Professional Documents
Culture Documents
net/publication/264082918
CITATIONS READS
7 15,374
2 authors, including:
Qutubuddin S. M.
Poojya Doddappa Appa College of Engineering, Gulbarga
27 PUBLICATIONS 153 CITATIONS
SEE PROFILE
Some of the authors of this publication are also working on these related projects:
Occupational Health, Safety and Ergonomic issues in Pulse Processing Industry View project
OCCUPATIONAL HEALTH, SAFETY AND ERGONOMIC ISSUES IN SMALL SCALE GARMENT MANUFACTURING UNITS View project
All content following this page was uploaded by Qutubuddin S. M. on 20 February 2015.
INTERNATIONAL JOURNAL OF
ENGINEERING RESEARCH
AND INDUSTRIAL
APPLICATIONS
(IJERIA)
T PUBLICA
EN
ASC
TIO
@
N l
ASCENT
l
I
A
PUNE, IND
www.ascent-journals.com
International J. of Engg. Research & Indu. Appls. (IJERIA).
ISSN 0974-1518, Vol.5, No. I (February 2012), pp. 111-126
Abstract
Anthropometry is the branch of ergonomics that deals with body shape and size. People possess
different sizes and there is a need to take these variations into consideration whenever a product or
work place is designed for their use. In industry the workstation design normally gives little
consideration to the anthropometric measurements of the anticipated user. Designs that are
incompatible with normal anthropometric measurements of a workforce could result in undesired
incidents. The work performed in an environment that does not focus on ergonomics principles could
lead to fatigue and discomfort and also injuries which are known as musculoskeletal disorders
(MSDs). An ergonomics approach to the design of an industrial workstation attempts to achieve an
appropriate balance between the worker capabilities and work requirements. Anthropometric
dimensions for a given population can be generated and arranged in table through statistical methods.
The need for such anthropometric databases is becoming increasingly important and grows in parallel
with the goal to achieve efficient system designs. With this idea the current paper focuses on
significance and need of anthropometric data for the manufacturing organizations.
----------------------------------------
Keywords : Ergonomics, Anthropometric data, Work station Design and Musculoskeletal disorders
© http: //www.ascent-journals.com
112 QUTUBUDDIN S. M., HEBBAL S. S. AND KUMAR A. C. S.
1. INTRODUCTION
Ergonomics principles, knowledge and data can be applied effectively for optimum design of
product, job, and workplace and system safety in industrial organizations. Human
performance can be improved considerably from such an application. In the design of work
systems in manufacturing industries, the primary concern has usually been the improvement
of the performance of the equipment alone. Little consideration is given towards matching
the abilities of the operator with the task requirements. Consequently, many industrial
workstations are poorly designed, resulting in lower worker productivity and unnecessary
injury at the workplace [3].
Therefore, in designing a manufacturing work system, the designer should not only attempt
to maximize worker productivity, but also try to improve worker satisfaction and minimize
safety hazards. It is possible to achieve such a desirable goal through proper application of
ergonomics principles and anthropometric data [2]. An ergonomics approach to the design of
an industrial workstation attempts to achieve an appropriate balance between the worker
capabilities and work requirements [3]. Despite their importance, poorly designed
manufacturing work systems are commonly found in industry [2].
Anthropometry is the branch of ergonomics that deals with body shape and size. People
possess different sizes and there is a need to take these variations in physical characteristics
into account whenever anything is designed for their use, from something as simple as a
pencil to something as complex as a chair or car. More precisely, Anthropometry may be
defined as the measurement of human beings. Factors which affect anthropometric
measurements include gender differences, ethnic differences, growth and development,
ageing, social class and occupation etc [5]. Anthropometry tables give measurements of
different body parts for men and women, and split into different nationalities, and age
groups. Hence, while designing a product or work place, first of all it is necessary to know
exactly for whom designing is done. The group of people for whom designing is carried out
is called the ‘user population’. In this context, Anthropometry is considered as the science
that measures the range of body sizes in a user population. [9].
