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An Ergonomic Evaluation of Work Place in Steel and Power Industry-A Case Study
An Ergonomic Evaluation of Work Place in Steel and Power Industry-A Case Study
An Ergonomic Evaluation of Work Place in Steel and Power Industry-A Case Study
Abstract— A large number of steel and power production activities or conditions that could cause accidents which may
industries are situated in the state of Chhattisgarh where lead to death, ill health or diseases.
availability of raw material is plentiful and cheap. This paper In order to avoid either catastrophic or non catastrophic
reports the results of an ergonomic study in steel and power accidents either controllable or uncontrollable factors within
production plant situated in Chhattisgarh. The main objective the work place can be achieved by adopting the ergonomic
of this paper is to evaluate the working conditions of the plant perspective design of the workplace. Ensuring conducive
from an ergonomics perspective and recommended feasible physical conditions plays vital role in enhancing the
solutions to management for implementation. The investigation productivity. In our study, we have observed the shop floor of
was done by a questionnaire survey as well as by observations steel as well as power production plant where the workers are
in the workplace as a single case study. The results indicated exposed to noise, vibration, climate and illumination are not at
that the plant conditions were stressful, with poor safety, weak permissible limit. However, strict enactment of laws by
interfacing with work equipment as well as physical workplace government bodies failed to ensure the various issues related
layout design. The results also revealed that noise, vibration, to the safety of employees. This paper comprises of five
climate, illumination, and working posture were not an sections at first introduction second a structured, relevant
acceptable limit as ergonomic perspective. However, major literature review, third methodology used to accomplish the
positive research finding was conducive condition in the work objectives of the fourth study, results and discussion followed
environment resulting low absence rate among employees due by a conclusion.
to illness.
II. LITERATURE REVIEW
Keywords— Steel, power, production, ergonomics, work design, Methodology of Literature Review: Both Nationally and
workplace, evaluation.
Internationally available Open access referred scholarly
I.
journals and publications related to the topic of this review has
INTRODUCTION
According to International Ergonomics Association (IEA): been considered. Key words used in the search were steel,
“Ergonomics (or human factors) is the scientific discipline power, production, ergonomics, work design, workplace, and
concerned with the understanding of interactions among evaluation. For this search, the most relevant papers in terms
humans and other elements of a system, and the profession of technical content were considered. Total thirty seven
that applies theory, principles, data and methods to design in research papers were reviewed.
order to optimize human well-being and overall system
performance.”[1] Several forces necessary for work, excessive forces are
injurious. Mechanical properties of skin have its importance
Ergonomics is the application of scientific principles, methods while doing manual work [4], Comprehensive workplace
drawn from a various disciplines for the development of
health promotion programs reduce disability days among blue
engineering systems, the role of human is significant [2].
collar employees and provide a good return on investment [5].
Automation and advancement of technology lead to
replacement of large amount of human resources in industrial Procedures and findings of a study of workplace learning
systems, however, some tasks are being done manually by arrangements in a mining and secondary processing plant [6].
human resources [3]. During the manufacturing process of Proposed that the level of control approach offers a potentially
0
steel temperature of 1600 C pig iron melts and collects at the rich interpretive framework for the effects of stressors on
bottom of the furnace. The waste gas from the blast furnace, performance [7].
which is rich in carbon monoxide, is burned in blast furnace Examined the reliability and validity of two
stoves to heat the air blown into the furnace and may be used musculoskeletal symptom surveys [8], a critical review of the
as a fuel elsewhere in the steel plant. applicability of theoretical models of health behavior to
workplace self-protective behavior [9]. The evidence for (or
The majority of operations in the steel and power industry against) the utility of ergonomic interventions it is mapping
exposes workers to a wide range of hazards or work place the issues in intervention to prevent musculoskeletal disorders
25 min 115
III. METHODOLOGY
The case study is the most flexible of all research designs,
allowing the researcher to retain the holistic characteristics of
real-life events while investigating empirical events. In Table : 2 Illumination Standard
general, a case study is an empirical inquiry which Category Range of Illumination Type of activity
(LX)
investigates a contemporary phenomenon within its real-life A. 20-30-50 Public area with dark
context: when the boundaries between phenomenon and surrounding.
context are not clearly evident and in which multiple sources B. 50-75-100 Simple orientation for
of evidence are used. [40]. According to the case study does short term visit
C. 100-150-200 Working space where
not claim any specific data collection methods, but “focuses visual task of high
on holistic description and explanation” [41]. Within this contrast or small size.
focus, the case study can be further described as D. 200-300-500 Performance of visual
task of high contrast or
particularistic, heuristic, or descriptive. Type of case study large size reading
discussed in this paper is exploratory and descriptive. A printing material, ordinar
questionnaire has been adopted from previous studies [42]. y inspection.
