Workstation
General Layout Principles
4:00 - 4:45
Workplace Design Guidelines - Summary
4:45 - 5:00
Session 2: Workplace and Equipment Design, Environmental
Design, Work Pace
8:00 - 9:00AM
Seated Workplace Design- Computer Workplaces
9:00 - 9:45
Problem Solving: Designing a Sub-Assembly Seated
Workplace
Break
9:45 - 10:00
Lighting, Noise, Temperature/Humidity
10:00- 11 :00
Work Pace - Impact on Recovery Time for Static Work
11 :00 - 11 :30
Automation/Human Interfaces/Complexity
11 :30 - 12:00
Lunch
12:00- 1:00 PM
Session 3: Reducing Overexertion Injuries Through Ergonomic
Design
Problem Solving: Assembly Line Tasks
1:00 - 2:00 PM
Repetitive Motions Problems - Risk Factors
2:00 - 2:45
Break
2:45 - 3:00
Techniques To Reduce the Risk Factors
3:00 - 3:30
Low Back Pain Risk Factors and Manual Handling
3:30 - 4:30
Problem Solving: Overexertion Injury Prevention
4:30 - 5:00

(
\'---//

Session 4: Resources, Cost/Benefit Analyses
8:00 - 9:00AM
Examples of Ergonomics Tools and Equipment to
Reduce the Risk for Overexertion Injuries
Cost/Benefit Analyses
9:00 - 9:45
Break
9:45 - 10:00
Problem Solving: New Design
10:00- 11 :45
Resources, Evaluations
11:45- 12:00
10/22/91

•

L

�Ergonomics Training Course for Engineers
Table of Contents
Topic
Schedule
Table of Contents
Aclmow1edgements

I

t
\.___/"

Starting Page Location
Syllabus
EDFPAW1
i

EDFPAW2

11

iv

Ergonomics Goals
Plant Ergonomics Programs - Overview
Costs of Poor Design
Capacity and Workload Determinants
Sensitizers to Stress
Ergonomic Approaches to Reduce Injuries
Recovery Time/Static Muscle Work
5 Questions AbOut Workplace Design
Ergonomics Problem Solving

1
2
6
8
9
11
13
20
21

The Variability of People, Anthropometry
Height and Reach Interactions
Using Anthropometric Data
Who Do We Design For ?
Best Height for a Standing Workplace
General Layout and Materials Flow
Designing to Minimize Effort

23
28
29
31
32
34
36

VDT Workplace Design Kit
VDT Workplace Analysis
Seated Arm Reach
How To Deal With Posture Problems
How To Deal With Visual Problems
Ergonomics Problem Solving

37
46
47
48
50
52

Environmental Factors - Lighting, Noise,
Temperature
Work Pace!fime Pressure
Job Control and Task Complexity
Human Reliability - Man vs Machine
Ergo Opportunities - Automation or People
Problem Solving Form

54
57
60
62
63
64

Risk Factors for Carpal Tunnel
Factors Affecting Grip Strength
.Risk Factor Analysis Form
Ergonomic Job Analysis Technique
Table 2: Levels of Muscle Effort
Table 3: Heavy Effort in Manual Handling

67
69
70
71
74
75

Risk Factors for Low Back Pain
Strength and Location
Maximum Force Applications
Kodak Lifting Guidelines
Summary - Guidelines to Reduce Back Pain
Analyzing Jobs For Low Back Risk Factors

76
78
79
80
82
85

Hand Tool Selection and Design

87

3

2
9

112, 140
112,140,150,338

24,217
24,217

8,285,290
20,24,30
285

13,446
218,255

23,50
52
28,101,179
20

----

17,30,50

-223,282

181

--

--151,244
151,254

360,254,403

15,122,151

140

135,340
135,338
384,446
360,403

256

�Cost/Benefit Analyses
Problem Solving Form - Cost/Benefit
Ergonomic New Design Analysis Form
Summary of Operation Design

91
97
100
101

12 Ergonomics Guidelines
Ergonomics Checklist
Resources - Bibliographies
Course Evaluation Form

103
108
114
end

10/22/91 SHR

313
365

559

�Acknowledgements

,~~

CJ

The illustrations on pages 25-28, 47, 80, and 81 are used with
permission from Eastman Kodak's Ergonomic Design for People at Work,
Volumes 1 and 2 published by Van Nostrand Reinhold. The tables, text,
and illustrations on pages 24, 78, 79, and 82-84 are from Working With
Backache by S. H. Rodgers. The article on pages 13-18 was published by
Thieme Publishers in Seminars in Occupational Medicine in March 1987.
The article on pages 11-12 was published in 1987 by the Polinsky
Foundation's Functional Capacities Assessment Network. The table on
page 62 is from Human Performance in Industry by Murrell, published by
Reinhold in 1965. Information on pages 9, 37 to 46,48-51, and 71 has
been developed in conjunction with Dr. Inger Williams. The analytical
technique on page 71 has been published by Hanley and Belfuss in a 1988
Occupational Medicine: State of the Art Review edition on Worker
Fitness Evaluations. All other material in this syllabus is by Dr. S.H.
Rodgers and permission to reproduce it must be obtained from her.

6/90 SHR

t

0

I

Lv

�...

4-Day Ergonomics Training Course For The
Eastman Kodak Company, Rochester, NY,
November 5-8,1991

Syllabus

.·

\

(__j

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�()

Eastman Kodak Rochester, 4-Day Ergonomics Training Course,
Training and Educational Resource Center, Nov 5-8,1991

Tuesday, November 5th: Overview, Posture and Productivity
8:00 8:309:009:45-

8:30 AM
9:00
9:45
10:00

Introductions and Overview
Work Capacity
·
Who Do We Design Fo'r ?
Break
f,

10:45- 11 :15
11:15- 12:00
12:00 - 12:45 PM

Posture and Productivity - Static Work,
Reach/Height Interactions
Work/Recovery Curves
Layout of Workplaces/ Automation
Lunch

12:45- 1:15
1:15- 2:15
2:15- 2:30

Problem Solving: Layout/Standing Work Design
Visual Work and Lighting - Bob Weneck
Break

10:00- 10:45

2:30- 3:15
3:15- 4:15
4:15- 4:30

Design of Seated Workplaces and Office
Ergonomics - Inger Williams
Problem Solving: Seated Workplace Design
Summary of Workplace Design Guidelines

Wednesday, Nov 6th - Preventing Overexertion Injuries
and Enhancing Human Reliability
8:00 - 8:30 AM
8:309:15
9:15- 10:00
10:00-10:15

Repetitive Motions Disorders
Risk Factors for Tendonitis, Carpal Tunnel, etc.
Ergonomic Job Analysis Form
Break

10:15-11:00
11 :00 - 12:00
12:00 - 12:45 PM

Problem Solving: Rep~titive Tasks
Tool Design and Selection
Lunch

12:45-1:15
1:15-2:15
2:15- 2:45

Ergonomics and Quality - Puzzle
Human Reliability- Overview
Reducing Job Complexity- Information, Pacing,
Controls/Displays/Automation
Break

2:45- 3:00

,
L

�3:00- 3:45
3:45- 4:30

Environmental Factors ilnfluencing Performance
Problem Solving: Information and Environment

Thursday, Nov 7th: Manual Handling and Costi;Benefit
Analyses
·
f

(_)

8:00- 9:00
9:00 -10:00
10:00-10:15

Hours of Work and Shiftwork - Carol McCreary
Systems Approach to MMH - Joel Wilson
Break

10:15-10:45
10:45 -11:30
11 :30 -12:00
12:00 -12:45

Low Back Risk Factors - MMH Guidelines
Problem Solving: Manual Handling
Frequent Lifting/ Total Workload
Lunch

12:45-2:00
2:00- 2:15
2:15- 3:15
3:15- 3:30

Problem Solving: Designing a New Handling Task
Cost-Benefit Analyses of Solutions
Problem Solving Using! Cost-Benefit Approach
Break

3:30-4:00
4:00-4:30

SuNeys/Checklists/Resources
Instructions for Day 4 Problem Solving Session
and Initial Preparation Time for Groups

Friday Nov 8th, 1991 : Problem Solving and Group Presentations - Cost-Justified Solutions

8:00- 10:45
10:45 - 11 :00
11 :00 - 11 :45
11:45-12:45
12:45- 2:00
2:00- 2:15
2:15- 2:45
2:45- 3:00

Time to Complete Presentation for Today
Break
Presentations
Lunch
Presentations
Break
Where From Here ?
Course Evaluations

Homework Suggestions:

(_)

Night Before Course: Review Volume 1, Ch 2, Appendix, Syllabus
Tuesday Night: Review Volume 1, Chs 3,4,5, Volunie 2, Work Patterns
Wednesday Night: Review Volume 2, Manual Handling
9/26/91 SHR

I

I

(...l,..

�Ergonomics Training Course
Table of Contents
(~\

\.

)

;~\

"-_)

_)

,_

Topic
Schedule
Table of Contents
Acknowledgements

Syllabus
i
iii
v

Starting Page Location
EDFPAW 1

EDFPAW2

General Industry Ergo Guidelines
Introduction and Course Goals
Ergonomics Goals
Capacities for Work
Factors That Increase Stress
The Variability of People
Anthropometric Data
Height and Reach Interactions
Using Anthropometric Data
Distributions and Design

1
2
3
4
6
7
8
10
11
13

Static Muscle Work
Recovery Time/Static Work
Design to Minimize Effort
Finding the Best Solutions
Ergonomic Problem Solving

14
22
27
28
29

Layout and Materials Flow Worksheet
Humans vs Machines
Automation or Manual Worksheet
Questions to Ask
Problem Analysis: Standing Work

31
33
34
35
36

Risk Factors for Carpal
Tunnel Syndrome
Factors Mfecting Grip Strength
Risk Factor Analyses
Ergonomic Job Analysis Form
Tables 2-3: Effort Definitions
Effort Estimation Scales
Problem Analysis: Repetitive
Work

38

151,244

40
41
42
45
47
50

151,254

Puzzle Exercise
Ergonomics and Quality
Paced Work - Time Pressure
Information Transfer- Controls
and Displays
Job Control and Task Complexity
Environmental Factors
Problem Solving Form

58
60
63

Risk Factors for Low Back Pain
Natural History Degenerative Disc
Manual Materials Handling
Strength and Location
Maximum Force Applications
Kodak Lifting Guidelines
Problem Analysis: Manl Handling

66
68
69
71
72
73
74

51
52
54
57

3
8,285,290
8,285,290
20,24,30
285
112,140,150

2
210,446,496
237
13,446
13,446
218,255

24,217
217

52

14
83

342

23,50

338

230
90,107,162

--

210, 242, 320

---

-135,340

15,122,151

-338
135,338
384,446
360,403
--

\

.

,..

{.,(,.,(.

�(~)

Repetitive Lifting Guidelines
Total Workload
General Guidelines/Lifting!
Repetitive Work

75
76
81

Ergonomic Design Analysis Form
Cost/Benefit Analyses
The Costs of Poor Design
Ergonomics in Old/New Design
Problem Solving Form

82
83
87
89
90

How to - Ergonomics Survey
Questions to Ask Line Workers
12 Ergonomics Design Guidelines

93
95
97

313
---

Ergonomics Project Instructions.
Extra Problem Solving Forms

102
103 ff

--

Course Evaluation Form

end

--

9/26/91 SHR

(~
~/

--

--

403
206,276,480

-----

9

--

-98

�Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS

2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

1-Day Ergonomics Seminar for Managers and
Engineers from 3 Sara Lee Meatcutting Plants
in the Cincinnati Area, November 25, 1991
Schedule
~·~
.

8:30- 8:45AM

9:15 - 10:15
10:15- 10:30

Introductions - Goals of Course, Preventing Injury and Illness
Through Reduction of Fatigue on a Job
Postural Fatigue - Static Muscle Loading, Work/Recovery Needs.
Ways to Reduce Static Loading.
Problem Solving: Postural Fatigue
Break

10:30-11:15
11:15 - 11:30
11:30-12:15 PM
12:15 - 1:00

Repetitive Work Fatigue- Risk Factors, Ergonomic Job Analysis
Techniques to Reduce Repetitive Work Fatigue
Problem Solving: Repetitive Work
Lunch

'"-----)

8:45- 9:15

1:00
1:45
2:15
2:30
3:00

-

1:45
2:15
2:30
3:00
3:15

3:15 - 4:25
4:25 - 4:55
4:55 - 5:00
\
/_r_.· ' - ' - - /

Cost/Benefit Analyses of Ergonomic Solutions - Selling Change
Fatigue Associated With Manual Handling Tasks
Techniques to Reduce Handling Fatigue
Problem Solving: Manual Handling
Break
Projects: Each Plant Team Work on a Problem Using the
Techniques Presented in This Course
Presentations: Each Team Present Their Solution (in 10 Minutes)
Final Comments

�Table of Contents
Page#

Topic
, ' \I
I

Table of Contents/Acknowledgments
Thoughts on Ergonomics Processes
Capacity and Workload Determinants
Ergonomic Approaches to Reduce Injuries
Recovery Time Needs for Repetitive Work
Work/Recovery Curves
Anthropometric Data
Height and Reach Interaction
Redesigning Jobs to Minimize Unnecessary Effort
Finding the Best Solution to an Ergonomics Problem
Ergonomics Problem Solving Forms
Risk Factors for Carpal Tunnel Syndrome
Risk Factor Evaluation Forms
Ergonomic Job Analysis Form
Table 2: Muscle Effort Levels
Table 3: Heavy Effort in Manual Handling Tasks
Extra Forms Ergonomic and Risk Factor Analysis
Cost-Benefit Analyses of Ergonomic Problem Solutions
The Costs of Poor Design
Cost Justifying Problem Solving Forms
1981 NIOSH Manual Lifting Guide Formula
Kodak Occasional Lifting Guidelines
Kodak Frequent Lifting Guidelines
Instructions for Problem Presentations
Extra Forms for Problem Solving
Ergonomic Case Study Form
Ergonomics Videotapes for Employee Awareness
S.H. Rodgers References in Ergonomics

1
2

5
7
9
15
16
17
18
19

20
24

27

28
31

32
33

34
38
40
46

47
48
49

50
56
57
58

Acknowledgements

r

The illustrations on pages 17, 47 and 48 are used with permission from Eastman Kodak's
Ergonomic Design for People at Work, Volumes 1 and 2 published by Van Nostrand Reinhold.
The illustration on page 16 is from Working With Backache by S.H.Rodgers. Information on
page 28 has been developed in conjunction with Dr. Inger Williams. The article on
work/recovery curves was published by Thieme Publishers in Seminars in Occupational
Medicine in March 1987. The analytical technique on page 28 has been published by Hanley
and Belfuss in a 19880ccupational Medicine: State of the Art Review edition on Worker
Fitness Evaluations. The formula on page 46 is from NIOSH's Manual Lifting Guide written in
July, 1981. All other material in this syllabus is by Dr. S.H. Rodgers and permission to
reproduce it must be obtained from her.

J
11/16/91

f,

�i

~·&lt;,~ll

)

Ergonomics Awareness Seminar
for Vermont Employers and VOSHA, Rutland, VT, December 3,1991
Sponsored by General Electric Aircraft Engine Plants, Rutland, VT
Presented by Suzanne H. Rodgers, PhD, Consultant in Ergonomics

30 min

A. VOSHA's Responsibilities to Reduce illjuries Related to
Ergonomic Problems in the Workplace- VOSHA

30 min

B. Overview of Ergonomics/Human Factors -Benefits to
Employers/Employees

60 min

C. Overexertion fujuries
1. Recognition of CTDs (Cumulative Trauma Disorders)
2. Fatigue Model to Explain CTDs
3. Risk Factors and Factors Affecting Grip Strength
4. Techniques to Reduce the Risk Factors
5. Early Detection and Medical Management of CTDs

60 min

D. Ergonomic Job Analysis Technique to Identify the Need for
Change in Tasks
1. Level of Effort Defined
2. Duration of Muscle Effort and Frequency of Effort
3. Total Time of Task and Pattern of Work

30 min

E. Job and Workplace Design Guidelines to Reduce the Risk for
CTDs at Work

120 min F.

Problem Solving Examples

60 min G. Setting Up an Ergonomics Process in Your Business

1.
2.
3.
4.
5.
6.

Management Commitment
Employment fuvolvement
Job Analysis
Hazard Prevention and Control
Medical Management
Training and Education

Suzanne H. Rodgers, Ph.D
.t(----.· ~

CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

�Occupational
Ergonomics

3-Hour Ergonomic Awareness Session for People on the
Ham Bone Lines, Bryan Foods, West Point, MS,
January 27, 28, 1992

Topics Covered
Preventing Excessive Fatigue
Designing Jobs to Reduce Small Muscle Stress
Finding the Best Work Patterns
Analyzing Jobs
Problem Solving - Ham Bone Line Jobs

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMA.N FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Ergonomics
\

/

I

Job Setisfection
Productivity
Quel ity
Sefety

3.5-Day Ergonomics Training Course for GE
Appliances Dishwasher Plant, Louisville, KY,
Fe_bruary 10-13, 1992

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1, AWARENESS SEMINARS
2, TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3, HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�Regulatory Agencies: Standards That Impact Industry and
Health care, Lecture/Discussion Session on Sunday, March 1, 1992
in San Antonio, TX for the Polinsky Advantage FCA's Seminar,
"Keeping Pace With Occupational Medicine" (90 minutes)

A. Ergonomics Guidelines Through OSHA
1. Ergonomics Program Management Guidelines for Meatpacking Plants

·

a. Primary Components
b. How Guidelines Have Been Used By OSHA Inspectors
c. Using the Guidelines Proactively Rather Than In Response to Citations

2. Ergonomics Program Management Guidelines for General Industry
a. Primary Components and How Used by OSHA Inspectors
b. Checklists- What To Be Aware Of In Using Them
c. ANSI Z-365 Standards Committee Work
B. NIOSH Guidelines for Manual Lifting
1. 1981 Guidelines vs 1991 Proposed Guidelines
2. Using the Guidelines to Evaluate Lifting Tasks

C. San Francisco Video Display Terminal Worker Safety Ordinance
1. Content
2. Applications and Concerns
3. Office Ergonomics Approaches
2/5/92 SHR

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

{716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�I

I
'.

\

~zanne

H. Rodgers, PhD.

Consultant In Ergonomics/Human Factors
169 Huntington Hills
ROCHESTER, NEW YORK 14622

Job Analysis and Placement- The Ergonomics Viewpoint
Lecture/Problem Solving Session on Sunday, March 1, 1992
in San Antonio, TX for the Polinsky Advantage FCA's Seminar,
"Keeping Pace With Occupational Medicine" (90 minutes)

A. Assessing Job Demands
1.
2.
3.
4.
5.
6.

Musculoskeletal Stresses
Cardiopulmonary Stresses
Perceptual Demands
External Pacing Stress
Job Environment
Psychosocial Stressors

B. Defining Work Capacities
1.
2.
3.
4.
5.
6.

Strength
Reach/Range of Motion
Endurance- Local Muscle and Whole Body
Tolerance of Environmental Stresses
Perceptual Capacities
Mental Capacities

215/92 SHR

(716) 544·3587

�Suzanne H. Rodgers, PhD.
Consultant In Ergonomics/Human Factors
169 Huntington Hills
ROCHESTER, NEW YORK 14622

Ergonomic Job Analyses and Design Guidelines
Support Material for Ergonomics Reviews of Jobs in 3 Departments
at Astra Valcour in Glens Falls, NY, March 12, 1992

Table of Contents

Topic
Identifying Ergonomics Problems
Anthropometric Data
Height and Reach Guidelines
· Overexertion Injury Risk Factors
Work-Recovery Curves for Muscles
Ergonomic Job Anallsis Technique
Table 2: Examples o Muscle Effort
Rating of Perceived Exertion Scales
Table 3: Definitions of Heavy Effort in Manual Handling
Strength in Different Locations
Maximum Forces for Design
Biomechanics of Lifting - Low Back Risk
NIOSH Lifting Guidelines
Kodak Lifting Guidelines
Extra Analysis and Problem Solving Forms
References - SH Rodgers

Pm:e #
1
7
10
11
12
13
16
17
19

20
21
22
23

25

27
31

Acknowledgements
The illustrations on pages 7 to 10, 17, 25 and 26 are used with permission from Eastman Kodak's
Ergonomic Designfor People at Work, Volumes 1 and2 published by Van Nostrand Reinhold in
1983 and 1986. The tables and illustrations on pages 20 to 22 are from Working With Backache
by S. H. Rodgers published by Perinton Press in 1985. Information on page 12 has been
developed in conjunction with Dr. Inger Williams. The analytical technique on pages 13 to 15 has
been published by Hanley and Belfuss in a 1988 Occupational Medicine: State of the Art Review
edition on Worker Fitness Evaluations. All other unreferenced material in this syllabus is by Dr.
S.H. Rodgers and permission to reproduce it must be obtained from her.

