Chapter 4: Workplace Design: Faculty of Engineering Industrial Engineering Department IE 342 Human Factors Engineering

Faculty of Engineering IE 342
Industrial Engineering Department Human Factors Engineering
Chapter 4: Workplace Design

 Key Topics
 Introducton
 Sizing the workplace to ft the body
 On the feet or sitng down?
 Manipulatng, reaching, grasping
 Handling loads
 Workplace Evaluaton Tools- Using Rapid upper limb
assessment (RULA)
 Controls & Displays
 Introducton
 The driver’s workspace in a vehicle a good examples of good and bad designs
scenario.
 The good examples generally relate to a supportve and comfortable seat.
 Suitable design & arrangements of displays & hand controls.
 The driver’s workspace is a bad design because it forces the driver to:
• Maintain the same body positon over long period.

• Keep the feet close to the pedals & hands on the steering wheel.
• Eyes focused on the road ahead.
 Sizing the workplace to ft the body

The factors that play a major role in determining the working height are:
1
1- Body dimensions are important for the design of
large piece of equipment and workspaces, especially
anthropometrics data that describe overall size (e.g.,
stature) (see fgure 20.1).
2- The worker’s body size also plays a major role in

determining the working height.
 Example of workbench, if it cannot be adjusted for
diferent height then then the platorm can provide
help by raising the short person. (see fgure 20.2)
 Sizing the workplace to ft the body (Cont.)
3- The other major determinant of the

proper work height is the task. (see
fgure 20.3))
 Another example of simultaneously

considering human engineering aspects is the
design of consoles, where instruments and
hand controls are arranged around the upper
body of the operator (see fgure 20.4)
Such design allows: quick reaches to controls and

good viewing of instruments
 Designing For The Standing Operator

 Standing is usually used when the work area requires mobility, or the operator has to
cover a large work area
 Working height design is critcally in the workplace design. Working height in

workplace design depends on the type of actvity (simple or heavy), size of the object
handled such as hand tools.
 In the working height design, the main reference point is the elbow height of the
worker, because the strongest hand forces and the most useful mobility are between
elbow and hip heights.
If the working height is too high the shoulders joint must be frequent as well as the
neck bent so, that may causing a shoulder and neck injuries.
 If the working height is too low the back must contnuously bent forward so, that
may causing a low back injury.
 Designing For The Standing Operator (Cont.)
 There are three general guidelines for standing workplace design:
1- Delicate work or fne manipulaton (i.e., drawing)

• Design for work surfaces 50–100 mm above the elbow height.
2- Manual work (i.e., light assembly)

• Design for work surfaces 100–150 mm below the elbow height.
3- Exerton of extensive manual efort or constant use of weight (i.e.,

heavy assembly or woodworking)
• Design for work surfaces 150–400 mm below the elbow height.
 Designing For The Standing Operator (Cont.)
50–100 mm above
the elbow height
100–150 mm
below the elbow
height 150–400 mm below
the elbow height
Diferent tasks require diferent work surface Heights—NIOSH

 On the feet or sitng down?

 There are tasks that require walking about. (person needs to bring the material to
workbench).
 In this case, the workbench is probably best
a bit below elbow height. (see fgure 20.5)
 There also may be periods in which the
worker does best while sitng (tall seat is
appropriate). (see fgure 20.5)
 In sitng task the legroom must not be missing

(if it is missing makes sitng awkward). (see
fgure 20.6))
 On the feet or sitng down? (Cont.)
 On the shop foor, elaborate seats are usually not suitable.
 Various kinds of stools and lean-ons (see fgure

20.7), can take some load of at least temporarily.
 Requiring a person to maintain the same

positon over long hours is not a good human
factors solutons in standing on one feet (see
fgure 20.r) or sit with awkward postures (see
previous slide fgure 20.6)).
 On the feet or sitng down? (Cont.)
 Modern technology has generated many tasks and jobs that requiring sitng.
Examples: airplanes, land vehicles and ofces

