Case Studies of Robots and Automation as Health/Safety Interventions in Small Manufacturing Enterprises.

This paper reviews the experiences of 63 case studies of small businesses (< 250 employees) with manufacturing automation equipment acquired through a health/safety intervention grant program. The review scope included equipment technologies classified as industrial robots (n = 17), computer numerical control (CNC) machining (n = 29), or other programmable automation systems (n = 17). Descriptions of workers' compensation (WC) claim injuries and identified risk factors that motivated acquisition of the equipment were extracted from grant applications. Other aspects of the employer experiences, including qualitative and quantitative assessment of effects on risk factors for musculoskeletal disorders (MSD), effects on productivity, and employee acceptance of the intervention were summarized from the case study reports. Case studies associated with a combination of large reduction in risk factors, lower cost per affected employee, and reported increases in productivity were: CNC stone cutting system, CNC/vertical machining system, automated system for bottling, CNC/routing system for plastics products manufacturing, and a CNC/Cutting system for vinyl/carpet. Six case studies of industrial robots reported quantitative reductions in MSD risk factors in these diverse manufacturing industries: Snack Foods; Photographic Film, Paper, Plate, and Chemical; Machine Shops; Leather Good and Allied Products; Plastic Products; and Iron and Steel Forging. This review of health/safety intervention case studies indicates that advanced (programmable) manufacturing automation, including industrial robots, reduced workplace musculoskeletal risk factors and improved process productivity in most cases.

Trends in Work-Related Musculoskeletal Disorders From the 2002 to 2014 General Social Survey, Quality of Work Life Supplement.

OBJECTIVE: To update trends in prevalence of back and upper limb musculoskeletal symptoms and risk factors from the 2014 Quality of Work Life (QWL) Survey. METHODS: Quadrennial QWL Surveys, 2002 to 2014 (with N = 1455, 1537, 1019, and 1124 in 2002, 2006, 2010, and 2014 surveys respectively) were analyzed for reports of back pain and pain in arms. RESULTS: In the fourth analysis of this survey, 12-year trends continue to show a decline in back pain and pain in arms. Key physical (heavy lifting, hand movements, very hard physical effort) and psychosocial/work organizational factors (low supervisor support, work is always stressful, not enough time to get work done) remain associated with back and arm pain, with the physical risk factors showing the strongest associations. CONCLUSION: Physical exposure risk factors continue to be strongly associated with low back and arm pain and should be the focus of intervention strategies.

Industrial exoskeletons: Need for intervention effectiveness research.

Exoskeleton devices are being introduced across several industry sectors to augment, amplify, or reinforce the performance of a worker's existing body components-primarily the lower back and the upper extremity. Industrial exoskeletons may play a role in reducing work-related musculoskeletal disorders arising from lifting and handling heavy materials or from supporting heavy tools in overhead work. However, wearing an exoskeleton may pose a number of risks that are currently not well-studied. There are only a few studies about the safety and health implications of wearable exoskeletons and most of those studies involve only a small number of participants. Before the widespread implementation of industrial exoskeletons occurs, there is need for prospective interventional studies to evaluate the safety and health effectiveness of exoskeletons across various industry sectors. Developing a research strategy to fill current safety and health knowledge gaps, understanding the benefits, risks, and barriers to adoption of industrial exoskeletons, determining whether exoskeleton can be considered a type of personal protective equipment, and advancing consensus standards that address exoskeleton safety, should be major interests of both the occupational safety and health research and practice communities.

Ergonomics assessment methods used by ergonomics professionals.

A web-based survey was conducted of ergonomics practitioners holding certifications in the U.S., Canada, Great Britain, Australia, and New Zealand. The survey follows 12 years after an earlier initial survey reported by Dempsey et al. (2005). Approximately 1221 eligible participants were invited by e-mail to participate, and 405 surveys were included in the final analysis. The survey queried use of basic instruments relevant to ergonomic practice as well as more specific analytical tools such as observational techniques for assessing postural demands of work and instrumentation for direct measurement of such demands. Some ergonomic assessment methods appear to have increased in their overall use by U.S. ergonomists compared to 2005 data. This was observed for: RULA, REBA, Psychophysical Upper Extremity Data, Strain Index, and ACGIH TLV for Hand Activity Level. There is minimal evidence of increased overall use of direct measurement approaches in the U.S. There appear to be geographic differences between countries/continents in terms of use of various methods. The use of mobile device/smart phone "apps" by ergonomists was queried and these technologies presently appear to be in early adoption phase with 24-28% of practitioners reporting use of an app in their ergonomics practice.

