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Universidad Autónoma de Nuevo

León School of Chemical Sciences

Industrial Engineer Administrator

Integrated Learning Product

Ergonomic study of a work station.

Ergonomics and Human

Factors Ing. Benito Armendáriz

Cantú.

Group 09Team 11

Díaz Garza Jesús Antonio 1909517

Lozano Hernández Mónica Lissete 1912247

Morales Rostro Valeria Judith 1909290

Ciudad Universitaria, San Nicolas de los Garza, November 30, 2022.

 Table of Contents
I. Introduction............................................................................................................. 3
a. History of the Company..........................................................................................3
b. Location..................................................................................................................4
C. Brief description of the work to be presented.........................................................4
d. Description of the product or one of its products....................................................5
II. Methodology..........................................................................................................6
Ergonomic tool used..................................................................................................... 6
Video of the risk situation or opportunity for improvement............................................6
III. Results................................................................................................................... 7
Formulas and tables used.............................................................................................7
Results of the ergonomic evaluation used....................................................................8
Result of the analysis....................................................................................................8
IV. Discussion.............................................................................................................9
Proposal for improvement.............................................................................................9
Drawing/Simulation........................................................................................................9
Lay out........................................................................................................................ 10
New ergonomic evaluation..........................................................................................11
Risks eliminated.......................................................................................................... 12
Implementation costs...................................................................................................12
DTA diseases probably eliminated..............................................................................13
Cost-benefit analysis...................................................................................................13
Conclusion.................................................................................................................. 15
 I. Introduction
a. Company History

FRISA
1971. FRISA starts operations as a small forging shop in Monterrey, Nuevo Leon,
Mexico.

1983. Exports to the United States begin, gaining recognition from the demanding oil
industry.

2003. FRISA Aerospace, a business unit dedicated to the forging of parts for the
aerospace industry, is born. AS9100 and NADCAP certifications are obtained.

2008. The plant located in Garcia, Nuevo Leon, Mexico, begins operations. Two
automated lines for rolling larger diameters are in operation.

2013. FRISA increases itsparticipation inopen die forging by creating a

specialized plant to serve this market.

2016. The steel mill, with a capacity of 350,000 tons of liquid steel, becomes operational,
turning FRISA into an integrated company.

2019. A distribution center is established in Texas, USA, dedicated to the bar segment
for service centers.

2020. FRISA Precision, a plant focused on final machining, starts operations.

FRISA currently has more than 2000 employees, 4 production plants, 50 years in the
market, 1 distribution warehouse, 1 steel mill, more than 60 countries where they are
present and more than 1000 customers worldwide. It is certified under ISO 9001:2015
and AS 9100. Their focus on quality and customer service allows them to produce
forgings that meet the highest quality standards and exceed customer expectations.
 b. Location

Valentín G. Rivero 270, Los Treviño, 66150 Santa Catarina, N.L.

*C- rern Redo n'

Frisa Plant
"Sata Carina

c. Brief description of the work you are going to present

The objective of the project is to analyze a workstation where there are risk situations
that may generate some damage to the integrity of workers, which is why it is intended
to perform a detailed ergonomic assessment to know to what extent the worker is
affected by their current environment.

In this case, it was decided to analyze the polishing of forged hollow bars at the FRISA
company in the Santa Catarina plant, where the worker is exposed to future injuries,
since his work area is not in optimal conditions. Therefore, we intend to carry out an
evaluation using ergonomic methods, in this case we will use the Suzanne Rodgers
method, to subsequently present a proposal for improvement that will help reduce the
injuries to which the worker is exposed.
 d. Description of the prodocfo or one of its products

FORMED HOLLOW BAR

The inside diameter of our hollow bars is forged as part of the part instead of being
drilled from a bar, creating exceptional options to reduce manufacturing time and cost
as well as material efficiency. Forging these parts as a single component allows us to
guarantee the strength of a high quality part. In addition, hollow bars provide a versatile
and efficient solution for mechanical and construction applications. Some of the
advantages of this product include reduced scrap and improved integrity.

PROCESS:

The inside diameter of our hollow bars is forged as part of the part instead of being
drilled from a bar.

• It starts with a cut ingot that is pressed to make a preform, followed by drilling a
hole in the center of the preform.
• Using a mandrel, the material is expanded to the desired dimensions.
• Additionally, we produce hollow bars by the reverse extrusion process, in which
the preform is forced to flow through a die in the opposite direction to the tool.

MATE R IALES

DIMENSION EN
 II. Methodology
Ergonomic tool used

The RODGERS method is most appropriate for assessing the risk of fatigue
accumulation in tasks that are performed for more than one hour and where awkward
postures or frequent strain are present. Based on the fatigue risk, a change priority can
be assigned to the specific task. It consists of dividing a job into tasks and determining
what percentage of the shift for each task is performed. Identify which tasks are
perceived as "difficult" by workers. Continue with the analysis of the primary tasks
performed (those that are done more than 10% of the time) and on any task considered
"difficult" no matter how much work they do. For each task and each body region, the
risk factors are evaluated, assigning each evaluated factor to a category. Descriptions
of exertion levels for different body parts, prolonged continuous exertion and frequency
of exertion are provided for data collection, which are used to represent the task, the
assignment of a continuous exertion time and the exertion per minute associated with
the chosen exertion.

