Synopsis on

Ergonomic evaluation and axiomatic design

of manual material handling activity for
medium scale industry

By

Amit Waman Bankar

Research Scholar,
JD College of Engineering & Management, Nagpur

Guide

Dr. B.R. Mahajan

JD College of Engineering & Management, Nagpur
Title:

Ergonomic evaluation and axiomatic design of manual material handling activity for medium
scale industry.
Abstract:
Manual handling occurs in almost all working environments, though workers in
construction, agriculture, hotels and restaurants are most likely to be exposed to heavy loads.
Manual handling of loads may cause cumulative disorders due to gradual and cumulative
deterioration of the musculoskeletal system through continuous lifting / handling activities,
e.g. low back pain. It can also cause acute trauma such as cuts or fractures due to accidents.
Work-related low back pain and injuries are the most common musculoskeletal disorders
caused by manual handling. Factors that increase the risk of injury include the load being too
heavy, large, difficult to grasp or unstable, the task being too strenuous or involving awkward
postures or movements, and the working environment lacking sufficient space, having
slippery, uneven or unstable floors, having extreme temperatures or poor lighting. Individual
factors also make some workers especially vulnerable.
Employers are required to carry out risk assessments, and take action to protect
workers from the risks of manual handling.
Prevention measures include:
• Designing and organising tasks to avoid manual handling completely, or at least
restrict it.
• Using automation and lifting equipment.
• Organising manual handling tasks in a safe way, with loads split into smaller ones,
and proper rest periods provided.
• Providing information and training to workers on tasks, and the use of equipment and
correct handling techniques.
In a developing country like India where industrial tasks are labour-intensive,
involving Manual Material Handling (MMH) in many situations; ergonomic evaluation is
important to identify unduly heavy tasks. It is also necessary to evaluate traditional work
methods, and to arrive at more efficient methods of work. In jobs which require prolonged
manual labour like construction jobs, service industry jobs, production jobs, assessment of
cardiovascular capacity may be used to determine a worker's level of fitness for work. To
tackle the issues as mentioned, various approaches, such as biomechanical, physiological and
physical evaluations may be used for proper quantification and minimization of risks of
Musculoskeletal Disorders (MSDs) and other occupational injuries associated with different
types of material handling tasks in order to reduce fatigue and physical stress.
Ergonomic evaluation/measurement tools provide objective information about the
physical demands of manual handling tasks that will help the user develop an effective
prevention strategy.
This study plans to identify ergonomics awareness towards MMH activities amongst
the workers, to identify the body discomfort or body pain of the workers, to study the risk
exposure in reference to MMH practiced by the workers, to simulate the model of MMH to
reduce occupational injuries and for better productivity and to develop aesthetic design of
MMH in the area.
It is proposed to select a production unit for study. The study plans to do evaluation of
ergonomic awareness among workers. The current method employed should be investigated
and redesign the work flow or the workstations. The study plans to suggest new
improvements in the existing system and analyse different system to improve worker
efficiency.
Objective of proposed project:
1. Study the current system of manual material handling and the layout
2. Indentify the safety parameters
3. Simulation by modelling of human system
4. Improvements & suggestions of new system implementation
5. Analysis of different system to improve worker efficiency

