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A Review On Ergonomic Factors that Lead to Stress in Manufacturing Industry

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 A REVIEW ON ERGONOMIC FACTORS THAT LEAD TO STRESS IN MANUFACTURING INDUSTRY

Jian Ai, YEOW

Faculty Business and Law
MultimediaUniversity
jayeow@mmu.edu.my

Khong Sin, TAN

Faculty Business and Law
Multimedia University
kstan@mmu.edu.my

Tee Suan, CHIN

Faculty Business and Law
Multimedia University
tschin@mmu.edu.my

Shiau Ching, E
Faculty Business and Law
Multimedia University

ABSTRACT

In today’s competitive global environment, worker productivity is an important element of a

company’s success. In order to deal with these competitive trends, many businesses will need to
change their internal operations such as teamwork, collaboration, expanded functionality, and
productivity. However, worker productivity can be significantly affected by high levels of stress that
experienced in the workplace. The increased complexity and the imperative of global competition
have exposed tremendous pressure on manufacturing workers and imposed the worker stress. The
main objective of this study is to identify the ergonomic factors that lead to stress in manufacturing
industry. In this study, four factors as well as independent variables are only selected to be tested
which are job scope, repetitive job, mental workload and physical environment. With supportive
literature review, a conceptual framework is developed to create awareness among workers as well
as manufacturers regarding workplace stress.

Key Word: Stress, job scope, repetitive job, mental workload, physical environment,
interpersonal relationship

--------------------------------------------------------------------------------------------------------------------------

1.0 Introduction

In today’s competitive global environment, worker productivity is an important element of a

company’s success. In order to deal with these competitive trends, many businesses will need to
change their internal operations. Many businessmen had forgone the ergonomics elements and
tends to face high turnover and poor performance. This is because worker’s productivity can be
significantly affected by high levels of stress that experienced in the workplace (Amble, 2005). The
imperative of global keen competition can exposed tremendous pressure on manufacturing workers
and imposed the worker stress (Salleh, Bakar and Wong, 2008). Additionally, stress is the negative
emotional or uncomfortable physical responses that happen if the requirements of the task given
cannot match the worker’s ability (Maxwell, 2004). Workers will experience stress if they perceives
negatively towards their work environment (Piko, 2006). Overload stress can result in poor effects
and able to affect a worker’s mental or physical health and even affect their work performance. In
long run, it directly affects company’s performance (Boswell, 2006).

The occurrence of work stress is alarming in manufacturing industry which involved the blue collar
workers. Research shows that poor ergonomics workstation environment is the main contributor to
the work stress problems (Makhbul and Idrus, 2009). During the last few years, ergonomic workplace
design has become an essential issue in many companies. The implementing of ergonomic practices
can be regarded as a means to maintain or enhance a company’s workforce and deal with the
competitiveness environment (Duffy and Salvendy, 1999; Karwowski et al, 1994). Sen (1984) stated
all manufacturing industries should apply ergonomics at the ealier stage before considering other
solutions. Many studies have been prove that, the positive effects of applying ergonomic activities
and principles in workplace design .Studies shown that by applying appropriate ergonomic principles
during workplace design can reduce many unwanted costs and workplace hazardous (Das and
Shikdar, 1999; Riley and Dhuyvetter, 2000).

2.0 Studies on Ergonomics and Stress

Previous studies demonstrated the term of ergonomics is composed from the Greek two words
‘‘ergon’’ means (work) and ‘‘nomos’’ means (laws). In fact, ergonomics literally means “the laws of
work” (Murrell, 1971; Sluchak, 1992). Ergonomics defined as human factors, is concern and discovers
information about human behavior, limitation, abilities, and other characteristics to the design of
machines ,tools, systems, jobs, tasks, environments, and workplace for safe ,productive, comfortable,
and effective human use (Chapanis, 1985; Sanders and McCormick, 1987). Today, the scientific
discipline of ergonomics can be divided into three main areas which are physical, cognitive, and
macro ergonomics. Based on the analysis by Karwowski and Rodrick (2001), physical ergonomics
deals with physiologic and anthropometric aspects of task design. In another previous analysis,
cognitive ergonomics is examines human mental processes such as apperception, coordination
information processing, and reaction (Vicente, 1999). On a similar study, in organizational
ergonomics, also known as ‘‘macro-ergonomics’’, the application is put on processes of socio-
technical systems, methods, structures (Karwowski, 2005).

