TransformYourHabits Edited

Ergonomics
Grow &
Innovate
Eliminate Reduce
Waste Variability
© 2005
2002 Textron Inc. Ergonomics V5.0 [01/2005] 1
Module Objectives
• To provide a general awareness of ergonomics

• To provide an example of an ergonomic issue
© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 2

D M A I C Roadmap
Create Align Project/ Define Process/
Define Project Set Goal Preliminary
Definition FOV’s
Validate Y Establish Define

Identify Sources of
Measure Measurement Baseline Performance
Variation and Waste
System Capability Objectives
(Subjective)
Statistical
Graphical Analysis Analyze Process
Analysis
Analyze of Families of
of Families of Flow
Variation
Variation
Identify Validate Plan Implement

Improve Solution Solution Improvements Improvements
Implement Determine Final Monitor Project

Control Develop Control
Process Process Performance
Strategy
Controls Capability Over Time
Roadmap Measure Phase
Validate Y Establish Define
Identify Sources of
Measurement Baseline Performance
Variation and Waste
System Capability Objectives
(Subjective)
• Accuracy/Bias • Data • Project Contract • C&E Diagram/IPO

• Linearity Collection/Sampling • Financial • C&E Matrix
Plan Evaluation
• Resolution • FMEA
• Process Stability • Survey Design
• Stability • Safety
• Baseline Process
• Audit • Ergonomics
Capability
• Attribute R&R • 7 Wastes
• Pareto
• Variable R&R • 5 Why ‘s
• Value Stream Map
• 5 S’s
• Validated Y’s • Process Stability • Updated Financials • List of potential

Measurement Understood • Updated Project Y KPIV’s or waste
System • Baseline Capability goals opportunities
Determined /VSM • Process Risks
Assessed

Lean DMAIC Example
Define Measure Analyze Improve Control
 Project contract &  Value stream  Takt time analysis  Implement flow  Visual control
form team mapping  Product Process  Implement pull  Mistake Proofing
 Identify metric(s)  Identify waste Flow Analysis  Implement layout (Poka-yoke)
 Spaghetti chart  Multi-cycle analysis design  Standard work
 Develop and/or  Load chart  Material  FMEA
validate  Constraint analysis presentation (POU,  Launch follow-on
measurement etc.) BB/GB projects
systems  Safety analysis
 Standard work  Schedule post-
 Establish baseline  Ergonomic analysis
 Balanced work closeout audit
capabilities and  Activity of the
improvement operator  SMED  Transfer ownership
targets (ie. Lead  Kaizen to process owner
Time, WIP, etc.)  Activity of the
machine  Simulation  Project Closeout
 Jidoka
(Autonomation)
 TPM
 Production
smoothing
 5S
 Heijunka
 FMEA

Applications
• Production, as well as Office

Ergonomic Awareness
• Ergonomics is a Science - Fitting jobs to people

and their capabilities.
• Ergonomics is also an Attitude - A way of looking

at the workplace differently.
Design for what people are physically good

at and design against what they are not
physically good at.
Ergonomics – 2 Avenues
• Used to improve performance
• Used to prevent injury/avoid safety related

issues and cost

Even for a World Class Athlete the Wrong
Design or Equipment Will Limit Performance.
Optimal Human Performance
Lost performance
Using the wrong equipment
Human Performance
hassle - pain - injury
Time

Optimal Manufacturing Performance
Mistakes & Defects

Using the wrong equipment
Product Quality
line slow downs - minor mistakes - Scrap!

MSDs are caused by
combinations of:
Force,
Frequency,
and Posture
MSD* How can we reduce

the potential for
MSD's? - the goal is
* Musculoskeletal Disorder
to eliminate one or
more components of
the triangle.
POSTURE

We want to eliminate the "Force"
leg:
MSD*
* Musculoskeletal
Disorder
• The human body is not good
at high force.
POSTURE
• Machines, power tools and
holding devices are good at
high force.
• Decrease risk by 4 times

when you effect force.