Literature review:
Baba Md Derosa , Dian Darina Indah Daruisb , Ishak Mohamed Basirc, ” A Study on
Ergonomic Awareness among Workers Performing Manual Material Handling Activities”,
World Conference on Technology, Innovation and Entrepreneurship, Procedia - Social and
Behavioral Sciences 195 ( 2015 ) 1666 – 1673, available on www.sciencedirect.com. The
author has studied that Manual material handling (MMH) is the most common cause of
musculoskeletal disorders (MSDs) and low back pain (LBP). It involves manual lifting,
lowering, carrying, pushing and pulling loads. This study has three main objectives, first: to
identify ergonomics awareness towards MMH activities amongst the workers; second, to
identify the body discomfort or body pain of the workers using Body Parts Symptom Survey
(BPSS); and third to study the LBP and MSDs risk exposure in reference to MMH practiced
by the workers using RULA. The respondents for the study were selected from the
production area. The author concludes that the current method employed should be
investigated and immediate changes should be applied. It is recommended that the
management should put more effort to increase workers ergonomics awareness especially
during MMH activities, to re-examine the MMH activities and redesign the work flow or the
workstations.
Ratri Parida , Pradip Kumar Ray, IITK, “Biomechanical modelling of Manual
Material Handling tasks: A comprehensive review” 6th International Conference on Applied
Human Factors and Ergonomics (AHFE 2015) and the Affiliated Conferences, AHFE 2015,
Procedia Manufacturing 3 ( 2015 ) 4598 – 4605 highlights that in many situations; workload
measurement in terms of Newtonian anthropometry and physiological parameters is
important to identify unduly heavy tasks, to evaluate traditional work methods, and to arrive
at more efficient methods of work. In jobs which require prolonged manual labour like
construction jobs, assessment of cardiovascular capacity may be used to determine a worker’s
level of fitness for work. To tackle the issues as mentioned, various approaches, such as
biomechanical, physiological and physical evaluations may be used for proper quantification
and minimization of risks of Musculoskeletal Disorders (MSDs) associated with different
types of material handling tasks in order to reduce fatigue and physical stress. Among all
evaluations, biomechanical evaluation deals with the study of the physical interaction of
workers with their tools, machines, and materials so as to enhance the worker’s performance
while minimizing the risk of MSDs. In this context, studies of various biomechanical models
(static and dynamic) are required to be studied. In this paper, a comprehensive review of the
concepts of static and dynamic models as applicable for MMH task is presented. Starting
with various types of static and dynamic models, the issues on occupational risk assessment
related to various manual handling tasks are discussed progressively. The distinctiveness of
the models are highlighted. Finally, based on the critical appraisal of the existing approaches,
future research directions on various models of biomechanical evaluation are delineated.
Mohamed Ismail, Muthukumar. K, 2Department of Mechanical Engineering, Bannari
Amman Institute of Technology, 1,2Sathyamangalam, Coimbatore, Tamil Nadu, India, ” Risk
Assessment in Manual Material Handling of an Edible Oil Company”, International Journal
of Trend in Scientific Research and Development (IJTSRD) Volume: 3 | Issue: 3 | Mar-Apr
2019 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470, highlights that the process of
Shifting material manually has the potential for injury to employees. The purpose of this
study is to assess and analyze the injury risk level in manual handling activity, as well as to
improve the condition. The observed manual material handling activity is truck loading. This
activity was analyzed using different software such as NIOSH equation, Rapid Entire Body
Assessment, and compression force using 3DSSPP software as well as Nordic body map
questionnaire was used to identify body discomfort level.

David M. Brodie, MS, CPE, director of Ergonomics Services for the Ergonomics
Center of North Carolina and contributing editor to the Ergonomics News e-newsletter has
emphasised that first step in addressing MMH in a facility is to admit that there is a problem,
manual materials handling is a risk that requires a resolution. The second step is to look at
MMH from a slightly different perspective, as simply a part of the business that needs to be
designed for safety, efficiency and productivity. He has described that there are three main
methods of risk assessment that are readily available for health and safety professionals to
use: NIOSH Lifting Equation (NLE), Liberty Mutual Tables (LMT) and the University of
Michigan Energy Expenditure Prediction (EEEP) model.

Pradip Kumar Ray, IIT, Kharagpur, in book chapter of Ergonomic Design of Products
and Worksystems—21st Century Perspectives of Asia of Springer, in paper titled “Ergonomic
Performance and Evaluation of Worksystem: A Few Applications” have emphasised on
human–machine interface design or simply interface design has become a core issue. It is
essential that design engineers and technologists need to have the knowledge of ergonomics
and human factors engineering. Ergonomic design and analysis has emerged as one of the
key areas of study and research over the past several decades in order to make the
worksystems ergonomically designed, operationally safe, and productive. The book addresses
the major issues, principles, and applications related to ergonomic design of products and
worksystems.