ASTM F48 Formation and Standards for Industrial Exoskeletons and Exosuits.

This paper provides an overview of a new consensus standards committee for exoskeletons, ASTM International F48, and describes the organization and current activities of this committee. Lack of product standards and certifications have been described as barriers to adoption of exoskeleton technologies in industry practice. While exoskeletons are not considered a traditional form of personal protective equipment (PPE) they are similarly wearable, and much of the interest in their application in the industrial/workplace domain is motivated by injury prevention. ASTM F48 believes that standards and certifications for exoskeletons in their manufacture, deployment, and use would enhance their adoption in the workplace.

Evaluation of a Workplace Exercise Program for Control of Shoulder Disorders in Overhead Assembly Work.

OBJECTIVE: The aim of this study was to assess effects of exercise on shoulder musculoskeletal symptoms among employees with overhead assembly work exposures. METHODS: A voluntary workplace shoulder exercise program was offered to employees in two automotive assembly departments, while two similar departments served as controls. N = 76 total workers participated. Shoulder Rating Questionnaire (SRQ) and Discomfort of the Arm Shoulder and Hand (DASH) symptoms were queried monthly for 7 baseline months, followed by 6 months that included exercise. RESULTS: SRQ scores were higher for exercisers than among controls in the 6 exercising months, but not in the baseline months. Although the group x month interaction was significant (P < 0.05), the temporal trend was inconsistent. CONCLUSIONS: Exercise may have temporarily lessened decline in SRQ. It is not clear whether shorter term differences were clinically meaningful or predictive of longer term disability prevention.

Serious injury and fatality investigations involving pneumatic nail guns, 1985-2012.

BACKGROUND: This article examines serious and fatal pneumatic nail gun (PNG) injury investigations for workplace, tool design, and human factors relevant to causation and resulting OS&H authorities' responses in terms of citations and penalties. METHODS: The U.S. Occupational Safety and Health Administration (OSHA) database of Fatality and Catastrophe Investigation Summaries (F&CIS) were reviewed (1985-2012) to identify n = 258 PNG accidents. RESULTS: 79.8% of investigations, and 100% of fatalities, occurred in the construction industry. Between 53-71% of injuries appear to have been preventable had a safer sequential trigger tool been used. Citations and monetary penalties were related to injury severity, body part injured, disabling of safety devices, and insufficient personal protective equipment (PPE). CONCLUSIONS: Differences may exist between construction and other industries in investigators interpretations of PNG injury causation and resulting citations/penalties. Violations of PPE standards were penalized most severely, yet the preventive effect of PPE would likely have been less than that of a safer sequential trigger.

Further Trends in Work-Related Musculoskeletal Disorders: A Comparison of Risk Factors for Symptoms Using Quality of Work Life Data From the 2002, 2006, and 2010 General Social Survey.

OBJECTIVE: To report trends for the risk of musculoskeletal disorders. METHODS: Three Quality of Work Life surveys examine the risk factors for musculoskeletal disorders. RESULTS: Findings similar for several risk factors, but differences across the reporting years may reflect economic conditions. Respondent numbers in 2010 were reduced, some risk factors had pattern changes, and there were sex and age differences. Trend analysis showed most significant changes were for the "work fast" risk factor. New 2010 "physical effort" item showed sex differences, and items reflective of total worker health showed strong associations with "back pain" and "pain in arms." CONCLUSIONS: Intervention strategies should focus on physical exposures and psychosocial risk factors (work stress, safety climate, job satisfaction, supervisor support, work fast, work freedom, work time) that have been consistently related to reports of musculoskeletal disorders. Economic conditions will influence some psychosocial risk factors.

Unstable sitting in the workplace--are there physical activity benefits?

The increasingly popular practice of using a stability ball (exercise/fitness ball) as a sitting surface runs counter to conventional human factors/ergonomics guidelines for seated workspace design. Employees sitting on stability balls in an office environment present safety risks that might be justifiable if the practice has a definitive benefit to the promotion of health. However, the published studies and best evidence to date call into question even the theoretical basis for this practice and do not suggest significant health benefits. First, biomechanical studies do not confirm the intended trunk muscle activation. Second, energy expenditure studies show a small (if any) increase in metabolic demand that is unlikely to be effective in combating sedentary work risk factors. Until studies demonstrate more conclusive benefits, the practice of stability ball sitting should be viewed skeptically as a general workplace recommendation in the interest of health or wellness.