We want to eliminate the
"Frequency" leg:
• We want to reduce the

MSD* frequency of motions per job
* Musculoskeletal cycle, not production rates.
Disorder
• We can do this by removing

POSTURE non-value added (or "wasted")
activity.
• Sometimes we refer to this

concept as "O.H.I.O." - Only
Handle It Once.
• Decrease risk by 4 times when

you affect frequency.

We want to eliminate the
"Posture" leg:
• We want to avoid weak postures

and work in straight, comfortable
MSD*
* Musculoskeletal
postures.
Disorder
• The weakest postures tend to be

POSTURE at the extremes of your range of
motion and the best tend to be in
the middle.
• These are called power or

neutral postures.
• Decrease risk by 10 times when

you affect posture

Trauma Bucket
YOUR JOB
TRAUMA
Don’t exceed
the limit of the
bucket.
MSD
YOUR BODY
HEALING
VALVE
Job Trauma Cannot Exceed Ability to Recover

Office Ergonomics
• The focus of ergonomics in an office environment is
almost exclusively on posture.
• Keyboards, monitors, phones, chairs, tables, standing jobs,
sitting jobs, etc.
• Fatigue & strain may impact performance
• Make ergonomic evaluation a part of the 5S
• Using an office ergonomics evaluation tool is
recommended
• Most evaluation tools help prioritize opportunities and
define solutions
• Office Ergonomics Evaluation Tools

Office Ergonomic Assessment http://www.ergotool.com
This site offers a FREE analysis of your workstation including recommended solutions! Using Humantech's
ergoTool™ v4.0, ergotool.com guides users through a series of questions to identify their most urgent
ergonomic needs.
3M Innovation http://www.3m.com/cws/selfhelp/index.html
This website offers an educational program that teaches the fundamentals of office ergonomics, including
physical, environmental & emotional elements
F-One Ergonomics http://www.office-ergo.com

This company provides tools for assessing and improving office ergonomics problems.

Production Ergonomics
Ergonomic reviews for:

•Activity – the activity being performed is the
source of MSD induced stress or injury. Examples
being drilling, hammering, assembling, etc…
• Environment – the environment is the source of
MSD induced stress or injury. Material presentation
to the operator causes operator to bend, stretch,
twist & turn, etc… in order to perform the
subsequent required activity
Need to design the environment/facility, as well as

the task to be your ergonomic advantage

Pull out
Ergonomic Awareness – Hit List

• Wash Rag – Twisting or turning of wrist from neutral position
• Elbows Out – Bad posture of hand/wrist cause over-compensation
from shoulders causing elbows to go out
• Shoulder too High/Low – Trying to keep shoulders level Find It!
• Hungry Head – Find a way to get rid of extra neck movements
• Bottoms Up(Butts Up)– When excessive bending at waist is required.
• Twist & Shout – Excessive twisting of the waist / repetitive twisting to
be avoided
• Horizontal Distance – Extending out over your work & optimal
comfort zone
• Sit vs. Stand – Choose appropriate method based on job task
• Bad Vibes – Vibrating machinery/tools cause numbness/soreness
• Don’t Give Me Static – Avoid holding poses for long periods of time
• Tool/Target – No stressful positions – Keep it straight!
Fix It!
• Comfort Zone – 10” X 10” sq between shoulders, in front of body
Seek all of these actions & make corrections!

Wash Rag
Find It!
• Wash Rag: Any twisting or

turning of the wrists from
their neutral position.
• These positions should be
avoided.
• To Reduce Stress- Keep it
Straight!
Work Doesn’t Need to

Be A Pain
Materials provided by Humantech, Inc.

Elbows Out
Find It!
• Elbows Out: Bad postures of the

hands and wrist cause over-
compensation from the
shoulders causing elbows to go
out.
• Check your tool/target to find
the problem!

