Ergonomics Shop floor Training material

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 Ergonomics
Is the science and practice of designing jobs and
workplaces to match the capabilities and limitations of
the human body.

Ergonomics means" fitting the job to the worker”

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 What is Ergonomics?
er·go·nom·ics
‘Ergonomics’ is derived from two Greek words’
Ergon meaning work and Nomos meaning principles or laws

Ergonomics = The Science of Work.

Ergonomics is not a new science, although the term

has become more common lately. The phrase was
first coined in 1857.
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 Why is it Important?

Application of ergonomics principles to work

practice allows prevention and control
musculoskeletal injuries arising from repetitive
or forceful movement or/and maintaining
awkward or constrained postures.

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 And what is the benefit?
Higher productivity
Higher Quality
Reduced employee injury
Increased morale
Greater job satisfaction
Lower medical costs
Reduced lost time
Lower absenteeism
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 Understanding Ergonomic
Fatigue
If activities exceed our personal limits of stamina
or strength (and this varies from person to
person), then two kinds of fatigue may result.
Localized fatigue:- effects the particular part of the
body that is working, for example the arms.
Whole – body fatigue occurs when several body
parts are over exerted.
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 Risk Factors
Frequent Hand Use
Arms Extended
Bending & Twisting
Static Body Posture
Using Force
Vibration
Contact Stress
Temperature
Noise
Fatigue
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 Definitions
Musculoskeletal Disorder (MSD) - A health disorder arising
from repeated bio-mechanical stress, repetitive motion injury,
usually resulting in injury to the tendons, tendon sheaths and
related bones, muscles, and nerves of the hands, wrists, back,
legs, elbows, shoulders and neck.

Ergonomics Team - Those responsible for identification and

correction of ergonomic hazards in the workplace. This team
includes Health and Safety personnel, supervisors, engineers
and associates.

Health and Safety Steering Committee - The team responsible

for coordination of ergonomic efforts and direction

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 Work related Muscular Skeletal Disorders
WMSDs are occupational disorders of
the soft tissues:

muscles
tendons
ligaments
joints
blood vessels
nerves

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 Causes
Prolonged, repeated or extreme exposure to multiple
WMSD risk factors can cause damage to a worker’s body.
Risk Factors include:
Excessive Force Repetition
Vibration Awkward Postures
Compression Static Postures
Inadequate Recovery Cold Temperatures

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 Personal factors
Some people are at greater risk of developing MSDs due
to personal factors.

Age and Gender Pregnancy

Hobbies Obesity
Previous Injuries Medications
Physical Condition Smoking
Medical conditions Fatigue
(diabetes and arthritis)

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 Symptoms of WMSDs
Painful aching joints, muscles
Pain, tingling or numbness
Fingers or toes turning white
Shooting or stabbing pains
Swelling or inflammation
Stiffness or difficulty moving
Burning sensation
Pain during the night
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 WMSD description Spinal chord

ne r
ves d
Blo o

muscle : effort > capacity

cramps, breaking Vertebra
Nerves network
compression Intervertebral disc
carpal tunnel syndrome capsule
waterproofness
Synovia
lubrication cartilage
osteoarthritis - cartilage destruction
Synovia skin :
arthritis - inflammation ligament
dislocation
sprain (pulled ligament)

tendon
tendinitis - overuse bursa : facilitate tendon & skin movements
Standing Sitting
bursite (inflammation)

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 Preventive ways
Work in neutral postures Use proper lifting
Reduce excessive force techniques and lift
& repetition. aides.
Keep everything in easy Ask for assistance with
reach and at proper difficult tasks.
heights. Take micro-breaks
Keep warm. (stand, stretch, change
Minimize static tasks).
unsupported postures Maintain a comfortable
and pressure points.
environment.

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 Engineering Controls

Workstation Design

Equipment Controls

Design of Work Methods

Tool and Handle Design

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 Parts are
moving
through carts

Sub assemblies
are loading
through lifters

Parts are
assembly with
Pneumatic
tools

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 Capacitor bank
testing with safety
chamber with safety
sensor.

Pallet lifting
through Vacuum
lifter

Parts are assembling

with automated screw
drivers.

Operator standing on
ladder and packing
with automated
packing machine.

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 Product moving
through
conveyors.

Parts are
moving
through
trolleys

Sub assembly
lifting through
chain hoist.