(716) 544·3587

�Table of Contents
Topic
OSHA and ADA and Ergonomics
Ergonomics in Industry
The Costs of Non-Ergonomic Design
Capacity and Workload Determinants
Who Do We Design For?
The Variability of People, Anthropometry
Height and Reach Interactions
Using Anthropometric Data

1
5
7

9
12
14
21
23

Strength Data - Strength/Location Interaction
Maximum Force Applications
NIOSH Lifting Guidelines
Kodak Lifting Guidelines

25

Recovery Time/Static Muscle Work
Ergonomic Job Analysis Technique
Table 2: Levels of Muscle Effort
Table 3: Heavy Effort in Manual Handling

30
37
41
42

Risk Factors for Carpal Tunnel
Risk Factors for Low Back Pain
Risk Factor Analysis Form
Environmental Considerations

43
45

5 Questions About Workplace Design
Designing to Minimize Effort
Ergonomics Problem Solving - New Design
General Layout and Materials Flow
Human Reliability - Man vs Machine
Ergo Opportunities - Automation or People
Job Control and Task Complexity
Environmental Factors - Lighting, Noise,
Temperature, Work Pace!fime Pressure
Seated vs Standing Work
Best Height for a Standing Workplace
Hand Tool Selection and Design
Visibility Issues
Dealing With Postural and Visual Problems
Design of a Subassembly Workplace - Control Panel
Design of Containers - Size, Handholds, Weights, Locations

-

Page#

12 Ergonomics Guidelines
Ergonomics Checklist
Examples of Questions
Resources - Bibliographies
Extra Forms
3/31/92

26
27
28

47
48

51
52

53
55
57

58
59
61
64
65
67

69
73
77
80
81

86
92
94

98

�Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14822

2-Hour Ergonomic Awareness Sessions for Supervisors,
Planners, and Engineers at General Electric's
Dishwasher Plant in Louisville, KY, April 6-8,1992

Syllabus
Table of Contents

Topic
OSHA Draft of General Ergonomics Program Guidelines
ADA Legislation (Americans With Disabilities Act)
Ergonomic Goals
The Costs of Poor Design
Recovery Time Needs for Repetitive Work
Work/Recovery Curves
Overexertion Injury Risk Factors
Risk Factor Analysis Form
Ergonomic Job Anallsis Technique
Table 2: Examples o Muscle Effort
Table 3: Definitions of Heavy Effort in Manual Handling
Kodak Lifting Guidelines
Anthropometric Data
Height and Reach Guidelines
Ergonomics Problem Solving Form
12 Ergonomic Design Guidelines
Extra Analysis and Problem Solving Forms
References - SH Rodgers

Pa2e#
2
4

13

14
16
22:
23
24
25

28
29

30
32

33

34
36
41
45

�Acknowledgements
The OSHA Ergonomics Program Management Recommendations for General
Industry outline is from an unpublished document being worked on within the
agency and regularly "leaked" to interested industry groups. This version appears to
be from the summer of 1990 draft. The ADA handout is from the new Technical
Assistance Manual on ADA available from EEOC as of February, 1992. The article
on pages 16-21 is from Thieme Publishers Seminars in Occupational Medicine:
Repetitive Motions Injuries of March, 1987. The illustrations on pages 30, 31 and
33 are used with permission from Eastman Kodak's Ergonomic Design for People at
Work, Volumes 1 and 2 published by Van Nostrand Reinhold in 1983 and 1986.
The illustrations on page 32 are from Working With Backache by S. H. Rodgers
published by Perinton Press in 1985. Information on page 25 has been developed in
conjunction with Dr. Inger Williams. The analytical technique on pages 25-27 has
been published by Hanley and Belfuss in a 1988 Occupational Medicine: State of the
Art Review edition on Worker Fitness Evaluations. All other unreferenced material
in this syllabus is by Dr. S.H. Rodgers and permission to reproduce it must be
obtained from her.

t.

�Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

4-Hour Ergonomics Training for Departmental Teams,
at Plant 3, GE Appliances, Louisville, KY, April 7, 1992
Table of Contents
Topic
General Industry Ergonomics Guideline - Draft
Plant Ergonomics Programs and Organization
Figure 1: The Costs of Poor Design
Identifying Ergonomics Problems
Work/Recovery Curves
Anthro12_ometric Data
Height/Reach Interaction
Risk Factor Analysis
Risk Factors for Carpal Tunnel Syndrome
Factors Mfecting Grip Strength
Ergonomic Job Analysis
Table 2: Examples of Muscle Effort Levels
Table 3: Definitions of Heavy Effort in Manual Handling
Extra Problem Solving Forms
Risk Factors for Low Back Pain
Strength and Location
Maximum Forces
Kodak Lifting Guidelines
Overexertion Injury Risk Factors
12 Guidelines for Design
References - SHRodgers

Startint: Pa2e
1
2
3
5
11
16
17
18
19
21
22

25
26

27

28

30
31
32
34
35
end

Acknowledgements
The illustrations on pages 17, 32 and 33 are used with permission from Eastman Kodak's

Ergonomic Design for People at Work, Volumes 1 and 2 published by Van Nostrand Reinhold.
The illustrations and tables on pages 16, 30, and 31 are from Working With Backache by
S.H.Rodgers. Information on pages 31 and 42-47 has been developed in conjunction with Dr.
Inger Williams. The curves on page 11 and the table on page 21 are described in an article on
work/recovery curves published by Thieme Publishers in Seminars in Occupational Medicine in
March 1987. The analytical technique on page 25 has been published by Hanley and Belfuss in
a 19880ccupational Medicine: State of the Art Review edition on Worker Fitness Evaluations.
All other material in this syllabus is by Dr. S.H. Rodgers and permission to reproduce it must
be obtained from her.

�6-Hour Ergonomics Course for Engineers at the Louisville, KY
General Electric Appliances Plant 3, April 8-9,1992
Syllabus
A. Scope of Ergonomics/Human Factors in Industry
B. Who Do We Design For?
1. General Issues
2. Anthropometric Data
3. Strength and Endurance Data
4. Environmental Considerations

C. Design of a New Line
1. Gathering Information for a New Design
a. Questions for Operators, Supervisors, Safety &amp; Health Specs.
b. Quality, Productivity, Rework, Scrap Data
2. Layout
a. Materials Flow
b. Environmental Issues- Lighting, Vibration, Noise, etc.
3. Line Heights
a. Seated vs Standing
b. Reaches Required
c. Postural Effects of Line Height Variations
4. Visibility Issues
a. Nature of the Target To Be Seen
b. Effect of Lighting on Visibility/Upper Body Posture
5. Subassembly- Control Panel Design
a. Heights/Reaches
b. ClearancesNisibility
c. Repetitive Work
c. Controls and Displays
6. Containers for Incommg and Outgoing Parts ,
a. Characteristics of Containers - Size, Handholds
b. Container W~ights
c. Locations in Workplace

D. General Ergonomics Guidelines for Design
1.
2.
3.
4.

Checklists/Guidelines
Resource Books
Philoso.Phical Guidelines - People vs Automation
Designmg to Reduce the Risk for Overexertion Injuries

�--,

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3-Day Ergonomics Training Course for
Amoco of Canada Fabrics and Fibers Plants
Hawkesbury, ONT, April14-16, 1992

Syllabus
_ _)

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

--~

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1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN

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Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
""HIGHER PRODUCTIVITY THROUGH JOB DESIGN""

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Resource Manual for the Ergonomics Core Team at
General Electric Aircraft Engine Plants in Rutland,VT

CJ

April 20-21, 1992

Schedule

Monday . April 20th
7:00
Review of Progress Since December
8:00
Review of Goals for Core Team Training/New Team Development
8:45
Break
9:00
Review of Material in Resource Manual/GE Manual/Kodak Books
10:00
Identification of Most Useful Information To Team Members
11:00
Suggested Material for Syllabus for Training New Teams
11:30
Lunch
12:30
Problem Solving: New Tapes
2:15
Break
2:30
Finalize Content for Training Session Syllabus
3:30
Adjourn
Tuesday. April 21st
7:00
Finalize Training Session Schedule and Respoonsibilities
8:00
Practice Sessions with Videotapes
8:45
Break
9:00
Practice Session (continued)
11 :00
Final Preparation for Course
11:30
Lunch

�Table of Contents
Topic
General Industry Ergonomics Guideline
Ergonomics Process Components
Ergonomic Program Approaches
Ergonomics Organizational Ideas
Characteristics of First Job
Use of the Problem Solv4lg_and Cost Analysis Forms
Analyzing Standing Reach/Height Requirements
Use of the Height/Reach Guidelines for Seated Work
Instructions for the Ergonomic Job Analysis Form
Use of the Lifting Guidelines Chart
Static Muscle Work Demonstration
Arm Reach and Height Demonstration
Factors Affecting Handgrip Strength
Hand Tools Demonstration
Assembly Task Perlormance Demonstration - Puzzle
Recovery Time Needs for Repetitive Tasks
Work/Recovery Curves
Anthropometric Data
Analysis of the VDT Workstation
Cost-Benefit Analysis
Costs of Poor Design
Training Module #1 -Ergonomics Overview
Training Module #2 - Repetitive Motions Problems
Training Module #3 - Manual Handling/Low Back Pain
Case Study Form
Work Practices in Repetitive Tasks
Recommended Videotapes on Ergonomic Subjects
Equipment for Ergonomics Work in Industry
Guidelines for Preparing Videotapes of Jobs
Resource Materials for Plants and Workers
Suggested Published Resource Materials
References - S.H. Rodgers

Startin2 Pa2e #
1
2

3

7
10
11
24

28

32
42

51
56
61

68

71

77
83
84
87

95
99
101
107

111
118
119

120
121
123
124
126
129

Acknowledgements

(_/

The illustrations on pages 27, 31, 47, 48, 84-86, and 115 are used with permission from Eastman
Kodak's Ergonomic Design for People at Work, Volumes 1 and 2 published by Van Nostrand
Reinhold. The tables and illustrations on pages 9, 68, 49 and 50 are from Working With Backache
by S. H. Rodgers. Information on pages 36 and 87-94 has been developed in conjunction with Dr.
Inger Williams. The article on Recovery Time Needs for Repetitive Work on pages 77-82 and the
table on page 108 has been published by Thieme Publishers in Seminars in Occupational Medicine
in March 1987. The analytical technique on page 36 has been published by Hanley and Belfuss in a
1988 Occupational Medicine: State ofthe Art Review edition on Worker Fitness Evaluations. The
outline on page 1 is from a draft copy of a proposed ergonomics guideline for general industry by
OSHA written in September, 1990. All other material in this syllabus is by Dr. S.H. Rodgers and
permission to reproduce it must be obtained from her.

�:'~
\ J

4-Day Ergonomics Training Course for
General Electric Aircraft Engine Plants
at Lynn, MA, May 4-7, 1992

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
'-'- ..)

3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�i

t·

4-Day Ergonomics Training Course

Monday: Ergonomics Overview/Update, Reducing Fatigue at Work,
Workplace and Equipment Design
7:30- 9:00AM
9:00- 9:15
9:15- 9:45
9:45- 10:15
10:15- 11:00
11:00- 11:30

Introductions &amp; Review of Ergonomics Activity at Lynn
Break

11:30-12:15 PM

Work Capacities- Who Do We Design For?
Preventing Fatigue: Work/Recovery Curves
Problem Solving: Postural Fatigue
Using Body Size Data - Heights and Reaches,
Visual Needs
Lunch

12:15- 12:45
12:45- 2:00
2:00- 2:30
2:30- 2:45

Problem Solving Exercise: Standing Workplace Height
Workplace Layout: Design to Reduce Extra Effort
Seated Workplace Design
Break

2:45- 3:30

Problem Solving: Seated Workplace Design

Tuesday: Preventing Overexertion Injuries and Reducing Error
7:30- 8:15AM
8:15- 8:45AM

0

8:45- 9:30
9:30- 9:45

Computer Workplaces
Risk -pactors for Tendonitis, CafJ?al Tunnel
Syndrome, and Other Overexertion Injuries
Ergonomic Job Analysis Form
Break

9:45- 11:00
11:00- 11:30
11:30- 12:15 PM

Problem Solving: Repetitive Tasks
Tool Design and Selection
Lunch

12:15- 1:00
1:00- 1:45
1:45- 2:15
2:15- 2:30

Ergonomics and Quality Performance - Puzzle
Improving Human Reliability - Reducing Job
Complexity and Providing Operator Control
Controls/Displays and Automation
Break

2:30- 3:30

Environmental Factors Influencing Performance

Wednesday: Manual Handling and Cost/Benefit Analyses
\
I

.
'--____/

7:308:309:009:30-

8:30
9:00
9:30
9:45

Low Back Pain- Job Risk Factors
Designing Manual Handling Tasks
Manual Lifting Guidelines
Break

l

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'

9:45 -10:45
10:45 -11:15
11:15 -11:30
11:30 -12:15

Problem Solving: Manual Handling
Total Workload/Hours of Work
Cost-Benefit Analyses of Ergonomic Problems
Lunch

12:30- 1:30
1:30- 2:15
2:15- 2:30

Problem Solving Using Cost-Benefit Approach
Surveys/Checklists/Resources
Break

2:30- 3:00
3:00- 3:30

Ergonomics Programs: Where From Here ?
Problem Selection for Day 4, Instructions for
Presentations

)

Thursday: Problem Solving and Presentations by Class Members
7:30- 11:30
11:30- 12:15 PM

Work on Presentations (with Oversight)
Lunch

12:151:452:003:30-

Practice Presentations
Break
Presentations to Managers
Action Plan Discussion, Course Evaluations

4/92SHR

i

"--j

1:45
2:00
3:30
4:00

�4-Day Ergonomics Training Program for the
Decatur, AL GE Appliances Plant, June 1-4,1992

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�4-Day Ergonomics Training Course
Day 1: Ergonomics Overview, Reducing Fatigue at Work,
Workplace and Equipment Design
7:30 - 8:30 AM
8:30- 9:00
9:00- 9:15
9:15- 9:45
9:45- 10:15
10:15- 11:00
11:00- 11:30

Introductions &amp; Review of Ergonomics Legislation
Scope of Ergonomics
Break

11:15- 11:30
11:30 - 12:15 PM

Work Capacities - Who Do We Design For ?
Preventing Fatigue: Work/Recovery Curves
Problem Solving: Postural Fatigue
Using Body Size Data - Heights and Reaches,
Visual Needs
Problem Solving: Standing Workplace Heights
Lunch

12:15- 12:45
12:45- 2:00
2:00- 2:30
2:30- 2:45

Finish Problem Solving Exercise
Workplace Layout: Design to Reduce Extra Effort
Seated Workplace Design
Break

2:45- 3:30

Problem Solving: Seated Workplace Design- VDTs

Day 2: Preventing Overexertion Injuries and Reducing Error
7:30- 8:30AM
8:30- 9:00
9:15- 9:45
9:45- 10:00

Risk Factors for Tendonitis, CafJ?al Tunnel
Syndrome, and Other Overexertion Injuries
Ergonomic Job Analysis Form
Factors Affecting Grip Strength, Level of Effort
Break

10:00- 11:30
11:30- 12:15 PM

Problem Solving: Repetitive Tasks
Lunch

12:15 - 12:45
12:45- 1:15
1:15- 1:45

Tool Design and Selection
Ergonomics and Quality Performance - Puzzle
Improving Human Reliability - Reducing Job
Complexity and Providing Operator Control
Controls/Displays and Automation
Break

1:45- 2:15
2:15- 2:30
2:30- 3:30

Problem Solving: Accident Investigation and
Ergonomics

Day 3: Manual Handling and Cost/Benefit Analyses
7:308:309:009:30-

8:30
9:00
9:30
9:45

Low Back Pain- Job Risk Factors
Designing Manual Handling Tasks
Manual Lifting Guidelines
Break
I

t

�9:45 -10:45
10:45 -11:15
11:15-11:30
11:30 -12:15

Problem Solving: Manual Handling
Total Workload/Hours of Work
Environmental Factors
Lunch

12:30- 1:30
1:30- 2:15
2:15- 2:30

Cost-Benefit Approach
Surveys/Checklists/Resources
Break

2:30- 3:15
3:15- 3:30

Ergonomics Programs: Where From Here ?
Problem Selection for Day 4, Instructions for
Presentations .

Day 4: Problem Solving and Presentations by Class Members and
Others With Ergonomics Training
7:30- 10:30
10:30-11:30
11:30 - 12:30

Work on Presentations (with Oversight)
Practice Sessions
Lunch

12:30 - 12:45
12:45- 1:00
1:00- 1:15
1:15- 1:30
1:30- 1:45
1:45- 2:15

Case Study # 1
Case Study # 2
Case Study # 3
Case Study # 4
Case Study # 5
Action Plan Discussion, Course Evaluations

5/92 SHR

t

i

l.L-

�Syllabus for a 1-Day Seminar on Applied Ergonomics for
Clients of The Therapy Source, Boise, 10, June 10, 1992

8:00- 8:30AM
8:30- 9:15
9:15- 9:45
9:45- 10:00
10:00 - 11 :00
/----\

I'-'
\..

11:00-12:00
12:00 - 1:00 PM

Introductions, Review of Content of Seminar
Overview of Ergonomics, Legislation (OSHA, ADA),
Benefits of Designing With Ergonomics in Mind
Designing Jobs to Prevent Fatigue
Break
Risk Factors for Overexertion Injuries on the Job Managing Carpal Tunnel Syndrome/Low Back Pain
Ergonomic Job Analysis Technique
Lunch

.

1:00- 2:00
2:00- 3:00
3:00- 3:15

Problem Solving: Overexertion Injuries
Office Ergonomics - VDT Users
Break

3:15- 3:45

Cost/Benefit Analyses of Ergonomic Problem
Solutions
Questions/Comments

3:45- 4:30

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS

/

2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�1-Day Ergonomics Seminar for the VA Medical Center in
Boise, 10, September 30, 1992

Schedule

8:00 - 8:30AM
8:30-9:45
9:45-10:00
10:00- 11:00
11:00- 12:00
12:00-1:00 PM
1:00-2:15
2:15-3:00
3:00-4:00
4:00-5:00

Introductions, Review of Areas of Interest
Defming Ergonomics Problems in the Workplace - Risk
Factors for Overexertion, Stress Factors
Break
Ergonomics and Low Back Pain - Reducing Risk Factors Postural and Manual Handling Requirements
Problem Solving: Handling Tasks - Patient Handling,
Receiving, Laundry, Supplies
Lunch
Office Ergonomics - Evaluation and Problem Solving Medical Administration, Clinics, etc.
Repetitive Tasks - Ergonomic Accommodations
Problem Solving - Repetitive Work - Food Preparation,
Cleaning, Pharmacy
Questions, Discussion

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�8:35
9:00
9:40
10:00
10:30
11:30
1:00PM
2:00
3:00-4:30
3:30
5:00

Patterns of Work - Shift Work, Job Organization - Day
Interviews, Questionnaires and Psychophysical MethodsWilliams
Workplace Measurements - Stuart-Buttle
Break
Biomechanical Analysis of Postures, Lifts- Cook
Lunch
Problem Solving: Manual Lifting Tasks- Cook
Risk Factors for Overexertion Injuries, Ergonomic Job
Analysis Technique- Rodgers
Vendor Demonstrations
Break
Adjourn

Friday, March 12th

8:00AM

8:05
9:15
10:00
10:30
10:45
11:45
1:15PM
1:20
2:15
3:15

Case Studies Showing Utilization of Different Techniques
for Analyzing Job Demands - Panel of All Faculty Members
Participating
Repetitive Tasks- Day, leader
VDT Workplaces - Williams, leader
Break
VDT Workplaces (continued)- Williams, leader
Manual Handling Tasks- Cook, leader
Lunch
Functional Assessments of Work Capacities and Capabilities
Tests of Functional Capabilities- Walker
Research on Static Strength Assessments and Lifting
C~pabilities - Golden
Adjourn

Saturday, March 13th

8:30AM

9:30
9:35
10:30

Relationship of Strength Assessments and Other Variables:
Testing Reliability and Relationship to Work CapabilitiesHickey
Testing for Susceptibility; Relating Capacities to Work
Requirements; Reasonable Accommodations
Studies on Early Detection of Repetitive Motions Disorders Cook
Break

�11:00
11:45

Medical Assessment of the Back - Parrotte
Lunch

1:00PM

Relating Job Demands to Functional Capacity Data and
Defining How Much Change is Needed to Make Jobs More
Ergonomic - Rodgers
When to Fix the Person and When to Fix the Job - Work
Hardening, Fitness, Ergonomics- Walker, Golden, Hickey, Day
Break
Examples of Reasonable Accommodations - Panel
Adjourn

2:00
3:00
3:30
4:30

Sunday. March 14th
8:30AM
8:35
9:05
9:35
10:00
10:30
11 :15
11:45
12:00

10/7/92 SHR/bl

Building Ergonomics Into the Occupational Setting
On-Site Therapy Clinics- Golden, Parrotte
Ergonomics and Wellness Programming - Day, Hickey
Ergonomics and Management Programs for Quality, etc.Rodgers
Break
Helping an Employer Respond to an OSHA Citation (or avoid
one) - Stuart-Buttle
Ergonomics Solutions- Ensuring Longevity of the
Ergonomics Process - Panel
Resources, Training, Equipment, etc.; Course Evaluations;
Credits - Panel
Final Adjournment

�()

:~~:a.o~i.cS:········ P~luti.nty ::t:::::

··~~i·:·i···s~ety :::::j:(i~··: ····+····

Ergonomics: Practical and Cost-Effective
Approaches to Improve Health, Safety and
Performance at Work

A 2-Day Seminar Sponsored by:
Safety Council, GRM Chamber of Commerce
National Safety Council
Professional Development Group, Inc.

0
Speakers: Michael Gladden, BSIE, MSIH
Suzanne H. Rodgers, Ph.D.

Location: PDG Training Center, Bushnell's Basin
Dates: November 23-24, 1992
-

=~t-=
IlL:
~
-

==
-

=-

~=-

~

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(
\
\.___j

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�n

Ergonomics: Practical and Cost-Effective Approaches to
Improve Health, Safety and Performance at Work
Suzanne H. Rodgers, Ph.D.

Michael Gladden, M.S.

Schedule
Day 1:
8:30AM Introductions
9:00 A. Why Ergonomics?

1.
2.
3.
4.
5.
6.
7.

