DFErgonomics 09302002

Design for Ergonomics
MPD575 DFX Jonathan Weaver
Development History
Originally developed by Cohort 1 students: Stephen Earl, Paul Geisler, & Larry Rhein Revised by Cohort 2 students: Winnie Jimenez, Sergio Munoz, Dave Paddock & Lester Weitman.
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Introduction to DFE DFE Process Key Principles of DFE Examples DFE Software DFE Hardware DFE Case Studies References Supplemental Readings
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Introduction to DFE
Ergonomics is .The science of matching things to people.
It pays to be precise about how things suit people. It is the difference between taking a guess and taking a measurement.
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Introduction to DFE
Ergonomics was created in 1949 from the Greek words:
ERGO = Work NOMOS = Natural laws Scientific study of humans interacting within their environment
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Introduction to DFE
Ergonomics considers the physical and mental aspects of people in relation to a product. By adding objective data about people into the design process, a product or environment can be designed so that all users are considered, not just those that resemble the designer.
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Introduction to DFE
Ergonomics is all about quality The fact that something can be used is just not sufficient it should be easy to use. Just because most people find it easy is not sufficient either a large and known percentage of people should be able to use it easily.
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Introduction to DFE
The outcome of applying Ergonomics is generally one or more of:
User success User satisfaction Speed Safety Reliability
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Introduction to DFE
Some Dos and Donts of using Ergonomics:
DONT 1. Dont think about most people or the average since that will lead to low standards. 2. Dont speculate. Try to recognize when you dont know something about the people you are designing for. 3. Dont design the product for yourself. Use objective data about people.
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Ergonomic Differences
n n
50th percentile U.S. male > 95th percentile U.S. female U.S. female stature resembles Japanese male stature
95th 95th 50th 95th 50th 5th
1900 1800 Height (mm)
50th
95th 50th 5th
1700 1600 1500 1400 1300

5th
95th 50th 5th 95th 50th 5th
U.S., German & Swedish Males
British Males
5th
Japanese Males
U.S., German & Swedish Females
British Females
Japanese Females
1200
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Introduction to DFE
DOS 1. Decide who is going to use the design age, sex, reach, strength, etc. 2. Focus on how different the worst-case users are from you. 3. Make explicit what the users goals will be as they use the product, and what will measure success.
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Introduction to DFE
DOS 4. Consider what happens to people outside the formal design range 5. Work out what users will need to know before they can complete the tasks. Build the learning into the product, or design out the need for it. 6. Take account of stress and competing demands on the users attention. Especially important when designing labels.
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Introduction to DFE
Human Factors engineering & Ergonomics are commonly used interchangeably. Human Factors is a discipline that optimizes the relationship between the technology and the humans. Anywhere you find technology and people interacting together, there will be a need for some form of human factors and ergonomics.
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Introduction to DFE
Human Factors engineering & Ergonomics considers the variation within a user population and manner in which this will affect individual and group performance for a given task. These variations include gender, age, sex, visual & mental capabilities, and strength.
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Introduction to DFE
Both Human Factors & Ergonomics are interdisciplinary sciences that deal with:
Human characteristics Capabilities and limitations for the purpose of designing products to achieve ease of use Comfort Convenience Health and safety
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Technical Fields that Interact with Ergonomics

Ind. Design
Envir. Medicine Applied Physiology
Anthropometry
Psychology
Ergonomics
Engineering
Statistics Dynamics
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Oper. Research
Introduction to DFE
Psychology - Experimental psychologists who study people at work to provide data on such things as: Human sensory capacities, Psychomotor performance, Human decision making, Human error rates, Selection tests and procedures, Learning and training. Anthropometry - An applied branch of anthropology concerned with the measurement of the physical features of people. Measures how tall we are, how far we can reach, how wide our hips are, how our joints flex, and how our bodies move. Applied Physiology - Concerns the vital processes such as cardiac function, respiration, oxygen consumption, and electromyography activity, and the responses of these vital process to work, stress, and environmental influences.
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Introduction to DFE
Environmental Medicine - Concerned with such environmental factors as noise, illumination, temperature, humidity, g-forces, radiation, and noxious gases and fumes, and their effects on health and human performance. Engineering - Provides information on electrical, mechanical, and chemical characteristics of elements and systems and principles of design, construction, and operation of structures, equipment, and systems. Statistics - For summarizing large amounts of data on human measurements and human performance, and to design sampling schemes and experiments for the conduct of human studies and performance measurements.
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Introduction to DFE
Operations Research - Quantitative methods for the analysis of the performance of manpower, machinery, equipment, and policies in government, military, or commercial spheres. Industrial Design - The design, color, arrangement, and packaging of equipment to combine functionality and aesthetically satisfying appearance.
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Introduction to DFE
Guides to Designing for Ergonomics:
Standards and Codes
Standards - A set of rules, conditions, or requirements that define terms; classify components, specify components; specify materials, performance, or operations; delineate procedures; or define measurements of the quantity or quality of materials, products, systems, services, or practices. Standards can be classified as being safety or performance based.
Examples of Standards: Federal and Military Standards Company Standards Foreign Standards
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Introduction to DFE
Standards cont.The most commonly used Standards for use by human-factors professionals: OSHA Standards: Prepared by the Federal Occupational Safety and Health Administration MIL-STD-1472D: Military Standard dealing with human-factors consideration in the design of equipment. NASA-STD-3000: Slightly broader range of topics than the MIL-STD. ANSI/HFS 100-1988 - Deals specifically with h.f. principals and practices in the design of visual display and terminals, associated furniture, and the office environment in which they are placed.
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Introduction to DFE
Standards cont.American National Standards Institute (ANSI) The most commonly used and most well recognized organization for standards. The organization is a federation of trade associations, technical societies, professional groups, consumer organizations, and industries that serves as the United States clearinghouse for voluntary standards activity at the national level. Limitations of Standards: Typically establish only minimum requirements. They are often too general.
They usually have to be tailored.