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 Unit packing
through
automated
stretch wraping
machine

PCB’s are
moving
through
conveyor

Unit’s packing
through pick
and place
machine

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 Administrative Controls &PPE
Job Enlargement

Job Rotation

Rest Pauses
Proper practices
Preventive Maintenance

Housekeeping

Enforcement of right Equipment

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 Body
Mechanics

• Use the largest joints & muscles to do the job

• Use 2 hands to lift rather than one, even with light objects
and tasks.
• Slide or push & pull objects instead of lifting
• Keep reaching to a minimum
• Carry objects close to body at waist level
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 Correct & Incorrect Techniques

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 Correct & Incorrect Techniques

Wear PPE

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 Bending

Unsupported
Back

Head Bent to
Look

Unsupported
Holding

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 UNIT Pickup Do’s and Don’ts

Bend back: Bad for spine Keeping back in natural position:

Good for Spine
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 Safe Operation of manual cart and Pallet cart
Push Pull

Trolley may hit the legs when No control over the

suddenly stopped. movement of Pallet truck.
No control over the It is difficult to push.
movement of trolley.
Difficult to see the material
being transported.

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 Safe operating on ramp
Hand Pallet cart movement on ramp

Unsafe movement.

Its difficult to control back

movement.

Chances of foot injury ,

fracture.

If load is more then

involve two or
more person.

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 Material Handling Equipment Do’s and Don'ts
Define the loads (Load should be less
Do not pull a hand trolley
than Max load of the trolley.)
always PUSH.
Maintain Space between legs & Wheels.
Do not Push a pallet truck
always PULL.
Follow the Stalk height.
Fork Lifts should be operated
Tie up while loose materials are handled.
only by the drivers who have the
approval.
Maintain clearing space during turning
points.
During lifting & loading always
check loads being lifted are
Do not put hand bellow the pallet while
below standard weight limit.
loaded on pallet Truck.

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 Improving quality
Increasing safety

Ergonomics

Improving efficiency Increasing health

Employee satisfaction

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 Stretching Exercises

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 LEG STRETCHES
SIDE
LUNGES
FOR INNER
THIGH
MUSCLES
FRONT LUNGES FOR
QUADRICEPS

BACK
THIGH
CALF STRETCH MUSCLE
(HAMSTR
ING)
QUADRICEPS (FRONT STRETCH
THIGH MUSCLE)
STRETCH

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 TRUNK STRETCHES

Back stretch

Side stretch

Forward trunk stretch

Piriformis seated stretch

Trunk rotation

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 UPPER LIMB STRETCHES

Anterior shoulder
muscle stretch
Biceps (anterior
Forearm outer muscles stretch arm muscle)
stretch

Triceps
(posterior arm
muscle) stretch
Forearm inner
Pectoral stretch muscles stretch Cross arm stretch

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 NECK STRETCHES AND ROTATION

Neck side stretch Neck rotation

Back to front neck stretch

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 Bend your head downwards
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 Bend your head Upwards

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 Bend your head to Right side

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 Bend your head to Left side
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 Rotate your elbows by keeping the Fingers on shoulder
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 Rotate your elbows by keeping the Fingers on shoulder

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 Stretch your fingers as shown

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 Stretch your hand as shown to left side

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 Stretch your hand as shown to Right side

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 Stretch your hand as shown to Upwards
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 Stretch your hand as shown at the backside

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 Bend your head to left side by keeping hand as shown

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 Bend your head to right side by keeping hand as shown

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 Stretch your hand as shown

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 Fold your Right hand as shown

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 Fold your Left hand as shown

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 Pull your thumb as shown

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 Tightly close your hands as shown

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 Open & fully stretch your fingers as shown

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 Stretch your hand as shown to the left side

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 Stretch your hand as shown to the Right side

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 Bend upwards as shown by keeping hands on back

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 Bend downwards as shown by keeping hands on back

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 Stretch your fingers as shown by turning on left side

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 Stretch your fingers as shown by turning on Right side

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 Pull your Right Feet after bending as shown

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 Pull your Left Feet after bending as shown
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 Lift your Right Leg as shown front side
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 Lift your Left Leg as shown front side
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 Lift your Right Leg as shown Back side
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 Lift your Left Leg as shown Back side
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 Rotate your feet one by one as shown
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 Benefits of Stretching Exercises

A good stretching work related exercise can be

beneficial to keep employees fit for their job tasks
Recommend is in shift about 3 repetition of each of
exercises and hold for 15 Seconds.
Take micro breaks during continuous work hours.
In case of heel pain and knee pain make use of
appropriate footwear.
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 Thank You
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