Video of me/ora's risk or opportunity situation

Link to video: https://youtube.com/shorts/3p1B4AqZiuM?feature=share

 III. Results

Formulas and tables used

HQ*W1 Moêmd AM*(A) 1f2 1M

121 1ZB

1,2,3 2,2,3
125
1,3,2 3,1,3 1ãZ 223
2. I.3 3.2.I
2,2,2 3,2,2 13S
2.3, I 3,2,3
2,3,2 3,3,2
3, 1,2 3,3, I
Results of the ergonomic evaluation used

Result of the analysis

After implementing the Rodgers method, it was found that the areas that require more
attention are the shoulders and lower body (legs, knees, ankles, feet and toes), which is
noticeable in the video shown because the operator performs his work in a "squatting"
position, which is not a firm or comfortable position for the type of activity he is
performing, and it is also observed that he performs a moderate force on his shoulders
when holding his work tool (polisher). However, the other areas of the body should also
be prioritized because they have a moderate level of risk that over time could seriously
affect the worker's health, causing DTA diseases that occur due to the repeated use of
muscles, tendons or joints in the worker's body.
 IV. Discussion
Proposal for improvement

According to the analysis of the risk factors that the worker is exposed to when polishing
the hollow bar, it is proposed to implement a special table in the work area for
operations such as welding, cutting or polishing metals, where the worker is expected to
leave his squatting position to perform the work standing up, which is intended to
reduce the risk to the lower body, also being in a more comfortable position, the
shoulders would benefit since the piece to be polished will be closer to the body and will
have a better support.

In addition, as part of the analysis of the worker's environment, it was observed that the
worker's PPE is deficient; he only has gloves and a disposable mask (for COVID-19
sanitary measures) and industrial shoes, so the use of more complete PPE to protect
the worker from damage caused by metal polishing, such as industrial glasses, apron
and protective sleeves made of leather, is also being sought. Finally, it was evaluated
that the work tool used exceeds 90 dB, so the use of earplugs is mandatory.

DibujolSimulation

A simulation was performed in FlexSim software of how the work area is intended to be
visualized after the improvement proposal:
Lay out

The layout of our proposal is as follows: a special table will be implemented for cutting,
welding and metal cutting, measuring 250 cm x 130 cm.

2.5m
New ergonomic evaluation
MUSCLE FATIGUE ANALYSIS BY SUZANNE RODGERS
Level of effort Rating
Part of
the Moderate (2) Effort Duration Frequency Severity
body
Turned head As in
Head turned to one
partially to one
side, fully backward moderate, but with
Collar side, backwards force or weight, 1 2 2
or forward about
or slightly head
20º.
forwards straightened
onward
Exerting forces or
Slightly unattached Arms off the body Holding weight with
arms, arms without support. hands off the body or
Shoulders 2 2 2 (M)
outstretched on Working above the above the body
some support head of the head

Tilted toward Upload loads or

forward without exerting force with the
Bent to one side or
weight, lifting heavy back turned,
Back bent over, arched 1 2 2
loads close to the elevated force or
back
body. Working load while bent over
overhead
Exercising forces
Arms away from the
Rotate the arm while with rotation.
Arms / body, no load Lifting
Elbows light loads close to
exerting moderate Lifting loads with 2 2 2 (M)
force. outstretched arms
the body
Handles too much
Moderate wrist
Slight forces or Sharp grip. Large
angles, especially turning angles at
Hands / weight that are
caught close to the flexion. Use of the wrist.
Fingers / 1 2 2 (M)
gloves with force
Wrists body. Straight wrists.
moderate Sliding
Comfortable grip. surfaces.

Tilt toward
Legs / Knees Standing upright. in front. To lie on a Exerting large forces
Walking without table. Weight on by pushing or lifting
/ Ankles /
bending or turning. one side only. loads. Stooping 1 2
Feet Weight distributed Pivoting while while exerting a
/ Fingers between both feet. exercising force
force
Duration <6 seconds Between 6 and 20 >20 seconds 15 Seconds = 2
seconds

Frequency < 1 per minute 1 to 5 per minute >5 per minute 4 per minute = 2

As can be seen, after conducting a detailed analysis of the risks to which the worker
was exposed in FRISA and conducting an ergonomic study of the new workstation, the
result was a significant improvement mainly in shoulders and lower body as these
presented a high risk of injury to the worker, however, an improvement was also
observed in other areas of the body, such as neck and back, which had a moderate
severity and with the improvement was obtained a light or good severity.
Risks eliminated

Some forced postures were eliminated, mainly in the legs, where there was a greater
risk of squatting during most of the work, eliminating any risk of future injuries in this
part of the body. In addition, by raising the level of the work area (with the help of the
table), a better handling of the work tool is obtained as it is closer to the body and with
greater support, eliminating forced postures in the neck, shoulders and arms.