 One example of seat that includes ergonomics features is automobile seat which is
quite comfortable and supportve.
 The designers provide the ofce chairs with ergonomics features as sketched in the
below fgure 20.10:
Ergonomics features are:

- Contoured and padded seat pan.
- Smooth “waterfall” contour at the front which avoid
pressure behind the knee.
- High backrest that conforms to the shape of the back.
- Both seat pan and backrest are adjustable.
 Manipulatng, reaching, grasping

 In repair and assembly tasks that require fnely controlled handling of delicate object or
instruments.
 In that type of sitng tasks the manipulatng

are done mostly easily at about elbow
height in front of the chest and close to the
body (see fgure 20.12).
 Repeated reaches, such as in assembly

work, are easy if the supply bins are
carefully set along periphery of
hand/arm movements. (see fgure
20.14 & 20.15).
 Handling Loads
 Moving a sizable object by hand from one locaton to another is called “Manual
Material Handling” (MMH).
 Load handling may remain on the same level and includes.
1- Pushing/ pulling 2- Turning 3- Carrying
4- Lifing/lowering
 Moving object around by hand ofen leads to injuries of the handler.

 Handling Loads (Cont.)
 It should pull or pushing the object using a

dolly, cart, trolley or conveyor instead of
carrying or lifing tasss (see fgure 20.16)).
 It is recommended to use the ergonomics mechanical aids while moving

objects inside a workplace to reduce human body injuries (see fgure in
next slide).
Summary of handling Optons (Ergonomics mechanical aids)

 Handling Loads (Cont.)
 Lifing or lowering loads is one the most injurious actvites.
 It is easier to lif an object from a worsbench or other high locaton than from
ground level (see below fgure 20.19).
 General Principles of Workplace and Design (Cont.)
1- General ergonomics workstaton design principles.

- Make the workstaton adjustable (to avoid awkward postures)
- Locate all materials and tools on the work-surface near to the worker.
- Provide adjustable and proper design chair.
- Use gravity to move the materials and parts on the worksurface.
- Convert standing task to sitng task
2- Design principles for repettve hand & wrist tasks (tools or object).
- Maintain straight wrist, avoid bending wrist (bend the tool, not the wrist)
- Avoid statc muscle loading on the hands (reduce weight & size of the object).
- Avoid stress on sof tssues (shorter handle tool; poor design).
Straight handle
- Reduce the number of repetton in using the object or tools per shif.
Bent handle
 General Principles of Workplace and Design (Cont.)
3- Design principles for lowering & lifing tasks (carrying tasks).

- Reduce number manual lifing of materials.
- Reduce the weight of the object (reduce capacity or load inside the object).
- Reduce the size of the object.
- Convert load lifing to pulling or pushing tasks (use non-powered conveyors, hand trucks & four-
wheel carts).
4- Design principles for pushing & pulling tasks.

- Eliminate pull or pushing tasks by using the mechanical aids (lif cart, automatc conveyors,
forklif).
- Reduce the force required for pull or push (reduce weight, use gravity and clean surface ).
- Reduce the distance of push and pull tasks (the distance between locatons).
- Replacing a pull task to push task since, push task needs a lower efort and force than pull task .
Various wrong (poor) working postures, define the potential affected body part,
and possible interventions for each posture.
1- Wrong working posture condition: 1- Wrong working posture condition:
2- Potential affected body part: 2- Potential affected body part:
3- Possible interventions : 3- Possible interventions :

- -
- -
Various wrong (poor) working postures, define the potential affected body part,
and possible interventions for each posture.
1- Ergonomics hazard(s) associated with this task:
2- Potential affected body part:
3- Possible interventions :
-
-
 Rapid Upper Limb Assessment Tool

 RULA, or rapid upper limb assessment, is a survey method
for determining musculoskeletal loads risks associated with
upper body postures in task performance.
 It is a screening tool that assesses biomechanical and
awkward postural loading on the whole body and focuses on
the necs, truns, and upper limbs.
 It assesses postural loading at a specifc moment in the work
cycle.