0

Occupational Injuries and illnesses
W orlCers Compensation Costs
Competitivity- Productivity and Quality Needs
Nature of the Workforce- Older, Women, Fewer for More Work
Interaction of PeoJ?le with Automation - New Concerns
Legislation Mfectmg Ergonomics - OSHA, ADA, Lifting Guidelines
Questions and Comments from Participants

10:15 Break
10:30 B. Starting an Ergonomics Process
1. Data Systems to Identify Areas of Concern - Health, Safety,
Human Resources (Turnover, Absenteeism), Productivity, Quality
Control, Scrap, etc.
2. Who Should Be Involved ?
3. Pilot Pro grams - How to Prioritize
4. Reactive and Proactive Approaches
5. Problem Solving Session- Working With Data to Prioritize Ergonomics
Projects

11:30 Lunch
12:15

C. Risk Factors for Occupational Injury and Illness
1. ·Factors Contributing to Fatigue or Overexertion at Work
2. Risk Factors for Upper and Lower Extremity Injuries and illnesses Tendonitis, Carpal Tunnel Syndrome, Shoulder and Knee Problems, etc.
3. Risk Factors for Low Back Pain - Posture and Safe Lifting Guidelines
4. Job Risk Factor Identification Exercise with Seminar Attendees

2:15 Break

�2.
2:30

D. Medical Management
1. Identification of Overexertion or Cumulative Injuries and Illnesses at Work
2. Initial Treatment
3. Referrals and/or Work Restrictions
4. Return-to-Work Issues
5. Work Hardening and Functional Assessments
6. Interaction of Ergonomics and ADA in the Medical Management Process
7. Questions from and Discussion with Attendees

(\
\. J

4:30 Adjourn
Day2:

8:30

E. Job Site Analysis
1. Survey Techniques - Questionnaires, Checklists, Postures, etc.
2. Relating Observations to Human Capacity Information to Determine Extent
of the Problem - Anthropometric Data, Strengths, etc.
3. Prioritization Techniques
4. Ergonomic Job Analysis Technique - Fatigue Prediction

10:00 Break
10:15

0

F. Problem Solving
1. Finding Root Causes of Ergonomic Problems
2. Developing a Problem Solvmg Team
3. Finding Cost-Effective and Practical Solutions
4. Reasonable Accommodations for Individuals vs Job Improvements for All
5. Case Studies: Office Workplace, Manual Materials Handling Tasks,
Repetitive Tasks

11:30 Lunch
12:15 F. Problem Solving Case Studies (cont'd)
2:00 Break
2:15 G. Proactive Ergonomics- Design Guidelines
1.
2.
3.
4.
5.

Heights, Reaches, Visibility, Clearances
Manual Handling and Force Exertion Guidelines
Environmental Tolerances and Guidelines
Tool Design
Pacing Guidelines

3:15 H. Making Ergonomics Changes
1.
2.
3.
4.
5.

Management Commitment
Selling Change - Problem Must Be Clear
Ergonomics When There is No Money Available
Building Ergonomics Concepts Into Your Business Processes
Questions from and Discussion with the Attendees

4:30 Adjourn

�Biograpical Information on Speakers for 2-Day Ergonomics Seminar
November 23-24,1992
Michael Gladden - Mike is currently a safety engineer/ergonomist employed by
the Xerox Corporation. He has 8 years of experience in providing ergonomics
support and guidance to manufacturing facilities with Xerox Corporation, General
Motors Corporation, and the Saturn Corporation. He obtained his Bachelor's degree
in Industrial Engineering in 1979 and his Master's degree in Industrial Hygiene in
1991, both from the University of Michigan at Ann Arbor. Mike has also taught
courses in Advanced Ergonomics and Personal Ergonomics orientation in the facilitie8
in which he has worked.
Suzanne H. Rodgers - Sue has been a full-time Consultant in Ergonomics since
1982 following 13 years as an ergonomist in the Human Factors/Ergonomics Group
at Eastman Kodak Company. Her current clients include General Electric, Mobil
Chemical, Amoco, Goodyear, the City of Rochester, Delco, Kodak, Astro Valcour,
Cabledata, Oneida Silver, the Boise, Idaho VA Hospital, and NIOSH. Sue earned her
Ph.D. in Physiology at the U of R Medical Center in 1967 and has taught as an
adjunct faculty member at the U of R Medical School (21 years) and at SUNY at
Buffalo in the Industrial Engineering Department (6 years). A major part of her
business is to train teams from production and support services to identify, analyze,
and find cost-effective and practical solutions to problems associated with job,
equipment, workplace, and environmental designs, and to train designers how to use
data on human capabilities in their work. Sue has authored 3 books on ergonomics
plus several chapters for professional journals and is a USA Editor for the English
JOurnal, Ergonomics .

�. .. ,_.·.·r·'
·. :(/('

Goals of the Course:
1. To provide attendees with information that will
recognize ergonomic problems at work and ·. ·
cost-effective manner.
. .. · .· · · ..-.,. ,.,.. ,
2. To provide up-to-date information on legislation · · ·•········
,..,.,..."'*"'·"'.,..,....,,..
related areas (ADA) and to show how to derive the
from
implementing an ergonomics process.
3. To provide information about the medical management of overexertion and
cumulative injuries and illnesses in order to reduce the opportunity for re-injury
while still getting people back to work in a timely manner.
4. To provide the attendees with techniques for doing job site analyses and for
developing reasonable accommodations, as needed, through a team problem
solving process.
5. To reinforce the information with case studies and examples of successful
ergonomic interventions to reduce occupational injury and illness while
improving people's ability to do quality work.

Who Should Attend:
. , ...· .
Safety and health specialists and representatives; human resources; Workers'
Compensation, and labor placement specialists; insurance and rehabilitiation
specralists; ergonomics coordinators, industrial engineers, production engineers;
supervisors, and key operators, labor representatives; occupational nurses and
physicians, vocational trainers and therapists, exercise physiologists; and
managers.

�Ergonomics: Practical and Cost-Effective
Improve Health, Safety and Performance
Outline
Day 1:

A. Why Ergonomics ?
1. Occupational Injuries and illnesses
2. Workers Compensation Costs
3. Competitivity- Productivity and Quality Needs
4. Nature of the Workforce- Older, Women, Fewer for More Work
5. Interaction of PeoJ?le with Automation- New Concerns
6. Legislation Mfectmg Ergonomics - OSHA, ADA, Lifting Guidelines
7. Questions and Comments from Participants

B. Starting an Ergonomics Process
1. Data Systems to Identify Areas of Concern - Health, Safety,
2.
3.
4.
5.

Human Resources (Turnover, Absenteeism), Productivity, Quality
Control, Scrap, etc.
Who Should Be Involved ?
Pilot Programs- How to Prioritize
Reactive and Proactive Approaches
Problem Solving Session- Working With Data to Prioritize Ergonomics
Projects

C. Risk Factors for Occupational Injury and Illness
1. Factors Contributing to Fatigue or Overexertion at Work
2. Risk Factors for Upper and Lower Extremity Injuries and illnesses Tendonitis, Carpal Tunnel Syndrome, Shoulder and Knee Problems, etc.
3. Risk Factors for Low Back Pain- Posture and Safe Lifting Guidelines
4. Job Risk Factor Identification Exercise with Seminar Attendees

D. Medical Management
1. Identification of Overexertion or Cumulative Injuries and illnesses at Work
2.
3.
4.
5.

Initial Treatment
Referrals and/or Work Restrictions
Return-to-Work Issues
Work Hardening and Functional Assessments
6. Interaction of Ergonomics and ADA in the Medical Management Process
7. Questions from and Discussion with Attendees
Day2:

E. Job Site Analysis
1. Survey Techniques - Questionnaires, Checklists, Postures, etc.
2. Relating Observations to Human Capacity Information to Determine Extent
of the Problem - Anthropometric Data, Strengths, etc.
3. Prioritization Techniques
4. Ergonomic Job Analysis Technique - Fatigue Prediction

�F. Problem Solving
1. Finding Root Causes of Ergonomic
2. Developing a Problem Solving Team
3. Finding Cost-Effective and Practical
4. Reasonable Accommodations for
5. Case Studies: Office Workplace, Manual··
Repetitive Tasks
G. Proactive Ergonomics- Design Guidelines
1. Heights, Reaches, Visibility, Clearances
2. Manual Handling and Force Exertion Guidelines
3. Environmental Tolerances and Guidelines
4. Tool Design
5. Pacing Guidelines
H. Making Ergonomics Changes
1. Management Commitment
2. Selling Change - Problem Must Be Clear
3. Ergonomics When There is No Money Available
4. Building Ergonomics Concepts Into Your Business Processes
5. Questions from and Discussion with the Attendees

�November 23rd Registrants
Bill Czech

Xorox Corporation
800 Phillips Road
Building 311 ..23B
Webster, NY 14580
422u2S47
Dous Stryker

Wegmans Risk Management Dept.
1500 Brooks Avenue

Box 844
Rochester, NY 14692

328-2550
Dr. Bruce, Barron
Occupational &amp; Medi~ Divi.skm
Strong Memorial Hospital
601 Elmwood Avenue Box 65~·
Rochester, NY 14642~863d.
275 ..9192
Steve Burton, Jane Prior and Ht-.rvici Russ,eU
Write Woman
2320 Brighton Henrietta Townline RoG!d

Roohesterl NY 14623
272-0960

�FAX from Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics
169 Huntington Hills- Center, Rochester, New York 14622
Phone# (716) 544-3587; FAX# (716) 266-8749

To:~])~J~~--~-~_. _-_ __
FAX#: (

Of:

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-------------------------------

Date: ~/~92

Comments:

Total Pages (incl cover) :

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�Acknowledgements

0

The illustrations and tables on pages C-16 to 19, C-22, and C23 are used with permission from
Eastman Kodak's Ergonomic Design for People at Work, Volumes 1 and 2 published by Van
Nostrand Reinhold in 1983 and 1986. The tables, text, and illustrations on pages C-15, C-20, and
C-21 are from Working With Backache by S. H. Rodgers published by Perinton Press in 1985.
The VDT Workplace Design Kit on pages F-8 to F-16 has been developed in conjunction with Dr.
Inger Williams. The article on pages C-1 to C-6 and the table on page C-lOb were published by
Thieme Publishers in Seminars in Occupational Medicine in March 1987. The analytical technique
on page E-23 and F-17 has been published by Hanley and Belfuss in a 1988 Occupational
Medicine: State of the Art Review edition on Worker Fitness Evaluations. The srticle starting on
page E-5 to E22 has been published in October, 1992 by Hanley and Belfuss in theOccupational
Medicine: State of the Art Reviews edition on Ergonomics The material on the 1991 NIOSH
Manual Lifting Guidelines is from a talk by A. Garg and T. Waters given in Denver, CO in June,
1992. The material on pages D-1 to D9 is from the January, 1992 ADA Technical Assistance
Manual from the EEOC. All other unreferenced material in this syllabus is by Dr. S.H. Rodgers
and permission to reproduce it must be obtained from her.

�Ergonomics and the ADA
Sponsored by Riccardi &amp; Burton Physical Therapy, P.C.
in Fulton, NY, December 11,1992

Schedule
8:00AM General Introductions, Review of Course
8:20 A. Why Ergonomics ?
1. OSHA, ADA and Ergonomics Opportunities
2. Benefits to the Business
8:45 B. What Makes Jobs Difficult?
1. Postures
2. Strength Requirements
3. Endurance Demands
4. Amount of Control Over Work Pattern
5. Other Factors- Complexity, Environmental Stressors
10:00
Break
10:15 C. Techniques for Job Site Analysis
1. Checklists - Risk Factors
2. Subjective Information Collection
3. Ergonomic Job Analysis Technique
4. Lifting Guidelines Use
5. Employee Monitoring or Job Simulation
12:00
Lunch
1:00 D. Case Studies
2:45 E. Examples of Reasonable Accommodations
3:15
Break
3:30 F. Developing an Ergonomics Process in a Company
4:00 G. Ergonomics Panel
5:00
Adjourn

Suzanne H. Rodgers, Ph.D.
Consultant in Ergonomics
169 Huntington Hills- Center
Rochester, NY 14622
(716) 544-3587; 266-8749 (FAX)

�Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

3-Day Ergonomics Courses for Engineers and Plant Production
Specialists at Goodyear Tire and Rubber Company,
Akron, OH, January 19-21, 1993
Syllabus
A. Scope of Ergonomics/Human Factors in Industry
B. Who Do We Design For?
1. General Issues
2. Anthropometric Data
3. Strength and Endurance Data
4. Environmental Considerations
C. Design of a New Line
1. Gathering Information for a New Design
a. Questions for Operators, Supervisors, Safety &amp; Health Specs.
b. Quality, Productivity, Rework, Scrap Data
2. Layout
a. Materials Flow
b. Environmental Issues- Lighting, Vibration, Noise, etc.
3. Line Heights
a. Seated vs Standing
b. Reaches Required
c. Postural Effects of Line Height Variations
4. Visibility Issues
a. Nature of the Target To Be Seen
b. Effect of Lighting on Visibility/Upper Body Posture
5. Subassembly- Control Panel Design
a. Heights/Reaches
b. ClearancesNisibility
c. Repetitive Work
c. Controls and Displays
6. Containers for Incommg and Outgoing Parts
a. Characteristics of Containers - Size, Handholds
b. Container Weights
c. Locations in Workplace
D. General Ergonomics Guidelines for Design
1. Checklists/Guidelines
2. Resource Books
3. Philosophical Guidelines- People vs Automation
4. Designing to Reduce the Risk for Overexertion Injuries

�3-Day Ergonomics Courses for Engineers and Plant Production
Specialists at Goodyear Tire and Rubber Company,
Akron, OH, January 19-21, 1993
Schedule
Tuesday, January 19,1993:
8:00AM A. Introductions, Scope of Ergonomics/Human Factors in Industry

8:30

B. Who Do We Design For?
1. General Issues
2. Anthropometric Data
3. Strength and Endurance Data
4. Environmental Considerations

10:00

Break

10:15

C. Design of a New Line or Machine
1. Gathering Information for a New Design
a. Questions for Operators, Supervisors, Safety &amp; Health Specs.
b. Quality, Productivity, Rework, Scrap Data
2. Layout
a. Materials Flow
b. Environmental Issues - Lighting, Vibration, Noise, etc.
3. Line Heights
a. Seated vs Standing
b. Reaches Required
c. Postural Effects of Line Height Variations

12:00

Lunch

1:00 PM
2:00

2:30
2:45

4:30

d. Problem Solving: Working Heights
4. Visibility Issues
a. Nature of the Target To Be Seen
b. Effect of Lighting on Visibility/Upper Body Posture
Break
5. Subassembly- Control Panel Design
a. Heights/Reaches
b. ClearancesNisibility
c. Controls and Displays
d. Problem Solving: Controls and Displays
Adjourn

Wednesday, January 20, 1993:
8:00
6. Risk Factors for Overexertion Injuries
a. Repetitive Motions Injuries
b. Manual Handling Tasks
c. Problem Solving: Avoiding Overexertion Injury Risk

�2.
10:00
10:15

12:00

Break
7. Containers/Cartsffrucks for Incoming and Outgoing Parts
a. Characteristics of Containers - Size, Handholds
b. Container Weights
c. Locations in Workplace
d. Push/Pull Forces for Hand Carts and Trucks
e. Materials Handling Approaches
Lunch

1:00 PM Problem Solving: Materials Handling Approaches
2:30

D. General Ergonomics Guidelines for Design
1. Checklists/Guidelines
2. Resource Books
3. Philosophical Guidelines- People vs Automation
4. Designmg to Reduce the Risk for Overexertion Injuries

4:00

Selection of Projects for Day 3

4:30

Adjourn

Thursday, January 21, 1993:
/-\

0

8:00AM Break Up Into Project Groups; Define Scope of Design Needs or
Production Problem
10:00

Break

10:15

Continue Working on Project

12:00

Lunch

1:00

Prepare Visual Aids for Presentations

2:00

Break

2:15

Presentations of Project Results (15 tminutes each)

3:30

Course Evaluations, Final Comments

3:45

Arrivederci

1/8/93 SHR
\

_j

�Ergonomics and Safety
Presentation to the Harris Corporation Safety Committee,
Rochester, NY, March 4, 1993, 12:00-1:00 PM

Outline

A. Harris Corporation Safety Committee Involvement in Ergonomics
B. National Activity in Ergonomics
C. Fatigue Model to Identify and Resolve Potential Ergonomics
Problems
D. Ergonomic Problem Solving Approaches
E. Ergonomics and Job Safety Analysis - Investigating Accidents
F. Setting· Up an Ergonomics Process at Harris Corporation

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y, 14622

�GENERAL INDUSTRY ERGONOMICS GUIDELINE

I.

MANAGEMENT COMMITMENT/EMPLOYEE INVOLVEMENT
A.
B.
C.
D.

II.

Top management commitment
Written Program
Employee Involvement
Regular Review and Evaluation

PROGRAM ELEMENTS
A.

Work site Analysis

B.

Hazard Prevention &amp; Control
1.
Engineering
2.
Work Practices
3.
PPE
4.
Administrative

C.

Medical Management
i.
Early detection - education
2.
Care/case management
3.
Intervention - Light duty work hardening, etc.
4.
Record keeping - Evaluation of program

D

Training + Education
1.
General
2.
Job Specific
3.
Supervisors
4.
Managers
5.
Engineers and maintenance

E.

Checklists and Screening Tests
1.
Work station
2.
Task analysis
3.
MMH
4.
VDT
5.
Symptoms
6.
Screening Tests

�Ergonomic Approaches to Improve Working Comfort in OEC
Winter, 1993

A. Purpose of the Training Session- Yesterday, Today, Tomorrow
B. Why People May Be Uncomfortable in Computer Workstations
1. Different Body Sizes and Standard Workplaces
2. Risk Factors for Discomfort and How to Reduce Them
C. Postural Discomfort
D. Visual Discomfort

E. Driving Factors for Discomfort and the Problem Solving Process
F. Rating Your Comfort and Requesting Assistance in Problem Solving
G. Lending Library Approach to Find Appropriate Comfort Enhancers Importance of Analysis Before Throwing Equipment at a Problem
H. Questions and Answers

Sue Rodgers, Ph.D.
Consultant in Ergonomics
169 Huntington Hills
Rochester, NY 14622
(716) 544-3587
(716) 266-8749 (FAX)

Inger Williams, Ph.D.
Consultant in Ergonomics
28 Shelter Creek
Fairport, NY 14450
{716) 377-7791
{also FAX#)

�2-Day Ergonomics Team Training Course
for the Optics Center of Bausch &amp; Lomb
Rochester, NV, May 10-11 , 1993
Syllabus
May lOth
8:00
8:30
9:00
9:30
9:45
10:30
11:15
11:30
12:30
1:30
2:00
2:15
3:00
3:45
4:15
5:00
May 11th
8:00
8:45
9:30
9:45
10:15
11:00
11:30
12:30
2:30
2:45
3:15
4:15
4:45

Introductions, Review of Course Goals, Overview
Fatigue Model for Defining Ergonomic Problems and Solutions
Muscle Work/Recovery Time Needs- Postural Work
Break
Problem Solving: Postural Work
Body Size Data- Use in Design and Analysis of Jobs/Workplaces
Height and Reach Interactions
Lunch
Problem Solving: Determining the Best Height for a Workplace
Seated Work- VDT Workplaces
Break
Problem Solving: VDT Workplace Evaluations and Solutions
Risk Factors for Repetitive Tasks
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks
Adjourn
Manual Materials Handling Risk Factors
Problem Solving: Manual Lifting
Break
Job Control and Job Complexity - Controls and Displays
Cost-Benefit Analyses - How to Sell Change
Project Selection for Last Session
Lunch
Work on Projects
Break
Prepare Presentations
Present Projects
Resources, Program Discussion, Evaluations
Adjourn

�2-Day Ergonomics Training Course for
the GE Plastics Mt Vernon Plant
Mt Vernon, IN, June, 1;993
Syllabus
Day 1:
8:00
8:30
9:00
9:30
9:45
10:30
11:15
11:30
12:30
1:30
2:00
2:15
3:00
3:45

4:15
5:00

Day 2:
8:00
8:45
9:30
9:45
10:15
11:00
11:30
12:30
2:30
2:45
3:15
4:15
4:45

Introductions, Review of Course Goals, Overview
Fatigue Model for Defining Ergonomic Problems and Solutions
Muscle Work/Recovery Time Nyeds- Postural Work
Break
Problem Solving: Postural.\Vork
Body Size Data- Use in Design and Analysis of Jobs/Workplaces
Height and Reach Interactions
Lunch
Problem Solving: Determining the Best Height for a Workplace
Seated Work- V:OT Workplaces
Break
Problem Solving: VDT Workplace Evaluations and Solutions
Risk Factors for Repetitive Tasks
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks
Adjourn
Manual Materials Handling Risk Factors
Problem Solving: Manual Lifting
Break
Job Control and Job Complexity- Controls and Displays
Cost-Benefit Analyses- How to Sell Change
Project Selection for Last Session
Lunch
\Vork on Projects
Break
Prepare Presentations
Present Projects
Resources, Program Discussion, Evaluations
Adjourn

�j

I

1

I

I

I

I

!

\

I

J

I

'

Ergonomics Awareness for
Mack Molding Company, Arlington, Vermont
August 2, 1993

Outline

A. Scope of Ergonomics - Who, What, Where, When, Why ?
B. Improving Working Comfort
1. Fatigue Model
2. Postural Comfort
3. Visual Comfort
C. Work Design to Improve Comfort
1. Risk Factors for Overexertion/Cumulative Injuries - How Much Is
Too Much?
a. Ergonomic Job Analysis Technique
b. Lifting Task Analysis
2. Examples of Job Analyses to Define Risk
D. Developing Cost Effective Solutions to Ergonomics Problems
1. Problem Solving Approach
2. Examples of Ergonomic Assists and Equipment
3. Evaluating "Ergonomic" Equipment
a. Evaluating Office Furniture Needs
b. Evaluating Tools and Equipment
E.

Case Studies

�(

------- '

..