On the other hand, the use of a more complete PPE eliminates the risk of damage to
the eyes by using protective eyewear, since when polishing there is a risk of burrs in the
eyes. The apron and leather sleeves eliminate the risk of burns, since metal polishing
sometimes causes sparks that could cause burns to the skin. In addition, the suggested
earplugs would reduce the risk of hearing loss for the worker.

Implementation costs

The cost of the table implemented is approximately $45,000.00 pesos, in addition, as

part of a greater protection to the personnel, the cost of an apron and the flesh sleeves
are $1840 and $665 respectively in the Travers Tool MX store, and the glasses are
$245 pesos. Earplugs were quoted at Uline and cost $550 for 200 pairs, since they are
disposable.

imp/emenfation Unit cost (Mxn)

Steel welding table $25,000
Leather protective apron $1,840
Moldable foam earplugs $550
(200 pieces)
Protective lenses $245
Flesh sleeves $665
TOTAL $28,300
DTA diseases probably eliminated

Traumatic disorders (TADs) are work-related musculoskeletal disorders resulting from

overuse of some part of the body by repetition or forced movements required in many
occupations, and which constitute one of the most frequent reasons for medical
consultation in the working population.

Cumulative trauma disorders have increased considerably in recent decades, to the

point of being considered the new industrial epidemic. The most common ATDs are: low
back pain, neck pain, shoulder pain, elbow pain (epicondylitis), carpal tunnel syndrome,
De Quervain tendonitis, ganglion cysts, tendonitis, synovitis, tenosynovitis, interdigital
neuritis, ulnar entrapment in Guyon's canal, among others.

The proposed actions are expected to reduce or eliminate the generation of some of
these DTA diseases such as carpal tunnel syndrome, by partially or totally eliminating
the vibrations caused in the hands by not having an adequate tool support; back
injuries, shoulder pain, shoulder tendinitis, by eliminating the work of the arms above
the head; Raynaud's syndrome, since it is generally caused in jobs that cause vibratory
movements: joint diseases in the knees due to the position in which the work is
performed; and finally, a lumbago, by correcting the performance of large amounts of
effort with a completely inadequate posture.

Cost-benefit analysis

It is considered that the proposed improvements bring with them an appropriate cost-
benefit, since although the savings generated by the proposal cannot be precisely
analyzed, it is a fact that it drastically reduces the possibility of the organization being
involved in the payment of penalties for occupational diseases, accidents at work and
compensation according to the type of disability, in which any of the three types of
disabilities are currently likely to occur.
(temporary, partial permanent or full permanent), which would entail high costs for the
organization, in addition to the cost of recruiting and training new personnel.
LEVEL OF DISABILITY
Temporary incapacity (contemplated
in art. 491 of the LFT)
Partial permanent disability
(Contemplated in art. 492 of the LFT)
Total permanent disability
(Contemplated in art. 495 of the LFT)
Death (Contemplated in art. 500 - 502
of LFT)
INDEMNIFICATION
The indemnity will correspond to the full
daily salary that the employee will not
receive due to the medical rest. Such
indemnity shall be paid from the first day
of the accident until the last day of
recovery.
The indemnity shall be that corresponding
to the calculation of the percentage
stipulated in the disability valuation table
over the amount determined if the
disability had been total permanent
disability.
The compensation will be the corresponding
to salary for a total of 1,095 days.
The indemnity will be that corresponding
to the payment of two full months'
salary to cover funeral expenses. In
addition to this, the family will be granted
the equivalent of 5,000 days' salary.
Conclusion

As observed throughout the ergonomic analysis of the workstation, a task is currently

being performed that puts the operator's health at risk, since there are four parts of the
body that perform a moderate level of effort and two parts that perform a high level of
effort, the latter being the shoulders and the lower body.

With the proposed method it is possible to eliminate all these risks related to the
ergonomic evaluation of the task, since when performing a simulation of the analysis of
the activity with the proposed method it is obtained that three parts of the body manage
to maintain a light level of effort, while the other three are qualified as moderate effort.

Although the cost per improved station may be a little high ($28,300), it is necessary to
consider all the benefits that these improvements entail, since they can reduce the risks
of some ATD diseases generated by this task, which were previously analyzed, in
addition to avoiding other types of occupational accidents related to improper handling
of the tool or the operator's working position, which are not included in the classification
of ATD disease, but are also hazards to which those responsible for the analyzed
activity are currently exposed.

Therefore, it is recommended that the company perform a more in-depth economic

analysis of this proposed improvement, due to the various quotations that can be
obtained for the main element of our proposal (special work table), in order to decide
whether it is viable to go for these elements or it is better to look for an alternative,
either with different suppliers or even manufacture this type of table on their own to
significantly reduce costs, but in no way should continue with the current working
conditions and ignore the great current ergonomic problem that the workers involved in
the exposed activity are facing.