Be A Pain

Shoulder Too High/
Too Low
Find It!
• Shoulder Too High/Too Low: Trying to

keep your shoulders level is the
goal.
• To alleviate your shoulder problems,
try to turn your entire body instead
of just one side.
• Check your tool/target to find a
possible problem!

Be A Pain

Hungry Head
Find It!
• Hungry Head: when your neck is

having to do work so you can see
your work area.
• Find a way to get rid of extra
neck movements.
the problem!

Be A Pain

Bottoms Up
Find It!
• Bottom Up: when excessive

bending at the waist is
required. If permissible try
squatting rather than bending.
• Support your back!
the problem!

Be A Pain

Twist and Shout
Find It!
• Twist and Shout: excessive

twisting of the waist while
performing a task.
• Repetitive twisting should be
avoided, try turning the entire
body to help your back.

Be A Pain

Horizontal Distance
Find It!
• Horizontal Distance: if you are

extended out over your work and
out of your optimal comfort
zone.
• Try to keep tasks in your work
reach arc!
the problem!

Be A Pain

Sit - Stand
Find It!
• Sit - Stand: a device that helps

reduce stress on your legs.
When little movement is needed
this is ideal.
• Consider your station for a
location of a sit-stand if your
walking isn’t excessive.

Be A Pain

Bad Vibes
Find It!
• Bad Vibes: Caused by

vibrating machinery or hand
tools. May cause numbness
or soreness and lead to
injury.
• Look for ways to reduce
vibrations and eliminate
them when possible!

Be A Pain

Don’t Give Me Static
(Contact)
Find It!
• Don’t Give Me Static: try to avoid

holding poses for long periods of
time, when they are outside of your
comfort zone.
• Try shorter motions that don’t require
locking into a position.
• Check your tool/target to find the
problem!

Be A Pain

Tool/Target
Fix It!
• Tool/Target: Evaluate tools used

to make sure they don’t cause
stressful positions. Change the
target when possible to reduce
bad postures.
• To Reduce Stress - Keep it
Straight!

Be A Pain

Comfort Zone
Fix It!
• Comfort Zone: area the worker

is most productive and least
likely to be injured.
• 10”x10” square between your
shoulders, in front of the
body.
• Stay in the work reach arc!

Be A Pain

Materials/Tools Point-of-Use
machine
(At Replenishment Point)
Locate
Tools and Materials at
Point-of-Use

Arrange Items at
Point-of-Use
Light Item
Storage Zone
Storage Zone
for
Heavy Objects
Light Item
Storage Zone
Arrange to promote good performance and safety over a

sustained period of time.
Arrange those items at
Point-of-Use (cont.)
DON’T DO
INCLINE BOX
BEND TOO DEEP OR
BEND AND TWIST
DON’T
Back Safety DO
REACH TOO HIGH WORK AT WAIST HEIGHT

Arrange those items at
Point-of-Use (cont.)
DO DO
Back Safety
DO
MATERIAL OFF THE

FLOOR PROVIDE MATERIAL
HANDLING DEVICES
PROVIDE ADJUSTABLE WORK

STATION HEIGHT

Wastes in a Process
• Defective products* • Processing • Over-production
• Transportation* • Inventories • Waiting*
• Excess motion*
*Can be impacted using ergonomic principles
Causes of Waste
• Layout (distance)* • Lack of training • Long setup time*
• Lack of adherence • Incapable processes • Poor work methods*
• Ineffective production • Lack of workplace • Poor maintenance
planning/scheduling organization* practices*
*Can be corrected using ergonomic principles

Lessons Learned / Pitfalls to Avoid
• Ergonomics is science with a set of tools.
• All evaluation tools are limited when done by
themselves, Ergonomics is no exception.
• Listen to your entire team…those doing the
work know the answers.
• It’s your job to provide the means for the
solution.
• Ergonomics improvement nearly always leads
to productivity improvement.
• Every project has opportunities to improve
Ergonomics and Safety.