The do not explain the Systems-Engineering Process.
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Introduction to DFE
Codes
Primarily concerned with safety matters, codes contain many regulations and recommendations that directly or indirectly address human-factor issues.
Examples of codes:
National Electrical Safety Code Life Safety Code BOCA National Building Code BOCA National Mechanical Code
OSHA
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DFE Process
Introduction to DFE DFE Process Key Principles of DFE Examples DFE Software DFE Hardware DFE Case Studies References
Supplemental Readings
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DFE Process
Why Ergonomics?
Olden Days: Tools & machinery made by individuals for themselves or a select few.
20th Century: Mass Production; designed for the average user.

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DFE Process
Our vehicles are manufactured for the masses. They are, therefore, tailored specifically to no one.
Ford Motor Design Center
(Ford Motor Company quote). 27 of 209
DFE Process
WHY NOW?: Global Markets reaching consumers with wider range of physical attributes. More competition can provide customers a choice of an easier to use product. Can be severe long term consequences unacceptable level of absenteeism, dissatisfaction, complaints, accidents and under-use of product.
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DFE Process
Main areas of interface study in ergonomics
Physical aspects of man machine interface Cognitive aspects of machineuser interface Workplace design & workspace layout Size, shape, color, texture of displays & controls The finding & understanding of instructions Layout of offices, factories, furniture, and computers
Physical environment
Psychological environment Job design, selection, timing
Effects of noise, heat, light, vibration

Organizational & group structures productivity Shift, instructions, training, aids
(Six principle areas of Ergonomic study, along with several examples of each).
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DFE Process
We see that human characteristics are extremely relevant to ergonomics, and those that are most frequently measured by ergonomists are
Physical characteristics
Psychological characteristics Biological characteristics
(The 3 primary areas of study).
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Key Principles of DFE

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Interface Reference Model (simple but eloquent)
User Machine Workspace Environment

(Primary interfaces are adjacent, others are secondary). 32 of 209

Input / Output Communication Model
Operator
Machine
(Shows that the outputs of one are the inputs of the other, and visa versa). 33 of 209

System Design Model
Statement of objectives
Separation of functions
Allocation of functions
Human devel. User/machine Interface System Integration
(Ergonomics should be part of the complete process, but are most intense in red areas). 34 of 209
Hardware devel.

Key principles of DFE VDC specific
Vehicle Design Center recommends three distinct guideline segments: Controls Guidelines Display Guidelines Seat Guidelines
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The Controls Guidelines determine:
Fundamental Criteria
Visibility, Interpretability, Accessibility, Operability
Mode Criteria
Continuous, Discrete, Binary, Data entry
Design Recommendations
Natural, Convenient, Feedback, Stereotype, Blind reach
Arrangement Criteria
Emergency/Frequency, Grouped, Interference, Stereotype
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The Display Guidelines determine:
Fundamental Criteria
Visibility, Interpretability
Mode Criteria
Quantitative, Qualitative, Range, Binary status
Design Recommendations
Simplest, Least precise, Stereotype, Distance/angle
Arrangement Criteria
Emergency/Frequency, Compact, Standards, Grouped
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The Seat Guidelines determine:
Comfort Criteria
Contour, Suspension firmness, Posture, Support
Accommodation Criteria
Width, Length, Height, Depth, Angle
Convenience Criteria
Adjustments, Self-evident, Pivots, Placement
Miscellaneous Criteria
Entry/Egress, Progressive resistance, Irritants
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Key principles of DFE generic Identify the clients needs Identify the users needs Consider operator OP/machine IP Consider operator IP/machine OP Identify ergonomic issues affecting design Evaluate ergonomic design effectiveness
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Process & Principles Summary effective ergonomic design begins at the onset of the task. Identify the needs of the client & user Incorporate into statement of objectives Maintain proportionate ergonomic effort Evaluate ergonomic effectiveness
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DFE requires teamwork! Communication is a very important factor, inside and outside of the team. Success relies on the knowledge, resources, and support of people outside your team and outside your organization (final customer/user)
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Ergonomics Team Members

Ergonomics Committee Management Purchasing
Materials
Accounting
Quality Medical
DFE Team
Engineering
Marketing Health and Safety
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Reactive Versus Proactive

Ergonomic Change Cost ($)
PD
Job 1
Design
Build
Launch
Operate
Proactive
Reactive
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Reactive Versus Proactive