A Biomechanical Assessment of Hand/Arm Force with Pneumatic Nail Gun Actuation Systems.

A biomechanical model is presented, and combined with measurements of tip press force, to estimate total user hand force associated with two pneumatic nail gun trigger systems. The contact actuation trigger (CAT) can fire a nail when the user holds the trigger depressed first and then "bumps" the nail gun tip against the workpiece. With a full sequential actuation trigger (SAT) the user must press the tip against the workpiece prior to activating the trigger. The SAT is demonstrably safer in reducing traumatic injury risk, but increases the duration (and magnitude) of tip force exertion. Time integrated (cumulative) hand force was calculated for a single user from measurements of the tip contact force with the workpiece and transfer time between nails as inputs to a static model of the nail gun and workpiece in two nailing task orientations. The model shows the hand force dependence upon the orientation of the workpiece in addition to the trigger system. Based on standard time allowances from work measurement systems (i.e. Methods-Time Measurement - 1) it is proposed that efficient application of hand force with the SAT in maintaining tip contact can reduce force exertion attributable to the sequential actuation trigger to 2-8% (horizontal nailing) and 9-20% (vertical nailing) of the total hand/arm force. The present model is useful for considering differences in cumulative hand/arm force exposure between the SAT and CAT systems and may explain the appeal of the CAT trigger in reducing the user's perception of muscular effort.

Workplace exercise for control of occupational neck/shoulder disorders: a review of prospective studies.

A review was conducted of prospective studies (1997-2014) examining the efficacy of exercise as a workplace intervention to control neck/shoulder pain, symptoms, and disability. The review identified 38 relevant studies - 20 were classified with positive effects, 13 with null effects, and 5 as inconclusive. Of the positive studies, 12 were consistent with Level I evidence, 3 with Level II evidence, and 5 with Level IV evidence. Specific resistance training (SRT) exercise appeared to be associated with more positive studies (eight Level I studies) than other exercise modalities such as general resistance training, general physical exercise, stretching, and movement awareness exercises. Studies of longer trial duration tended toward more null findings and lower program compliance. Evidence for a primary preventive effect of workplace exercise is minimal. The findings of this review suggest that workplace exercise can be effective as tertiary prevention and therapeutic relief of neck/shoulder symptoms, at least over the shorter term.

Residential building stakeholders' attitudes and beliefs regarding nail gun injury risks and prevention.

Pneumatic nail guns are ubiquitous at residential construction sites across the United States. These tools are noted for the traumatic injuries that can occur from their operation. Different trigger mechanisms on these tools are associated with different levels of risk. Residential building subcontractors and workers, both native-born and immigrant, were brought together in focus groups to discuss their attitudes and beliefs regarding risk factors for nail gun injury as well as barriers to the adoption of safer technology. Participants' comments are organized first by influences on traumatic injury occurrence or prevention and later by sociotechnical system category. Participants attributed influences on injury risk to personal and external causation factors in all sociotechnical system categories; however, participants more frequently described influences on injury prevention as related to workers' behaviors, rather than to external factors. A discussion of these influences with respect to attribution theory and sociotechnical models of injury causation is presented.

Relationships between observational estimates and physical measurements of upper limb activity.

This study examined the internal validity of observational-based ergonomic job analysis methods for assessing upper limb force exertion and repetitive motion. Six manual tasks were performed by multiple 'workers' while direct measurements were made to quantify force exertion and kinematics of the upper limb. Observational-based analyses of force and upper limb motion/repetition were conducted by 29 professional ergonomists. These analysts overestimated the magnitude of individual force exertions - temporal aspects of force exertion (duty cycle) were estimated more accurately. Estimates of the relative severity of repetitive motions among the jobs were accurate. Absolute counts of repetitive motions were less accurate. Modest correlations (r(2) = 0.28 to r(2) = 0.50) were observed between ratings of hand activity level and measured joint velocities. Ergonomic job analyses relying on systematic observation should be applied and interpreted with consideration given to the capabilities and limitations of analysts in estimating the physical risk factors. These findings are relevant to a better understanding of the internal validity of ergonomic job analysis methods based on systematic observation.

Handle grip span for optimising finger-specific force capability as a function of hand size.