Key Learning Points
•
•
•
•
•
•

Module Objectives Revisited
• To provide a general awareness of ergonomics

• To provide an example of an ergonomic issue
In appendix:
• To serve as an additional reference guide for
Black Belts and their teams

Appendix
Grow &
Innovate
Eliminate Reduce
Waste Variability
© 2005
2002 Textron Inc. Ergonomics V5.0 [01/2005] 40
Pull out
Ergonomic Awareness – Hit List

• Wash Rag – Twisting or turning of wrist from neutral position
• Elbows Out – Bad posture of hand/wrist cause over-compensation
from shoulders causing elbows to go out
• Shoulder too High/Low – Trying to keep shoulders level Find It!
• Hungry Head – Find a way to get rid of extra neck movements
• Bottoms Up(Butts Up)– When excessive bending at waist is required.
• Twist & Shout – Excessive twisting of the waist / repetitive twisting to
be avoided
• Horizontal Distance – Extending out over your work & optimal
comfort zone
• Sit vs. Stand – Choose appropriate method based on job task
• Bad Vibes – Vibrating machinery/tools cause numbness/soreness
• Don’t Give Me Static – Avoid holding poses for long periods of time
• Tool/Target – No stressful positions – Keep it straight!
Fix It!
• Comfort Zone – 10” X 10” sq between shoulders, in front of body
Seek all of these actions & make corrections!

Ergonomic Tools

Ergonomic Tools
•Ergonomic Action Form – Survey

•Seated Workstation Design Guidelines
•Workstation Design Guidelines
Before you use any of these tools please

consult an Ergonomics expert.

Seated
Workstation
Design Guidelines

Workstation
Design Guidelines

Workstation
Design Guidelines

Workstation
Design Guidelines

Example: Ergonomic Review of the
Chrysler Minivan Duct Work Cell
Heat Stake Duct Prep

These two are in the appendix.

Heat Stake - Overview
Tasks to Perform Operation:
• Retrieve duct from hot

plate
• Place in heat stake
• Attach parts
• Activate heat stake
• Attach anti-vibration
sticker
• Place duct on staging
rack

What Are the Major Ergonomic Challenges?
Heat Stake
• Frequent High Force Pinch Grips (wash rag)
Attaching parts and labels
• Frequent Wrist Deviations (wash rag

Retrieving ducts
Attaching parts and labels
• Frequent Full Elbow Extension (horizontal

distance)
Retrieving ducts
Retrieving and attaching parts
Placing ducts on outgoing racks
• Frequent Back Bending (bottoms/butts up)

Retrieving parts from bins
Placing ducts in heat stake
Attaching label

Heat Stake Recommendations
1. Lift&Tilt Tables for Parts Bins
2. Drop Side Bins on Load Levelers Hi Impact
3. Lower Staging Rack
4. Auto-peeler for Vibration Stickers
5. Auto Eject Mechanism 5 1
8 6
6. Belt Conveyor Between 2 3
Heat Stake & Duct Prep

7
7. Present “Hockey Sticks” Separated
Hard 11
Easy
8. Gravity Feed Bins for All Parts
10 4
9. Place All Parts Under Heat Lamp
10. Use Spray Lubrication in Hot Plate
9
11. Speed Up Door on Hot Plate
Low Impact

Heat Stake Time Savings
28%
savings
Time (seconds)

NS Duct Prep - Overview
Tasks to Perform Operation:
• Place duct on fixture

• Drill screw into duct
• Cut away flashing
• Inspect duct - perform
minor repairs
• Mark inspected areas
• Suspend duct on
ongoing rack

What Are the Major Ergonomic Challenges?
NS Duct Prep
• Frequent High Force Pinch Grips (wash rag)
Removing flashing
• Frequent Wrist Deviations (wash rag)

Using driver
Removing flashing
• Frequent Shoulder Raises (shoulders too high/low)

