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Ergonomic Hazard Risk Assessment at

Manufacturing Industry
Rofithah Omar, Nurul Aini Hasbullah, Sakinah M.Azam, Nur Hidayah Mazni, Nur Hazimah Mustafa,
Nurul Shazmin Nasaruddin, Nurul Harzira M.Nor, Nurul Sahira M.Azam, Radziah Zainuddin & Revin Ramuh
IEEE Conference Publishing
Students of Business Information System
University Technology PETRONAS, Malaysia

Abstract
This study is to define and recognize the risks of ergonomic
hazard assessment at manufacturing industry. Ergonomics can be
characterized by means of science of appropriating works to the
human rather than making the human fitting with the work. It puts
individuals in the importance place, making so as to consider their
abilities and confinements beyond any doubt that the task,
equipment, information and surroundings of works outfit to all of
employees. Ergonomics issue can be detect by checklist
specification, making works observations and conversation with
the employees. Mainly, the issue tended to by the manufacturings
ergonomics are includes the designing of workplace, jobs and tools
design. Moreover, ergonomics study and consider a person in all
aspects of physical and mental. The risk elements and effects in
manufacturing industry consist of temperature extreme, force,
static posture, contact stress, vibration, repetition, and psycho
social. Lastly, enhancements in manufacturing in each risk are
being discussed.

I.

ACKNOWLEDGMENT

The research for this journal is the second project for Health
and Safety Environment course which enrolled by the
students of semester May 2015 of Universiti Teknologi
PETRONAS. First, we would like to praise to God for the
chances and support given by Him we finally managed to
finish and produce this writings which not everyone have
chances to develop it. In developing the ideas presented
here, we have received helpful inputs from the lecturers of
this course whom coordinated by Dr Asna Mohd Zain.
Lastly, a token of appreciation given to all members who
managed to perform and develop this journal.
II. INTRODUCTION
Risk assessment can be defined as a systematic process in
evaluating any potential risks that might happen in an
organization. In an organization, whether it is big or small
company, it is compulsory for an employer to implement
risk assessment analysis as a part of managing the health
and safety of the workplace. In order to implement this, a
health and safety officer must know the possibilities of a
workplaces situation that might cause harm to the
employees and decide the right and sensible measures in
preventing the harm that might occur in a workplace.
Practically, risk assessment is a deep observation at the
workplace to identify situations or any process that may
cause harm or risk especially to the workers.
Steps taken in enforcing the risk assessment is
firstly identify the hazards in the workplace environment.

Secondly, the responsible officer must know who might be


harmed, and how worker could be harmed by the situation.
After identification of hazard has been made, the officer
need to analyze and evaluate the risk associated with the
hazard. Then, appropriate measures must be taken as a way
in eliminating the hazard or controlling the hazard. A full
report based on the findings and reviews about the
assessment must be made and update the report if necessary.
Risk assessment is very important and it has to be
implemented in a workplace environment as it involves the
workers life in risk.
In this research, we have narrowed our research
scope into ergonomic hazard risk assessment at
manufacturing industry. We decided to scope our project in
ergonomic research as ergonomic has been a common
problems that usually occur in a workplace environment.
The term ergonomic is imitative beginning two Greek
words which are ergon meaning work and nomoi
meaning natural laws. Ergonomic is concerned the fit
between human and their work. Ergonomic is a study of
human capabilities and abilities in relationship to work
demands. It is science about appropriate the work to the
human rather than making the human fits into the work. An
important purpose why ergonomic is an important aspect in
organization is it would affect workers performance as well
as the organization performance. Because of ergonomic
factors, employees might be diagnosed with minor or
serious injuries. Some examples of ergonomic-related
injuries are CTDs (cumulative trauma disorders), RSIs
(repetitive stress injuries) and RMIs (repetitive motion
injuries).
In manufacturing industry, ergonomic factors must
take in conscience. For example, in nuclear factory,
employers must equip the workers with proper safety
equipment like personal protective equipment (PPE) in
order to protect individuals from hazard. Nowadays, a high
incidence and works prevalence connected with
musculoskeletal disorders ware reported in construction
labor as well as manufacturing industry. Musculoskeletal
disorder is a disorder caused by ergonomic factors. It is a
disorder involving the use of muscles, bones, tendons, blood
vessels, nerves and other soft tissues. It might happen
because of repetitive action, static posture, awkward posture
or force. All these factors, we can reduce it by taking in
account about ergonomic aspects that causes these disorders
to occur. Thus, it is very crucial for an employer to enforce
risk assessment analysis in the organization in order to
ensure a comfortable working lifestyle is maintained.