Victor Paquet, USA, in the research paper titled “Evaluation of manual materials
handling in highway construction work” described in this paper the systematic evaluation of
MMH activities in highway construction and other types of non-routinized work. These can
be used to identify job tasks having potentially hazardous MMH exposures, and to provide
information needed for the appropriate re-design of tasks or materials to reduce physical
loading on the musculoskeletal system.
 Dr. Michael C. Godoy “ Assessment Of The Kinematics Of Handling Loads: Basis
For Design And Development Of Ergonomic Intervention “International Journal of
Contemporary Applied Researches Vol. 6, No. 6, June 2019, focused on assessment of
kinematics of handling loads and development and design of ergonomic intervention. To
achieve the goal of the study, the researcher used descriptive and case study type of research
to assess and evaluate the impact of improper or awkward working posture of the workers at
Kape at Kakaong Batangas which rooted from manual handling and lifting of coffee beans
sacks before loading to the hulling machine. The study is suitable for elimination of
ergonomic risk factors associated with manual material handling.

Amare Matebu, Design Of Manual Material Handling System Through Computer

Aided Ergonomics: A Case Study At Bdtsc Textile Firm, International Journal for Quality
Research , 2014, emphazied that designing of lifting, pushing and pulling activities based on
the physical and physiological capabilities of the operators is essential.
The purpose of this study is to analyze manual material handling (MMH) working
posture of the operators using 3D Static Strength Prediction Program (3DSSPP) software and
to identify major areas causing long last injury of operators. The research has investigated the
fit between the demands of tasks and the capabilities of operators. At the existing situations,
the actual capabilities of operators have been computed with the help of 3DSSPP software
and compared with NIOSH standards.

Dhananjay Ikhar, Ergonomic Design of Products and Worksystems - 21st Century

Perspectives of Asia pp 69-81, studied Formulation of Mathematical Model to Investigate
Magnitude of Musculoskeletal Pains Among Cotton Spinning Operators.

M. Satheeshkumar, Ergonomic Design of Products and Worksystems - 21st Century

Perspectives of Asia pp 117-130, carried research on ‘Study on Work-Related
Musculoskeletal Disorders among Coir Industry Workers in the State of Kerala, India“

R. Rajesh, Ergonomic Design of Products and Worksystems - 21st Century

Perspectives of Asia pp 25-36, carried research on “Interventions for Combined Manual
Material Handling Tasks Based on Biomechanical and Physiological Responses“
 P. Ashok, Ergonomic Design of Products and Worksystems - 21st Century
Perspectives of Asia, “Musculoskeletal Disorders and Workplace Analysis of Assembly
Section in a Submersible Pump Industry: An EMG-Based Approach”

M. M. Ayoub and Jeffrey C. Woldstad, Models in Manual Materials Handling,

Published (as Chapter 15) in Biomechanics in Ergonomics, edited by Shrawan Kumar
(Taylor & Francis, 1999), documented previous research to model and understand the adverse
effects of manual materials handling tasks on workers has come from three distinctly
different approaches. The author concludes that research to model and understand the adverse
effects of manual materials handling tasks on workers has come from three distinctly
different approaches. Each has provided insight into the hazards of individual task
components that are often encountered in many jobs. Unfortunately, each approach is
specifically directed at task components and none of these approaches has proven effective at
dealing with jobs in their entirety. At the present time typical manual material handling jobs
have a variety of different work components that make it difficult to apply any of the three
methods in a pure sense. It is the authors’ opinion that future modelling efforts should and
will concentrate on providing insight into the musculoskeletal risks of jobs and careers,
instead of tasks. Whether this is done by combining the task level approaches documented in
this chapter into a composite measure, or through an entirely different method is not entirely
clear at this time.
Scope for further development based on literature review:
The scope is to study the manual material handling for ergonomic evaluation and
aesthetic design for medium scale industry in Indian context. The further scope is to develop
a manual for guidance on management of manual material handling in the workplace for
Indian medium scale industry.
Details of proposed research work:

a) Methodology

• Selection of production industry for study

• System analysis of existing manual material handling
• Study and collection of literature
• Simulation by modelling of human system
• Implementation of new system
 • Validation

