Design for Ergonomics

1. Design for Ergonomics MPD575 DFX Jonathan Weaver

2. Development History • Originally developed by Cohort 1 students: Stephen Earl, Paul Geisler, & Larry Rhein • Revised by Cohort 2 students: Winnie Jimenez, Sergio Munoz, Dave Paddock & Lester Weitman.

3. Design for Ergonomics • Introduction to DFE • DFE Process • Key Principles of DFE • Examples • DFE Software • DFE Hardware • DFE Case Studies • References • Supplemental Readings

4. Design for Ergonomics • Introduction to DFE • DFE Process • Key Principles of DFE • Examples • DFE Software • DFE Hardware • DFE Case Studies • References • Supplemental Readings

5. Introduction to DFE Ergonomics is ….”The science of matching things to people.” • It pays to be precise about how things suit people. It is the difference between taking a guess and taking a measurement.

6. Introduction to DFE • Ergonomics was created in 1949 from the Greek words: • “ERGO” = Work • “NOMOS” = Natural laws Scientific study of humans interacting within their environment

7. Introduction to DFE • Ergonomics considers the physical and mental aspects of people in relation to a product. • By adding objective data about people into the design process, a product or environment can be designed so that all users are considered, not just those that resemble the designer.

8. Introduction to DFE • Ergonomics is all about quality • The fact that something can be used is just not sufficient – it should be easy to use. • Just because most people find it easy is not sufficient either – a large and known percentage of people should be able to use it easily.

9. Introduction to DFE The outcome of applying Ergonomics is generally one or more of: • User success • User satisfaction • Speed • Safety • Reliability

10. Introduction to DFE • Some Do’s and Don’ts of using Ergonomics: • DON’T • Don’t think about ‘most people’ or ‘the average’ since that will lead to low standards. • Don’t speculate. Try to recognize when you don’t know something about the people you are designing for. • Don’t design the product for yourself. Use objective data about people.

11. 95th 95th 50th 95th 50th 95th 95th 50th 5th 50th 5th 50th 95th 5th British Males 5th 50th 5th Japanese Males U.S., German & Swedish Females 5th British Females Japanese Females Ergonomic Differences • 50th percentile U.S. male > 95th percentile U.S. female • U.S. female stature resembles Japanese male stature 1900 1800 1700 Height (mm) 1600 U.S., German & Swedish Males 1500 1400 1300 1200

12. Introduction to DFE • Some Do’s and Don’ts of using Ergonomics: • DO’S • Decide who is going to use the design – age, sex, reach, strength, etc. • Focus on how different the worst-case users are from you. • Make explicit what the users’ goals will be as they use the product, and what will measure success.

13. Introduction to DFE • Some Do’s and Don’ts of using Ergonomics: • DO’S • Consider what happens to people outside the formal design range • Work out what users will need to know before they can complete the tasks. Build the learning into the product, or design out the need for it. • Take account of stress and competing demands on the users attention. Especially important when designing labels.

14. Introduction to DFE • Human Factors engineering & Ergonomics are commonly used interchangeably. • Human Factors is a discipline that optimizes the relationship between the technology and the humans. • Anywhere you find technology and people interacting together, there will be a need for some form of human factors and ergonomics.

15. Introduction to DFE • Human Factors engineering & Ergonomics considers the variation within a user population and manner in which this will affect individual and group performance for a given task. • These variations include gender, age, sex, visual & mental capabilities, and strength.

16. Introduction to DFE • Both Human Factors & Ergonomics are interdisciplinary sciences that deal with: • Human characteristics • Capabilities and limitations for the purpose of designing products to achieve ease of use • Comfort • Convenience • Health and safety

17. Technical Fields that Interact with Ergonomics Ind. Design Envir. Medicine Applied Physiology Anthropometry Engineering Ergonomics Psychology Statistics Dynamics Oper. Research

18. Introduction to DFE Psychology - Experimental psychologists who study people at work to provide data on such things as: Human sensory capacities, Psychomotor performance, Human decision making, Human error rates, Selection tests and procedures, Learning and training. Anthropometry - An applied branch of anthropology concerned with the measurement of the physical features of people. Measures how tall we are, how far we can reach, how wide our hips are, how our joints flex, and how our bodies move. Applied Physiology - Concerns the vital processes such as cardiac function, respiration, oxygen consumption, and electromyography activity, and the responses of these vital process to work, stress, and environmental influences.