The diagram shows the relationship between cost and time Ergonomic solutions will be more complex and will need more money as the design nears completion. Normally, ergonomics analysis is applied to existing products and then reaction plans are developed. Proactive gives the option to see and resolve problems when the resources (people, money, etc.) are available The cost of ergonomic changes is inversely related to the availability of funds.
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Ergonomic issues into a Product Development Milestone

Concept Phase
J1
Final Program Status Lessons Learned are identified & fed forward for Continuous Process Improvement Current Production Jobs in Plant with Similar Product
Job Improvement Cycle
Ergo Issues that are Product related
Ergo Issues that are Process related
Assigned to Product Engineers for Evaluation & Resolution
Assigned to Process Engineers/Product Specialists for Evaluation & Resolution
Ergonomics Team Assigned to Complete Reviews
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The chart shows the DFE roll into Product Development milestone considering similar products or processes. Ergonomic issues can be fixed when the cost of such fixes is relatively low. DFE gives the option to apply ergonomics principles into the PD planning process.
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DFE Rules for LEAN

The change to Lean is a very good opportunity to improve ergonomics. The next twelve rules together with a team work, are important to improve process ergonomics: 1. Avoid bending forward at the waist 2. Keep the work close to your body 3. Avoid twisting your trunk 4. Avoid lifting or working above shoulder height. 5. The work height depends on the task and the operator.
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DFE Rules for LEAN (contd)

6. Keep the duration of muscle effort short 7. Minimize walking distances. 8. Lift or lower only loads less than 40 pounds. 9. Bend the tool not the worker. 10. Maintain your tools and equipment. 11. Keep work in front of worker 12. Changes Postures and motions.
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EXAMPLES
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GOOD EXAMPLES
Good ergonomic designs
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GOOD EXAMPLES
Computer Hardware Design Example: The KEYBOARD
The keyboard on the left is the standard computer keyboard.

The keyboard on the right is called a left handed keyboard, which has the numeric keypad on the left hand side.
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GOOD EXAMPLES
Split Keyboards: Product on the left has an integrated mouse feature. Product on the right has an integrated wrist rest.
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GOOD EXAMPLES
Adjustment for wrist splay in the horizontal plan: 0-30, continuously variable. Adjustment for wrist pronation - vertical tenting 0-30, continuously variable. Keyboard on left has larger space bars, while keyboard on the right still incorporates the wrist rests.
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GOOD EXAMPLES
Larger keys for individual with limited hand mobility or individuals with large hands. Keys put in alphabetic order for children.
Keyboard on the right integrates the use of a trackball.
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GOOD EXAMPLES
Optimal split-your arms go out straight in front of you. Lateral tilt so thumbs are effectively elevated. Built-in, padded palm supports.
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GOOD EXAMPLES
Reduce wrist stresses associated with Carpal Tunnel Syndrome. Move mouse clicks to your feet. Macros up to 13 keystrokes.
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GOOD EXAMPLES
Computer Hardware Design Example Continued: The MOUSE
Various sizes for right and left hand users. Thumb button for double clicking and scrolling without moving the mouse.
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GOOD EXAMPLES
Designed as a pilot stick, it encourages a natural, vertical hand position with the thumb pointing upwards. A full 1.5 inches of length adjustment and low lateral profile and a raised palm rest.
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GOOD EXAMPLES
Is the trackball for user preference or another attempt to redesign a bad problem?
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GOOD EXAMPLES
Computer Hardware Design Example: The KEYBOARD and MOUSE FIXERS
Wrist rests for the keyboard and mouse.
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GOOD EXAMPLES
Reduce wrist stresses associated with Carpal Tunnel Syndrome. If the keyboard and mouse were designed correctly in the first place, would you need to correct them?
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BAD EXAMPLES
Examples of where Ergonomics was not applied
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BAD EXAMPLES
There are two problems with these doors.
Handles are designed for pulling rather pushing.
Photograph courtesy of www.baddesigns.com
The two sets of doors work in opposite ways.