b) Expected Outcome

• The production unit of medium scale industry in India will be able to

understand the cause and effect of occupational hazard due to manual material
handling.
• The employer will be able to provide information about the physical demands
of manual handling tasks that will help the user develop an effective
prevention strategy.
• Employers will be able to carry out risk assessments, and take action to protect
workers from the risks of manual handling.
• The worker will be able understand its safe and permissible capacity in MMH.
• The study will help in reducing or preventing injuries thereby lowering costs
by eliminating Workers Compensation Board claims.
• The study will be able to help reducing the use of medical services.
• The implementation of MMH guidelines will help in reducing employee
turnover, absenteeism, retraining and low productivity levels resulting from
working with discomfort.
• The study will be able to help in increasing productivity, employee morale, as
well as product and service quality.
• The implementation of the study will help to ensuring compliance with
legislation.

c) Plan of research work

• Review the literature to identity the extent of gap in research.

• Selection of the medium scale industry for study of material handling system.
• Study of manual material handling in the selected company.
• Analysis of parameters of manual material handling causing occupational
hazards and safety.
• Modelling and Simulation by modelling for manual material handling system.
• Development of new system with changes.
• Analysis of the new system.
 • Formulation of manual for guidance on management of manual material
handling in the workplace for Indian medium scale industry.

d) Application to industry/society

The study will benefit the industry by

• Reducing or preventing injuries thereby lowering costs by eliminating
Workers Compensation Board claims.
• Reducing the use of medical services.
• Reducing employee turnover, absenteeism, retraining and low productivity
levels resulting from working with discomfort.
• Increasing productivity, employee morale, as well as product and service
quality.
• Ensuring compliance with legislation.
The society at large will be benefitted by having a good happiness index and healthy
working environment for the workers.

References:
1. A Review on Ergonomics Risk Factors and Health Effects Associated with Manual
Materials Handling, Al Amin MS, Nuradilah Z, Isa H, Nor Akramin M, Febrian I and
Taufik, Advanced Engineering Forum Vol. 10 (2013) pp 251-256 Online: 2013-12-
30, © (2013) Trans Tech Publications, Switzerland,
doi:10.4028/www.scientific.net/AEF.10.251
2. European Agency for Safety and Health at Work - http://osha.europa.eu
3. Snook, S. H., Irvine, C. H., and Bass, S. F., 1970, Maximum weights and workloads
acceptable to male industrial workers, American Industrial Hygiene Association
Journal, 31, 579-586.
4. M. M. Ayoub, Jeffrey C. Woldstad, Biomechanics in Ergonomics, edited by Shrawan
Kumar (Taylor & Francis, 1999), pp. 267–305. Copyright © 1999 Taylor & Francis.
5. Wenqian Zhang , Shuhai Fan , Jiawei Xiong, Siyu Chen, A Biobjective Model for
Manual Materials Handling with Energy Consumption Being Accounted For,
Hindawi, Mathematical Problems in Engineering, Volume 2018, Article ID 3474352,
11 pages.
6. Sue Hignett,Lynn McAtamney, Rapid Entire Body Assessment (REBA), Applied
Ergonomics 31 (2000) 201}205, 1999.
7. Mirta Widia, Siti Zawiah, Md. Dawal, Nukman Yusoff, Maximum acceptable
frequency of lift for combined manual material handling task in Malaysia.
8. Amare Matebu, Birhanu Dagnew, Design Of Manual Material Handling System
Through Computer Aided Ergonomics: A Case Study At Bdtsc Textile Firm,
International Journal for Quality Research 8(4) 557–568 ISSN 1800-6450.
9. Ratri Parida, Pradip Kumar Ray, Biomechanical modelling of Manual Material
Handling tasks: A comprehensive review, 6th International Conference on Applied
Human Factors and Ergonomics (AHFE 2015) and the Affiliated Conferences, AHFE
2015, Procedia Manufacturing 3 ( 2015 ) 4598 – 4605.
10. Muhammad Ragil Suryoputro, Khaerul Wildani, Amarria Dila Sari, Analysis of
manual material handling activity to increase work productivity (Case study:
manufacturing company), MATEC Web of Conferences 154, 01085 (2018).

Signature Signature

Dr. B.R. Mahajan Dr. S.R. Choudhary

Guide Principal
JDCOEM JDCOEM