SIGNIFICANCE OF ANTHROPOMETRIC DATA FOR… 113
2. WORKSTATION DESIGN
As highlighted above, ergonomics deals with the engineering of machines for human use and
with the engineering of human tasks for operating machines. It is concerned with the ways of
designing equipment or machines, facilities and work environments, so that they match
human capabilities and limitations. The objectives of ergonomics are to increase the
efficiency and effectiveness with which work is performed and to maintain and promote
worker health, safety and satisfaction [2]
Often in industry the workstation is designed in an arbitrary manner, giving little
consideration to the anthropometric measurements of the anticipated user. The physical
114 QUTUBUDDIN S. M., HEBBAL S. S. AND KUMAR A. C. S.
dimensions in the design of an industrial workstation are of major importance from the
viewpoint of production efficiency, and operator physical and mental well-being. Small
changes in workstation dimension can have a considerable impact on worker productivity,
and occupational health and safety. Inadequate posture from an improperly designed
workstation causes static muscle efforts eventually resulting in acute localized muscle
fatigue, and consequently in decreased performance and productivity, and in enhanced
possibility of operator related health hazards [3].
An obstacle in the implementation of the ergonomic recommendations in a real world design
situation is the human variability in size and capability. It is a challenge to the designers to
come up with solutions which will optimally fit the diverse anthropometry of the users and
satisfy their task demands [3]. An engineering/structural anthropometry approach is used in
determining the workstation dimensions. In different parts of the world the workforce is
different and diversified; therefore, it is important to design the workplace based on the
anthropometry of the users [5].
An industrial workstation design objective is to ensure that the majority of the population of
the intended user group can be accommodated comfortably, without any harmful posture.
For the physical design of industrial workstations, the four essential design dimensions are:
[3] (a) work height, (b) normal and maximum reaches, (c) lateral clearance and (d) angle of
vision and eye height.
If work is performed in awkward postures or with excessive effort, fatigue and discomfort
may be the result. Under these conditions muscles, tendons, ligaments, nerves, and blood
vessels can be damaged. Injuries of this type are known as musculoskeletal disorders
(MSDs). MSDs can increase the cost of doing business both directly and indirectly. Direct
costs may include medical services and higher workers’ compensation premiums. Indirect
costs from increased employee turnover, absenteeism, and retraining may also occur.
Productivity, product quality, and employee morale may also suffer [4].
SIGNIFICANCE OF ANTHROPOMETRIC DATA FOR… 115
materials or performing extremely precise tasks may contribute to eye strain and awkward
postures.
The following are common postures found in the manufacturing environment that can be
considered when designing workplace or products [9].
• Standing
• Sitting
• Reaching
• Moving
3.2. Repetitive Motions
In repetitive work the same types of motions are performed over and over again using the
same muscles, tendons, or joints. The amount of repetition can be affected by the pace of
work, the recovery time provided (i.e., number and length of muscle relaxation breaks), and
the amount of variety in work tasks. The pace of work may be controlled by the employee
performing the task, machines, other employees, or administrative procedures. Examples of
jobs involving machine-controlled pace include working on assembly, packaging, or quality-
control lines.
3.3. Forceful Exertions
Force is the amount of muscular effort expended to perform work. Exerting large amounts of
force can result in fatigue and physical damage to the body. The amount of force exerted
when moving or handling materials, tools, or objects depends on a combination of factors.
3.4. Pressure Points (local contact stress)
Pressure points result from the body pressing against hard or sharp surfaces. Certain areas of
the body are more susceptible because nerves, tendons, and blood vessels are close to the
skin and underlying bones. These areas include the sides of the fingers, palms, wrists and
forearms, elbows, and the knees.