Rowan and Wright (1995) further describe ergonomics is the complexity relationship between
workers and their jobs that occur in all aspect of the workplace. According to Shikdar et al, (2002),
manufacturing industry is an intricacy human machine workplace environment. Studies in
ergonomics principle can produce data and guidelines for manufacturing industrial applications, such
as the improvements of ergonomics work station designs, and better machines design (Karwowski,
1998). However, there is limited application and low acceptance in the manufacturing industries and
poorly designed workstations are common in manufacturing industries (Konz, 1984).A study
conducted by Eklund (1995) found that poor ergonomic workplace was associated with physical and
emotional stress, as well as low productivity and poor quality of work. This was particularly true for
workers who at the manufacturing industries. Morioka et al, (2005) had been conducted a study
relate to the occupational health on manufacturing workers that exposed to neglect of ergonomics
applications workstation such as exposed to cold environment will significantly result in the greater
the change in blood pressure and may bring effect to worker’s health.

The negative forces and health issues is extremely harmful to the related worker. On top of that,
studies also show conclusively that there is a strong relationship between stress and performance.
Mental and physical health effects can lead to stress would reduce an individual capacity to perform
at work (Sharpley et al, 1996). In addition, stress can seriously affect company performance,
efficiency and competitiveness. In a study of stress and performance in manufacturing industry, it
shows that stress disorders can cost organizations few hundred of billion and reduce the
productivity, worker absenteeism and disability among their cognitively. Therefore, it is essential for
organizations to find ways to maximize job satisfaction among workers in order to reduce job stress
(Blix, Curise and Mitchell, 1993).

According to James (1987), the most significant workplace stress factors are the amount of control
over an individual’s own abilities. However, other factors such as the relationship between co-
workers and supervisor; workplace environment, role conflict, work schedule may also lead to
workplace stress. Prior researchers have found that, almost manufacturing job condition can lead to
workplace, yet depending upon workers reaction to it. There are few criteria of work condition that
almost cause stress for workers which includes time deadlines, work overload, poor relationship
between supervisor, repetitive work, machine paced task, lack of control, rotating shift work ,
cognitive demand, role ambiguity and physical environment (House 1981; Sutton and Rafaeli, 1987).
In another study, there was evidence on the blue collar workers are exposed to heat, noise, air
pollution, shift work, physical burden, task demand, organization structure, long working period,
poor social interaction with the superiors, and poor workplace design. All these ergonomic factors
indicated a positive relationship with workplace stress (McLean, 1974; Williams, 2003).

3.0 Prior Research of Independent Variables

3.1 Job Scope

According to McLean et al,(1998), job scope can be refers to the extent of the boundary between a
person employment relationship and other portions of one’s life for example the amount a person
job responsibilities spill over into their own life. However, the job scope can vary from narrow to
broad. The more broadly workers describe their work responsibilities, the more likely they
experience the work related stress (Morrison, 1994). In the job literature, job scope help to describe
the real purpose of a job, the major responsibilities and accountabilities of a job ,the key attributes,
experience and education desirable for the person to conducting a job (Palmer and Valet, 2001).
In addition, job description also includes information about working conditions, equipment used,
tools, relationship with other positions, understanding of the role, knowledge, abilities, and skills
needed to accomplish and perform the task and job (Schneider and Konz, 1989). Another study
illustrated that; job of a manufacturing worker is multi-faceted. The role of a manufacturing worker
depends on the type factory they are working with. The manufacturing workers need to carry out
variety of functions like packing, processing, sorting, operating the machines and so on (Young,
1992). Manufacturing workers reporting of stress when they are working to deadlines and having
work overload ( Jones et al. 1998).