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BAD EXAMPLES
Commonly used handle types for this style of door.
The problem is you dont know which end of the handle to push.
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BAD EXAMPLES
Manufacturers package both the shampoo and conditioner in nearly identical bottles. Should be able to easy separate the two without too much difficulty.
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BAD EXAMPLES
Other than the letter difference in these labels, these two bottles of Insulin types. This could be serious if one selects the wrong type.
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BAD EXAMPLES
The problem is that the handle to move the cabinet is very close to the top drawer and is more obvious than the actual drawer handle.
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BAD EXAMPLES
Which light would choose ?
There are so many traffic lights at this intersection, one would have to wonder how many people get confused when they arrive at this intersection.
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BAD EXAMPLES
The outlet here is just below the mirror over a sink. You cannot plug it as shown as it hits the mirror, and you cannot flip it up-side-down because the prongs do not match up.
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BAD EXAMPLES
These cupholders block access to the radio and cassette player. Not only hard to use the radio, but increase the risk of spilling something into the cassette player.
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BAD EXAMPLES
Two very common mechanical pencils. The problem with the top one is that you would constantly be taking off the cap and when you use the eraser you would keep advancing the lead. The bottom one has a simple button to advance the lead.
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BAD EXAMPLES
Frustrated with VCR cases ?
It is suppose to be easy when you return the VCR tape back to the holder. Very common mistake people make when returning the tape to the case is that there is only one way to put it back into the case.
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BAD EXAMPLES
OUTCH watch out for that bar
How many times have you been in this situation ? Most turn styles like this one do not take in consideration the various heights of individuals.
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BAD EXAMPLES
IS IT 40 MPH OR 40 RPM ?
This poorly designed instrument cluster has the speedometer and the tachometer using the same scaling. The only item helping in choosing between the two is the odometer.
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BAD EXAMPLES
The older stove top controls on the left are more difficult to determine which one controls each of the four burners, while the newer style on the right matches the pattern of the burners.
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BAD EXAMPLES
People generally expect the controls to be close to the device. Here the CD buttons are close to the tape player and the tape player controls are close to the CD player.
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BAD EXAMPLES
TRUNK
FUEL
Separating these controls would make inadvertent opening of the trunk less likely. The greater the separation, the less likely it would be to accidentally open the trunk lid when opening the fuel door.
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BAD EXAMPLES
Which button should I push ? There are so many different labels and displays on these pumps, it makes it very difficult to find the start button.
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BAD EXAMPLES
The first required action to use this Glue Stick product is the removal of the cap. The cap in this case is the small dark end, typically leading consumers to try to remove the large white feed-end first. Solution: label, resize.
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BAD EXAMPLES
The two vertical controls are difficult to differentiate due to location, lighting, and texture. Being the primary switch for the vehicle dome light, the left control could be more accessible. Solution: relocate or change texture.
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BAD EXAMPLES
The left control makes excellent use of color to identify temperature-mix. The right control makes no use of color, perpetuating waste by inadvertent use of the vehicle AC compressor. Solution: add color indicators.
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BAD EXAMPLES
The solid arrow on the left indicates the direction to push to engage the windshield washer pump, but so do the hollow double arrows on the right. Solution: reposition hollows arrows.
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BAD EXAMPLES
Two different wiper controls made by the same manufacturer, the only problem is that they are not consistent in their operation.
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BAD EXAMPLES
Traditionally, rearview mirror levers give no indication of which position is normal and which is for filtered viewing. Have you ever experienced this anomaly? Solution: add symbols, different mechanism.
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BAD EXAMPLES
As can be seen from these examples, gas cap location may differ from vehicle to vehicle, sometimes even within the same manufacturer.
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BAD EXAMPLES
This gas cap door is hard to determine which end you would select to open the door. Good designs would have a lip on the door to grab onto.
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BAD EXAMPLES
Program Information Customer: Program Name/Description: Work Task #: Model Year: Volume: General Motors GM Gen IV IAFEM Prototype Delivery HGPVH 2005 1.2 - 1.5million Program Mgr.: Lead Design Sup.: Lead Design Eng.: GMSS Rep.: Applications Mgr.: Applications Sup.: Applications Eng.: Key Team Contacts Paul Geisler (acting) Brian Condron Jim Kempf John Glynn Bob Hatch Garlan Huberts Paul Geisler 313-248-9431 313-390-9483 313-390-9322 248-458-2028 734-458-0814 734-458-0537 313-248-9431 Program Description As a result of the RFP that was given to GM for a GEN IV IAFEM, Visteon is one of the 5 suppliers chosen to provide functional evaluation hardware. GM will choose one supplier for Beta (engine) level hardware. The evaluation units are due 11/1/00. Production sourcing by GM is expected 1/22/01. Resouce Plan Matrixed team of 5 full time - to support program. Program Mgr, Lead Eng., Support to Lead Eng., App's Eng., Fuel Sys. Eng. Support personnel will be needed from many organizations.
Timing Status Key Event Manufacture SLS Prototypes Complete SLS Testing Complete Core Design Tooling Completed Complete Testing of Prototype Delivery of Prototype Unit to GM Test & Calibrate Demo Vehicle Delivery of Demo Vehicle Production Sourcing by GM Required Date ######## ######## ######## ######## ######## ######## ######## ######## ######## Forcasted Date ######## ######## ######## ######## ######## ######## ######## ######## ########
Company MPI BASF Wynn's Dow
Sourcing/Tier 2 Description of items sourced Design/Engineering Plastics Gaskets NVH materials
Program Issues GM may force design of an Aluminium manifold. GM truck may not want on engine air cleaner.
Visteon Issues Critical Personnel are still needed on team. Mark Miller is needed as Support role to Lead Design Eng. Request on site seating in VEMA bldg. ETB design 1-designer, 0.5 systems Program Manager - TBD Identify Visteon's fuel injector strategy Identify Visteon strategy if forced to go with Aluminium manifold
A real life example of bad visual effects which we have all seen and most of us are guilty of. If it doesnt convey the message, is it worth putting in?
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BAD EXAMPLES
Everyone is E237 has had initial difficulties in determining which switch controls the projector screen, and just which lights the other switches control. Solution: label or reposition.
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BAD EXAMPLES
This steering wheel exhibits good and bad ergonomic design. The cruise controls are lighted, well textured, and easily defined. The horn button is unlit, not easily defined, yet is more likely needed during an emergency.
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BAD EXAMPLES
While a display may be artistically balanced, this is not a guarantee of good ergonomic design. Note the same degree of smudge on the green label as on the yellow switch. Solution: combine, reposition, change colors.
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GOOD vs. BAD EXAMPLES