III. LITERATURE REVIEW


Ergonomics applies the facts about typical person
behaviour, skills, limitations and other aspects for create and
design the jobs, tools, technologies, tasks and surroundings
for advantageous, not harm, contented and effective worker
use [1]. Factors that includes in Ergonomics are body
posture and movement (sitting, stand-up, stimulating,
dragging, pulling), and environmental issues (noise, light,
heat, moisture) that can effected the human when works [2].
The ergonomics draws on the methodical disciplines
containing the human physiology and psychology,
biomechanics, industrial hygiene, anthropometry and
kinesiology [3]. Therefore, knowing and familiar with the
ergonomic and its risk elements in the workplace especially
at manufacturing industry is an important earliest step in
improving hazards and successful employee safety and
protection.
Researcher mentioned that the ergonomic hazard is the
injured of the strains, sprains, and other problems. These
injuries can happen by carrying out the same motion over
and over again using physical force or being in an awkward
position [4]. According to Sherry (1999), when ergonomic
hazards are recognized and arranged from an organized
workplace in analysis, corrective activities and works enable
to be scheduled and taken. Sherry also stated that the risk
reduction approaches usually include workers, work
practice, personal protective equipment and administrative
controls. Engineering controls consist of planning, design or
transforming the equipment, workplace and tools uses when
carrying out the jobs [5]. Successful plans effected in
decrease of injuries, and its also affected with the qualities
of work and productivity. Most of manufacturing worker get
used to tasks, workplace, machines and tools to help for
decrease the stress on an employees body and eliminate
several potentially that caused to musculoskeletal disorders
or MSDs at workplace [3]. In place of the process of
ergonomic to be effective, an organization must committed
to the procedure, workers in the development and be
responsible for the essential resources to guarantee the
accomplishment [6].
Researcher states that OSHA successfully used their system
related with MSDs in lots of manufacturing industries which
displayed the outcome in decreases of workers'
compensations expenses ranging from 36% to 91% in some
companies [7]. These MSDs disorders a various labels, as
well as named with repetitive stress injuries, repeated
trauma, cumulative trauma disorders, and occupational
overexertion syndrome. These painful and a lot of others
disabling injuries mostly grow slowly over weeks, months,
and years [3]. In 2002, researcher found nonfatal injuries
and disorders more than 1.4 million people involving days
away since work were verified in private manufacturing,
43.0% were strains and sprains, 26.5% were physical
overexertion, and another 14.5% involved overexertion
specifically during lifting [7]. MSDs typically connected
with workers exposure to numerous risk factors that can
cause the illness conditions, not only get from an event or

trauma such as a collapse, smash, or bang. MSDs also can


cause different conditions, such as body discomfort,
Learning the ergonomic hazards in manufacturing
industry will make workers or people who related to this
manufacturing industry to identify straightforward,
inexpensive changes and reflect on the attitude. However, it
may require to ask a qualified ergonomist if not discover a
straightforward explanation or if a problem is difficult.
Implementing an ergonomics and human factors
methodology be able to save money in the long term by
escaping the costly accidents, decreasing injuries, reducing
sickness absence, and increasing the value and productivity
of workers [8].
HSE guidance already lists their system including
practical evaluation checklists and advice given for the
efforts of an ergonomic with others productivity, cost
reduction and quality assurance activities [6]. Many
resolutions to the ergonomic difficulties in the place of work
are simple and low-cost has been lists in OSHA, even after
the manufacturing industry implementing a workplace free
of ergonomic hazards [3].
IV. RISK ASSESSMENT METHOD
a)

Risk Assessment Method of Researcher


Ergonomic hazards can be referred to the condition of
workplace that leads to the musculoskeletal body system or
scientifically named as musculoskeletal disorders (MSDs)
of the worker if there is no precaution takes place [3].
Ergonomic hazards encompassed repetitive and forceful
movements, vibration, temperature extremes, and awkward
postures that arise from improper work methods and
improperly designed workstations, tools, and equipment [6].
In manufacturing industry perspectives, the MSDs are
mostly cause by cumulative trauma. For example, carpel
tunnel syndrome, tendinitis and back injuries. [3]
Repetitive methods normally occur when the same or
similar movements are performed frequently. In
manufacturing industry, most of the activities were done
repeatedly in handling machine, arranging, cleaning process,
twisting and many more. Another good example for
repetitive activity is the assembly line which is used for
assembling automobiles and household appliances like the
production of personal computers. There are several ways to
decrease the number of repetitions. Which include divide
the task equally to two workers, use automation where
possible and feasible and when possible, have the worker
alternate hands to reduce number of repetitions performed
by one hand.
Exposure to vibration can occur while using power tools
or while driving motorized vehicles. Besides that, vibration
from power tools may stress the finger, hand and arm
tissues/muscles. Whole body vibration from driving
motorized vehicles may stress the spinal tissues/muscles. In
manufacturing industry, vibrations occur when handling big
machine to produce something [3]
Generally, in ergonomic hazard risk, OSHA provides us
with many guidelines of manufacturing best practices that
include:

Lifting heavy loads;


Carrying bulky loads or loads far away from the
body;
Frequent lifting;
Bending the trunk, as when picking items up off the
floor or when reaching into a bin;
Twisting the trunk;
Static loading, such as holding or carrying objects
for long periods of time;
Pushing or pulling.