Ergonomic Workplace Analysis
Ergonomics Problem Solving for GE Transportation
Teams, Erie, PA, August 26-27, 1993

Outline

A. The Fatigue Model for Predicting Potential CTDs
B. Analyzing Jobs for CTD Risk Factors
C. Ergonomic Job Analysis Technique
D. Problem Solving
1. Highly Repetitive Tasks
2. Postural Stress
3. Manual Handling Tasks
E. Defining the Benefits of Ergonomic Improvements in the
Workplace

L~•~
Jll'~
Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS
(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 1~

�2.5-Day Engineers' Training Course in
Ergonomics - Designing for People

Amoco Foam Products Technical Center
Atlanta, GA, September 20-22, 1993

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 ' 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�...

Ergonomic Workplace Analysis
Ergonomic Refresher Course for Amoco Fabrics &amp; Fibers,
Hazelhurst, GA, November 18-19, 1993
Outline

A. The Fatigue Model for Predicting Potential CTDs
B. Analyzing Jobs for CTD Risk Factors
C. Ergonomic Job Analysis Technique
D. Problem Solving
1. Highly Repetitive Tasks
2. Postural Stress
3. Manual Handling Tasks
E. Defining the Benefits of Ergonomic Improvements in the
Workplace

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�3.5 Day Ergonomics Training Course
for the GE Aircraft Engine Plant in
Evendale, OH, January4 -7,1994

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�3.5-Day Ergonomics Training Course
Day 1: Ergonomics and Legislation Overviews, Reducing Fatigue,
Workplace and Equipment Design
8:00 - 8:30AM
8:30 - 9:00
9:00 - 9:30
9:30- 10:00
10:00- 10:15

Introductions, Course Goals
Ergonomics Overview
Legislation Relating to Ergonomics - OSHA, ADA
Designing Jobs to Reduce Fatigue
Break

10:15- 10:45
10:45- 11:30
11 :30 - 12:30

Work and Recovery Time Needs - Postural Stress
Problem Solving: Fatigue Reduction/Posture
Lunch Break

12:301:151:302:30-

Using Anthropometric Data for Design
Heights and Reaches
Problem Solving: Working Heights
Break

1:15PM
1:30
2:30
2:45

2:45- 3:15
3:15-3:45
3:45- 4:15

Office Workplaces - VDT Use
Layout Analyses
Discussion: Enabling Employers To Design Jobs
Ergonomically

Day 2: Repetitive Tasks, Ergonomic Job Analysis, Human
Reliability, Ergonomics and Quality, Automation,
Information Flow, Environment
8:00 - 9:00AM
9:00- 9:45
9:45- 10:15
10:15- 10:30

Risk Factors for Repetitive Motions Problems
Ergonomic Job Analysis Technique
Problem Solving: Ergonomic Job Analysis
Break

Problem Solving: Ergonomic Job Analysis cont'd
Using the Ergonomic Job Analysis Technique to Define
Light Duty Jobs and to Develop Priorities for
Ergonomics Interventions in the Workplace
11:30- 12:30 PM Lunch Break

10:30- 11:00
11:00- 11:30

12:301:00 1:302:15 -

1:00AM Human Reliability, Accident Analyses
1:30 .. Problem Solving: Ergonomics and Accident Analysis
2:15
· Ergonomics and Quality- Puzzle Exercise
2:30
Break

2:30- 3:15
3:15- 4:15

Environmental Factors- Noise, Vibration, Heat, Cold,
Lighting
DiscussiOn: Integrating Ergonomics Into Plant
Operations - Safety, Engineering, Purchasing

c•

�2.

, ~~,

Day 3: Manual Materials Handling, Total Workload, Cost-Benefit
Analyses, Programmatic Issues Relating to OSHA and ADA
Legislation

j

8:00 - 9:00AM
9:00- 10:00
10:00"' 10:15
10:15- 10:45
10:45- 11:00
11:00- 11:30
11:30- 12:15

Low Back Pain Risk Factors
Guidelines for Manual Handling Tasks - NIOSH, Kodak
Break
Problem Solving: Lifting and Lowering
Guidelines for Pushing and Pulling
Frequent Lifting and Overall Workload Guidelines
Lunch Break

12:15 - 1:00PM Using the Guidelines to Develop Plant Policies On
1:00
1:45
2:00
2:45
3:15

-

1:45
2:00
2:45
3:15
4:15

Manual Materials Handling
Hours of Work and Shiftwork
Break
Problem Solving: Manual Handling Tasks
Cost-Benefit Analysis To Sell Ergonomic Change
Problem Solving: Cost Benefit Analyses

Day 4: Project, Presentations, Program Discussion, Resources
8:00- 9:45
9:45- 10:00

Work on Projects, Prepare Presentations
Break

10:00- 11:00
11:00- 12:00

Project Presentations
Review of Ergonomics Applications and Program
Development, Resources, Evaluations

10/92SHR

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SMITHKLINE BEECHAM
CIDRA- PUERTO RICO
MARZO 24 - 2G DE 1994

SUZANNE H. RODGERS, PhD
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS DESIGN
3. HEALTH AND SAFETY PROGRAMS

(715) 544-3587. 169 HUNTINGTON HILLS. ROCHESTER, N.Y. 14622

�Schedule for the Ergonomics Problem Solving Course
conducted by Dr. Suzanne H. Rodgers, SB, Cidra, PR
Wednesday, March 24, 1994: Fatigue Problem Solving on
Postural and Repetitive Stresses, Manual Handling Tasks
8:00AM
The Fatigue Model and Overexertion Injuries
8:30
Ergonomic Problem Solving Approach
9:30
Developing Solutions to Ergonomic Problems
Break
10:00
10:15
Ergonomic Job Analysis Technique
11:00
Problem Solving: Postural and Repetitive Tasks
12:00
Lunch

1:00PM
2:00
2:30
2:45
3:30
4:00

Presentations on Problem Solving Projects
Manual Handling Guidelines Review
Break
Problem Solving: Manual Handling Tasks
Presentations on Manual Handling Projects
End of Day

Thursday, March 25, 1994: Office Ergonomics, Human
Reliability, Designing with Capacity Data, Cost/Benefit
Analyses
8:00AM
Self-Help Approach to Office Ergonomics
9:00
Human Reliability and Accident Investigations
9:45
Break
10:00
Problem Solving: Accident Investigations
11 :00
Presentations on Investigation Findings
12:00
Lunch

1:00PM
1:30
2:30
2:45
3:30

Designing With Capacity Data- Data Review
Problem Solving: Designing a Workplace/Handling Task
Break
Presentations on Design Projects
Cost/Benefit Analyses

Friday, March 26,1994: Ergonomics Process Issues, Projects
8:00AM
Ergonomics Processes- Building It Into The Business
Start Work on Projects
9:00
12:00
Lunch

1:00PM
2:15

Prepare Presentations
Make Presentations to Managers
("

(_

�PROGRAMA
SOLUCION DE PROBLEMAS ERGONOMICOS
DIRIGIDO POR: SUZANNE H. RODGERS
SMITHKLINE BEECHAM CIDRA- PUERTO RICO

Mh§rcoles, marzo 24, 1994: Soluci6n de Problema de Fatiga en Esfuerzos
Posturales y Repetitivos, Tareas de Manejo Manual
8:00AM
8:30
9:30
10:00
10:15
11 :00
12:00

El Modelo de Fatiga y Lesiones par Agotamiento
Acercamiento a Ia Solucion del Problema Ergonomico
Desarrollando Soluciones a Problemas Ergonomicos
Descanso
Tenica de Analisis de Trabajo Ergonomico
Solucion de Problema: Tareas Posturales y Repetitivas
Almuerzo

1:00PM
2:00
2:30
2:45
3:30
4:00

Presentacion de Proyectos de Solucion de Problemas
Manejo del Manual Revision de Directrices
Descanso
Solucion de Problema: Tareas de Manejo Manual
Presentaciones sabre Proyectos de Manejo Manual
Fin de Ia Sesion

Jueves, marzo 25, 1994: Ergonomia en Ia Oficina, Confiabilidad Humana,
Disenando con Datos de Capacidad, Analisis de Costo/Beneficio
8:00AM
9:00
9:45
10:00
11:00
12:00

Acercamiento de Ayuda Personal a Ia Ergonomfa en Ia Oficina
Confiabilidad Humana e Investigaciones de Accidentes
Descanso
Solucion de Problema: Investigaciones de Accidentes
Presentacion sabre los Resultados de Ia lnvestigacion
Almuerzo

1:00PM
1:30
2:30
2:45
3:30

Disenando con Datos de Capacidad - Revision de Datos
Solucion de Problema: Disenando Ia Zona de Trabajoffarea Manual
Descanso
Presentacion Sabre Proyectos de Diseno
Analisis de Costa/Beneficia

Viernes, marzo 26, 1994: Temas de Proceso Ergon6mico, Proyectos
8:00AM
9:00
12:00

Procesos Ergonomicos- Crean dolo Dentro del Negocio
Empiece a Trabajar en los Proyectos
Almuerzo

1:00
2:15

Prepare las Presentaciones
Haga las Presentaciones a los Gerentes

�Table of Contents - Cidra Course
Topic
A. Fatigue
Recovery Time Needs for Repetitive Work
Work/Recovery Time Graphs for Static Work

Starting Page
A1
A7

B. Problem Solving
A Functional Job Analysis Technique
Ergonomics Problem Solving Form
5 Questions About Workplace and Job Design
Finding the Best Solutions
Problem Solving Form, end
Ergonomic Job Analysis
Table 2: Examples of Muscle Effort Levels
Table 3: Heavy Effort in Manual Handling Tasks
Extra Job Analysis and Risk Factor Analysis Forms
Ergonomic Principles for Layout and Flow
Best Height for a Standing Workplace
Human Reliability Form
Summary of Ergonomic Analyses, When to Use Them

B15b

C. Office Ergonc-:-Analysis of the Vu. Nark Station
Body Discomfort Scale
Risk Factors for Discomfort
Observed Postures Checklist
Self-Help to Increase Seated Work Comfort
Examples of Workplace Assists

C1
C2
C3
C4
C5
C7

D. Guidelines
12 Ergonomics Design Guidelines
Standing Height/Reach Capabilities
Kodak Lifting Guidelines
Maximum Forces
E. Cost/Benefit and Projects
How to Do and Ergonomics Survey
Examples of Questions to Ask Production People
Cost/Benefit - Existing and New Design
Cost-Benefit Analyses of Problem Solutions
The Costs of Poor Design
Cost Justification Problem Solving Form
Instructions for Problem Presentations
Extra Forms

B1 ff
B2

B3
B4
B5
B6
B7
B8
B9
B11

B13
B15

D1
D6

D7
D9

E1

E3

ES
E6
E10
E12

E15
E16 ff
(

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�CONTENIDO
Tern a

A. Fatiga
Necesidades de Tiempo de Recuperacion para Trabajo Repetitive
Trabajo/Tiempo de Recuperacion para Trabajo Estatico. Graficos
B. Problema/Soluci6n
Una Tecnica Funcional de Analisis de Trabajo
Forma para Ia Solucion de Problema Ergonomico
5 Preguntas Acerca de Ia Zona de Trabajo y Diseiio del Trabajo
Encontrando las Soluciones Mejores
Forma para Solucion de Problema, termina
Analisis de Trabajo Ergonomico
Tabla 2: Ejemplos de Niveles de Esfuerzo Muscular
Tabla 3: Esfuerzo Fuerte en Tareas de Manejo Manual
Formas para Analis,is de Trabajo Adicional y Factor de Riesgo
Principios Ergonomicos para Exponer y Desarrollar
Altura Mas Adecuada para una Estacion de Trabajo de Pie
Forma de Confiabilidad Humana
Sumarios de Analisis Ergonomico, Cuando Usarlo

F1
F7

P/S1ff
P/S2
P/S3
P/S4
P/S5
P/S6
P/S7
P/S8
P/S9
P/S11
P/S13
P/S15
P/S15b

C. Ergonomia en Oficinas
Analisis de una Estacion de Trabajo con Terminal de Video
Nivel de Molestia Corporal
Factores de Riesgo de Molestia
Lista de Posturas Observadas
Ayuda Personal para lncrementar el Confort del Trabajo Sentado
Ejemplos de Ayudas en el Ia Estacion de Trabajo
D. Directrices
12 Directrices de Diseiio Ergonomico
En Posicion de Pie/Capacidades de Alcance
Directrices de Levante de Kodak
Esfuerzos Maximos

E/01
E/02
E/03
E/04
E/05
E/07

D1
D6
D7
D9

E. Costo/Beneficio y Proyectos
Como Hacer una Encuesta Ergonomica
Ejemplos de Preguntas para Hacer al Personal de Produccion
Costa/Beneficia- Diseiio Existente y Nuevo
Costa/Beneficia - Analisis de Soluciones de Problemas
El Casto de un Diseiio Pobre
Forma Solucion del Problema de Justificacion de Casto
lnstrucciones para Presentaciones de Problemas
Formas Adicionales

C/B1
C/B3
C/B5
C/B6
C/B10
C/B12
C/B15
C/B16ff

�Acknowledgements
The illustrations on pages D6, D7, and D8 are used with pennission from Eastman Kodak's
Ergonomic Design for People at Work, Volumes I and 2 published by Van Nostrand Reinhold in
1983 and 1986. The table on page D9 is from Working With Backache by S. H. Rodgers
published by Perinton Press in 1985. The computer workplace material on pages C1 to C7 has
been developed in conjunction with Dr. Inger Williams. The article on pages A1 to A6 was
published by Thieme Publishers in Seminars in Occupational Medicine in March 1987. The
analytical technique on pages B6, B7, and B9 has been published by Hanley and Belfuss in a 1988
Occupational Medicine: State of the Art Review edition on Worker Fitness Evaluations and in more
detail (B1 ff) in October, 1992by Hanley and Belfuss in the Occupational Medicine: State of the
Art Reviews edition on Ergonomics All other unreferenced material in this syllabus is by Dr.
S.H. Rodgers and pennission to reproduce it must be obtained from her.

�. '

RECONOCIMIENTOS
Las ilustraciones en las paginas 0*7, y 08 son empleadas con el permiso
de Eastman Kodak, Ergonomic Design for People at Work, VoWmenes 1 y
2 publicados par Van Nostrand Reinhold en 1983 y 1986. La tabla en Ia
pagina 09 viene de Working With Backache par Suzanne Rodgers
publicada par Perinton Press en 1985, Los materiales de las paginas 0*1
a 07 han sido desarrollados en conjunto con el Dr. Inger Williams. La
tecnica analftica en las paginas P*6, P7, y P8 ha sido publicado par
Hanley y Belfuss en 1988 Occupational Medicine: State of the Art Review
editado en Worker Fitness Evaluation yen mas detc,!Jle (B1ff) en octubre,
1992 par Hanley y Belfuss en Occupational Medicine State of the Art
Review edici6n Ergonomia. El material restante no referenciado es de Ia
Ora. Rodgers y debe solicitarse su permiso para reproducci6n.

D: Directrices
P: Problema/Soluci6n
0: Ergonomfa/Oficinas

�'

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6

E3

Office Ergonomics Training Session for
the ARCO Chemical Beaver Valley Plant,
April 6, 1994

Schedule

8:30-9:30
9:30-10:15
I 0:15 - I 0:30
I 0:30- II :30

II :30 - 12:30
12:30-4:30

Factors That Determine Comfort and
Discomfort in Seated Work
Problem Solving: Postural and Visual Comfort
Break
Techniques for the Evaluation of Office
Workplaces, Comfort, and the Most
Cost-Effective Solutions to Ergonomic
Problems
Lunch
·Site Visits - Problem Solving

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-$87 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y•.14622

�~
~
6

"

Office Ergonomics Training Session for the
City of Rochester, City Council Room, May 3,1994
Schedule
9:00- 10:15
10:15-10:30
10:30-11:00
11 :00 - 12:00

Factors That Determine Comfort and
Discomfort in Seated Work
Break
Problem Solving: Postural and Visual Comfort
Techniques for the Evaluation of Office
Workplaces, Comfort, and the Most
Cost-Effective Solutions to Ergonomic
Problems

Dr. Rodgers and Dr. Williams will be available to visit individual
departments over the next few weeks. Please contact Tassie
Bolton if you would like to take advantage of this additional
help to strengthen your skills as office ergonomics problem
solvers.

Suzanne H. Rodgers, PhD
Consultant in Ergonomics
169 Huntington Hills
· Rochester, NY 14622
(716) 544-3587

Inger M. Williams, PhD
Consultant in Ergonomics
28 Shelter Creek
Fairport, NY 14450
(716) 377-7791

�-.-

1-Day Ergonomics Course for Engineers at Smith Kline
Beecham Clinical Laboratories, May 4,'93, Upper Merion, PA

Syllabus

Schedule

8:00AM
8:30
9:30
10:00
10:15
10:30
11:00
11:45

Introductions, Goals, Review of Projects
Fatigue Model - Design to Reduce Fatigue
Designing with Anthropometric Data
Break
Height and Reach Interaction
·
VDT Workplace Desi~
.
Problem Solving: Usmg Anthropometric Data in Design
Lunch

12:45 PM
1:15
1:45
2:15
2:45
3:00
4:00
4:45

Complete the Problem Solving Exercise
Factors Affecting Quality Performance
Risk Factors for Overexertion Injuries- Upper Extremities
Ergonomic Job Analysis Technique
Break
Manual Handling Task Design
Problem Solving: Designing to Prevent Overexertion Injuries
Resources, Course EvaluatiOns

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y_ 14822

�SmithKiine Beecham Clinical Labs, Collegetown, PA
July 19-21, 1994
Evaluations Summary
A. Overall Evaluation of the Course
1. Very informative. Learr",Jed to see things in a different light (Billing).
2. · Very good- made me aware of many important items and explained
some things that we might have known instinctively (Clinical Tax.).
3. I found this ergonomics seminar very useful. Excellent tool towards
solution of these types of concerns (Dist. Mgr.).
4. Good (Employees Health Admn).
5. Sue Rodgers presents an excellent class and is a resourceful
instructor (Facilities).
6. Very good. Amazing how fast you can learn this ! (OHS Nurse).
7. Excellent speakers/presenters. Very good hands-on course training
(OHS Nurse).
"
8. Good information, excellent syllabus to be used as a future reference.
Active participation helped to facilitate understanding of the process
(OHS Nurse).
9. Great- very informative and educational. A relaxed and enjoyable
atmosphere (OS&amp;EA).
10. Excellent (Safety).
11. The course was excellent. I will never loE:&gt;k at processes with the same
eye and attitude (Safety).
12. Very good- it helped me to see how small things need to be looked at
to solve more major problems (Specimen Processing).
13. Excellent- very important information that I can bring back to Boston
to help reduce future problems and help employees get relief from
unnecessary pain (Referral Supv).
14. Outstanding ! (Supv. Specimen Processing).
15. Excellent- did not expect such an extensive course (Medical Tech II).
16. Excellent (Tech II).
17. Excellent- Good work-related analogies. Good explanations on how
the body functions in regards to job performed (Tech Rep.).
18. Very good. It really made you look at things you do everyday in a
different way (Tech Serv. Rep.).
19. Excellent. I never imagined you would be able to hold my interest for
three full days !! Even after the experience, I feel I am a neophyte
(Tech Supr).
20. Extremely useful information. Gave you many ways to look at a
problem (Training Coord).
21. I think the course was very informative. This new information could
lead to reduced cost, more productive workers (Not Indicated).

�2.
B.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

11.
12.
13.

14.
15.
16.
17.

18.
19.

20.
21.

Most Useful Information
Learned to look at the ways different people do their jobs - address
different problems (Billing).
Measurements, max weights, how to recognize problems- most of
course (Clinical Tox.).
Types of injuries, etc. (Qist. Mgr).
Workbook, fun slides, oharts and graphs, and support (Employee Health
Admin).
That many ergonomics problems often have a simple solution and do
not require large dollars being spent (Facilities).
Ergonomics problem solving and presentations (OHS Nurse).
Walk through and talking with employees- viewing tapes of areas of
concern (OHS Nurse).
Ergonomics training manual (OHS Nurse).
Information on office ergonomics, on up and coming problem (OS&amp;EA).
How to observe potentially serious problems. Amount of emphasis on
higher quality, increased productivity, decreased costs. Specific
examples from instructor's past experience (Safety).
All information was very useful. Lifting and posture were most
beneficial to me (Safety).
How to evaluate risk factors. How to make presentations to
management (Specimen Processing).
Evaluating the job and finding the problems. There is some common
knowledge but this course lets you see all the problems, even ones
that may not have seemed a problem in the past. You look at the task
differently now (Referral Supv).
The technical analysis techniques for finding optimal work stations
(Supv. Specimen Processing).
How to set back and look at a job with a critical eye -to see how many
actions/influences are involved in a job (Medical Tech II).
A new and improved way of looking at our work situation and maybe
doing some good as far as helping a fellow employee (Tech II).
How ergonomics also relates to quality and quantity. Good information
on how to recognize potential problems and solve current ones (Tech
Rep.)
How to evaluate positions etc. with formulas (Tech SeN. Rep.).
Providing me with a new form of critical eye required to learn how to
address approaching the work situation. Also extremely valuable
guidance on how to question and approach the humans to be affected by
our suggestions (Tech Supr.).
All info extremely applicable to most job areas (Training Coord.).
With the information learned, we can reduce cost and, most important,
people can lead healthier lives (Not Indicated).

�3.
C.
1.
2.

13.