Good and bad ergonomic designs
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This is a bad application of ergonomics because lifting put a strain on the back of the user
This is a good application of ergonomics because it puts less strain on the back of the user
This is a bad application of ergonomics because in order to operate this device the User need to apply pressure downward on the handle in order to raise the vehicle placing strain on the upper arm and shoulder as well as the back
This is a good application of ergonomics because you rotate the handle placing less strain on the arm and back muscles.
This is a bad application of ergonomics because in order to make juice you must apply a twisting pressure on the orange that places a strain on the wrist
This is a good application of ergonomics because you simply utilize downward pressure that doesnt place a severe strain as the other juicer
This is a bad application of ergonomics because pulling on a line through a pulley places strain on the upper arms and back
This is a good application of ergonomics because you are basically winding the sail up by means of a winch ratchet arrangement which places less strain on the upper body
This weed puller shows a good application of ergonomics because it doesn't place any undue strain on the user's body.
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This weed puller is an example of bad application of ergonomics, because it places a strain on the upper legs and lower back of the user.
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DFE Software
ErgoManagerTM (human perf. & analysis) JACKTM (human modeling & simulation) SAFEWORK (virtual human modeling) PeopleSize (anthropometry software)
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ErgoManager
What is ErgoManager?
ErgoManager is a suite of software solutions for use within an office environment: ErgoSURE - assesses postural risk.
ErgoSentry - a customizable work pacing and reinforcement tool for individual workflow management and employee training. Surveyor - collects data for reporting on user and company-wide ergonomic tendencies.
ErgoManager
Ergonomi c Manageme nt Tools

Postural Assessment Tool
Keyboarding and Mousing Activity Monitoring and Break Tool
Stretching, Exercise and Training Plug-ins
Training Tool
Symptom Survey
History of System Data
Electronic Data Collection
Training Reinforcement Tool
Management Reporting and Analysis Tool
(The 3 main modules and 6 sub-modules that make up the ErgoManager software product).
ErgoManager
Why use ErgoManager?
Improve Office Productivity Improve Worker Efficiency Improve Worker Comfort, and
ErgoSURE ErgoSentry
ErgoAnalyzer, UserNotes, Computer-based Training, Guardian & More
Surveyor How To Do Manuals
ErgoManager
Why use ErgoManager ? (cont.)
Interactive
Educational Training Tool
Customizable Quick & easy

to use
Simple Weblike interfaces (ergonomic)

(An example of typical web-like hypertext is shown).
ErgoManager
ErgoSURE
Just Point and
Click!
(ErgoSURE allows easy quantification of employees work posture).
ErgoManager
ErgoSURE
Analyze injury
potential
Consistent
Quick & easy
to use
(ErgoSURE covers complete upper-body evaluation).
ErgoManager
ErgoSURE
Systematically
assess posture
Record how an
employee is working
(Allows easy logging of performance data).
ErgoManager
ErgoSURE
Reporting and analysis from ErgoSure
RULA
Rapid Upper Limb Assessment
Scoring:
Best = Low Score Worst = High Score
(And allows individual and group statistical tracking and display).
ErgoManager
ErgoSentry
Computer-based Training Workpacing Education
Ergonomic Monitoring
Simple Visual Indicator
(ErgoSentry green bar charts are used to display higher-stress timeframes).
ErgoManager
ErgoSentry - ErgoMap
Interactive
Training Tool
Customizable
Quick & easy
to use
(An example of a click-on Ergo Map used to educate workers on ergonomic ramifications).
ErgoManager
Surveyor
Gather
important information from employees

Electronic and
networked
Fully
Customizable
Quick & easy
to use
(One example of many surveys and quizzes used to develop performance and trend metrics from).
ErgoManager
Surveyor
Measure ANY influence on productivity

(Metric reporting capabilities on an individual, group, and division basis are possible).
ErgoManager
Surveyor
Measure ANY influence on productivity

(Data compilation and transmittal can be transmitted to the home base for final evaluation).
ErgoManager
ErgoManagerTM Summary EM will improve office productivity, worker comfort, reduce risks, and achieve compliance.
Cornell University Study EM improves users productivity 10% to 40% Reduce risks of RSIs and associated costs Reduce employee turnover, provide increased sense of well-being and improved morale Compliant with existing and future state and federal regulations

DFE Software
Magnitude (human performance & analysis) JACK (human modeling & simulation) SAFEWORK (virtual human modeling) PeopleSize (anthropometry software)
TM
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JACKTM
TM
Human Modeling & Simulation
JACK is an ergonomics and human factors product that helps enterprises improve the ergonomics of their product designs and workplace tasks by providing:
Biomechanically accurate Digital Humans Placement of DH in your virtual environment Task assignment to DH Performance analysis of DH
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JACKTM
(Shows blue range for left arm spine back, red range for right arm spine back & forward, and green range for the summation or virtual interior). 116 of 209
JACKTM
Why use Digital Humans? Because many enterprises are presently facing a barrage of similar problems:
Shorten design times
Reduce development costs