3.5. Vibration
Vibration exposure is of concern when it is continuous or of very high intensity. Using
vibrating tools such as sanders, grinders, chippers, routers, impact guns, drills, chain saws,
SIGNIFICANCE OF ANTHROPOMETRIC DATA FOR… 117
and circular saws can cause exposure to hand-arm vibration. Tools that are not properly
maintained or are inappropriate for the task may increase the amount of hand-arm vibration.
These exposures may result in fatigue, pain, numbness, and tingling, increased sensitivity to
cold and decreased sensitivity to touch in the fingers, hands, and arms. Whole-body vibration
commonly results from sitting or standing on work surfaces that vibrate.
Therefore, contributing factors should be minimized in work tasks as much as possible to
prevent fatigue, pain, and disability.
3.6. Conditions that cause MSDs
Occupational Safety and Health Administration, U.S. Department of Labor have reported the
following conditions that are likely to cause MSD problems [11]
• Exerting excessive force
• Excessive repetition of movements that can irritate tendons and increase pressure on
nerves
• Awkward postures, or unsupported positions that stretch physical limits, can compress
nerves and irritate tendons;
• Static postures, or positions that a worker must hold for long periods of time, can restrict
blood flow and damage muscles;
• Motion, such as increased speed or acceleration when bending and twisting, can increase
the amount of force exerted on the body;
• Compression, from grasping sharp edges like tool handles, can concentrate force on
small areas of the body, reduce blood flow and nerve transmission, and damage tendons
and tendon sheaths;
• Inadequate recovery time due to overtime, lack of breaks, and failure to vary tasks can
leave insufficient time for tissue repair;
• Excessive vibration, usually from vibrating tools, can decrease blood flow, damage
nerves, and contribute to muscle fatigue.
• Whole-body vibration, from driving trucks or operating subways, can affect skeletal
muscles and cause low-back pain; and
118 QUTUBUDDIN S. M., HEBBAL S. S. AND KUMAR A. C. S.
• Working in cold temperatures can adversely affect a worker’s coordination and manual
dexterity and cause a worker to use more force than necessary to perform a task.
These risk factors, either alone or in combination, can subject workers’ shoulders, arms,
hands, wrists, back, fingers, neck and legs to thousands of repetitive twisting, forceful, or
flexing motions during a typical workday. To contribute to MSDs, however, these risk
factors must be present for a sufficient duration, frequency, or magnitude.
3.7. Considerations to reduce MSDs or CTDs
MSDs or CTDs may occur in both office and manufacturing settings. Following are some
considerations to help reduce the likelihood of occurrence of MSDs or CTDs
• Eliminate tasks that require fast, highly repetitive arm movements or that impose
sustained static postures
• Beware of pressure points where the wrist, forearm, or other parts of the body contact an
edge or hard feature on a desk or table
• Minimize shoulder flexion and abduction
• Minimize holding weighted objects in hands
• Reduce or eliminate forceful applications of heavy peak exertions
• Require workers to take frequent breaks
4. ANTHROPOMETRIC DATA
Anthropometric dimensions for each population are generally ranked by size and described
as percentiles. When the heights of a group of adults are considered it may be found that,
most of their heights are close to some common height. A few may be noticeably taller and a
few may be noticeably shorter than this common height. This 'common height' will be near
the average such as the 'mean' or ‘mode’ in statistics and is shown in anthropometry tables as
the fiftieth percentile, often written as '50th %ile'. This means that it is the most likely height
in a group of people. For majority of the population, if a graph is plotted for the heights (or
any other dimensions) of our group of people, it would look similar to as that is shown in
fig.1. [12].
SIGNIFICANCE OF ANTHROPOMETRIC DATA FOR… 119
(designing for the smallest or the largest, usually for the 5th percentile or the 95th percentile),
an example being the design of the doorpost height for the largest person’s stature (plus
ample clearance) and designing a shelf for the smallest person’s functional reach. The third
and last method is designing for an average. This method is only acceptable when one is
using the workplace for a very short duration. This method is usually avoided by an
ergonomist as it does not accommodate a large segment of the user population. An example
is designing work surface heights in a bank for customers’ elbow height [5]. Some typical
examples of using the percentiles for work place design are presented in table.1.