Least Useful Information
N/A (Dist. Mgr).
The graphs and charts are useful but I believe a better explanation of
what information can be learned from plotting and graphing would be
beneficial (Facilities).
Some of the technicalletctures were not as interesting and, therefore,
more difficult to comprehend (i.e., lifting guideline graphs) (OHS
Nurse).
None (OHS Nurse).
Formulas- will have to practice (OHS Nurse).
A few of the charts, curves etc. More time could have been spent for
problem review and problem solving (Safety.).
None (Safety).
Although not all is applicable all the information is useful. Much can
be applied to other areas not just job performance (Specimen
Processing).
"
Everything is useful, maybe not on one project but may be useful down
the road (Referral Supv).
Everything we saw could be used if not in present job perhaps during
an evaluation of another (Medical Tech II).
I cannot say all aspects of the information will be useful to us (Tech
II).
Don't eliminate anything- perhaps a little less on the lifting
mechanics and studies/theories (Tech Supr.).
None (Training Coord.)

D.

Specific Suggestions for Improvement

3.

4.
5.
6.
7.
8.

9.
10.
11.
12.

1.

Should be longer- probably a week, with more prep time for projects
(Clinical Tax.).
2. Look for improvements that are cost effective (Dist. Mgr.).
3. More time to spend on information (Employee Health Admin).
4. Limit lecture time- especially the more technical information to 30
min. a session, then perhaps include an interactive exercise (OHS
Nurse).
5. More specific instructions for presentation (OHS Nurse).
6. Encourage audience to participate more and require them to
participate more. This will keep their interest a little more (OS&amp;EA).
7. None at this time (Safety).
8.. Increase the length of the training session. There's a lot of
information to be absorbed in three days (Specimen Processing).
9. More involvement in mathematical features- graphs, etc. Instead of
just explaining, break into groups and actually do the calculations
(Referral Supv.).

�4.
10. List all formulae and tables in one section for easy analysis (Supv.
Specimen Processing).
11. Really none - however, it is a lot of information to absorb in a short
amount of time. Perhaps follow up with Carol or Sue to keep us
informed of new issues or problems (Medical Tech II).
12. Not qualified to make a1suggestion- maybe we could have some
follow-up meetings (Tech II).
13. More problem solving (Training Coord.)
14. More videos, organize workbook (Not Indicated).

6/94 SHR/bl

�Ergonomics Training Course for General
Electric Aircraft Engines in Lynn, MA,
October18-21, 1994

Syllabus

~11~-!
Suzanne H. Rodgers, Ph.D
Consultant in Ergonomics
HIGHER PRODUCTIVITY THROUGH JOB DESIGN
169 HUNTINGTON HILLS 0 ROCHESTER. NEW YORK 14622
Phone: (716) 544-3587 0 Fax: (716} 266-8749

�2.5-Day Engineers' Training Course in
Ergonomics- Designing for People

Amoco Foam Products Technical Center
Atlanta, GA, October 24-26, 1994

Syllabus

~11~-~
Suzanne H. Rodgers, Ph.D
Consultant in Ergonomics
(

HIGHER PRODUCTIVITY THROUGH JOB DESIGN

\'-____./
169 HUNTINGTON HILLS ~ ROCHESTER. NEW YORK 14622
Fax.· (7161 266-8749

Phone: (716) 544-3587 :J

�2.5-Day Ergonomics Course for Engineers at the Amoco Foam
Products Technical Center, Atlanta, GA, October 24-26,1994
~

Schedule

)

Day 1:
8:00AM

8:30

A. Introductions, Scope of Ergonomics/Human Factors in Industry
B. Who Do We Design For?
1. General Issues
2. Anthropometric Data
3. Strength and Endurance Data
4. Environmental Considerations

10:00

Break

10:15

C. Design of a New Line or Machine
1. Gathering Information for a New Design
a. Questions for Operators, Supervisors, Safety &amp; Health Specs.
b. Quality, Productivity, Rework, Scrap Data
2. Layout
a. Materials Flow
b. Environmental Issues - Lighting, Vibration, Noise, etc.
3. Line Heights
a. Seated vs Standing
b. Reaches Required
c. Postural Effects of Line Height Variations

12:00

Lunch

1:00PM
2:00

2:30
2:45

4:30
Day 2:
8:00

d. Problem Solving: Working Heights
4. Visibility Issues
a. Nature of the Target To Be Seen
b. Effect of Lighting on Visibility/Upper Body Posture
Break
5. Subassembly- Control Panel Design
a. Heights/Reaches
b. ClearancesNisibility
c. Controls and Displays
d. Problem Solving: Controls and Displays
Adjourn

6. Risk Factors for Overexertion Injuries
a. Repetitive Motions Injuries
b. Manual Handling Tasks
c. Problem Solving: Avoiding Overexertion Injury Risk

�2.
10:00
10:15
/

~,

)

12:00

Break
7. Containers/Carts!frucks for Incoming and Outgoing Parts
a. Characteristics of Containers - Size, Handholds
b. Container Weights
c. Locations in Workfclace
d. Push/Pull Forces or Hand Carts and Trucks
e. Materials Handling Approaches
Lunch

1:00PM Problem Solving: Materials Handling Approaches

=)

2:15

Break

2:30

When To Automate - Man /Machine Capabilities

3:30

D. General Ergonomics Guidelines for Design
1. Checklists/Guidelines
2. Resource Books
3. Philosophical Guidelif\es- Peofcle vs Automation
4. Designmg to Reduce the Risk or Overexertion Injuries

4:00

Selection of Projects

4:30

Adjourn

Day 3:
8:00AM Break Up Into Project Groups; Define Scope of Design Needs or
Production Problem, Apply Analysis Techniques, Guidelines, etc.
10:00

Break

10:15

Prepare Presentations

10:45

Make Presentations

12:00

Evaluations, Adjourn

9/23/94 SHR

�..

--

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~I
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--~~i:·&amp;···s~ety :::::j:Q~··: ·····~·····

Ergonomics Team Training and Problem
Solving for Amoco Foam Products,
Atlanta, GA, October 27,1994
Syllabus

11:30
12:00

Schedule
Preventing Postural Fatigue
Reaches and Heights
Break
Problem Solving: Postural Fatigue
Repetitive Tasks - Techniques to Analyze and Solve
Problems
Problem Solving: Repetitive Tasks
Lunch

12:45
1:30
2:15
2:30
3:00
3:30
3:45
4:00

Problem Solving: ReJ?etitive Tasks - continued
Manual Handling Gmdelines
Break
Problem Solving - Manual Handling
Ergonomics and Safety - Human Reliability
Cost Benefit Analysis
·
Resources, Evaluations
Adjourn

8:00
9:00
9:30
9:45
10:30

Suzanne H. Rodgers, Ph.D
Consultant in Ergonomics
HIGHER PRODUCTIVITY THROUGH JOB DESIGN
169 HUNTINGTON HILLS 0 ROCHESTER. NEW YORK 14622
Phone: (716) 544·3587 0 Fax: (715) 265-8749

�Ergonomics Team Training Course for Amoco Foam
Products, Atlanta, GA, October 27,1994
Course Evaluation
I. Overall Evaluation of the Course

II. Most Useful Information

Ill. Least Useful Information
/

-

\

~j

IV.

Specific Suggestions for Improvement

Job and Department: _ _ _ _ _ _ _ _ _ __
Date: _ _ _ _ _ __
10/94 SHR

�Ergonomic Training for Smith Kline Beecham Clinical Labs
Atlanta Cluster, November 15-17, 1994
j

Evaluations Summary
A.

Overall Evaluation of the Course

1.
2.

19.
20.
21.
22.

Very good, very vital to our company (Data Entry).
Wonderful instruction on how to i.d. and rate jobs and ergonomic
problems (DSRII).
Quite an eye-opener, very educational (DSR/Safety).
Very good and very much needed (Analyst).
Excellent (Lead Tech).
Wonderful introduction to the team approach to solve problems related
to ergonomics (Lead Tech/Safety).
Very informative, helpful to improve both quality of job satisfaction
and reduce injury (Manager).
Very good course. The material will be very helpful and should
generate lots of teams and improvements (Manager).
Very good because of dealing with problems that pertain to our lab
(Med Tech).
Very informative in diagnosing ergonomic issues. Sue was quite
knowledgeable in addressing the key topics and helpful in thinking out
the entire picture (Med Tech).
Very good use of physiology to explain why we suffer everyday pains
at work--pain that most people can't visualize (Med Tech).
Very good--excellent depth of knowledge by Dr. Rodgers, interesting/
anecdotal information kept it interesting (NIDA).
Very informative and thought provoking. Will change the way I look at
work spaces (PhlebotomisVSKJF).
Excellent, more practical than any I have attended (QA/Safety).
Very relaxed and informal. Very educational (QA/Safety).
Excellent, Dr. Rodgers and Joe Milligan did a wonderful. Also, the
Marriott personnel treated us well !(Safety and Purchasing Manager).
Very good, excellent instructor (Secretary, HR).
Very good. Room size was inadequate for size of group (Supervisor,
Spec. Proc.).
Excellent (Supervisor).
Enjoyed presentation, very informative (Tech Coor).
It was a good course with lots of information (Trainer/Specimen Pro).
Good course content (Not Indicated).

B.

Most Useful Information

1.

Risk factors for work (solving problems) and analysis (Data Entry).

3.
4.
5.
6.
7.
8.
9.
10.

11.
12.
13.
14.
15.
16.
17.
18.

�~~- .....

-

...

,.._ ~

7.
8.
9.
10.
11.
12.
13.

Was there any? (Med Tech).
Some of the data could have been more current (Safe. &amp; Pure. Manager).
Data compiled in 1980's (Secretary, HR).
Strength measurement for my particular area (Supervisor, Spec. Proc).
None (Supervisor).
The way the formulas for deciding what hardware was ergonomically
correct came about (Trainer).
The amount of physiology background. Although very informative, it is
not information that will be retained (Not Indicated).

D.

Specific Suggestions for Improvement

1.

We need longer than three days to absorb this information (Toy with
info, if you wiii!)(Data Entry).
More hands-on in-person tours of areas, video great but naked eye
better (DSRII).
Maybe extend course time (DSR).
Look at shortening course (Analyst).
More organization of team work. Larger room (Lead Tech).
Work through several problems in more detail start to finish before
attempting to solve own (Manager).
So much information, could shorten course a little but overall a very
worthwhile program (Manager).
Deal a little more with our videos. I would have like to have seen more
jobs (Med Tech).
None (Med Tech).
Bigger meeting space (NIDA/Safety).
Maybe go over needed bookwork and then spend more time in split
groups that work around same areas. That way story time would be
more interesting, if we could relate (Phlebotomist).
More time (QA/Safety).
Allow more time than one hour to present "projects" from a three day
seminar (Safety and Purchasing Manager).
More time spent on specific issues affecting the company involved.
Longer presentation time for attendees (Secretary).
None (Supervisor).
None (Tech Coor).
Make course a little less technical, unless you are talking to engineers
(Trainer).
Work more on specific situations and maybe actually solve two or
more actual ergonomic problems (Not Indicated).

2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

12.
13.
14.
15.
16.
17.
18.

11/17/94 SHR/bl

�2-Day Ergonomics Training Course for the
Amoco Fabrics &amp; Fibers Ergonomics Team
Rocky Mount, NC, November 29-30, 1994
Syllabus
Day 1:
10:00
10:30
11:00
11:30
12:00
1:00
1:30
2:00
2:30
3:00
3:15
3:45
4:30
5:30

(

\

Day2:
7:30
8:45
9:30
9:45
10:15
11:00
11:15
12:00
1:00
2:15
2:45
3:15
3:30

Introductions, Review of Course Goals, Overview
Fatigue Model for Defining Ergonomic Problems and Solutions
Muscle Work/Recovery Time Needs- Postural Work
Problem Solving: Postural Work
Lunch
Body Size Data- Use in Design and Analysis of Jobs/Workplaces
Height and Reach Interactions
Seated Work- VDT Workplaces
Problem Solving: Using Body Size Data for Design Evaluation
Break
Risk Factors for Repetitive Tasks
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks
Adjourn
Manual Materials Handling Risk Factors
Problem Solving: Manual Lifting ·
Break
Human Reliability - Accident Investigation
Cost-Benefit Analyses- How to Sell Change
Project Selection for Last Session
Work on Projects
Lunch
Work on Projects
Prepare Presentations
Present Projects
Suzanne H. Rodgers, Ph.D
Evaluations
Consultant in Ergonomics
Adjourn
HIGHER PRODUCTIVITY THROUGH JOB DESIGN

..

,

169 HUNTINGTON HILLS 0 ROCHESTER, NEW YORK 14622
Phone: (716) 544-3587 0 Fax: (716} 266-8749

�Table of Contents

/~
'

'

Topic
A Functional Job Analysis Technique
Work/Recovery Time Curves
Table 1: Risk Factor Analysis
Anthro2_ometric Data
Height/Reach Curves - Standing
Height/Reach Curves - Seated Work
VDT Workplace Design Kit
Analysis o(VDT Workstation
Visual Target
Process for Evaluating Comfort in a Seated Workplace
Ergonomics Survey - Office Job Demands Form
Postural Comfort Rating Form
Visual Comfort Rating Form
Observed Postures Checklist
Self-Help to Increase Seated Work Comfort
Risk Factors for Upper Extremity Disorders
Table 1: Factors Affecting Grip Strength
Ergonomic Job Analysis Form
Table 2: Examples of Muscle Effort Levels
Table 1: Risk Factor Analysis
Extra Forms
Figure 1: Risk Factors for Low Back Pain
Occasional Lifting Guidelines - Kodak
Frequent Lifting Guidelines - Kodak
Accident Investigations - Ergonomics Viewpoint
Human Reliability Analysis Form
Instructions for Problem Presentations
Summary of Ergonomic Analyses - When to Use Them
Extra Forms
Case Study Form for Documentation
Recommended Videotapes on Ergonomic Topics
References - S .H.Rodgers

Startin2 Pa2e
1
19
20
21
22
23

24

33
34

35

37
38
39

40
41

44

46
47

48
49
50
52

54
55
56
57
58
59

62
66
67

68

Acknowledgements
The illustrations on pages 22, 23, 54, and 55 are used with permission from Eastman Kodak's
Ergonomic Design for People at Work, Volumes 1 and 2 published by Van Nostrand Reinhold in
1983 and 1986. The illustration on page 21 is from Working With Backache by S.H. Rodgers
published by Perinton Press in 1985. The computer workplace material on pages 24 to 43 has been
developed in conjunction with Dr. Inger Williams. The analytical technique on pages 47 and 50 has
been published by Hanley and Belfuss in a 1988 Occupational Medicine: State of the Art Review
edition on Worker Fitness Evaluations and in more detail (pages 1-19, "A Functional Job Analysis
Technique") in the October, 1992 issue of the same series by Hanley and Belfuss on Ergonomics,
edited by J.S.Moore and A. Garg. All other unreferenced material in this syllabus is by Dr. S.H.
Rodgers and permission to reproduce it must be obtained from her.

�'}

·•...
..
-.

.
..
··..
.
··
·.....
.
.
..
.
_

..··
....

··.....
.

Ergonomic Job Analysis Technique ReviewFatigue Model by S.H. Rodgers, Ph.D.

l

Training for Xerox Ergonomics Team
Members and Engineers, December 9,1994

J

( __

,

~

-

Lc.Jt-~
~n~~
Suzanne H. Rodgers, Ph.D
Consultant in Ergonomics

HIGHER PRODUCTIVITY THROUGH JOB DESIGN
169 HUNTINGTO~ HILLS 0 ROCHESTER. NEW YORK 14622
Phone: (716) 5·H-3587 0 Fax: (716) 266-8749

�Table of Contents

(

Starting Page
1
A Functional Job Analysis Technique
19
Recovery Time Needs for Static Work
20
Risk Factors for Repetitive Motions Disorders
20
Factors Affecting Grip Strength
21
Risk Factors for Low Back Pain
23
Kodak Lifting Guidelines
25
Accident fuvestigations
26
Human Reliability Form
27
Ergonomic Job Analysis Forms
30
Risk Factor Analysis Problem Solving Forms
Summary of Ergonomic Analyses and When to Use 34
Them
37
Ergonomic Case Study Documentation Form
38
References- S.H.Rodgers

Topic

Acknowledgments

The materials in this syllabus, unless otherwise noted, are the property of Dr.
Rodgers. Permission to reproduce them outside of the grOU£S participating in
the training program should be obtained from her. Phone: (715) 544-3587; Fax:
(716) 266-8749. Mailing Address: 169 Huntington Hills, Rochester, NY 14622

�~
~
6

Office Ergonomics Training Session for the
Rochester Police Department, Public safety
Building, Room 635,9:00 to 12:00 noon, March 13,1995

Schedule
9:00 - 9:15 AM
9:15- 9:45
9:45- 10:15
10:15- 10:30
10:30- 11:00
11:00- 11:15
11:15- 11:30
11:45 - 12:00

Ergonomics in the Office Setting
Factors That Determine Postural Comfort or Discomfort
in Seated Work
Visual Comfort and Discomfort in Computer Work
Break
Problem Solving: Postural and Visual Comfort
Techniques for the Evaluation of Comfort in Office
Workplaces
Guidelines for Selection of Equipment in New Workplaces
Cost-Effective Solutions to Office Ergonomic ProblemsDefining Driving Factors
·

Tassie Bolton and Dr. Rodgers or Dr. Williams will be available to visit your
workplaces over the next few weeks. Please sign the sheet here or contact Tassie
Bolton if you would like to take advantage of this additional help to strengthen your
skills as office ergonomics problem solvers. If a colleague who is not here today
would like assistance, please indicate her/his name and location on the sheet.

Suzanne H. Rodgers, PhD
Consultant in Ergonomics
169 Huntington Hills
Rochester, NY 14622
(716) 544-3587

Inger M. Williams, PhD
Consultant in Ergonomics
28 Shelter Creek
Fairport, NY 14450
(716) 377-7791

�... ·-

2.5-Day Ergonomics Training for GE Aircraft Engines
Ergonomics Teams in Hooksett, NH, May 10-t1,1995
Syllabus
Day 1:
7:15
7:30
7:45
8:00
8:30
8:45
9:30
10:15
10:30
11:00
11 :45
12:30
1:00
1:30
1:45
2:45
3:15-4:00
Day 2:
7:15
8:00
8:45
9:15
9:30
10:30
11:00
11:45
2:00
2:15
3:00
3:45-4:00

l_

Introductions, Review of Course Goals, Overview
Recent OSHA Activities in Ergonomics
Fatigue Model for Defming Ergonomic Problems and Solutions
Muscle Work/Recovery Time Needs- Postural Work
Break
Problem Solving: Postural Work
Body Size Data- Use in Design and Analysis of Jobs/Workplaces
Height and Reach Interactions
Problem Solving: Determining the Best Height for a Workplace
Lunch
Problem Solving (contd)
Seated Work- VDT Workplaces
Problem Solving: VDT Workplace Evaluations and Solutions
Break
Risk Factors for Repetitive Tasks
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Tasks
Manual Materials Handling Risk Factors
Problem Solving: Manual Lifting
Human Reliability and Accident Analysis
Break
Cost-Benefit Analyses- How to Sell Change
Project Selection for Last Session
Lunch
Work on Projects
Break
Work on Projects
Prepare Presentations
Evaluations

Suzanne H. Rodgers, Ph.D.
Consultant in Ergonomics
169 Huntington Hills
Rochester, NY 14622
(716) 544-3587 (0)
(716) 266-8749 (Fax)

Day 3:
7:15
Complete Presentation Preparations
8:00
Discussion of Ergonomics Teams' Future Activities
9:15
Break
9:30-11:00 Project Presentations to Managers

�3.0-Day Ergonomics Team Training Course for Sf
/ SmithKiine Beecham Clinical Lab, May 24-26, 1995
..

!

Evaluations Summary

A.

1.
2.

3.

4.
5.
6.
7.
8.

9.
10.
11.
12.
13.

14.

I
Overall Evaluation of the Course

Enlightening and informative. Presented risk factors most people
would not usually be aware of in the workplace (Business Services).
Very interesting and informative, good participation due to
organization. Anecdotes and stories very helpful to show us different
perspectives (CRC Rep).
I was not only surprised but extremely impressed with the last three
days of our ergonomics training, well worth my time (Client Service
Supervisor).
Very informative. I learned a lot from Rich and Sue (Lead DSR).
Thought course was very insightful. Learned a lot of useful
information and techniques (Data Entry).
Very good, comprehensive, a lot of information and we were well fed
too ! (Data Entry).
Excellent. Good supporting documentation, references and visuals
(Human Resources).
I learned alot in this training. Before this, I didn't realize that small
things we do contribute a lot in relation to our work. This course is
very educational (Lab Clerk).
Good (Network Tech).
An eye opener! Covered the information needed for our presentation.
Nice mix between films, slides, book and graphs (Phleb. Coordinator).
Very good. Lots of information and pertinent examples to help us
relate it to our work (Phlebotomist Support):
Excellent. Lots of information, lots of application of all areas. Useful
tools (Safety Officer).
Learned different approach to human factors. Highly recommend to
extend to other sites. Expand/enforced ergonomic knowledge and
resources (SH&amp;E).
This has been great ! I was one who began not knowing anything about
ergonomics. Now I feel educated ! Not only that, but I want to learn
more (Training Coordinator).

B.

Most Useful Information

1.

Learning how to view and analyze workers method of doing a job
(Business Services).
Office ergonomics pertains more to my job (CRC Rep).
Overall definition and explanation of ergonomics. I'll never look at

2.
3.

�2.
4.
5.
6.

7.
8.
9.
10.
11.
12.
13.
14.