19. Introduction to DFE Environmental Medicine - Concerned with such environmental factors as noise, illumination, temperature, humidity, g-forces, radiation, and noxious gases and fumes, and their effects on health and human performance. Engineering - Provides information on electrical, mechanical, and chemical characteristics of elements and systems and principles of design, construction, and operation of structures, equipment, and systems. Statistics - For summarizing large amounts of data on human measurements and human performance, and to design sampling schemes and experiments for the conduct of human studies and performance measurements.

20. Introduction to DFE Operations Research - Quantitative methods for the analysis of the performance of manpower, machinery, equipment, and policies in government, military, or commercial spheres. Industrial Design - The design, color, arrangement, and packaging of equipment to combine functionality and aesthetically satisfying appearance.

21. Introduction to DFE Guides to Designing for Ergonomics: Standards and Codes Standards - A set of rules, conditions, or requirements that define terms; classify components, specify components; specify materials, performance, or operations; delineate procedures; or define measurements of the quantity or quality of materials, products, systems, services, or practices. Standards can be classified as being safety or performance based. Examples of Standards: Federal and Military Standards Company Standards Foreign Standards

22. Introduction to DFE Standards cont.- The most commonly used Standards for use by human-factors professionals: OSHA Standards: Prepared by the Federal Occupational Safety and Health Administration MIL-STD-1472D: Military Standard dealing with human-factors consideration in the design of equipment. NASA-STD-3000: Slightly broader range of topics than the MIL-STD. ANSI/HFS 100-1988 - Deals specifically with h.f. principals and practices in the design of visual display and terminals, associated furniture, and the office environment in which they are placed.

23. Introduction to DFE Standards cont.- American National Standards Institute (ANSI) - The most commonly used and most well recognized organization for standards. The organization is a federation of trade associations, technical societies, professional groups, consumer organizations, and industries that serves as the United States clearinghouse for voluntary standards activity at the national level. Limitations of Standards: Typically establish only minimum requirements. They are often too general. They usually have to be tailored. The do not explain the Systems-Engineering Process.

24. Introduction to DFE Codes Primarily concerned with safety matters, codes contain many regulations and recommendations that directly or indirectly address human-factor issues. Examples of codes: National Electrical Safety Code Life Safety Code BOCA National Building Code BOCA National Mechanical Code OSHA

25. DFEProcess • Introduction to DFE • DFE Process • Key Principles of DFE • Examples • DFE Software • DFE Hardware • DFE Case Studies • References • Supplemental Readings

26. DFEProcess Why Ergonomics? • Olden Days:Tools & machinery made by individuals for themselves or a select few. • 20th Century:Mass Production; designed for the “average” user.

27. DFEProcess “Our vehicles are manufactured for the masses. They are, therefore, tailored specifically to no one.” Ford Motor Design Center (Ford Motor Company quote).

28. DFEProcess • WHY NOW?: • Global Markets reaching consumers with wider range of physical attributes. • More competition can provide customers a choice of an easier to use product. • Can be severe long termconsequences - unacceptable level of absenteeism, dissatisfaction, complaints, accidents and under-use of product.

29. DFEProcess (Six principle areas of Ergonomic study, along with several examples of each).

30. DFEProcess We see that human characteristics are extremely relevant to ergonomics, and those that are most frequently measured by ergonomists are… • Physical characteristics • Psychological characteristics • Biological characteristics (The 3 primary areas of study).

31. Key Principles of DFE • Introduction to DFE • DFE Process • Key Principles of DFE • Examples • DFE Software • DFE Hardware • DFE Case Studies • References • Supplemental Readings

32. User Machine Workspace Environment Key Principles of DFE Interface Reference Model(simple but eloquent) (Primary interfaces are adjacent, others are secondary).

33. Operator Machine Key Principles of DFE Input / Output Communication Model (Shows that the outputs of one are the inputs of the other, and visa versa).

34. Key Principles of DFE System Design Model Statement of objectives Separation of functions Allocation of functions Human devel. User/machine Interface Hardware devel. System Integration (Ergonomics should be part of the complete process, but are most intense in red areas).