Work overload are defined as one of the psychological stressors in ergonomics. For instance the
requirements for working fast and complex work , not enough time to perform the task, and having
conflicting demands. A study conducted by Kawakami, Haratani, and Araki, (1992) reported the
excessive workload, and lack of control over work pace were significantly associated with work stress
symptoms among the electronic workers in may bring negative impact to performance and quality of
goods. On the other hand, Margolis et al, (1974), conducted a study of more than one thousand
workers and found that overload correlated positively with variety indicators of stress responses,
such as low self- esteem, low motivation, and absenteeism.
Prior study illustrated that, work demands at workplace was measured by excessive workload, long
shift work time especially at night, short duration of rest time, and work overtime (Sutherland &
Cooper, 1988). On the other hand, a study that focus at Korea manufacturing industries
demonstrated that the workers were experience with time pressure and long working hour as the
significant triggers of work stress (Park & Lee, 1996). In addition, shift workers with improper work
schedule and long working hours leads to poor sleep and psychological stress (Savery and Luks,
2000). Therefore, one of the causes of stress among manufacturing worker is poor job scope.

3.2 Repetitive Job

The definition of repetitive job can be defined as job where short and monotonous job cycles, with
closely exertion patterns, and repeated at excessive level of frequency. However, in the review of
Kilbom (1994) different definitions for repetitiveness work are state, mainly based on the length of
single work cycles. For an explanation of high repetitiveness, it has been used in literature single
cycle time lesser than thirty seconds of the work cycle time involves performing the similar type of
motion (Silverstein et al. 1986, Ketola et al. 2001). Colombini (1998) reported that, repetitive task
which nonstop repeat for a minimum of 60 minutes can be considered as repetitive work.

Repetitive work can also define by physical work characteristics such as upper extremity movements,
and correlated with psychosocial factors in ergonomics. As an example, assessment of repetitiveness
is the work cycle time, which can be related to perceived work demands and time pressure
(Lundberg, 1999). In addition, repetitive work is also associated with lack of job control and decision
making and skill discretion. Therefore, is reasonable that the psychosocial workload related to
repetitive work can strongly lead to stress symptoms, repetitive stress injuries and musculoskeletal
disease (Carayon, 1999 and Huang, Feuerstein & Sauter, 2002).A common repetitive work is always
demand low energy consumption, but if the work is frequent in its appearance, or short in duration,
and cycle in process, the recovery time of the musculoskeletal organs are limited and thus lead to
repetitive stress (Luopajarvi et al,1979).

The factors that generate to workplace stress not only if task demands are high, but also if demand
are too low, which may occur in many repetitive and monotonous work conditions (Lundberg, 1995).
Assembly work is an essential activity to industrial production. However, workers those who
connected to assembly work are having repetitive stimulation, high physical demands, is
characterized by long term uneventful monitoring of the production process (Johansson, 1989). In a
food industry study, the food processing industry are in unpleasant work environment ,high
repetitive task and monotonous, likewise workers are usually expected to perform the given tasks at
a high speed while the ergonomics factors are consider not the most favourable (Chiang et al, 1990
and Campbell 1999).

According to the Occupational Safety and Health (OSH) profile in manufacturing sectors in Malaysia,
the workplace health issues usually involve electronic, automotive, food industry workers, and steel
industry workers (Ismail, Yeo, Haniff et al, 2009). These workers are manual handling may lead to
physical strain and pain, and currently facing ergonomic risk factor due to repetitive job. Several
workers physical stress can be identify such manual handling high peak load, continuous postures,
vibration, repetitive work, and acceleration of movement (Pinzke and Kopp, 2001). Another study
found that, workers in the company manufacturing various kinds of ear protection equipment such
as produces earplugs were exposure to extreme force and repetitive movement of the wrists, hands,
arms associated with repetitive manual work stress and musculoskeletal symptoms (Kuorinka et al,
1987)
Furthermore, the modern industrial assembly line workers have to pay fully attention and energy to
handle with the products that move at a fast and dizzying rate in the production line. In addition,
some of the tasks in the product production process cannot be automated; hence many production
lines are relying on assembly workers to visually inspect and manually handling, or pack the finished
good. Assembly workers are stand for a longer period and continuously use their hands in the
product packaging process. In addition, assembly workers need to repeated the motions over and
over by doing the same task hundreds of times a day, and experience time pressure by keeping up
with products coming from the production line without distraction and latter lead to repetitive job
stress ( Armstrong , Punnet and Ketner, 1989).Therefore, another causes of stress in manufacturing
industry is repetitive job.