E. 500-750-1000 Performance of visual
We have used single case using survey instrument. The data task of medium high
has been anonymously collected from the workers during their contrast or small size.
duty hours at various shops and places on the premises of steel F. 1000-1500-2000 Performance of visual
task of low contrast or
and power plant located in Chhatisgarh. The data has been very small size.
collected from various departments of the plant comprising: G. 2000-3000-5000 Performance of visual
Central Workshop, Water Treatment Plant, and Civil task of high contrast or
very small size over a
Department. The aim of data collection for the analysis of the prolong period.
workplace, ergonomic conditions prevailing. H. 5000-7000-10000 Performance of special
A questionnaire comprises of fifteen relevant questions. The visual task of extremely
low contrast or
questionnaire covers all aspects of ergonomics suitability and small size
other physical condition concerning issues of work place. The
sample size was thirty four.
About the company: Coal-based sponge iron plant a leader in It has been observed in some parts of plant i.e central work
manufacturing coal-based sponge iron in India. Leads the shop and civil department not following the illumination
Indian market in this sector and has the world’s largest coal- standards especially category A, D is missing in central work
based sponge iron plant, with a capacity of producing 1.32 shop. Category F,G missing in Civil department. We offered
MTPA DRI. It is the only sponge iron manufacturer in the our recommendations as per existing illumination standard of
country with captive raw material resources and power steel industry i.e table 2.
generation. It has modern rail and a universal beam mill. The
mill has a wide range of products ranging from long rails up to
121 meters to medium and large size parallel flange beams
and columns. The product mix includes: Track Rails, Crane
Rails, Parallel Flange Beams and Columns and Channels.
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Paper ID: 06
the workers. A few problem areas identified are related with
Practices observed at workplace for ergonomic the noise from the equipments, workplace environment like
evaluation: flooring, covering, fire extinguishers etc, vibrations, equipment
lighting, and indoor climatic conditions.
Table:3 Few respondents faced problems with the ergonomics
Problems with Physical Conditions concerned with Yes (%) No conditions caused by lifting, repetitive work and working
(%) posture. Some of the problems we observed at the organization
(i) Workplace environment 43 57 with respect to Physical conditions Ergonomic aspects Safety
(ii) Noise 86 14 (conditions causing determined risk of accidents).
The factors mentioned above do not hamper the productivity of
(iii) Vibration 71 29
the company but it is evident manner but they definitely
(iv) Lighting 43 57 hamper the efficiency of the workers in a long run.
(v)Climate 64 36
The workers could be able to give their optimum performance
at workplace if the working conditions are favorable and when
(vi)Ergonomics 26 74 these conditions do not pose as a hindrance. Thus, putting an
(vii) Conditions at workplace which can cause 79 21 effort towards improving the existing conditions at workplace
determined risk of accidents will ensure high work output from the workers. This helps in a
(viii) Conditions in the work environment that 94 6 smooth functioning of the company as well as employees’
contribute to absence due to illness
safety are an integral and the most important issue of the
company.
From table: 3 interpretations of problems observed through our
survey one of the positive finding of the workplace. Six percent
of respondents say that there are such conditions in the work Safety: Safety (Conditions causing
environment that contribute to absence due to illness. determined risk of accidents)
Table : 4
(i) Factors that cause work place environment problems
In Percentage
Physical Conditions:
Work place layout 57
Workplace Environment
Space 43 Noise
Ergonomic Aspects
(ii) Factors that cause problems with physical conditions related to noise Vibrations
Lighting
Equipment 92 Indoor Climate
Ventilation 08
Figure: 1 A framework for ergonomic workplace evaluation
(iii) Factors that cause problems with physical conditions concerned
with lighting
Letting in day light 16 Safety (conditions causing determined risk of accidents):
Proper safety measures must be taken into consideration by
Equipment Lighting 67
placing fire extinguishers at equal intervals, first aid kits etc.
Room Lighting 17 Physical conditions:
(iv) Factors that cause problems with Indoor Climate Workplace Environment: The problems with workplace
environment related to workplace layout solved by redesigning
Heat 67 the workplace using structured and scientific approach.
Smell 22 Noise: Since noise from equipments in operation is
unavoidable, ear plugs must be provided to the workers and its
Cleaning 11
usage is mandatory for every worker prone to high noise levels.
(v) Factors that cause problems related to Ergonomics Vibrations: Vibrations should be minimized at the source or by
Working Posture 33
reducing the force transmitted, by converting vibration energy
into thermal energy by using mechanical or hydraulic dampers
Repetitive Work 22 and by altering body position or body support.
Lifting 45 Lighting: Problems with equipment lighting can be minimized
by letting in day light. Contrast, quality and amount of
illumination should be improved by incorporating the concept
The survey was majorly concerned with the analysis of the of sustainable green design, HVAC of plant.
physical conditions present at the workplace considered for this Indoor Climate: Majority of the respondents uncomfortable
study. Overall the physical conditions provided to the workers with the indoor climate caused by heat. Providing good
at the organization considered in this study were favorable for ventilation, installation of industrial coolers, however for the
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