Based on the case study, Laura used questionnaires,


observation and direct method for it risk assessment. These
exposure were assessed with combined methods before a
conclusion were made. Direct method normally used in
static or clinical settings to assess range of joint motion and
the body posture or regional flexibility. Frequently, direct
method is related to electrical instrumental methods such
goniometric system, optical scanning system, sonic system,
electromagnetic system and accelerometer-based system.
V. PREVENTION METHOD

b) Our Risk Assessment Method


Physical exposure to ergonomic risk has been assessed
using different kind of method such as computer-aided
analysis, workers self-report, observations, videotaping and
direct or instrumental techniques. Each of the risk
assessment method is related to particular ergonomic hazard
and assessed differently based on needs. In this report, a
case study were given as example of the risk assessment
methods related to ergonomic hazard and definition for the
assessment method would be included to understand the
method better.
To measure the risk, common questions were focused on
how frequent the event or incident occur and how severe is
the consequences of the event or incident. The risk was then
analyse and rated by the hazard likelihood and severity
before any prevention method could be plan. Observation or
self-report assessment is likely related to risk analysis
method. One of the risk assessment methods is self-report
assessment. The worker could make complain for any pain
or uncomfortable work experience due to ergonomic hazard
of the workplace or work environment. However, this
method had disadvantage of it being inaccurate.
A company in United Kingdom, Sofgen Limited conduct
it risk assessment by inspecting and observing their workers
work environment and the report were made in table graph
to rate the risk. It was rated with three scales of high,
medium and low. Each of the risk rates was set with
precaution method to control or reduce the risk. Sofgen used
assessment method of simpler observational techniques
which gather subjective data from workers as assessment of
physical or psychosocial desire. Observational techniques is
credited for it inexpensive and practical use. The exposure
towards the hazard is scored to determine the exposure limit
for workers.
A case study by Laura Punnet (1998) evaluates the extent
of exposure to ergonomic stressors in motor manufacturing.
In the research paper, it mention about level of
musculoskeletal disorders of the upper extremity and related
soft tissue. The study was conducted at a vehicle stamping
plant and vehicle engine foregathering plant in USA. The
participants were observed, interviewed and physical
examination of musculoskeletal system was conducted. A
set of question items were exposure to non-neutral postures,
work pace, vibration, manual forces to handle tools and
parts, and mechanical pressures from hand held tools of
usual job. After the risk were graded, it result on 36% of
worker having upper extremity disorders based on the
symptoms and 30% based on physical examination for both
manufacturing. However, the engine plant has slightly
higher rates of disorders.

a)

Prevention Method of Researcher


Ergonomics applies information about human behaviour,
abilities and limitations and other characteristics to the
design of tools, machines, tasks, jobs and environments for
productive, safe, comfortable and effective human use
[1].The goal of ergonomics is to provide maximum
productivity with minimum cost, in this context the costs
expressed as a physiological or health costs to workers[5].
In the work environment, there is rarely a large number of
tasks that are beyond the ability of most of the job effect[4].
According to Stephen (1999), ergonomics has been
defined and its main focus is on design of appropriate work
with people because it takes into account their capacity and
capability. Matching the job requirements the ability of
workers is the approach adopted in to reduce the risk of
muscle injury as a result of manual material handling.
[7]The goal for the design of the workplace is to design for
as many people possible and to have an understanding of the
principles of ergonomics posture and movement that played
a significant role in the provision of a work environment
that is safe, healthy and comfortable[8].
The attitudes and movement in the workplace will be
determined by the task and the workplace, muscles,
ligaments and joints of the body involved in adopting the
posture, running movement and use power[3]. Muscles
provide the power required to adopt postures or movements.
Poor posture and movement can contribute to local
mechanical stress on muscles, ligaments and joints, leading
to complaints of the neck, back, shoulder, wrist and other
parts of the musculoskeletal system [2].
Risk assessment is a process that involves more detailed
understand the task at hand, to collect all relevant technical
details of the task, identify if there are factors of risk /
danger [4]. This time, explore what options or solutions that
are available to reduce or eliminate risk factors / hazards and
put a plan in place to introducing control measures agreed.
Posture determines which joints and muscles used in
activity , more stress is placed on the spinal disks when
lifting, lowering or operating expense on a bent back or
twisted than when the back straight. According to Grandjean
(2000), activities require frequent or prolonged labor for
more than shoulder height became very depressed. Risk
assessment of manual handling activities and Display
Workstation screen equipment must always take into
account Ergonomic principles. The table outlines the
appropriate the factors to be taken into account as part of
risk assessment process.