35. Key Principles of DFE Key principles of DFE – ‘VDC specific’ • Vehicle Design Center recommends three distinct guideline segments: • Controls Guidelines • Display Guidelines • Seat Guidelines

36. Key Principles of DFE The Controls Guidelines determine: • Fundamental Criteria • Visibility, Interpretability, Accessibility, Operability • Mode Criteria • Continuous, Discrete, Binary, Data entry • Design Recommendations • Natural, Convenient, Feedback, Stereotype, Blind reach • Arrangement Criteria • Emergency/Frequency, Grouped, Interference, Stereotype

37. Key Principles of DFE The Display Guidelines determine: • Fundamental Criteria • Visibility, Interpretability • Mode Criteria • Quantitative, Qualitative, Range, Binary status • Design Recommendations • Simplest, Least precise, Stereotype, Distance/angle • Arrangement Criteria • Emergency/Frequency, Compact, Standards, Grouped

38. Key Principles of DFE The Seat Guidelines determine: • Comfort Criteria • Contour, Suspension firmness, Posture, Support • Accommodation Criteria • Width, Length, Height, Depth, Angle • Convenience Criteria • Adjustments, Self-evident, Pivots, Placement • Miscellaneous Criteria • Entry/Egress, Progressive resistance, Irritants

39. Key Principles of DFE Key principles of DFE – ‘generic’ • Identify the client’s needs • Identify the user’s needs • Consider operator OP/machine IP • Consider operator IP/machine OP • Identify ergonomic issues affecting design • Evaluate ergonomic design effectiveness

40. Key Principles of DFE Process & Principles Summary – effective ergonomic design begins at the onset of the task. • Identify the needs of the client & user • Incorporate into statement of objectives • Maintain proportionate ergonomic effort • Evaluate ergonomic effectiveness

41. Key Principles of DFE DFE requires teamwork! Communication is a very important factor, inside and outside of the team. Success relies on the knowledge, resources, and support of people outside your team and outside your organization (final customer/user)

42. Ergonomics Team Members Ergonomics Committee Purchasing Management Materials Engineering Accounting DFE Team Marketing Quality Health and Safety Medical

43. Ergonomic Change Cost ($) Design Build Launch Operate Proactive Reactive Reactive Versus Proactive PD Job 1 Availability of Funds ($)

44. Reactive Versus Proactive • The diagram shows the relationship between cost and time • Ergonomic solutions will be more complex and will need more money as the design nears completion. • Normally, ergonomics analysis is applied to existing products and then reaction plans are developed. • Proactive gives the option to see and resolve problems when the resources (people, money, etc.) are available • The cost of ergonomic changes is inversely related to the availability of funds.

45. Ergonomic issues into a Product Development Milestone Concept Phase J1 Final Program Status Lessons Learned are identified & fed forward for Continuous Process Improvement Ergo Issues that are Product related Ergo Issues that are Process related Assigned to Product Engineers for Evaluation & Resolution Assigned to Process Engineers/Product Specialists for Evaluation & Resolution Current Production Jobs in Plant with Similar Product Ergonomics Team Assigned to Complete Reviews Job Improvement Cycle

46. Key Principles of DFE • The chart shows the DFE roll into Product Development milestone considering similar products or processes. • Ergonomic issues can be fixed when the cost of such fixes is relatively low. • DFE gives the option to apply ergonomics principles into the PD planning process.

47. DFE Rules for LEAN The change to Lean is a very good opportunity to improve ergonomics. The next twelve rules together with a team work, are important to improve process ergonomics: • Avoid bending forward at the waist • Keep the work close to your body • Avoid twisting your trunk • Avoid lifting or working above shoulder height. • The work height depends on the task and the operator.

48. DFE Rules for LEAN (cont’d) 6. Keep the duration of muscle effort short 7. Minimize walking distances. 8. Lift or lower only loads less than 40 pounds. 9. Bend the tool not the worker. 10. Maintain your tools and equipment. 11. Keep work in front of worker 12. Changes Postures and motions.

49. EXAMPLES • Introduction to DFE • DFE Process • Key Principles of DFE • Examples • DFE Software • DFE Hardware • DFE Case Studies • References • Supplemental Readings

50. GOOD EXAMPLES Good ergonomic designs