Improve quality Increase productivity
Enhance safety
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JACKTM
(DH shows realistic and complex joint and body interaction with a virtual product concept). 118 of 209
JACKTM
Digital Humans in product design allows you to gain insight about the customer.
Positioning and comfort Visibility Ingress & egress Reaching and grasping Foot pedal operation Multi-person interaction Strength assessment
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JACKTM
This added customer insight allows you to realize these benefits during PD process:
Faster time to market Higher product quality
Reduced development costs

Safer products Improved productivity
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JACKTM

TM
The basic principles of JACK

Build a virtual environment
Real-time, CAD/CAE models
Create a digital human

68 joints, 33 spine & hands, 135 DOF, NASA anthropomorphic studies
Define DH size and shape

SAE, frame, height, body segment extremes
Position DH in your virtual world

Posture, behavior, environmental relationship
Assign your DH tasks

Field of view, movement, size and component swapping
Analyze DH performance
View cones, reach, test fit, force, torque
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JACKTM
(Shows 2 body size reach envelopes from 2 different seat positions, and relationship to virtual product concept). 122 of 209
JACKTM
Task Analysis Toolkit

Lower back force analysis
Strength analysis Metabolic energy expenditure Fatigue/recovery time analysis Posture analysis
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JACKTM
(Can measure and analyze lower-back stress from X-repetitions of virtual product ingress/egress cycles). 124 of 209
JACKTM
Occupant Packaging Toolkit

SAE packaging guidelines
Comfort assessment Advanced reach analysis Advanced anthropometry Specialized part libraries
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JACKTM
(Even sophisticated virtual product scenarios can be coupled with complex DH interactions). 126 of 209
JACKTM
JACKTM Summary digital human modeling software, supports and promotes:

Virtual concept evaluation Earlier targeting of population segments DH descriptor combinations Interfaces with CAE & CAD work Reduced PD cycle Faster ergonomic product to market

DFE Software
TM
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The Human Modeling Software
for Advanced Ergonomic Design

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GENICOM CONSULTANTS Inc.

Founded in 1984, Genicom Consultants Inc. is known as a center of competence in Human Modeling around the world as well as a development firm. Genicom has basically two divisions:
R&D division in which they develop products such as SAFEWORK, the most complete human modeling software available commercially Human factors consulting division in which they analyze, correct and design workstations.
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SAFEWORK is a software tool which creates virtual humans of various percentiles to study fit and accessibility in a workstation. Features include:
Mannequins with 103 anthropometric variables
Numerous forms of analysis (postural,reach, etc.) Simulate tasks by using animation Transparent interfacing to most CAD systems
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SOFTWARE BREAKDOWN
Anthropometry Postural Analysis Libraries Concepts Vision Animation Collision Detection
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(Example of a simulation where the individuals are entering into a bus). 134 of 209
(Highlighted area shows how driver is effected by the surroundings of drivers area). 135 of 209
(User is able to select a given variable and allowed to edit the various dimensions). 136 of 209
(Profile editor allows the user to choose from the various types of body builds) 137 of 209
(Side view of driver station showing the critical dimensions with the model used) 138 of 209
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Basic Scene
(Examples of human models used in the postural analysis module of the software) 140 of 209
Single Range of Motion
(Postural analysis of the human thigh area) 141 of 209
Coupled Range of Motion
(Postural analysis of the human thigh area and by adding movement to leg) 142 of 209
Postural score and limitation database
(Statistical data on the area in which the user is examining) 143 of 209
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(Demonstration of the capabilities of the library functions of the software) 145 of 209
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(Ambinocular vision view of what the user would see if sitting at the control desk) 149 of 209
(Vision attribute selection window allowing the user various display options) 150 of 209
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(Animation editor allow the user modify, delete, and add various animations 152 of 209
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(Collision detection editor allows used to see interferences with in a product) 154 of 209
(Collision detection editor allows used to see interferences with in a product) 155 of 209
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Summary of Why People Use SAFEWORK ?

User Friendly Environment Full 3D Mannequin Representation
Access to Standard Population Statistics

Posture Analysis Virtual Viewing Animation Capabilities
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DFE Software
TM
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What is PeopleSize ?
PeopleSize is .. a software package which gives data on human sizes through a virtual interface. The main advantage of of the program is that you visualize the item you are designing in relation to the human body.
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How does the process work?

Point and click three step process Select the measurements you want by pointing and clicking on any triangle of the color illustrations of the human body Visualize the item you are designing in relation to the human body
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Step One
Select the nationality, age group, and percentile value.
Example: UK male, 18-64, 1st percentile

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Step Two
Click on the icon you desire to see the larger illustration.
Choose from full body views to individual body parts to even full body infant views. Views available vary depending on population data.
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Step Three
Click on the various triangles to select the dimension you want.
Each triangle is a measurement landmark. Over 280+ dimensions to choose from.
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Output Dialog
As you select each dimension, the output dialog gives you dimensions for the population you specified in Step One.
Automatic adjustments are added for clothing and sitting slump.
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Examples: Full body, front view seated position
Each arrow represents a critical measurement
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Examples: Full body, front view
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Examples: Head: front view
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Examples: Hand positions: various
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Examples: Hand: front view
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Examples:
Full body, side view (infant)
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Client List companies using PeopleSize