 Four main applicaton of RULA are:
• Measure musculoskeletal risk.

• Compare the musculoskeletal loading and postures of current
and modifed workstaton design.
• Evaluate outcomes such as productvity or suitability of
equipment
• Educate operators about musculoskeletal risk created by
diferent working postures.

 The risks is calculated into score of 1 “low” to 7 “high”
 The method divided into 15 steps.
 It covers the arm part analysis (upper arm, lower arm and wrist), muscle state,
hand tools weight, necs, upper truns, leg and also muscle state and force for legs
part.
Before
Ergo-plus.com
 Rapid Upper Limb Assessment Tool (Cont.)
Ergo-plus.com
 Rapid Upper Limb Assessment Tool (Cont.)
 The total score is 5
Afer
 Case Study
Control and Displays

 Controls &Displays
 The relaton between control and surroundings are more complicated in most
technical system.
 For example, in automobile there several controls to determine its movement, and
the results of our control actons show on several gauges and via windows.
 The automobile system are more complicated than bicycle. The results of faulty
control actons or misreading of the display are usually much more severe in car.
 Many human-machine systems are even more convoluted.

 Controls & Displays (Cont.) -Human-machine systems

 “Human-machine systems” means that the human and the machine have a
reciprocal relatonship with each other.
• Operator perceives this informaton and must • Display provides informaton & feedback about
be able to understand and assess correctly the progress of producton
(percepton).
• Interpretaton decision
depends on the knowledge,
skill and mental capabilites of
the operator
• Producton the machine carries

out the producton process as
programmed.
• Controls use to communicate the operator decision to

the machine; operator inputs “feed forward” afectng
the system
Example# 1 : a control panel of mixing drum

Example# 1 : a control room in a power plant

Example# 1 : a cockpit of a train

Example# 1 : an aircraf cockpit

Example# 1 : a cockpit of an atomic ship

 Controls & Displays (Cont.)
 Coding of controls helps to identfy them, how to operate them, the efect of their
actvaton and their status.
 The major coding practces use:
1- Shape: appeals to both vision and touch
2- Locaton: to indicate importance and

sequence of operaton.
3- Size: to make operaton fast and easy.
4- Mode of operaton: such as pushing,

turning, or sliding.
5- Color: efectve when lit.
6- Labeling: efectve when read.
 Several of these coding techniques mentoned are used together (e.g., a car
controls).
 Some of controls examples are:
1- Bar snob: is easy to grasp and operate (if of
proper dimensions).
2- Toggle switch: also is easy to grasp and

operate but it has only two or three possible
setngs.
3- Round snob (Rotary): is easy to handle and

it can have setngs than a bar knob and toggle.
Also, the setngs can be contnuous or in steps.
4- Push-butons: are fast-operated controls, but

they usually have only two setngs, which may
be difcult to distnguish.
More types
Wheel Push buton
Horizontal lever Toggle switch
Vertcal lever Rotary selector

(to/from body) (Knob bar)
Vertcal lever Rotary Knob

(across body)
Joystck (lever) Small crank
Pedal Large crank

Comparing controls
Suitability for tasks involving:
Range Force Accuracy Speed Control type
Unsuitable Unsuitable Unsuitable Good Push buton
Unsuitable Unsuitable Unsuitable Good Toggle switch
Unsuitable Unsuitable Good Good Rotary selector
Fair Unsuitable Fair Unsuitable Knob
Good Unsuitable Poor Good Small crank
Good Good Unsuitable Poor Large crank
Fair Fair/Poor Good Poor Wheel
Poor Poor Poor Good Horizontal lever
Short: Poor Vertcal lever

Poor Long: Good Fair Good (to/from body)
Vertcal lever
Unsuitable Fair Fair Fair (across body)
Unsuitable Poor Good Good Joystck (lever)
Unsuitable Good Poor Good Pedal

 There are diferent types of pointers

displays:
1- Moving pointer over fxed

scale
2- Fixed pointer over moving

scale
3- Digital counter
Example of poor display is Altmeters: is used

in aircraf to indicate the fying height.
- It is considered as a poor display since:
• It is difcult to read
• It is easy to misread
• It leads to numerous of emergencies and accidents.