Five grip spans (45 to 65 mm) were tested to evaluate the effects of handle grip span and user's hand size on maximum grip strength, individual finger force and subjective ratings of comfort using a computerised digital dynamometer with independent finger force sensors. Forty-six males participated and were assigned into three hand size groups (small, medium, large) according to their hands' length. In general, results showed the 55- and 50-mm grip spans were rated as the most comfortable sizes and showed the largest grip strength (433.6 N and 430.8 N, respectively), whereas the 65-mm grip span handle was rated as the least comfortable size and the least grip strength. With regard to the interaction effect of grip span and hand size, small and medium-hand participants rated the best preference for the 50- to 55-mm grip spans and the least for the 65-mm grip span, whereas large-hand participants rated the 55- to 60-mm grip spans as the most preferred and the 45-mm grip span as the least preferred. Normalised grip span (NGS) ratios (29% and 27%) are the ratios of user's hand length to handle grip span. The NGS ratios were obtained and applied for suggesting handle grip spans in order to maximise subjective comfort as well as gripping force according to the users' hand sizes. In the analysis of individual finger force, the middle finger force showed the highest contribution (37.5%) to the total finger force, followed by the ring (28.7%), index (20.2%) and little (13.6%) finger. In addition, each finger was observed to have a different optimal grip span for exerting the maximum force, resulting in a bow-contoured shaped handle (the grip span of the handle at the centre is larger than the handle at the end) for two-handle hand tools. Thus, the grip spans for two-handle hand tools may be designed according to the users' hand/finger anthropometrics to maximise subjective ratings and performance based on this study. Results obtained in this study will provide guidelines for hand tool designers and manufacturers for designing grip spans of two-handle tools, which can maximise handle comfort and performance.

Cutting off the nose to save the penis.

INTRODUCTION: The average bicycle police officer spends 24 hours a week on his bicycle and previous studies have shown riding a bicycle with a traditional (nosed) saddle has been associated with urogenital paresthesia and sexual dysfunction. AIM: The objective of this study was to assess the effectiveness of the no-nose bicycle saddle as an ergonomic intervention and their acceptance among male bicycle police officers. METHODS: Bicycle police officers from five U.S. metropolitan areas were recruited for this study. Officers completed: (i) the International Index of Erectile Function Questionnaire (IIEF); (ii) computerized pressure measurements at the points of contact on the bicycle; the handlebars, the pedals, and the saddle; (iii) one night of nocturnal Rigiscan assessment; (iv) penile vibrotactile sensitivity threshold assessed by computerized biothesiometery. Officers selected a no-nose saddle for their bicycles and were asked to use the intervention saddle exclusively for 6 months, at which point they were retested. MAIN OUTCOME MEASURES: Perineal pressure, urogenital numbness, penile vibrotactile sensitivity threshold, erectile function as measure by International Index of Erectile Function Questionnaire (IIEF) and Rigiscan. RESULTS: After 6 months, 90 men were reassessed. Only three men had returned to a traditional saddle. The results are presented for those who used the no-nose saddle continuously for 6 months. There was a 66% reduction in saddle contact pressure in the perineal region (P < 0.001). There was a significant improvement in penis tactile sensation (P = 0.015). There was a significant improvement in erectile function assessed by IIEF (P = 0.015). There were no changes noted in the Rigiscan measures. The number of men indicating they had not experienced urogential paresthesia while cycling for the preceding 6 months, rose from 27% to 82% using no-nose saddles. CONCLUSIONS: (i) With few exceptions, bicycle police officers were able to effectively use no-nose saddles in their police work. (ii) Use of no-nose saddles reduced most perineal pressure. (iii) Penile health improved after 6 month using no-nose saddles as measured by biothesiometry and IIEF. There was no improvement in Rigiscan(R) measure after 6 months of using no nose saddles, suggesting that a longer recovery time may be needed..

Evaluation of handle shapes for screwdriving.

This study investigated the effects of screwdriver handle shape, surface, and workpiece orientation on subjective discomfort, number of screw-tightening rotations, screw-insertion time, axial screwdriving force, and finger contact forces in a screwdriving task. Handles with three longitudinal cross-sectional shapes (circular, hexagonal, triangular), four lateral shapes (cylindrical, double frustum, reversed double frustum, cone), and two surface materials (plastic, rubber coated) were tested. Individual phalangeal segment force distributions indicated how fingers and phalangeal segments were involved in the creation of total finger force (15.0%, 34.6%, 34.5%, and 15.9% for the index, middle, ring, and little fingers; and 45.7%, 22.4%, 12.9%, and 19.0% for the distal, middle, proximal, and metacarpal phalanges, respectively). From this finding, the index and little fingers appeared to contribute mainly in the guiding and balancing of the screwdriver handles, whereas middle and ring fingers played a more prominent role in gripping and turning. Participants preferred circular and hexagonal longitudinal-shaped and double frustum and cone lateral-shaped handles over the triangular longitudinal-shaped handles, and cylindrical and reversed double frustum lateral-shaped handles. Circular, cylindrical, and double frustum handles exhibited the least total finger force associated with screw insertion. In terms of combinations of longitudinal and lateral shapes, circular with double frustum handles were associated with less discomfort and total finger force.