C.
1.
2.

anything the same (Client Service Supervisor).
How to look at jobs and find ways to help improve people's comfort and
job (Lead DSR).
How to adjust my work station to where I am most comfortable (Data
Entry).
Evaluation of risk factors, risk analysis; design of work environment
for people using keyboards; actual analyses of work environments;
preparation for project presentation (Data Entry).
Dr. Rodgers--anything she said, her presence was a fantastic tool
itself ! (Human Resources).
Evaluating the job's physical movement. This way we can use it in the
future on following projects (Lab Clerk).
Hand outs, printed materials and videos (Network Tech).
Seeing the physical plant after being taught what to look for. The
videos made the difference (Phleb. Coordinator).
How to identify the problems and how they have been solved in other
places (Phlebotomist Support).
Use of information in practice-training in evaluation and presentation
(Safety Officer).
Fatigue factors and lift data. Also physiological effects (SH&amp;E).
New eyes ! Looking at an old situation in a new way. Also a different
way to ask questions about accidents (Training Coordinator).

Least Useful Information

All of it was in some way useful (Business Services).
Lifting--not in my job area, but useful information nonetheless (CRC
Rep).
3. The lift guideline graph seemed to give me extreme difficulty.
Hopefully next year at this time I will understand graphs (Client
Service Supervisor).
4. Analyses of work environment not related to jobs in the lab (Data
Entry).
5. Too much analytical background information for general populace
(Human Resources).
6. None (Lab Clerk).
7. Presentation (Network Tech).
8. The lifting guidelines graph. Had some trouble applying it the first
part of the discussion (Phleb. Coordinator).
9. Too hard to find anything not valuable (Safety Officer).
10. Actually it was all useful in a different way (Training Coordinator).

�3.
D.

Specific Suggestions for Improvement

;.
j

1.
2.

More time to digest information (Business Services).
Technical information was useful but difficult to absorb on full
stomach (CRC Rep).
3. Keep up the great work. Thank you Rick and Sue ! (Client Service
Supervisor).
4. There is a lot to learn. Maybe if we had more time, maybe five days
for training, a lot more could have been learned (Data Entry).
5. More time to work on projects, more on relaxation exercises to relieve
tension (Data Entry).
6. Speak louder or use microphone (Lab Clerk).
7. More time, more handouts (Network Tech).
8. None really--a very enjoyable presentation. Thank you (Phleb.
Coordinator).
9. More reference to manual so we can find the information readily
(Phlebotomist Support).
10. Get more information to prepare videos for presentation when camera
might be needed during training (Safety Officer).
11. Spend more time with presentations--give specifics/examples to
others less knowledgeable of presentations (SH&amp;E).
12. More time to analyze information before the presentations (Training
Coordinator).
5/26/95 SHR/bl

�.~··

Ergonomics Training Course for Thomson Professional
Publishing Ergonomics Teams, Webster, NY, June 12,13,15,1995
Syllabus
Day1:

7:30AM
8:00
8:30
9:00
9:30
9:45

11:00
12:00
12:30PM
1:45

2:00
2:15
2:45

3:30
Day 2:

7:30AM
8:30
8:45

9:30
12:00
12:30
1:00
2:00
2:30
2:45

3:00
3:30
Day 3:

7:30AM
12:00
12:30PM
2:00
2:30
3:30

Introductions, Review of Course Goals, Overview
Fatigue Model for Defming Ergonomic Problems and Solutions
Human Capacity and Stress Sensitizers - Inger Williams, Ph.D.
Muscle Worlc/Recovery Time Needs- Postural Work
Break
Problem Solving: Postural Work
Body Size Data- Use in Design and Analysis of Jobs/Workplaces,
Height and Reach Interactions
Lunch
Problem Solving: Determining the Best Height for a Workplace
Risk Factors for Repetitive Tasks
Break
Ergonomic Job Analysis Technique
Problem Solving: Repetitive Work
Adjourn
Visual Work- Inger Williams, Ph.D.
Manual Materials Handling Risk Factors
Problem Solving: Manual Lifting
Break
Lunch
Ergonomics and Accident Analysis
Problem Solving: Accident Analysis
Reports on Accident Analyses
Break
Cost-Benefit Analyses- How to Sell Change
Discussion: Implementing an Ergonomics Process; Choose Projects
Adjourn
Work on Projects
Lunch
Prepare Presentations
Present Projects to Managers
Resources, Evaluations
Adjourn

S.H. Rodgers, Ph.D.
Consultant in Ergonomics
(716) 544-3587 (0)
(716) 266-8749 (Fax)

(
~

�-=·:t~·~·~

=-==
===-

-=-

Suzanne H. Rodgers, Ph.D
Consultant in Ergonomics

----· -· - - · ··- --

..

---·

--·-··-··-----·-----

169 HUNTINGTON HILLS 0 ROCHESTER. NEW YORK 14622
1'/Jmw.· (71!i) !144-3:,1\7 0 Fax: {716} 266-8749

Ergonomics and the Computer Workplace
Office Ergonomics Training Session for Amoco
Corporation Personnel in Chicago, Illinois,
November 3, 1995

Outline
A. Why Office Ergonomics ? Driving Factor Approach.
B. VDT Workplace Design- TI1eoretical and Real
1. Use of Body Size Data
2. Functional Design with T\1ultiple Variables
C. Visual Aspects of Computer Work
1. Visual Discomfort
2. Layout and Lighting
3. Color and Readabil!ty
D. Repetitive Task Problems in the. Office
1. Risk Factors for Injury/Illness
2. Workplace and Job Factors Contributing To Risk
3. Techniques to Reduce the Risk
E. Selecting Computer Workplace Fumiture
1. Determining Job Requirements
2. Defining Needed Features
3. Defining Work Pattem and Load
4. Evaluating; Available Fumiture
5. On-Site P1lot Study and Data Collection
6. Lending Library

�Ergonomic Principles for Design - A 2-Day Course for
Engineers in the Bausch &amp; Lomb Contact Lens Division
Rochester, NY,

December 7-8, 1995

Syllabus

Lc.Jt:
~n~~
Suzanne H. Rodgers, Ph.D
Consultant in Ergonomics

HIGHER PRODUGriVITY THROUGH JOB DESIGN
169 HUNTINGTON HILLS 0 ROCHESTER. NEW YORK 14622
Phone: (716] 544·3587 :J Fax: (716) 266-8749

�Ergonomics Principles for Design - 2-Day Course for Engineers
at Bausch &amp; Lomb's Contact Lens Division, December 7-8, 1995
Instructor: Suzanne H. Rodgers, Ph.D., Consultant in Ergonomics

Day 1: Ergonomics and Legislation Overviews; Design to Reduce
Fatigue; Clearances, Reaches, Heights, Visibility, Layout

/

7:30AM Caloric Intake, Introductions, Course Goals
8:00
Regulations, Scope of Ergonomics
Designing Jobs to Reduce Fatigue- Work/Recovery Time Needs
8:15
Ergonomic Problem IdentificatiOn Exercise: 3 Contact Lens Jobs
8:45
9:30
Postural Break
9:45
Who Do We Design For? Using Anthropometric Data for Design
10:15
Reducing Postural Stress and Fatigue- Design of Seated and
Standing Workplaces- Clearances, Heights, Reaches
11:00 Visual Work and VDT Workplaces- Inger Williams, Ph.D.
12:00
Caloric Intake- On Your Own
12:45
Problem Solving: Seated Workplaces- Contact Lens Inspection Tasks
1:30PM Layout Issues - Ergonomics and Flow, Ergonomics and Automation
2:00
Postural Break
2:15
Projects: Applying Ergonomics Design Data to Specific B&amp;L Contact Lens
Division Examples - 4 project groups
Report Out the Design Projects
3:45
4:30
Adjourn

Day 2: Designing to Prevent Overexertion and Repetitive Work
Illnesses and Injuries; Design to Minimize Human Error,
Cost/Benefit Analyses; Building Ergonomics Into the Business
7:30AM Caloric Intake, Questions Answered, Commercial Videotape Shared
8:00
Risk Factors for Upper Extremity and Low Back Problems
9:00
Ergonomic Job Analysis Technique to Determine the Fatigue Potential
of a Task and How to Reduce It
9:30
Stretch Break
9:45
Lifting and Force Exertion Guidelines - How Much Is Too Much ?
10:15
Applying Risk Factor Data to Specific B&amp;L Contact Lens Examples
11:15
Human Engineering Issues -Information Transfer, Reducing Complexity,
and Reducing Error Opportunities
12:00
Caloric Intake - On Your Own
12:45PM Problem Solving: Desi~ning a Packing/Shipping Job- 3 teams
2:00
Report Out Design ProJect
Exercise Break
2:30
2: 45
Cost/Benefit Analyses to Sell Ergonomic Changes at the Design or at the
Production Level
3:15
Integrating Ergonomics Into the Business- Sustaining the Process
3:45
Selection of Design Projects for 2-day Follow-On Training
Resources, Course Evaluation
4:15
Adjourn
4:30

'
l,

�2-Day Ergonomics Training Course
Table of Contents
Starting Page Location

Topic
Schedule
Table of Contents
Acknowledgements
Introduction and Course Goals
Ergonomics Legislation - US
The Cost of Poor Design
Capacities for Work
Factors That Increase Stress

I

Syllabus
i
ii
111

1
2
7
9

11

EDFPAWl
--

--

EDFPAW2

---

------

338

Recovery Time/Static Work
Identifying Ergonomic Problems
Risk Factors for Discomfort
Ergonomics Problem Solving
Questions to Defme Job Demands
Measurements andJob Improvements
Risk Factor Analysis
Anthropometric Data
Height and Reach Interactions
General Guidelines for Anthro Data Use
Problem Analysis: Standing Work
General Layout Guidelines Form
VDT Workplace Design Kit
Process for Evaluating Comfort Seated
Observed Postures Checklist
Self-Help in VDT Workplace Comfort
Chair Characteristics
Analysis of VDT Work Station

12
13
19
20
21
22
24
25
29
31
33
35
37
46
48
49
51
52

A Functional Job Analysis Technique
Risk Factors for Repetitive Motions
Injuries - Carpal Tunnel Syndrome, etc.
Factors Affecting Grip Strength
Ergonomic Job Analysis Form
Table 2: Muscle Effort Levels
Risk Factor Analysis Form
Risk Factors for Low Back Pain
Strength and Location
Maximum Force Applications
Kodak Lifting Guidelines
Summary of Operation Design
Problem Solving Form

53
71

--

73
74
75
76
77
79
80
81
83
85

---

Accident Investigation Ergonomics
Human Reliability Analyses
Ergonomics and Quality
Information Transfer
Paced Work!fime Pressure
Job Control and Task Complexity
Man/Machine Functions

88
89
90
92
96
99
101

9
210,446,496
237
217

---

--285
18,20,24,28,30,50

---

142,218,2$5

23,50
14

---

--

15,122,151

151,244
151,254

-135,340
135,338
360,384,446
403

-181

�Automation or Peoiple Form
Design Project Data Collection/Guidelines
12 Ergonomic Design Guidelines
Ergonomics Processes - Action Plans
Recommended Videotapes
References - SHRodgers
Cost-Benefit Problem Solving Form
Problem Presentations
Summary of Ergonomic Analyses
Extra Problem Solving Forms
Course Evaluation Form

102
103
106
111
116
117
118
121
122
126ff
end

--

--365
-

559

---

--

Acknowledgements
The illustrations on pages 26-30, 81, and 82 are used with permission from Eastman Kodak's
Ergonomic Design for People at Work, Volumes 1 and 2 published by Van Nostrand Reinhold.
The tables and illustrations on pages 25, 51, 79 and 80 are from Working With Backache by S.
H. Rodgers. Information on pages 11, 37-45, 48-50, 52 and 74 has been developed in
conjunction with Dr. Inger Williams. Work/recovery curves based on those on page 12 and the
material on page 73 have been published by Thieme Publishers in Seminars in Occupational
Medicine in March 1987. The analytical technique on page 74 has been published by Hanley and
Belfuss in a 1988 Occupational Medicine: State of the Art Review edition on Worker Fitness
Evaluations. The article on pages 53-70 was published by the same press in 1992 in the
Ergonomics issue edited by J.S.Moore and A.Garg. The outline on page 2 is from a draft copy
of a proposed ergonomics guideline for general industry by OSHA written in September, 1990,
and the outline of the proposed OSHA standard on ergonomics is from The Occupational Safety
and Health Reporter.. All other unreferenced material in this syllabus is by Dr. S.H. Rodgers
and permission to reproduce it must be obtained from her.

�1

Suzanne H. Rodgers, Ph.D.
r-~~onsultant

,

In Ergonomics

_~69

Huntington Hills- Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

Ergonomics Training and Awareness Courses
Offered by Suzanne H. Rodgers, Ph.D.,
Consultant in Ergonomics, Rochester, NY
June, 1997 Update
Table of Contents
Course

Startin&amp; Paee

General Ergonomics Awareness Courses
Management - 1 to 2 hours
Supen'isors and Team Leaders- 2 to 4 hours
Union Representatives/Health &amp; Safety Specialists
Safety or EHS Committee - 6 to 8 hours
Associates/Team Members/Hourly Workers- 1 to 8 hours
Health &amp; Safety/Human Resources Specialists- 2 to 8 hours
Process Engineering/Planning Specialists - 2 to 8 hours
Machine and Equipment Designers- 2 to 8 hours
General Ergonomics Training Courses
Ergonomics Steering Committee - Coordinators - 1 day
EHS Team- Primary Ergonomic Response Team- 3 to 4 days
Work Center Ergonomics Teams- 4 days
Process Engineers/Planners/Layout Specialists - 2 to 4 days
Machine or Product Designers - 2 to 4 days
. Medical Specialists - In-House and Contract - 1 to 2 days
Refresher Course (Kick-Up) for Teams- 1 to 2 days

..,

3
3
3
4
4
4
5
5

6
7
7 ..
7
8
8
9
9

Specialized Topics - Ergonomics Training Courses
Office and Computer Workplace Ergonomics- 4 to 8 hours
An Ergonomics Approach to Accident Analysis - 8 hours
Ergonomic Approaches to PreYenting and Managing Low
Back Pain - 4 to 8 hours ·
Ergonomic Approaches to Reducing Repetitive Motions
Disorders in the Workplace- 4 to 8 hours
Strategies for the Prevention of Musculoskeletal Injuries and
Illnesses in Occupational Tasks - 1 to 2 days
The Design of Manual Handling Tasks - 1 day
Engineering Courses Using a Current Project - 1 to 2 days

10
10
10

Costs for Ergonomics Awareness and Training Courses

12

11

11
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1]
11

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Dr. Suzanne Rodgers

�WORKSHOPERGONOM~

ARGENTINA

AGENDA

Julio/Agosto, 1997

�Lunes 28 de julio de 1997 - Resumen de Ergonomia, Capacidades, Postura y
Productividad

8:00-8:30
8:30-9:00
9:00-9:45

lntroducciones y Resumen
Capacidad de Trabajo
l,Para quien disenamos?

9:45- 10:00

Descanso

10:00- 10:45
10:45-11,15
11:15-12:00

Postura y Productividad . Trabajo Estatico, lnteracciones de
Alcance/Aitura
Curvas de Trabajo/Recuperaci6n
Soluci6n de Problema: Reducci6n de Fatiga.

12:00 - 12:45

Almuerzo

12:45 - 13:45
13:45-14:15

Soluci6n de Problema: Diseno del Iugar de trabajo de pie
Diseno del Iugar de trabajo sentado y trabajo visual

14:15- 14:30

Descanso

14:30 - 15:00
15:00- 16:00

Soluci6n de Problema: diseno del Iugar de trabajo sentado
Revision del Trabajo: Posturas

�Martes 29 de julio de 1997 - Previniendo Lesiones por esfuerzo excesivo, Tareas
repetitivas, Manejo manual

8:00-8:30
8:30-9:15
9:15- 10:00

Des6rdenes por movimientos repetitivos
Factores de riesgo para tendinitis, sindrome del tune! carpiano, etc.
Forma para Analisis Ergon6mico del Trabajo

10:00-10:15

Descanso

10:15- 10:30
10:30-11,30
11:30- 12:00

Selecci6n y Disefio de Herramienta
Soluci6n de Problema: Tareas Repetitivas
Revision del Trabajo : Tareas Repetitivas

12:00- 12:45

Almuerzo

12:45 - 13:45
13:45- 14:00
14:00- 14:30

Dolor en Ia espalda baja; Factores de riesgo en el trabajo
lmpedimentos en las extremidades superiores yen Ia espalda baja en
el trabajo
Directrices de manejo manual

14:30- 14:45

Descanso

14:45 - 15:30
15:30 - 16:00

Soluci6n de problema: manejo manual
Levantamiento frecuente/Carga Total de trabajo/horas de Trabajo

�Miercoles 30 de julio de 1997 - Confiabilidad Humana, analisis de Costo/Beneficio,
Proyectos

8:00-8:30
8:30-9:00
9:00-9:30

Reduciendo Ia complejidad del Trabajo: Informacion, Ritmo
Confiabilidad Humana: Controles/Paneles y Automatizaci6n
Factores Ambientales influenciando el desemperio

9:30-9:45

Descanso

9:45- 10:30
10:30-11:15
11:15- 12:00

Analisis de Costo/Beneficio de Soluciones
Encuestas/Listas de Cotejo/Recursos/Procesos Ergon6micos
Empezar a trabajar en proyectos

12:00- 12:45

Almuerzo

12:45 - 14:30

Trabajar en proyectos

14:30 - 14:45

Descanso

14:45 - 15:45
15:45 - 16:00

Presentaciones de Proyectos
Evaluaciones del Curso

�Jueves 31 de julio de 1997

8:30

Ergonomla reactiva

10:00

Descanso

10:30

Definir, priorizar, solucionar e implementar soluciones
para problemas ergon6micos

12:00

Almuerzo

13:00

Ergonomla preventiva

Dr. Rodgers

13:30

La ergonomla en el diseno y anal isis de procesos

Dr. Rodgers

14:30

Descanso

15:00

Uso de datos conocidos de Seguridad y Media
Ambiente para prevenir futuras enfermedades o danos
ergon6micos

Dr. Rodgers

16:00

Analisis del costa ergon6mico

Dr. Rodgers

17:00

Cierre del dla

Dr. Rodgers

Dr. Rodgers

�Viernes 1 de agosto de 1997

8:30

Anillisis y presentaciones de proyectos ergon6micos
de los participantes

10:00

Descanso

10:30

Continuaci6n: Analisis y presentaciones de proyectos
ergon6micos de los participantes

12:00

Almuerzo

13:00

Continuaci6n: Analisis y presentaciones de proyectos
ergon6micos de los participantes

14:30

Descanso

15:00

Continuaci6n: Analisis y presentaciones de proyectos
ergon6micos de los participantes

17:00

Comentarios finales y Clausura

Dr. Rodgers

Dr. Rodgers

Dr. Rodgers

Dr. Rodgers

P. Campos

�S.H. Rodgers, Ph.D.

Fax:716-266-8749

Jun 11 '97

9:28

P.04

Suuested Amendments to the May 27th Ergonomics Workshop
Sehedule .. 6/11/97 • S.H.Rodgers
Monday~

July 28th

Plant Tour. ~eview of Accident Data, Orientation for Plant Managers or
Supervisors. Check out Training Facilities, Review Videotapes, Meet
Team(s)

Tuesday, July 29th (use Monday schedu~e with changes indicated below)
10:30am

The Fatigue ModCl for Assessing Musculoskeletal Stress

1:00pm

Postural Fatigue Job Analysis and Problem Solving

3;00 pm

Designing to Minimize Static Muscular Fatigue at Work

Wednesday, July 30th (use Tuesday schedule with changes indicated below)
8:30

am

10:30 am

Office Ergonomics and Seated Workplace Design
Repetitive Motions Disorders .. eros - Risk Assessment

1:00 pm

·Problem Solving: Seated and Visual Work

3:00 pm

Using Ergonomics Data and Guidelines for New Design

Thursday, July 31st (use Wednesday schedule wi~h changes indicated

below)
8:30 am

Manual Materials Handling Guidelines

!O:OOam

Problem Solving: Manual Handling Tasks

1:00pm

An Ergonomic Approach to Accident Analysis

3:00 pm

Project: Accident Analysis

�S.H. Rodgers. Ph.D.

Fax:716-266-8749

Jun 11 '97

9:28

P.05

Friday, August 1st (use Thursday schedule with changes indicated below)

8:30 am

Cost-Benefit Analysis for Ergonomics Projects and Selling
Change

10:30 am

Select Project and Start Analyses

1:00pm

Work on Projects and Presentations

3:30 pm

Presentations on Projects (15 minutes each)•

* :Managers and Supervisom should attend th'* presentations
6111/f¥1 SHR

�Ergonon1ics Training for New En1ployees
Office of E1nergency Co1nn1unications
Rochester, NY, August 19,1997

Outline
I. Reducing Discomfort and Fatigue Through Ergonomics

II. Risk Factors for Back and Upper Extremity Discomfort
III. Risk Factors for Eye and Head Discomfort
IV. Dtiving Factor Analysis of Seated Discomfort
V. Strategies to Improve Comfort
VI. Ergonomics Resources in OEO and the City

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

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Applied

Ergonomics:
An Evidence Based
Approach
Suzanne Rodgers, Ph.D.

i

Sept 22, 1997
Vancouver, B.C.
Sept 24, 1997
Edmonton, Alberta

~-

Profes~ional

Training Seminars

Sept 26, 1997
Toronto, Ontario

�Applied Ergonomics

This workshop will enable you to prwrrze change and use
problem solving techniques to determine cost effective
changes.

INSTRUCTOR:
Sue Rodgers, Ph.D. earned her doctorate in physiology from
the University of Rochester, New York. From 1968 to 1982
she worked in Eastman Kodak Company's Human Factors
Section and served as Group Leader for the application of
ergonomics to the work place. She is the technical editor and
principal author of the two volume reference books by
Kodak's Human Factors Section, Ergonomic Design for
People at Work. In 1982, Dr. Rodgers started her own
consulting and training business. Its focus is to help companies
and service organizations initiate in house ergonomics
programs in order to reduce occupational illness and injury
and improve workers' quality performance. Her clients
include General Electric, Goodyear Tire and Rubber
Company, General Motors, Eastman Kodak, NIOSH, Amoco,
the City of Rochester, and SmithK!ine Beecham. Dr. Rodgers
is the author of Working with Backache, edited and contributed
to the March, 1987 issue of Seminars in Occupational
Medicine on "Repetitive Motions Injuries", and has
contributed chapters on job evaluation and ergonomics to
occupational medicine and physical therapy books.
She
speaks often at national and international medical and
industrial conferences.