4- Display with signal colors
This type of display depend on the colors
Red color
Green color
Blue color
 Types of Displays (Cont.)
 The four broad categories of visual displays include:

1. Check display
a. Approximate value.
b. Trend of a changing variable.
c. Example: car fuel indicator.
2. Qualitatve display
d. Indicates whether or not a given conditon exists.
e. Generally does not provide extensive detail.
3). Quanttatve display

f. Indicates the exact numeral value that must be read.
g. Exact informaton that must be determined.
4. Representatonal display
h. Capable of ofering a variety of statc or dynamic
informaton.
i. They can portray either working models or simplifed
diagrams of a complex process, system, or machine.

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Faculty of Engineering IE 342

Industrial Engineering Department Human Factors Engineering

Chapter 4: Workplace Design

 Suitable design & arrangements of displays & hand controls.

• Maintain the same body positon over long period.

 Sizing the workplace to ft the body

2- The worker’s body size also plays a major role in

 Sizing the workplace to ft the body (Cont.)

3- The other major determinant of the

 Another example of simultaneously

Such design allows: quick reaches to controls and

 Designing For The Standing Operator

 Working height design is critcally in the workplace design. Working height in

 Designing For The Standing Operator (Cont.)

 There are three general guidelines for standing workplace design:

1- Delicate work or fne manipulaton (i.e., drawing)

2- Manual work (i.e., light assembly)

3- Exerton of extensive manual efort or constant use of weight (i.e.,

 Designing For The Standing Operator (Cont.)

Diferent tasks require diferent work surface Heights—NIOSH

 On the feet or sitng down?

 In sitng task the legroom must not be missing

 On the feet or sitng down? (Cont.)

 On the shop foor, elaborate seats are usually not suitable.

 Various kinds of stools and lean-ons (see fgure

 Requiring a person to maintain the same

 On the feet or sitng down? (Cont.)

Examples: airplanes, land vehicles and ofces

Ergonomics features are:

 Manipulatng, reaching, grasping

 In that type of sitng tasks the manipulatng

 Repeated reaches, such as in assembly

 Load handling may remain on the same level and includes.

1- Pushing/ pulling 2- Turning 3- Carrying

 Moving object around by hand ofen leads to injuries of the handler.

 Handling Loads (Cont.)

 It should pull or pushing the object using a

 It is recommended to use the ergonomics mechanical aids while moving

Summary of handling Optons (Ergonomics mechanical aids)

 Handling Loads (Cont.)

 Lifing or lowering loads is one the most injurious actvites.

 General Principles of Workplace and Design (Cont.)

1- General ergonomics workstaton design principles.

 General Principles of Workplace and Design (Cont.)

3- Design principles for lowering & lifing tasks (carrying tasks).

4- Design principles for pushing & pulling tasks.

1- Wrong working posture condition: 1- Wrong working posture condition:

2- Potential affected body part: 2- Potential affected body part:

3- Possible interventions : 3- Possible interventions :

1- Ergonomics hazard(s) associated with this task:

2- Potential affected body part:

 Rapid Upper Limb Assessment Tool

 Rapid Upper Limb Assessment Tool

• Measure musculoskeletal risk.

 Rapid Upper Limb Assessment Tool

 The method divided into 15 steps.

 Rapid Upper Limb Assessment Tool

 Rapid Upper Limb Assessment Tool (Cont.)

 Rapid Upper Limb Assessment Tool (Cont.)

 The total score is 5

Control and Displays

 Many human-machine systems are even more convoluted.