b) Our Prevention Assessment Method


Ergonomic hazard are caused by inappropriate position
of the workplace and any equipment during working. They
can cause a very serious pain and injuries to the body, arms,
neck, back and some body parts in one time. So, the are
some pivotal methods to avoid from any hazard that can
cause bad impact which some of the accident or injuries
comes from negligence.
Firstly, lifting and carrying are one of the most
activities that people do. Sometime, it can give bad impact
to our body and people surround. Make sure that the
workplace is designed properly the so workers have enough
space to move safely when lifting and carrying. The workers
also have to provide smaller boxes or containers to make
lifting easier and reduce the need for lifting and carrying.
Therefore, they need to provide hand trucks and other lifting
devices, and keep them in good condition. Lastly, workers
need to be provided with training in safe lifting methods and
so on.
As we know, trade mark Safety First was used for a
long time. So, follow the Safe Work Practices. Plan your lift
before you start. Do not try to carry excessive or overloaded
things. You have to make extra trips if necessary or ask for
help and use the gloves if necessary to avoid any
unexpected injuries and accident. Make sure you have a
clear path to bring you the load or else provide a guidance to
guide you. When the load is moving, make sure the load is
close to our body. Look where you are going. Do not lift or
move when you cannot see in front. It may cause accident
and injuries to yourself and people around you also. During
lowering the load down, let your leg muscles carry it down.
Be sure our fingers and toes are clear before setting the load
down.
For bending and reaching activities, you have to set up
work processes to limit the need for reaching or bending
position. Then, provide any storage for heavy items on
lower shelves to avoid reaching. Use ladders and footstools
of the right size, and keep them in good condition. Do not
bend or reach to get a heavy or awkward heavy item. Ask
for help to lift and move it properly. Do not put load above
your shoulders. Never use a box, cart, or other equipment to
reach for objects. Do use a ladder properly and let it be
appropriate with the task.
Last but not least, please provide mechanical
equipment to do repetitive tasks if it is provided. It may help
you to do the work more easy.
HSE safety are
recommended worker to do the rotation on tasks, especially
those that require using the same motion over and over
again. Provide floor mats to protect against constant impact
with hard surfaces. Anyways, workers have to take a few
minutes to stretch and do others activities, especially if you
need to spend a lot of time carrying loads or repeating the
same activities. You have to make sure that you use a good
posture during carrying the loads. When walking or standing
for long periods, workers need to take a break and rotate
their tasks with the others to avoid injuries. Take break and
avoid to do work all day long instead of non-stop working.
It can cause injuries to our body.

VI. CONCLUSION
As we know, poor ergonomics at the workplace can lead
to a number of serious physical problems. It is the common
factor that can lead to the serious physical problems which
is musculoskeletal disorders (MSDs). The musculoskeletal
disorders (MSDs) is known a repetitive motion syndrome
that will lead to diseases and affected to nerves, tendons and
muscles. The syndrome is frequently occurring due to the
situation where we expose our body to any situations such
as forceful exertion, vibration and awkward positions.
The Second effect of musculoskeletal disorders (MSDs) is
carpal tunnel syndrome. The syndrome always happens in
a duct at the wrist. Due to this syndrome, it will reduce the
strength and ability of our hand and can lead to permanent
nerve damage and even partial paralysis. In fact, if the
condition is still remains same, it may force us to live with
the pain and limited use of our hand or arm eternally. So, to
reduce all the syndrome that may happen to us, we as a
human need to pay attention to how our arm is going on
such like at the neck, shoulder, hand wrist and fingers.
In other words, we need to overlook back about our
condition of our wellness due to each individual body of us
is different in term of size, shape and capability. We also use
different tools, sit, stands and moves in a different position
every day. So, we need to pay attention to how our body
feels when we are working. We need to identify what
causes pain, numbness, or other symptoms. If we still
ignore the symptoms for too long, we may unable to
perform our current job. In the very worst cases, we may
develop such a major painful at out our body and works.
So, we need to pay attention to how our body feels when we
are working.

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