WORKSHOP DESCRIPTION:
Ergonomics is the study of work with the goal of designing
jobs, workplaces, equipment and environments to be within
the capabilities and tolerances of most people. In this
presentation, Dr. Rodgers will review four types of ergonomic
job analyses and discuss the strengths and weakness of each
for assessing job stress on the musculoskeletal system.
Four jobs will be analyzed using these techniques covering
postural, repetitive, and manual handling tasks. Methods for
moving from the job analysis to the development of solutions
for improved job demands will be discussed. Quantification of
the effort through job analysis is emphasized in order to defme
the degree of risk on a job.

SEMINAR GOALS:
To provide an overview of ergonomics analysis and problem
solving techniques.
To identify, evaluate and fmd effective solutions for tasks that
are difficult to perform or where injuries or illnesses have
been seen.
To evaluate several job analysis methods in the solution of
ergonomic problems at work, and to determine which are
appropriate for different types of work.
To learn how to use quantitative data in assessment of risk for
injury

Program
AGENDA- (8:30A.M. -5:00P.M.)
1.

When is ergonomic job analysis needed?

2.

Types of job analysis - Strengths and weaknesses.

a.
b.
c.
d.
3.
4.
5.
6.
7.
8.

Interview data - descriptive.
Check lists.
Computer models - biomechanical analysis.
Fatigue analysis.

Case studies using four job analysis techniques.
Problem solving from job analysis information.
Case study- Repetitive work- upper extremity problem.
Case study- Manual handling -low back pain.
Case study - Office ergonomics.
Discussion and questions.

FEE:
$185.00 + $12.95 GST (Total $197.95) (Payable to:
Professional training Seminars). The tuition fee qualifies for
deduction under the Income Tax Act. GST # 125642504.
Early Bird Registration, 10% discount (prior to August 22,
1997; $166.50 + $11.66 GST =Total$ 178.16)
Group discount, 10% for three or more participants from the
same facility ($166.50 + $11.66 GST = Total $ 178.16 ).
Lunch is included.

CONTACT:
Maureen Dwight
Professional Training Seminars
371 Markham Street
Toronto, Ontario M6G 2K8
Phone: (416) - 961-2669
Outside Toronto: (800)-915-8950
Fax:
(416) - 925-6823
e-mail: www.seminars.on.ca

:Z
0

LOCATION:
Simon Fraser University at Harbour Center
Vancouver, B.C.
Sept 22, 1997
Grant McEwan College
Edmonton, Alberta Sept 24, 1997
Airport Board of Trade
Toronto, Ontario Sept 26, 1997

t :ll
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~

�Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN

Maureen Dwight, PT
Professional Training Seminars
371 Markham Street
Toronto, Ontario M6G 2K8
(416) 961-2669

3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

Applied Ergonomics - An EvidenceBased Approach.

)

Job Analysis and Problem Solving
Workshop

'

September 24,'97 Edmonton, Alberta
Grant McEwen College
September 26,'97 Toronto, Ontario
Airport Board of Trade

�A Guide to the Understanding of
Work-Related Musculoskeletal
Discomfort, Illness, and. Injury in
Repetitive Work

General Electric Aircraft Engines
Hooksett, New Hampshire
September 30, 1997
&lt;-..;

Outline
A. Fatigue, Acute Over-Exertion, Chronic Injury/Illness
B. Risk Factors for Repetitive Motions
C. Strategies to Reduce the Risk for Injury and Illness

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMIC:S!&gt;'~MAN FACTORS
. "HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE. EQUIPMENT AND PRODUCT DESIGN

J. HEALTH AND SAFETY PROGRAMS

�Ergon(nnics 1'raining for Ne'v En1ployees
Office of E1nergency ConHnunications
Rochester, NY, December, 1997

Outline
I. Reducing Discomfort and Fatigue TI1rough Ergonomics
II. Risk Factors for Back and Upper Extremity Discomfort
III. Risk Factors for Eye and Head Discomfort
IV. Driving Factor Analysis of Seated Discomfott
V. Strategies to Improve Comfort
VI. Ergonomics Resources in OEO and the City

Suzanne H. Rodgers, Ph.D
'CONSULTANT IN ERGONOMICS/I!UMAN FACTORS
"HIGHER PRODUCTIVITY TltnOliGII JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF llliMAN FAC:TORS IN
WOfiKPLAGE, EQ!JII'MENI ANlll'llOOllCI DESIGN
3. IIEALHI AND SAFETY PflOGIIAMS

(716) 544-3567 • 16911UNTINGTON I !ILLS • HOC! lESTER, N.Y. 14622

••

�Ergonomics Training for New Employees
Office of Emergency Communications
Rochester, NY,. June 18, 1998

Outline
I. Reducing Discomfort and Fatigue Through Ergonomics

II. Risk Factors for Back and Upper Extremity Discomfort

ill. Risk Factors for Eye and Head Discomfort
IV. Driving Factor Analysis of Seated Discomfort
V. Strategies to Improve Comfort
VI. Ergonomics Resources in OEO and the City

Suzanne H. Rodgers. Ph.D
Consultant m Ergonomic.&lt;

HIGHER PRODUCTIVITY THROLIGH JOB DESIGN
lnf• HL'h"TJNGTOI'\ HILLS :J RO:HESTE!'. NEW YOR}: 14£i:!:2
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�Ergonomics
Job Set i sfect ion
Productivity
Quality

·····.~

Safety

Ergonomic Job Analysis and Problem Solving
Review Course Syllabus
July, 1998

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1. AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEA~TH AND 1'L."~gry: .PROGRAMS

(716) 544·3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�()
'

,'

Ergonomics Team Training for General
Electric Aircraft Engines, Evendale, OH
July 20-23,1998

Syllabus

••.
Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

1, AWARENESS SEMINARS
2. TRAINING ON USE OF HUMAN FACTORS IN
WORKPLACE, EQUIPMENT AND PRODUCT DESIGN
3. HEALTH AND SAFETY PROGRAMS

(716) 544-3587 • 169 HUNTINGTON HILLS • ROCHESTER, N.Y. 14622

�100-r------------.,

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SWOl Reducing Accidents Through Ergonomics
City of Rochester Training Program by
Sue Rodgers, Ph.D., Consultant in Ergonomics
Tassie Demps, Safety Specialist~ BER
February 9 &amp; 16 or April 20 &amp; 21, 1999, 8 am-12 noon

Goals:
To learn ways to analyze occupational accidents and injuries that can
lead to cost-effective preventive measures to reduce risk in the future.
To become familiar with ergonomics information relevant to risk
definitions and to learn to apply that information to work problems.
To learn more about the proactive approach to safety being developed
by the Safety Specialist and Ergonomics Consultant and the
Supervisors' Role in its success.

�Suzanne H. Rodgers, Ph.D.
Consultant In Ergonomics
169 Huntington Hills - Center
Rochester, New York 14622

(716) 544-3587
(716) 266-8749 (FAX)

2-Day Ergonomics Training Course for Engineers
at USCS, IBS, Cabledata in
El Dorado Hills, CA, March 18-19, 1999
Syllabus
Schedule:
Start Time

Topic

Day 1
8:00 AM
8:30
9:00
10:00
10:15
11:30
12:00
1:00PM
1:45
2:30
3:15
3:30
4:00
5:00

Overview of Course -Review of Videotaped Jobs
Ergonomic Design Guidelines- Upper Limits
Anthropometric Data- Population Capabilities
Break
Problem Solving: Workplace and Job Design
Seated Workplace Design
Lunch
Problem Solving: Layout
Repetitive Work: Fatigue and Job Pattern
Problem Solving: Repetitive Tasks .
Break
Pacing and Quality Performance
Problem Solving: Paced Work
Adjourn

Day2
8:00AM
9:15
10:00
10:15
12:00
1:00PM
2:00
3:30
4:30

Manual Handling and Force Guidelines
Problem Solving: Lifting and Pushing
Break
Problem Solving: Repetitive Lifting
Lunch
Incorporating Ergonomics Guidelines Into New Design
Problem Solving: Ergonomics in New Design/Selection of
Equipment
Selling Ergonomic Improvements
Resources, Course Evaluations, and Adjourn

�2-Day Ergonomics Training Course for Engineers at USCS, IBS,
Cabledata in ElDorado Hills, CA, March 18-19, 1999
Table of Contents
Starting Page
1
I

iiL.

1

3
5
6
8
12
14
17
19
28
31

33
37
39
40
41
43
44
45
46
47
48
49

59
66
83
84

Topic
Table of Contents
Acknowledgements
Job Analysis Techniques and Solution Strategies
Rapid Ergonomics Job/Workplace Review
Figure 1: Ergonomic Risk Factors
Figure 1: Risk Factors for Low Back Pain
Anthropometric Data
General guidelines for Using Anthropometric Data
Clearances
Reaches- Standing and Sitting
VDT Workplace Design Kit
Observed Postures- Seated Work and Self-Help
Process for Evaluating Comfort- Seated Work
Chair Selection
Determining Best Height for Standing Workplace
Ergonomics Principles for General Layout and Flow
Problem Solving Form- Anthropometric Data Use
Risk Factors for Upper Extremity Discomfort
Table 1: Factors Affecting Grip Strength
Work/Recovery Times for Static Work
Functional Job Fatigue Analysis Form
Table 2: Examples of Muscle Effort Levels
Table 3: Definitions of Heavy Effort
Ergonomic Problem Solving Analysis Form
Basis for Supervisory and Employee Awareness Training
Self-Help Approach to Reduce Risk
Methodology for Fatigue Analysis in Repetitive Jobs
Figure 3: Sustained Effort Time Limits
References for Fatigue Analysis

(

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Cai/OSHA Ergonomics Problem Solving Course2 Oakland2 CA2
May 4-62 1999
EZ Ergo Re[.

Teacher

Topic

Sue

lntros!Expectations
Types of Jobs Seen
Befores and Afters
Importance ofDefming Risk
Hazard vs Good Design
Problem Solving Approach- Task Analysis, Risk
Factors, Whys?

Day 1:

4-5
8-10, 17

Ira
Sue

9-17, 72-73

Ira
Sue

41-51

/:)

28-32, 40-41
19-26

Ira
Sue
Ira&amp; Sue

Risk Factors and Occupational Hazards - Anatomy
Fatigue
Guidelines for Determining Risk in Workplace
Design- Reaches, etc.
Examples of Solutions
Techniques for Assessing Risk- Checklists, etc.
Postural Stress and Workplace Design- Problem
Solving

Day2:
18
9-17
40-41, 66-71
36-39

41-43

57-65,33-36,
42-43
\

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2-3
44, 74-75

Sue
Ira
Sue
Ira
Ira&amp; Sue

Contributing Factors to Musculoskeletal Disorders
Risk Factors- Effort Intensity
Fatigue Rating Technique
Approaches to Reduce the Risk
Ergonomic Tooling
Repetitive Tasks -Problem Solving

Sue
Sue
Ira

Manual Materials Handling- Biomechanics and
Psychophysical Analyses- NIOSH Guidelines
Kodak Lifting Guidelines
Push/Pull
Improvements in MMH

Ira &amp; Sue
Sue
Ira

Problem Solving - MMH
Cost Effective Solutions- Multifactorial
Exercises to Reduce Risk ofMSDs/Health Care

Ira

�Providers

Day3:
2-3, 47-51
52-53

Sue &amp; Ira
Sue

76-84,
Section IV

Ira

Effective Programs- Critical Factors
Building Ergonomics Into Other Processes
Define Problem Before Solving It
Resources

Sue &amp; Ira

Projects- Problem Solving/Solutions

5/3/99

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SWOl Reducing Accidents Through Ergonomics
City of Rochester Training Program by

t:~

Sue Rodgers, Ph.D., Consultant in Ergonomics
Tassie Demps, Safety Specialist~ BHRM
May 18th and 25th, 1999, 8 AM to 12 noon, Colfax Street
Training Center

Goals:
.
To learn ways to analyze occupational accidents and injuries that can
lead to cost-effective preventive measures to reduce risk in the future.
To become familiar with ergonomics information relevant to risk
definitions and to learn to apply that information to work problems.
To learn more about the proactive approach to safety being developed
by the Safety Specialist and Ergonomics Consultant and the
Supervisors' Role in its success.

�Course Schedule
May 18th morning
8:00

Introductions/Course Goals/ Accident Data and Form

8:30

Ergonomic Approach to Accident Investigations - Why ?

9:15

Exercise to Find Multiple Factors in an Air Crash

9:45

Break

10:00

Using Human Capabilities Data to Assess Risk for Injury

10:45

Review of Several Accidents and Jobs in the City

11 :45

Chose Projects for Next Week's Session

12:00

Adjourn

May 25th morning
8:00

Feedback on Topics Where More Time Is Needed

8:30

Reports on Accident Investigations Done

9:45

Break

10:00

Discussion on Topics Chosen Earlier and Feedback on Reports

11:45

Concluding Remarks and Course Evaluations

12:00

Adjourn

/

r

�I.
I

Treinamento de Ergonomia
para
;
GE Celma e GE Varig
Novembro de 1999.

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"
(7~ 6} 544-3587 • Fax (716} 266-8749
Email SHAODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

�•

I

)uzanne H. Rodgers, Ph.D.
:onsultant In Ergonomics
l69 Huntington Hills - Center
~ochester, New York 14622

(716) 544-3587
(716) 266-8749 (FA~)

Ergonomics Opportunities at GEES Celma and Varig, Petropolis and
Rio de Janeiro, Brasil, Summary of Jobs Seen in November, 1999 as
Part of Ergonomics Team Training

Table of Contents

pages 1-21

Summary of Jobs Videotaped at GE Celma and GE Varig
GECelma
A. GEREP, CEMGB
B. GEMOG, EQLPC
C. GEMOG, EQLPT
D. GEREP, EQPQI
E. GEMSS, EQMAM
F. GEACE, EGNDT
G. GEACE, EGPAC
H. GEACE, EGEAC
I. GEPMI, EQJ85

GEVarig

1-2
2-3
3-4
4-5

6-7
7-8
8
8-9
9-10

11- 14

GECelma
A.GEREP
B. DIFAB
C. Other Jobs from Projects- 1 Celma, 2 Varig

15-18
18-20
20-21

Office-related Consultations and Observations at GE Celma
A. Black Belts' Office
B. Sourcing and Vendor Communications Offices

1- 2
2- 5

Grip Strengths of Ergonomics Team Training Course Members
Appendix: Ergonomic Equipment Vendors!URLs

pages 1 - 5

3 pages
8 pages

�City of Rochester Parks Department Wellness Program
April 13, 2000

I.
A.
B.
C.
D.

...... \

Risk Factors for Low Back Pain
Postural Risk Factors
Manual Handling Tasks
Force Exertion
Combined Risk Factors -Fatigue

II.

Guidelines for Reducing Risk to the Back
A. Keeping the load or force close to the body
B. Stable footing
C. Good grip
D. Minimize twisting
E. Minimize time in awkward postures- mini-breaks
F. Slide instead of lift
G. Lift between knees and mid-chest levels
H. Get help on bulky lifts

III.

Review of Some Jobs for Low Back Risk Factors
A. Tree trimming
B. Cemetery cement work
C. Parks brush removal, equipment handling

._· ••• &lt;

�r)
\ ~
...

Low Back Pain Risk Factors
A. Postures Sustained for 15 seconds or More
1. Bending forward
2. Leaning to one side
3. Twisting
4. Arching the back - overhead work
5. Crouching
6. One-sided standing
7. Extended reaches
8. Constant standing
9. Constant sitting
10. Long truck/car rides, especially over uneven terrain
11. Feet at different levels- side of hill, stepping out of the truck, etc.

B. Manual Handling Activities
1. Lifting, lowering or force exertion more than 14 inches in front of the
body
2. Lifting, lowering, or exerting force while twisting
3. Unevenly weighted loads (e.g., chain saw)
4. Shifting loads (e.g., bags of chemicals)
5. Exerting high forces while kneeling
6. Handling items or exerting forces below knee level or above shoulder level
7. Poor grasping points
8. Lifting with a sudden acceleration or jerk
9. Handling wide objects on one side of the body
10. Sustained carrying
11. Frequent handling of items (&gt;3/minute for 3-second lifts)
C.

Other Contributors
1. Slippery walking surfaces, especially ice and snow
2. Projections, obstructions that limit access to a work area and may be
struck
3. Climbing
4. Poor housekeeping, trash/litter

�Ergonomics Team Training Course forGE Superabrasives,
Worthington, OH, June 6-9, 2000

Syllabus

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 • Fax (716) 266-8749
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

�Outline of the Course (8:00AM to 3:45PM)
Day One
Ergonomics Scope and Potential Legislation
Fatigue and How to Reduce It
Postural Risk Factors
Problem Solving: Postural Stress
Design of Workplaces -Using Anthropometric Data
Problem Solving: Working Height Determinations
Office Ergonomics
Problem Solving: Seated Workplace Design
Layout of Workplaces

Day Two
Work-Related Musculoskeletal Disorders- Definitions, Risk
Factors, Control Measures
Ergonomic Job Analysis Technique to Prioritize the Need for
Change on a Job - Fatigue Prediction
Problem Solving: Repetitive Tasks
Low Back Pain and Disorders - Risk Factors and Control
Measures
Guidelines for Safe Force Exertions
Guidelines for Safe Lifting
Total Physical Workload- Guidelines for Good Job Design
Problem Solving: Manual Handling Tasks

Day Three
Ergonomics and Quality- Information Transfer
Environmental Guidelines- Heat and Humidity, Noise, Lighting
An Ergonomic Approach to Accident Analysis
Problem Solving: Accident Follow-Up from an Ergonomics
Viewpoint
Cost/Benefit Analysis of Ergonomic Problem Solutions
Ergonomics Program Goals at Worthington and Activities
Identifying Projects for Rest of Course
Initial Analysis of Jobffask- Data Collection

�Day Four
Work on Projects With Coaching
Prepare Presentations for Managers
Make Presentations (10 minutes each) to Managers
Evaluations

�Ergonomics Team Training Course for GEAE Evendale,
Evendale, OH, October 9-13, 2000

Syllabus

\f""

fVv
L~~~
~II~~

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 • Fax (716) 266-8749
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622
··~··

�Office Ergonomics - Evaluating Workplaces
GEAE Evendale, 10/13/2000
Table of Contents
Topic
Office Ergonomics -Self Help...
Postural and Visual Comfort Rating Forms
Risk Factors for Discomfort
Process for Evaluating Comfort in a Seated Workplace
Observed Postures ... and Self-Help to Improve Comfort
Analysis of the VDT Workstation- Visual
Posture and Vision and Productivity
Factors That Contribute to Visual Discomfort
Questionnaire to Evaluate Job Requirements ...
Anthropometric Data
VDT Workplace Design Kit
Seated Arm Reach
General Guidelines for Chair Selection
Examples of Workplace Assists ...
Extra Forms

Starting Page
1
2
4
5
7
10
11

12
13
15
16

25
26
30
31

Acknowledgements
The illustration on page 15 is from Working With Backache by S.H.Rodgers, published
by Perinton Press in 1985. The illustration on page 25 is from Eastman Kodak's
Ergonomic Design for People at Work, Volume 1, published by von Nostrand Reinhold
(now Wiley and Sons) in 1983. All of the other material has been developed by Inger
Williams, Ph.D. and S.H. Rodgers. Permission to reproduce it must be obtained from
them.