3.3 Mental Workload

Mental (or cognitive) workload can be defined as the portion of operator information processing
resources, or capacity, which is required to meet cognitive task demands (Eggemeier et. al, 1991).
Literature reflects mental workload can be a multi-faceted phenomenon. Mental workload can
related to physiological stress in ergonomics (Nissen, & Bullemer, 1987).There are many ways to
define mental workload. Some of which could be to describe the portion of operator information
processing resources or capacity that required to meet production system demands while other
descriptions mental workload as the mental effort that the human operator control or supervision
relative to his or her capacity (Curry ,et.al, 1979; Eggemeier, et .al, 1991).
A study on the impact of cognitive demands and performance in manufacturing environments
demonstrated an adaptable production system has more cognitive requirements than manufacturing
systems and places more explicit cognitive demands on individuals (John, Karwowski and Furr, 2009).
An individual’s work conditions have been enlarged by automation and increase the individual’s work
demand, excessive information which eventually move job task into a higher level of cognition stress
(Rasmussen, 2000). Moreover, this cognitive stress has been proved within the contexts of the work
stress model and the psychological or mental effects associated with higher level workload,
diminished job control on machine, and increased job pressure (Vicente et al,1987).

Cognitive stress factors can be including mental workload, overload information processing, having
problem in solving engineering, maintenance, manufacturing tasks, and not understanding the
information displayed on the machine (Lawson et.al, 2006).In microelectronics industry workers
cognitive stress cause by forcing the maintenance production technician to engage in difficult
perceptual or thinking activities such poorly labeled displays, difficulty in diagnosing a fault in the
machine’s software because of inadequate job aids, and lack of system documentation to help
remember all the steps in a maintenance task.

A study illustrated that, unlimited demands on quality and multi-skilling almost involving job
enlargement and intensification of work. In fact, the lean production transfer the responsibilities to
workers and the workers are responsible for the quality of the products and other non-production
tasks such as tasks of maintenance of the machines, quality control of the products, the maintenance
of the workplace and so on. In addition, lean production also emphasizes the requirement of workers
skills and conceptual knowledge that need for problem solving (Jackson & Mullarkey, 2000).
According to Womack, Jones and Roos, in the lean production line, the workers need to think
proactively in order to find solutions before the problems become serious.

Normally, lean productions require high level of cognitive processes such as learning, reasoning, fast
decision making or problem solving, expert multi-skilling with unlimited work demand. The
implementations of lean manufacturing have negative impacts on workers such as increased
cognitive stress and work demand. This fact was supported by empirical studies of (Saurin & Ferreira,
2009). Lean manufacturing uses high-level cognitive processes, and excessive work demand with
skilled. The term Lean implies a significant cognitive demand on workers. In addition, the quality of
the workplace environment, as perceived by the workers, can be strong associated with the cognitive
demand stress (John, Karwowski and Furr, 2009). Therefore, mental workload is also one of the
causes of stress.

3.4 Physical Environment

Physical environmental stress can be defined as unpleasant working conditions, such as excessive of
temperatures, noise, chemical smell, poor lighting, vibration, dust, or overcrowding (McGrath, 1978).
Poor physical environment was associated both workplace environment stress and job
dissatisfaction. (Davis, 1984). In addition, this specific physical factors that affect individual
performance will depending on both the work environment and personal differences. Furthermore,
the adverse physical environment can decrease the worker concentration towards tasks (Nubile &
Sherman, 1999). Environmental conditions can be range from normal factors to extreme factors
conditions such as, excessive noise, bad smell, poor lighting, extreme heat or cold and dust.
Uncomfortable environmental conditions may possibility lead to workplace stress, low performance,
and poor quality. (Knisley, 2005).