The need for anthropometric databases is becoming increasingly important and grows in
parallel with the goal to achieve efficient system designs. The available literature reveals that
attempts have been made to generate anthropometric tables and also apply this data for the
design of product and work places there by incorporating ergonomics principles.
Table 1 Percentile consideration for the purpose of design of product or work place [12]
matrix uses two parameters, the user's body height and sex, to estimate recommended
workstation settings (in numerals) based on ergonomics principles. Three estimation
processes have been used. Firstly, relevant body member measurements are estimated from
the body height. Then, both x- and y-coordinates of key body reference points are calculated.
Finally, the coordinates of the VDT workstation's reference points are determined to match
with those of the body reference points. The recommended settings are then derived from
these reference points. The computation is based on an assumption that the recommended
seated posture for a prolonged keyboard operation is an upright posture, with both lower
arms forming a right angle with the upper arms, no wrist bending, and both feet resting
comfortably on the floor. Authors claim that, one of the occupational risk factors leading to
the development of carpal tunnel syndrome (CTD) among VDT users is body posture. The
proposed body height-workstation settings matrix provides a list of recommended settings
for both male and female users with different body heights. The results serve as initial
settings to help VDT users conveniently adjust their workstations so that an ergonomic
seated posture is obtained.
Das and Sengupta have proposed a methodology for designing a work station with
ergonomics approach which involve the following steps [3]
• Obtain relevant information on the task performance, equipment, working posture and
environment through direct observation, video recording and/or input from experienced
personnel
• Identify the appropriate user population and obtain the relevant anthropometric
measurements or use the available statistical data from anthropometric surveys
• Determine the range of work height based on the type of work to be performed. Provide
an adjustable chair and a foot rest for a seated operator and an adjustable work surface or
platform for a standing operator
• Layout the frequently used hand tools, control and bins within the normal reach space.
Failing that, they may be placed within the maximum reach space. Locate control or
handle in the most advantageous position, if strength is required to operate it
• Provide adequate elbow room and clearance at waist level for free movement
SIGNIFICANCE OF ANTHROPOMETRIC DATA FOR… 123
• Locate the displays within the normal line of sight Consider the material and information
flow requirements from other functional units or employees
• Make a scaled layout drawing of the proposed workstation to check the placement of
individual components
• Develop a mock-up of the design and conduct trials with live subjects to ascertain
operator-workstation fit.
• Obtain feedback from the interest groups
• Construct a prototype workstation based on the final design
The systematic ergonomics approach to designing an industrial workstation described above
was applied to the design of a supermarket check stand workstation [3].
An effort has been made [2] to incorporate ergonomics principles and data to design a
manufacturing work system by considering the manufacturing task comprised of drilling four
holes on a prepared steel plate. The components of the manufacturing work system included:
manufacturing task, power-feed drill press, jig, fixture and other equipment, workplace
layout, operator training and (hard) production standard and feedback. The ergonomically
designed manufacturing work system proved to be effective and efficient in terms of
manufacturing processing time, safety, training time, and worker productivity, satisfaction,
and job attitudes.
Shikdar and Kindi [1] have reported a research work whose objective was to study and
identify ergonomic deficiencies in computer workstation design in typical offices. Physical
measurements and a questionnaire were used to study 40 workstations. Major ergonomic
deficiencies were found in physical design and layout of the workstations, employee
postures, work practices, and training. The consequences in terms of user health and other
problems were significant. Forty-five percent of the employees used nonadjustable chairs,
48% of computers faced windows, 90% of the employees used computers more than 4
hrs/day, 45% of the employees adopted bent and unsupported back postures, and 20% used
office tables for computers. Major problems reported were eyestrain (58%), shoulder pain
(45%), back pain (43%), arm pain (35%), wrist pain (30%), and neck pain (30%). These
results indicated serious ergonomic deficiencies in office computer workstation design,