Suzanne H. Rodgers, Ph.D
'·

~'

CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 • Fax (716) 266-8749
Email SHRODGERS@aol.com
169 Huntington Hills • Rocheste;, NY 14622

�2-Dav Er2onomics Team Trainin!! Course for GEES MiamiPower Systems~ Jt,ebruary 1-2~ 2001
w

~

~

Syllabus

Section 1:
SeCtion 2:
Section 3:
Section 4:
Section 5:
Section 6:
Section 7:
Section 8:
Section 9:

OSHA 2000 Ergonomics Program Standard
Ergonomics, Fatigue, and Body Size Data
Office Ergonomics- Evaluating Workplaces
Reducing Work-Related rvtusculoskeletai Disorders
Reducing Strains and Sprains by Improving Manual
Handling Tasks
Factors A1Iecting Quality Performance, Environment
An Ergonomics Approach to Accident Analysis
Ergonomics Processes, Cost/Benefit Analyses
Project Information and Extra Fon:ns

Suzanne H. Rodgers, Ph.D· · · ·
CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 •' Fax (716)
266~.87
49 ·
. .
:1
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

�Ergonomics Job Analysis and Applications in the Field
A Course for Loss Control Specialists and Others at the
California State Compensation Insurance Fund, March, 2001

Course Outline
Day 1:
Review of Ergonomics Areas of Particular Interest to Attendees
Review of Musculoskeletal Risk Factors That Ergonomic Job Design Addresses
OSHA Ergonomics Program Standard- Job Analysis Requirements
Other Job Analysis Techniques- Fatigue Analysis
Problem Solving to Develop Cost-Effective Solutions for the Business
Day2:
Using Accident/Incident and Health Data to Identify Ergonomics Opportunities
Getting Management Commitment to Ergonomics in a Business
Effective In-House Ergonomics Programs for Employers
Lessons Learned About Ergonomics Training
Measuring the Effectiveness of an Ergonomics Program
Case Studies

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 • Fax (716) 266-87 49
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

�Ergonomic Job Analysis and Applications in the Field
Table of Contents
Topic
Table of Contents
Acknowledgements

Starting Page

Basis for Supervisory and Employee Training- MSDs
Table 2: A Self-Help Approach to Reducing the Risk ...
Figure 1: Risk Factors for Low Back Pain -Checklist
OSHA Ergonomics Program Standard- Job Analysis
Table W -1: OSHA Basic Screening Tool
Moore-Garg Strain Index
NIOSH Work Practices Guidelines- 1991
Snook Tables for Lifting, Carrying, Pushing and Pulling
RULA Employee Assessment Worksheet
Rapid Entire Body Assessment
Washington State Ergonomics Standard Appendix
ACGIH TLVs for Hand Activity
Rodgers Priority for Change (Fatigue Analysis)
Observed Postures for People in Seated Workplaces
A Functional Job Analysis Technique
Predicting Ergonomically -Acceptable Highly Repetitive Tasks
Job Analysis Techniques and Solution Strategies
Lessons Learned: Ergonomics in the Trenches
A Process for Identifying Ergonomic Opportunities ...
A Process for Analyzing Workplace Accidents,
Rapid Ergonomics Job/Workplace Review ...

ii
1

11
18

20
22
24

26
29
38

39
42
48

50
54

57
74
83
85

89
98
104

106
111
112
115

Securing Management Commitment and Employee Involvement
Ergonomics Process Components
Thoughts on Ergonomics Programs and Processes in Plants
Ergonomic Program Approaches
Lessons Learned About Ergonomics Training
Return-to-Work/Medical Management Approaches- Ergonomics
Assessing the Effectiveness of an Ergonomics Process
Ergonomic Case Study
Bibliography- Rodgers

131
132

Graphs and Forms for Problem Solving

134ff

119

121

125

,_

�Acknowledgements:
The material on pages 20 to 23 is from the November 14, 2000 Federal Register publication of the OSHA
Ergonomics Program Standard 1910. The summary of several job analysis methods on pages 24 to 53 has
been taken, with his permission, from an excellent website by Dr. Thomas Bernard of the University of
South Aorida College of Public Health in Tampa. The URL is http://www.bsc.usf.edu/~tbemard/ergotools.
The illustrations on pages 136 and 144 are from Eastman Kodak's Ergonomic Design for People at Work,
VoJumes 1 and 2 published by van Nostrand Reinhold (now Wiley and Sons) in 1983 and 1986 in New
York City. The article on pages 57-73, "A functional job analysis technique" appeared in a monograph on
Ergonomics edited by A. Garg and J.S. Moore and published by Hanley and Belfus of Philadelphia in their
series, Occupational Medicine: State of the Art Reviews. The article on pages 74 to 82 is from the
Proceedings of ErfloCon'98, the Silicon Valley Ergonomics Conference on May 3-6, 1998 in San Jose,
CA, pages 3-11. The article on pages 98 to 103 was published in Aoolie4 Occupational and Environmental
Hylriene 15(7): 529-534in 2000. The material on pages 135 and 143 is from Workine-withBackache by
SH Rodgers, 1986. Dr. Inger Williams developed the material on pages 54 to 56 and 137 in co1Uunction
with SH Rodgers. Everything else in the syllabus, unless otherwise noted, was developed by S.H.
Rodgers, and permission to reproduce it must be obtained from her.

I I

Li

�E11gonomics Semina~R&gt;n Musculai?Fatigue Evaluation and
Pmblem Solving to Develop Stmtegies to Dec11ease the Risk of
Occupational MSDs, Lawrence Livermore National Laboratory, Feb. 19,2003

Outline
Muscular Fatigue in Occupational Tasks
Recovery Time Needs in Static Muscular Work
Rodgers' Muscle Fatigue Analysis Tool
Problem Solving and Solution Strategy Generation
Case Studies from LLNL- Glassware Washing, Demolition Work
Overhead, Photographer

Table of Contents
Starting Page
A Participatory Approach to Categorize Fatigue on Occupational Tasks
I
Work/Recovery Curves
6
Rodgers Muscle Fatigue Analysis Tool
7
Discomfort Survey Form
18
An Ergonomics Problem Solving Technique
20
Basis for Supervisory and Employee Training- MSDs
35
Table 2: A Self-Help Approach to Reduce Risk of MSDs
45a
A Functional Job Evaluation Technique
51
References- SHR
68
Extra Forms

..

�University of Alabama at Tuscaloosa Ergonomics Training Course for Health and Safety
Consultants, College of Continuing Studies, September 16-17,2003.
Outline of Course

Day One
A. Overview - Scope of Ergonomics
1. What to look for on surveys
2. Mistakes to avoid- My lessons learned
B. Fatigue
1. What causes fatigue?
2. How do we measure fatigue?
3. How do we reduce fatigue?
4. Postural work
5. Repetitive tasks
6. Heavy work

C. Problem Solving
1. Defining the problem
2. Problem solving technique
3. Examples of low cost solutions

D. Use of Body Size and Strength Data to Assess Risk
1. Anthropometric Data
2. Hand Grip Strength
3. Lifting Strength
Day Two
E. Accident Investigation
1. Looking at Accident Data
2. Finding Root Causes of Accidents
3. Making Jobs Safer
F. Case Studies- Using the Forms
G. Cost/Benefit Analysis of Ergonomics Improvements

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 • Fax (716) 266-8749
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

�Ergonomics Awareness Course for the City of Rochester
February 18th and March lOt\ 2005 at SWO's Colfax Street Training Room
Presenter: Sue Rodgers, Consultant in Ergonomics

Suzanne H. Rodgers, Ph.D
Ergonomics =Designing with People in Mind

Syllabus Table of Contents

CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

(716) 544-3587 • Fax (716) 266-8749
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

Starting Page

(

Work-Related Musculoskeletal Disorders
A Checklist to Categorize Muscle Fatigue ...
Musculoskeletal Disorders and How to Reduce Them
Musculoskeletal Risk Factors
Rodgers Muscle Fatigue Analysis
An Ergonomics Problem Solving Process

11
13
14

Office Ergonomics - Comfort Assessment
Individual Ergonomic Workstation Evaluation Form
Process for Evaluating Comfort in a Seated Workplace
Finding Your Comfortable Viewing Distance
Types of Assist Devices

15
16
17
19
20

Natural History ofDegenerative Disc Disease
Risk Factors for Low Back Pain and Ways To reduce Them
Lifting Strength
Lifting Guidelines
Carrying Guidelines
Force Exertion Guidelines

23
24
28
29
34
35

Work Design- Organizational Factors
Total Workload, Shift Work, and Overtime
Job Analysis and Solution Strategies
Evaluating Workplace Interventions

36
38
43
45

Analysis of a Headstone Setting Task
Extra Forms

48
50

Equipment Sources
Design and Selection recommendations for hand Tools

55
56

1
6

8

�w&lt;.

'l•'

Follow-Up Ergonomics Training and Awareness for B.G.
Sulzle, Syracuse, NY, May 17,2005

Table of Contents
Page
1
General Comments About Getting an Ergonomics Process Started
2

Who Should Be Trained?

3

How Do You Get Their Attention? Demonstrations.

6

Risk Factors for Injuries -Videos, Checklists

23

Fatigue Interactions

27

Ergonomic Problem Solving- Participative, Strategies, Why? Why?
Why?

29

Solutions- Examples of Equipment, Outcomes of Problem Solving
Solutions

36

Information on Human Capabilities

44

Examples of Job Demands That Should Be Addressed

48

Extra Forms

L-.ut~
~~~~

Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

srs.;-

(~)

5'1&gt;.s

544-3587 • Fax(~) 266-8749
Email SHRODGERS@aol.com
169 Huntington Hills • Rochester, NY 14622

�Ergonomics Awareness for New Emergency Communications Specialists
Emergency Communications Department, September 26, 2005, 9:30-11 :OOAM

A.

What is Ergonomics and Why Should you Know About It?
1. Designing for People
2. Injury, Illness, and Fatigue Prevention

B. The Telecommunicators' Workplace
1. Adjusting the Keying and Visual Heights and Distances
2. Adjusting the Chair
3. Organizing the Workplace
4. Visual Demands - Optimizing them
C. What to Do If You Have Musculoskeletal Discomfort
1. Early reporting
2. Recovery activities

.Suzanne H. Rodgers, Ph.D
CONSULTANT IN ERGONOMICS/ HUMAN FACTORS
"HIGHER PRODUCTIVITY THROUGH JOB DESIGN"

_.t;'y;'

$-j.:,-544-3587 • Fax~) 266-8749
Email SHRODGERS@aol.com
i 69 Huntington Hills • Rochester, NY i 4622
~)

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                  <text>&lt;p&gt;Suzanne H. Rodgers, Ph.D. (1939-2017)&lt;/p&gt;
&lt;p&gt;Suzanne H. Rodgers, Ph.D. was an internationally recognized scholar, consultant and leader of the field of occupational ergonomics. She received her doctorate in Physiology in 1967 from the University of Rochester School of Medicine and Dentistry in Rochester, New York. After a two-year post-doctoral fellowship in London where she studied the control of blood pressure, heart rate and respiration, she joined the Human Factors/Ergonomics Group at Eastman Kodak Company in Rochester, New York. Working with engineers, medical specialists, psychologists and computer and statistical specialists, Dr. Rodgers spent the next thirteen years studying people at work. In 1982, she left Kodak to start her own ergonomics consulting and training business with the focus on participatory approaches to ergonomics problem solving. From 1982-1988, she taught IE 436/536 “The Physiological Basis of Human Factors” to students of the Department of Industrial Engineering at the State University of New York at Buffalo [now the Department of Industrial and Systems Engineering at the University at Buffalo, SUNY].&lt;/p&gt;
&lt;p&gt;Dr. Rodgers was a principal author and technical editor for Kodak’s two-volume series, &lt;i&gt;Ergonomic Design for People at Work&lt;/i&gt;, published in 1982 and 1986, and the second edition that was published in 2004. She also wrote &lt;i&gt;Working with Backache&lt;/i&gt; that was published in 1985. She has published a number of important journal articles and position papers in ergonomics and medical journals, and spoke frequently at professional conferences. For many years, she was an important leader and organizer of the Lucien Brouha Work Physiology Symposium.&lt;/p&gt;
&lt;p&gt;Dr. Rodgers had a profound impact on many ergonomics professionals, hundreds of students and thousands of workers. This collection illustrates some of the many contributions Dr. Rodgers made as a leader and pioneer of the ergonomics profession. It includes samples of her textbooks, journal articles, worksite training syllabi, conference presentations and other professional and personal contributions. This collection also contains examples of her writing, illustrations, and workshop/conference schedules.&lt;/p&gt;</text>
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&#13;
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&#13;
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&#13;
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&#13;
This online collection is a compilation of photographs by Irene Haupt beginning with the 2000 June in Buffalo. Haupt, a graduate of the State University of New York at Buffalo, has been documenting the Buffalo arts scene through her photography since 1976. During that time she has worked for, or with, some of the most notable institutions in Buffalo, including the Irish Classical Theatre, Studio Arena Theater, the Kavinoky Theatre, the Buffalo Philharmonic Orchestra, the Theatre of Youth, the Albright-Knox Art Gallery, and the State University of New York at Buffalo. In addition to her specialty of theater photography, Irene Haupt has also devoted much of her career to the photography of musicians and musical events, especially the contemporary music scene in Buffalo. A broader representation of Irene Haupt's photographs of musical activities in Buffalo are also available online in the Irene Haupt Photographs of Musicians in Buffalo .&#13;
&#13;
The musicians who have participated in the June in Buffalo festival include University at Buffalo faculty members David Felder, Cort Lippe, Jeffrey Stadelman, Cheryl Gobbetti-Hoffman, Jonathan Golove, Tony Conrad, Stephen Manes, Tony Arnold, Magnus Mårtensson, Jon Nelson, Movses Pogossian, and Jan Williams. Visiting artists have included Lukas Foss, Amy Williams, Helena Bugallo, Charles Wuorinen, Joji Yuasa, George Crumb, Augusta Read Thomas, Bernard Rands, Philip Glass, Steve Reich, Harvey Sollberger, Roger Reynolds, John Harbison, Dora Ohrenstein, Philippe Manoury, Jonathan Harvey, John Corigliano, and the New York New Music Ensemble.&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
This online collection is a compilation of photographs by Irene Haupt beginning with the 2000 June in Buffalo. Haupt, a graduate of the State University of New York at Buffalo, has been documenting the Buffalo arts scene through her photography since 1976. During that time she has worked for, or with, some of the most notable institutions in Buffalo, including the Irish Classical Theatre, Studio Arena Theater, the Kavinoky Theatre, the Buffalo Philharmonic Orchestra, the Theatre of Youth, the Albright-Knox Art Gallery, and the State University of New York at Buffalo. In addition to her specialty of theater photography, Irene Haupt has also devoted much of her career to the photography of musicians and musical events, especially the contemporary music scene in Buffalo. A broader representation of Irene Haupt's photographs of musical activities in Buffalo are also available online in the Irene Haupt Photographs of Musicians in Buffalo .&#13;
&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
This online collection is a compilation of photographs by Irene Haupt beginning with the 2000 June in Buffalo. Haupt, a graduate of the State University of New York at Buffalo, has been documenting the Buffalo arts scene through her photography since 1976. During that time she has worked for, or with, some of the most notable institutions in Buffalo, including the Irish Classical Theatre, Studio Arena Theater, the Kavinoky Theatre, the Buffalo Philharmonic Orchestra, the Theatre of Youth, the Albright-Knox Art Gallery, and the State University of New York at Buffalo. In addition to her specialty of theater photography, Irene Haupt has also devoted much of her career to the photography of musicians and musical events, especially the contemporary music scene in Buffalo. A broader representation of Irene Haupt's photographs of musical activities in Buffalo are also available online in the Irene Haupt Photographs of Musicians in Buffalo .&#13;
&#13;
The musicians who have participated in the June in Buffalo festival include University at Buffalo faculty members David Felder, Cort Lippe, Jeffrey Stadelman, Cheryl Gobbetti-Hoffman, Jonathan Golove, Tony Conrad, Stephen Manes, Tony Arnold, Magnus Mårtensson, Jon Nelson, Movses Pogossian, and Jan Williams. Visiting artists have included Lukas Foss, Amy Williams, Helena Bugallo, Charles Wuorinen, Joji Yuasa, George Crumb, Augusta Read Thomas, Bernard Rands, Philip Glass, Steve Reich, Harvey Sollberger, Roger Reynolds, John Harbison, Dora Ohrenstein, Philippe Manoury, Jonathan Harvey, John Corigliano, and the New York New Music Ensemble.&#13;
&#13;
Complete details about the annual collections can be found in their respective finding aids.&#13;
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&#13;
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&#13;
This online collection is a compilation of photographs by Irene Haupt beginning with the 2000 June in Buffalo. Haupt, a graduate of the State University of New York at Buffalo, has been documenting the Buffalo arts scene through her photography since 1976. During that time she has worked for, or with, some of the most notable institutions in Buffalo, including the Irish Classical Theatre, Studio Arena Theater, the Kavinoky Theatre, the Buffalo Philharmonic Orchestra, the Theatre of Youth, the Albright-Knox Art Gallery, and the State University of New York at Buffalo. In addition to her specialty of theater photography, Irene Haupt has also devoted much of her career to the photography of musicians and musical events, especially the contemporary music scene in Buffalo. A broader representation of Irene Haupt's photographs of musical activities in Buffalo are also available online in the Irene Haupt Photographs of Musicians in Buffalo .&#13;
&#13;
The musicians who have participated in the June in Buffalo festival include University at Buffalo faculty members David Felder, Cort Lippe, Jeffrey Stadelman, Cheryl Gobbetti-Hoffman, Jonathan Golove, Tony Conrad, Stephen Manes, Tony Arnold, Magnus Mårtensson, Jon Nelson, Movses Pogossian, and Jan Williams. Visiting artists have included Lukas Foss, Amy Williams, Helena Bugallo, Charles Wuorinen, Joji Yuasa, George Crumb, Augusta Read Thomas, Bernard Rands, Philip Glass, Steve Reich, Harvey Sollberger, Roger Reynolds, John Harbison, Dora Ohrenstein, Philippe Manoury, Jonathan Harvey, John Corigliano, and the New York New Music Ensemble.&#13;
&#13;
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&#13;
June in Buffalo provides young composers the opportunity to work with senior composers from around the world. The invited faculty members not only have works performed at the festival, they also present lectures, seminars, and master classes. The student composers have the opportunity to hear their works in performance by professional musicians of the highest caliber.&#13;
&#13;
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&#13;
The musicians who have participated in the June in Buffalo festival include University at Buffalo faculty members David Felder, Cort Lippe, Jeffrey Stadelman, Cheryl Gobbetti-Hoffman, Jonathan Golove, Tony Conrad, Stephen Manes, Tony Arnold, Magnus Mårtensson, Jon Nelson, Movses Pogossian, and Jan Williams. Visiting artists have included Lukas Foss, Amy Williams, Helena Bugallo, Charles Wuorinen, Joji Yuasa, George Crumb, Augusta Read Thomas, Bernard Rands, Philip Glass, Steve Reich, Harvey Sollberger, Roger Reynolds, John Harbison, Dora Ohrenstein, Philippe Manoury, Jonathan Harvey, John Corigliano, and the New York New Music Ensemble.&#13;
&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
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&#13;
The Irene Haupt Photographs of June in Buffalo document the annual contemporary music festival held at the University at Buffalo, The State University of New York. The festival was begun in 1975 by composer Morton Feldman who directed the festival 1975-78 and in 1980. The festival was dormant from 1981 through 1985. David Felder revived the festival in 1986 and has been its director since that time.&#13;
&#13;
June in Buffalo provides young composers the opportunity to work with senior composers from around the world. The invited faculty members not only have works performed at the festival, they also present lectures, seminars, and master classes. The student composers have the opportunity to hear their works in performance by professional musicians of the highest caliber.&#13;
&#13;
This online collection is a compilation of photographs by Irene Haupt beginning with the 2000 June in Buffalo. Haupt, a graduate of the State University of New York at Buffalo, has been documenting the Buffalo arts scene through her photography since 1976. During that time she has worked for, or with, some of the most notable institutions in Buffalo, including the Irish Classical Theatre, Studio Arena Theater, the Kavinoky Theatre, the Buffalo Philharmonic Orchestra, the Theatre of Youth, the Albright-Knox Art Gallery, and the State University of New York at Buffalo. In addition to her specialty of theater photography, Irene Haupt has also devoted much of her career to the photography of musicians and musical events, especially the contemporary music scene in Buffalo. A broader representation of Irene Haupt's photographs of musical activities in Buffalo are also available online in the Irene Haupt Photographs of Musicians in Buffalo .&#13;
&#13;
The musicians who have participated in the June in Buffalo festival include University at Buffalo faculty members David Felder, Cort Lippe, Jeffrey Stadelman, Cheryl Gobbetti-Hoffman, Jonathan Golove, Tony Conrad, Stephen Manes, Tony Arnold, Magnus Mårtensson, Jon Nelson, Movses Pogossian, and Jan Williams. Visiting artists have included Lukas Foss, Amy Williams, Helena Bugallo, Charles Wuorinen, Joji Yuasa, George Crumb, Augusta Read Thomas, Bernard Rands, Philip Glass, Steve Reich, Harvey Sollberger, Roger Reynolds, John Harbison, Dora Ohrenstein, Philippe Manoury, Jonathan Harvey, John Corigliano, and the New York New Music Ensemble.&#13;
&#13;
Complete details about the annual collections can be found in their respective finding aids.&#13;
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&#13;
The Irene Haupt Photographs of June in Buffalo document the annual contemporary music festival held at the University at Buffalo, The State University of New York. The festival was begun in 1975 by composer Morton Feldman who directed the festival 1975-78 and in 1980. The festival was dormant from 1981 through 1985. David Felder revived the festival in 1986 and has been its director since that time.&#13;
&#13;
June in Buffalo provides young composers the opportunity to work with senior composers from around the world. The invited faculty members not only have works performed at the festival, they also present lectures, seminars, and master classes. The student composers have the opportunity to hear their works in performance by professional musicians of the highest caliber.&#13;
&#13;
This online collection is a compilation of photographs by Irene Haupt beginning with the 2000 June in Buffalo. Haupt, a graduate of the State University of New York at Buffalo, has been documenting the Buffalo arts scene through her photography since 1976. During that time she has worked for, or with, some of the most notable institutions in Buffalo, including the Irish Classical Theatre, Studio Arena Theater, the Kavinoky Theatre, the Buffalo Philharmonic Orchestra, the Theatre of Youth, the Albright-Knox Art Gallery, and the State University of New York at Buffalo. In addition to her specialty of theater photography, Irene Haupt has also devoted much of her career to the photography of musicians and musical events, especially the contemporary music scene in Buffalo. A broader representation of Irene Haupt's photographs of musical activities in Buffalo are also available online in the Irene Haupt Photographs of Musicians in Buffalo .&#13;
&#13;
The musicians who have participated in the June in Buffalo festival include University at Buffalo faculty members David Felder, Cort Lippe, Jeffrey Stadelman, Cheryl Gobbetti-Hoffman, Jonathan Golove, Tony Conrad, Stephen Manes, Tony Arnold, Magnus Mårtensson, Jon Nelson, Movses Pogossian, and Jan Williams. Visiting artists have included Lukas Foss, Amy Williams, Helena Bugallo, Charles Wuorinen, Joji Yuasa, George Crumb, Augusta Read Thomas, Bernard Rands, Philip Glass, Steve Reich, Harvey Sollberger, Roger Reynolds, John Harbison, Dora Ohrenstein, Philippe Manoury, Jonathan Harvey, John Corigliano, and the New York New Music Ensemble.&#13;
&#13;
Complete details about the annual collections can be found in their respective finding aids.&#13;
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