Numerous studies demonstrate that many situations in manufacturing working life that can become
stressful. These include the problems with the physical environment, such as heat stress, poor
lighting, excessive cold, or excessive noise (Anderson et al, 1977; Jick and Payne, 1980). According to
Larocco, House, & French (1980), stressful physical work environments can lead to workers’
psychological strain. Prior research found the heat stress is the aggregate physical and environmental
problems that constitute the extreme heat for someone’s body including inner body heat operation
due to working hard. However, there are many situations in industry where hot working climate can
be caused by industrial operations itself. In another study, there was evidenced on the relationship
between poor physical environment and heat stress. In the same text, the study indicated that, the
glass manufacturing is the truly hot work environment; the workers are exposed continuously to high
temperature (Leithead and Lind, 1964 ; Muchler, 1991).

From a physiological point of view, the cold environment may be defined as an environmental
condition that activates the thermoregulatory system to lessen heat loss from a person’s body to the
environment and possibility lead to uncomfortable sensations of cold (Rintamaki et al, 2005). In
addition, the international standard of Ergonomics of the thermal environment indicated that, air
temperature of 12 °C or below is considered cold indoor environment. According to Mercer (2003)
and Hassi et al, ( 2005), exposure to cold working condition can cause cold-related health problems
such as stress, illness and cold-induced injuries and bump up the risk of work accidents (Chau et al,
2008).Previous research found that, the cold environment temperature, can lead workers stress. The
research finding shows the environmental factors that associated to workers in meat-processing
industry such as cold working condition, humidity, air movements, and handling with cold products
during packing (Griefahn, Mehnert, Brode, et al. 1997, Campbell 1999).

Another study is that related to physical environment stress is the high noise workplace can cause
stress to manufacturing workers. Generally, noise can be defined as unwanted sound. The word
“sound” itself it describes as either physical stress cause by vibrating object. Vibration is result from
the high speed rotating machines, mechanical or friction impacts that involved in machine operation.
In addition, noise can classify into various type, including narrow band noise, wide band noise and
impulse noise (Behar, Chasin and Cheesman, 2000). More literature defined that, noise can act as a
physical and a psychological stimulus (Akerstedt and Landstrom, 1998). This working environment
can reduce workers coping capacity, morale and motivation. In fact, excessive exposure to loud noise
will irreversibly damage the ear, resulting in hearing loss.
Parimalam et al, (2006) made a study of ergonomic intervention in India showns that poor physical
environment in garment manufacturing unit was an alarming problem. Within the study, the sewing
operators were face with lack of task lighting was an important deficiency noticed in the sewing
machine. The workers always complained occurrence of accidents, headache, and visual strain
caused by insufficient light at the workplace. These include inappropriate lighting, excessive noise
from the embroidery machines, dust, unsuitable furniture and insufficient protection from dangerous
chemicals. Workers who work in such adverse working environment are prone to workplace stress
(Ghosal , Chakrabarthi, 1987).

4.0 Discussion and Conclusion

Previous researchers also reveal that, manufacturing industrial job scope strongly associated
with stress or depression symptoms (House, 1979 & Rocco et al, 1980). Moreover, there was
evidence that workers in repetitive works are especially at high risk of mentally and physically stress.
Berggren, (1992) also emphasized that lean productions need high level of cognitive demand and the
implementations of lean manufacturing have a significant relationship between workplace stress.
This was supported by empirical study of (Treville and Antonakis, 2006). Last but not least, poor
environment conditions including excessive noise, poor light, extreme heat or cold and dust
may have a significant relationship between workplace stresses (Knisley, 2005).

Based on the supportive literature review, it had narrative proven that ergonomics factors such as
job scope, repetitive job, mental workload and physical environment had significantly lead to stress
among workers in manufacturing industry. These factors need to be taken care seriously among all
manufacturers in order to control their performance and reduce turnover. However, other
ergonomics factors such as grip force, workplace design, and other psychological factors should be
consider for future research. Moreover, other research method like survey or interview may help to
strengthen the factors that lead to stress in manufacturing industry. In a nutshell, factors like job
scope, repetitive job, mental workload and physical environment may lead to stress among worker
and it may impact the overall company’s performance.

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