Effect of bicycle saddle designs on the pressure to the perineum of the bicyclist.

PURPOSE: Increasing awareness of an association between bicycling and male sexual dysfunction has led to the appearance of a variety of bicycle saddles that share the design objective of reducing pressure in the groin of the cyclist by removal of the narrow protruding nose of the saddle. This study compared three of these saddle designs to a traditional sport/road racing saddle with a narrow protruding nose in terms of pressure in the region of the perineum (groin) of the cyclist. METHODS: Saddle, pedal, and handlebar contact pressure were measured from 33 bicycle police patrol officers pedaling a stationary bicycle at a controlled cadence and workload. Pressure was characterized over the saddle as a whole and over a region of the saddle assumed to represent pressure on the cyclist's perineum located anteriorly to the ischial tuberosities. RESULTS: The traditional sport/racing saddle was associated with more than two times the pressure in the perineal region than the saddles without a protruding nose (P < 0.01). There were no significant differences in perineal pressure among the nontraditional saddles. Measures of load on the pedals and handlebars indicated no differences between the traditional saddle and those without protruding noses. This finding is contradictory to those studies suggesting a shift toward greater weight distribution on the handlebars and pedals when using a saddle without a nose. CONCLUSIONS: The recommendation of a saddle without a narrow protruding nose appears to be justified to reduce pressure to the perineum of the bicyclist.

Accuracy and validity of observational estimates of wrist and forearm posture.

Numerous observational methods for analysis of working posture of the wrist/forearm have been reported in the literature yet few of these methods have been validated for the accuracy of their posture classification. The present study evaluated the accuracy of estimates of working posture made by 28 experienced ergonomists using methods of scaling upper limb posture typical of those reported in the literature. Observational estimates of wrist/forearm posture of four jobs presented on video-recording were compared with posture levels measured directly with an electrogoniometer system. Ergonomists using a visual analogue scale tended to underestimate peak and average wrist extension with mean errors of -29.4% and -10.5% of the joint ROM, respectively (p<0.05). While estimates of wrist flexion, pronation and supination resulted in less bias, variability in observer error was large for all wrist postures. The probability of an analyst misclassifying the most frequently occurring posture using a three- and a six-category scale was 54 and 70%, respectively. The probability of misclassifying peak posture was 22 and 61% using a three- and a six-category scale respectively. This suggests a trade-off between the degree of precision afforded by the categorical scale and the likelihood of posture misclassification. Estimates of the temporal distribution of posture among the categories appeared to be biased towards more neutral postures than were measured for the jobs. This indicated the possibility of a trend towards underestimation of posture duration severity by the ergonomists.

Accuracy and validity of observational estimates of shoulder and elbow posture.

This study investigated the accuracy of video-based observational posture analysis for the elbow and shoulder. Posture analyses were conducted by 28 ergonomists for four jobs presented on a traditional VHS format video recording. Estimates of posture from the observational-based methods were compared with values measured directly with an optical motion capture system. Ergonomists used categorical posture scales and a continuous visual analog scale to estimate the peak and most frequently occurring or average posture for each job. Use of a three-category scale resulted in misclassifications of peak and most frequently occurring elbow and shoulder posture with a probability averaging 30.1%. With the six-category posture scale this average probability of misclassification increased to 64.9%. Using a continuous visual analog scale peak shoulder elevation was the only posture for which the average error among ergonomists' estimates was significantly different from zero (p<0.05). Correlations between the estimated postures and measured postures were higher and statistically significant (p<0.05) for elbow flexion and shoulder elevation (r2 between 0.45 and 0.66) but were considerably lower and not significant (r2 between 0.03 and 0.18) for the peak and average horizontal shoulder abduction. Ergonomists' estimates of the temporal distribution of shoulder posture, indicating the duration severity of the posture, appeared to be biased such that the percentage of the cycle time in each posture category was estimated as more uniformly distributed than the measured values indicated.