- American Airlines
- British Airways - British Rail Research - Ford Motor Company - Hewlett Packard
- London Transport
- Ministry of Defense - Motor Industry Research - Nissan Motor Group - Scandinavian Airlines
- Jaguar
- Land Rover
- Transport Research Labs

- Volvo BV
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Summary of PeopleSize
Check current designs against different populations and user groups Ensure new designs fit the desired percentages of the population Look-up data to create or justify designing specifications Saves time by having all the data in one package
See the effects of clothing on your users
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DFE Hardware
IETM (Interactive Electronic Technical Manuals) Third Age Suit - Design Center Vehicle Bucks NVH Partial-Mannequin Anthropomorphic Mannequins Articulating Mannequins
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DFE Case Studies

DFE Case Studies
IETM (Interactive Elect. Tech. Manuals) Third Age Suit - Design Center Jaguar X OSHA Refrigerator Assembly
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DFE Case Studies

DFE Case Studies
IETM
Third Age Suit - Design Center Jaguar X OSHA Refrigerator Assembly
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DFE Case Studies

Why IETM? (Interactive Electronic Technical Manual)
Aircraft innovation rise
Demanding civilian, military, and FAA requirements
Aircraft maintenance plateau

Increased demands on mechanics Unmanageable technical manual volumes
Greater risk potential Need for Innovation in aircraft maintenance

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DFE Case Studies

Layered Problem
Aircraft
Larger System complexity Systems increasing Electrical interfaces Quality demands
Manuals
Increasing volume Increasing detail More complex More regulations FAA pressure
Technicians
Morale decreasing Psychology effect Apathy developing Productivity down Accuracy affected
(Aircraft maintenance is a layered problem) 179 of 209
DFE Case Studies
( as well as a circular problem). 180 of 209
DFE Case Studies

Proposed IETM Solution
Before
Traditional AME skills Technical manual repository 30,000 pages of text reference materials for F-18 Static manual references Multiple read & inspection locations
After
Added AME skills Personal portable high density media storage/playback Several high density DVDs or ROM cards for multi-media storage Dynamic user-manual interaction via hypertext & hypermedia links Single on-site reading & inspection location
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DFE Case Studies

Transitional Milestones Hardware
Existing record & playback equipment
Software
User/media interaction - hypertext, hypermedia
Ergonomics (Key)
Technician OP / Device IP Device OP / Technician IP
Operator Machine
Customer
Tech, Civilian, Military, FAA
(As of 1998, filled stars indicate solutions, empty stars indicate areas still needing resolution). 182 of 209
DFE Case Studies

Ergonomics (Key)
Technician OP / Device IP
Speech recognition, joysticks, head-mounted gyro
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DFE Case Studies

Ergonomics (Key)
Device OP / Technician IP, HDMs
(Consumer PD finally delivered a translucent monocular which could meet OP/IP needs). 184 of 209
DFE Case Studies

Milestone Achievements
Hardware
Record & personal playback
Software
User/media interaction, hypertext, hypermedia
Ergonomics
IP / OP & IP / OP
Customer
Technician, Civilian & Military aviation, FAA
(Since 1998, ergonomics has delivered a complete solution, now under Customer review). 185 of 209
DFE Case Studies

IETM Summary a quality ergonomic solution will more likely to result in:
Increased morale Maintained quality level
Increased productivity
Improved safety Improved competitive position
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DFE Case Studies

DFE Case Studies
IETM
Third Age Suit - Design Center Jaguar X OSHA Refrigerator Assembly
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DFE Case Studies

Why the Third Age Suit?
To gain insight into the physical capabilities of customers in the 3rd age demographic
To let young engineers and designers experience the effects of the aging process, by actually wearing the suit To attempt to maintain our competitive position
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DFE Case Studies

Third Age Suit - Design Center
(Show Video if Possible)
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DFE Case Studies

Third Age Suit Summary
To proactively improve our overall design process by taking advantage of promising new tools and methodologies to stay competitive.
To more accurately consider the needs of the population in the 3rd age range.
Though not easy to properly fit to ones individual body, the insight gained from the accelerated aging effect is extremely worthwhile.
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DFE Case Studies

DFE Case Studies
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DFE Case Studies

Jaguar X-Type:
Recognized ergonomics would provide competitive advantage. Provided owners with extensive seat & steering wheel adjustability. Carefully positioned all control switches.
Even designed in switch feel & sound.
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DFE Case Studies

Jaguar X-Type:
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DFE Case Studies

DFE Case Studies
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DFE Case Studies

OSHA Recommendations for Assembly:
Use slip resistant gloves to avoid increasing grip force required for lifting. Reach zones: > waist & < shoulder Trigger Grips: >2 fingers distributes force Use cushioned mats (anti-fatigue) to reduce lower back injuries. Rotate people thru different operations, to avoid stressing one muscle group.
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DFE Case Studies