Placing duct on fixture
Removing flashing
Suspending duct on outgoing rack
• Frequent Back Twisting (twist and shout)
Removing flashing
Marking inspected areas
Suspending duct on outgoing rack

NS Duct Prep Recommendations
1. Height Adjustable Fixture with
Rotational Capabilities
Hi Impact
2. Part Lock on Fixture
3. Move Outgoing Cart Closer
4. Belt Conveyor Between Heat Stake
and Duct Prep 7
1
4 3
Workstation
5. Cut Out Work Surface 2
5 8
6. Footrail Hard Easy

11 9
7. Duct on Sliding Fixture

8. Ball Handle on Drill Tool 10 6
9. Swivel Hose Coupling

10. Heat Lamp for Staged Ducts
11. Tool Balancer with Dock for Air
Driver Low Impact

Reference Material:
• General Ergonomics Resource Information
• www.Humantech.com (Ergonomics & Lean)
• www.ergoweb.com (General Ergonomics)
• www.library.unisa.edu.au/internet/pathfind/ergo.htm
• Self Survey Tools
• www.humantech.com/pdfs/self_assess01-temp.pdf
• Other Resource Links
• www.humantech.com/resources/resource_links
• DoD Ergonomics Working Group
• http://chppm-www.apgea.army.mil/ergowg/product.htm
• CUErgo Cornell University Ergonomics Web Site

• http://ergo.human.cornell.edu/
• HUMOSIM University of Michigan Ergonomics Web Site

• http://www.engin.umich.edu/dept/ioe/HUMOSIM/
• http://www.osha.gov/SLTC/computerworkstations_ecat/checklist.html> -
VDt workstation checklist from OSHA
• http://www.cdc.gov/niosh/ergopage.html - NIOSH web page
• http://www.hfes.org - HFES web page
• w3.textron.com/ehs/ehs/policies/index.htm

NS Duct Prep Time Savings
20%
Savings
Time (seconds)

Configuration Management
Revision Date Author Description of Change

2.0 4/2004 Jon Wiederecht Block Change Release
5.0 12005 J. Green Added to Green Belt Training

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Ergonomics

• To provide a general awareness of ergonomics

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 2

Validate Y Establish Define

Identify Validate Plan Implement

Implement Determine Final Monitor Project

• Accuracy/Bias • Data • Project Contract • C&E Diagram/IPO

• Validated Y’s • Process Stability • Updated Financials • List of potential

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 4

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 5

• Production, as well as Office

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 6

• Ergonomics is a Science - Fitting jobs to people

• Ergonomics is also an Attitude - A way of looking

Design for what people are physically good

• Used to improve performance

• Used to prevent injury/avoid safety related

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 8

hassle - pain - injury

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 10

Mistakes & Defects

line slow downs - minor mistakes - Scrap!

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 11

MSD* How can we reduce

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 12

• Decrease risk by 4 times

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 13

• We want to reduce the

• We can do this by removing

• Sometimes we refer to this

• Decrease risk by 4 times when

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 14

• We want to avoid weak postures

• The weakest postures tend to be

• These are called power or

• Decrease risk by 10 times when

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 15

Job Trauma Cannot Exceed Ability to Recover

• Office Ergonomics Evaluation Tools

F-One Ergonomics http://www.office-ergo.com

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 17

Ergonomic reviews for:

Need to design the environment/facility, as well as

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 18

Ergonomic Awareness – Hit List

Seek all of these actions & make corrections!

• Wash Rag: Any twisting or

Work Doesn’t Need to

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 20

• Elbows Out: Bad postures of the

Work Doesn’t Need to

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 21

• Shoulder Too High/Too Low: Trying to

Work Doesn’t Need to

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 22

• Hungry Head: when your neck is

Work Doesn’t Need to

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 23

• Bottom Up: when excessive

Work Doesn’t Need to

© 2005 Textron Inc. Ergonomics V5.0 [01/2005] 24

• Twist and Shout: excessive

Work Doesn’t Need to