124 QUTUBUDDIN S. M., HEBBAL S. S. AND KUMAR A. C. S.
CONCLUSIONS
The work proposed in this paper concentrated on the significance of ergonomic knowledge,
in particular the application of anthropometric data in the design of products and work
systems and its outcome points out that consideration of the variability in human capabilities
while designing, or modifying equipment, tools, work tasks, and the work environment is of
prime concern of modern manufacturing industries. Employees’ abilities to perform physical
tasks may vary because of differences in age, physical condition, strength, gender, stature,
and other factors. One answer for this problem is to use ergonomics in your workplace for
day to day activities, because it is concerned with the fit between the demands of the
workplace and the employees who perform the work.
Information technologies has made available means for studying and analyzing human size
and shape in 3-dimensional forms (3D), and generate human models for anthropometric
analysis. These advances in anthropometric science and support of computer-based human-
form modeling have opened various research avenues for improving workplace and
protective equipment design in manufacturing organizations. Accordingly, the authors have
identified a long term research work to develop a computer assisted system for industrial
ergonomics which support the application of ergonomics knowledge and data for the design
of work systems in manufacturing organizations. The progress in these directions will be
reported later.
126 QUTUBUDDIN S. M., HEBBAL S. S. AND KUMAR A. C. S.
REFERENCES
[1] Shikdar Ashraf A. and Al – Kindi Mahmoud A. - Office Ergonomics: Deficiencies in Computer
Workstation Design International Journal of Occupational Safety and Ergonomics (JOSE)
2007, Vol. 13, No. 2, 215–223
[2] Das Biman - An Ergonomic Approach To Designing A Manufacturing Work System
International Journal of Industrial Ergonomics, 1 (1987) 231-240
[3] Das’ Biman and Sengupta Arijit K. - . Industrial workstation design: A systematic ergonomics
approach Applied Ergonomics Vol 27, No. 3. PP. 157-163. I996
[4] Department of Industrial relations, Cal/OSHA Consultation Service, Education and Training
Unit- Easy Ergonomics A practical approach, 1999
[5] Fernandez Jeffrey E. - Ergonomics in the workplace, Facilities Volume 13 · Number 4 · April
1995 · pp. 20–27
[6] Kothiyal Kamal and Tettey Samuel - Anthropometry for Design for the Elderly International
Journal Of Occupational Safety And Ergonomics 2001, Vol. 7, No. 1, 15–34
[7] AI-Haboubi Muhammad H - Anthropometry for a mix of different populations Applied
Ergonomics Vol 23 No 3 June 1992
[8] Feyen Robert, Liu Yili, Chaffin Don, Jimmerson Glenn and Joseph Brad - Computer-aided
ergonomics: a case study of incorporating ergonomics analyses into workplace design Applied
Ergonomics 31 (2000) 291}300
[9] Scott Openshaw, Allsteel and Erin Taylor, Allsteel - Ergonomics and Design A Reference Guide
2006 Allsteel Inc.
[10] Nanthavanij Suebsak - Body height-workstation settings matrix: A practical tool for ergonomic
VDT workstation adjustment International Journal of Industrial Ergonomics 18 (1996) 215-219
[11] U.S. Department of Labor, Occupational Safety and Health Administration - Ergonomics: The
Study of Work, 2000 (Revised)
[12] www.ergonomics4schools.com/lzone/anthropometry.htm- Anthropometry
Qutubuddin S. M. Hebbal S. S.
PDA College of Engineering PDA College of Engineering
Gulbarga-585102, Karnataka State, India Gulbarga-585102, Karnataka State, India
Email : syedqutub16@gmail.com Email: shivahebbal@yahoo.co.in
Kumar A. C. S.
JNTU College of Engineering,
Hyderabad, AP State, India
Email : acskumar@yahoo.com