OSHA Refrigerator Assembly:
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Introduction to DFE DFE Procedures Key Principles of DFE Examples DFE Software DFE Hardware DFE Case Studies References Supplemental Readings
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References
Burgess, John H (1986). Designing for Humans: The Human Factor in Engineering, Petrocelli Books, Princeton, New Jersey. Woodson, Wesley E. and Conover, Donald W. Human Engineering Guide for Equipment Designers, Second edition, University of California Press, Berkley,1964. Chapanis, Alphonse (1965). ManMachine Engineering, Wadsworth Publishing, London.
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References
Chapanis, Alphonse (1996). Human Factors in Systems Engineering, John Wiley and Sons, Inc., New York, NY, USA Kantowitz, Barry and Sorkin, Robert (1983). Human Factors, Understanding PeopleSystem; John Wiley and Sons, Inc., New York, NY, USA McCormick, Ernest J (1970). Human Factors Engineering, McGraw-Hill Co., New York, NY, USA
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References
OBrien, Thomas G. and Charlton, Samuel G. (1996). Handbook of Human Factors Testing and Evaluation; Lawrence Erlbaum Associates, Publishers, Mahwah, New Jersey, USA Andreasen, Myrup/S. Kahler/T. Lund "Design for Assembly", Second edition, IFS Publications/Springer-Verlag, Berlin, Heildelberg, New York, Tokio. 1988
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References
Woodson, Wesley E. and Conover, Donald W. Human Engineering Guide for Equipment Designers, Second edition, University of California Press, 1964 OReilly & Associates, Inc.; 2000 www.patientcenters.com/wheels/news/adaptive .html SAE 2000-01-0169; Ergonomic Consideration in Steering Wheel Control SAE 2000-01-2167; A Generic Process for Human Model Analysis
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References
SAE 1999-01-1913; Measuring of Human Anthropometry, Posture and Motion
SAE 2000-01-2156; Digital Humans and Electromagnetic Motion Capture

SAE 2000-01-2165; Application of the 3-D CAD Manikin RAMSIS to Heavy Duty Truck Design at Freightliner Corporation Human Factors and Ergonomics, Wright State University, www.web2.cs.wright.edu
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References
NexGen Ergonomics, www.nexgenergo.com Cornell University Ergonomics, www.ergo.human.cornell.edu Human Factors International, www.humanfactors.com Darnell, M. J. Bad Human Factor Designs, www.baddesigns.com Open Ergonomics, PeopleSize 2000, www.openerg.com SAFEWORK, www.safework.com
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References
Ford Adv. Engrg Design Dept., 1997, A Human Factors Design/Evaluation Manual Galer, Ian A. (1987), Applied Ergonomics Handbook
University of Pennsylvania, Center for Modeling & Simulation, http://www.upenn.edu/computing/printout/arc hive/v12/4/jack.html
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References
University of Pennsylvania, JACK Home Page, http://www.cis.upenn.edu/~hms/jack.html EAI, Engineering Animation Inc., http://www.transom.com/
Magnitude, Computer Ergonomic Software, http://www.magnitude.com/main/about.html

Human Factor Issues in Aircraft, http://members.aol.com/geo13/ietm.htm
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References
The Ergonomics Society http://www.ergonomics.org.uk Ergonomics http://www.ergonomics.org
Human Factors & Ergonomics Society http://www.hfes.org OSHA (Success stories & case abstracts) http://www.osha-slc.gov/SLTC/ergonomics/index.html
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Introduction to DFE DFE Procedures Key Principles of DFE Examples DFE Software DFE Hardware DFE Case Studies References Supplemental Readings
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1996 Human Factors & Ergonomics Societys 40th Annual Proceedings Presidential Address:
Good Ergonomics is Good Economics by Hal W. Hendrick:

Available @ www.hfes.org
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The Ergonomics Societys overview of ergonomics, from their web homepage Available @
www.ergonomics.org.uk
Additional articles identified by Cohort 2 students will be made available as further readings.
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Design for Ergonomics

MPD575 DFX Jonathan Weaver

Design for Ergonomics

Design for Ergonomics

1900 1800 Height (mm)

95th 50th 5th

1700 1600 1500 1400 1300

95th 50th 5th 95th 50th 5th

U.S., German & Swedish Males

U.S., German & Swedish Females

Technical Fields that Interact with Ergonomics

They usually have to be tailored.

20th Century: Mass Production; designed for the average user.

Ford Motor Design Center

(Ford Motor Company quote). 27 of 209

Effects of noise, heat, light, vibration

Key Principles of DFE

Key Principles of DFE

User Machine Workspace Environment

Key Principles of DFE

Key Principles of DFE

Key Principles of DFE

Key Principles of DFE

Key Principles of DFE

Key Principles of DFE

Key Principles of DFE

Key Principles of DFE

Key Principles of DFE

Ergonomics Team Members

Reactive Versus Proactive

Reactive Versus Proactive

Ergonomic issues into a Product Development Milestone

Ergo Issues that are Product related

Ergo Issues that are Process related

Assigned to Product Engineers for Evaluation & Resolution

Assigned to Process Engineers/Product Specialists for Evaluation & Resolution

Ergonomics Team Assigned to Complete Reviews

Key Principles of DFE

DFE Rules for LEAN

DFE Rules for LEAN (contd)

The keyboard on the left is the standard computer keyboard.

Wrist rests for the keyboard and mouse.

Handles are designed for pulling rather pushing.

Photograph courtesy of www.baddesigns.com

The two sets of doors work in opposite ways.

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com

Photograph courtesy of www.baddesigns.com