ergonomics, quality control and legal factors

ERGONOMICS

Ergonomics is defined as the relationship between man and machine and the application of
anatomical, physiological and psychological principles to solve the problems arising from man-
machine relationship. The word ‘ergonomics’ is coined from two Greek words – ‘ergon’, which
means ‘work’ and ‘nomos’, which means ‘natural laws’. Ergonomics means natural laws of
work.

From design considerations, the topics of ergonomic studies are as follows:

1. Anatomical factors in design of driver’s seat.

2. Layout of instrumental dials and display panels for accurate perception by the operators.

3. Design of hand levers and hand wheels.

4. Energy expenditure in hand and foot operations.

5. Lighting, noise and climatic conditions in machine environment.

The aim of ergonomics is to reduce the operational difficulties present in man-machine joint
system and thereby, reduce the resulting physical and mental stress

Sitting position at workplace impacts productivity. Discuss.

1. Why do you need to know about ergonomics as an engineer?

The discipline of ergonomics is not nearly as old as medicine, or even industrialization, but it
arose as a consequence of an extreme social situation: World War II. With all the able- bodied
young men drafted to war, industrialists faced a need to suddenly adapt workplaces to the
needs and limitations of a new, more diverse workforce consisting of women, phys-ically
disabled, and other previously overlooked groups of society. At the end of the war, society itself
had changed to the point where it was acceptable for many of these groups to remain in
employment.
While this first effort concerned itself mostly with physical work, later historical develop-ments
showed that it was possible to also improve workplaces in relation to human mental capability,
teamwork and organizations. Today, it is in the best interests of most industries to build
workplaces where the greatest possible diversity of people are able to perform well, meaning
that physical, cognitive and organizational sides of ergonomics are equally powerful aspects in
the design of inclusive workplaces. As ergonomics widened its scope, it became the concern of
more and more stakeholders. Today, it is worthwhile to know that ergonomics has the potential
to concern, engage and/ or provoke many more people than just the workplace designer, the
ergonomist or the worker.

2. What is the purpose of production ergonomics?

It can be assumed that anyone in charge of a production system would want all of its sub-
components to function together with as much ease and efficiency as possible. When part of
that production system is human, the performance of the system as a whole may vary
depending on the daily form of the human workers. Although humans have great potential to
bring flexibility, innovation and problem-solving skills to the production system, they are at
risk for developing work-related musculo-skeletal disorders (alternately abbreviated MSDs or
WMSDs) as a result of physical work that overloads the human body. Symptoms of such risks
include discomfort, pain and recurring injuries,and the consequences of unhealthy loading
include suffering, inability to work and high costs for the company (in terms of compensation,
productivity losses and replacement of personnel). Also, human mental capacities are
dependent on sufficient support, stimulation and opportunities for rest. Without these health
factors, confusion, irritation, misinterpretation and serious errors can occur, potentially
causing material or personal harm. Finally, the interactions between human workers can at
best be a source of support, stimulation and a feeling of identity, but if they are dysfunctional
they can also cause demotivation, dissatisfaction and lack of engagement. In other words, the
purpose of production ergonomics is to design a workplace that is proactively built to remove
the risks of injury, pain, discomfort, demotivation and confusion.
How a company chooses to handle production ergonomics may vary with their size,
organizational form, previous history of involving ergonomics expertise, project experiences,
access to standards, previous knowledge of methods and tools, and expectations of different
stakeholders in the company on the person put in charge of ergonomics. A proactive approach
towards production ergonomics is characterized by getting ergonomics knowledge into the early
planning stages, seeing ergonomics as a source of long-term cost savings and a high regard for
keeping the workforce healthy. A reactive approach, on the other hand, usually leaves
ergonomics issues and risks unaddressed until problems start cropping up, such as worker
pain, injuries and sick leave. Quite frequently, companies with a reactive ergonomics approach
will try to solve problems with a healthcare service angle, which only serves to take care of the
symptoms and not the root cause of the problem, which then remains as a risk to other
workers.
3. How are ergonomics and human factors connected to engineering?
Engineers have a distinct advantage as workplace designers and improvers: companies that
hire engineers expect them to independently come up with analyses and suggestions for
change as part of improving systems and operations. Expectations from company leadership on
an engineer’s mind-set and skills often lead to a role where they are trusted to come up with
practical suggestions and even make decisions that change the workplace.
Other roles with ergonomics and human factors knowledge, such as ergonomists, occupational
health and safety (OHS) agents, medical/ health service staff, consultants, etc. may not always
have the same mandate, expectation or training to suggest design changes, purchases, work
task modifications, etc. – and if they do, those with a medical or physiotherapeutic background
may be limited in scope to merely providing an analysis output, but not to contribute towards a
new design solution (unless the company in question is ergonomically mature enough to make
this possible using cross-functional teams; but this practice is not to be taken for granted).
Also, a disadvantage of addressing ergonomics and human factors from the medical/ health
angle is that they are often not able to act until workers have actually been complaining or
have gotten injured – and in such cases, interventions may end up tailored to easing the
situation only for the injured worker on an individual basis. It may be hard from that angle to
argue for any comprehensive changes in a proactive manner, if management is not convinced
that the problem can recur and cause trouble again. Therefore, workplace change agents with
an engineering role have a greater leverage to make sustainable improvements, because they
may be able to do something to address the root cause in the work system that may be a risk
for many workers. In other words, an engineer who has good knowledge of ergonomics (and its
monetary value) can have a very positive long-term impact on business because their
knowledge about human needs and capabilities can be translated into feasible system design
changes that can avert systemic health and safety risks. That is, engineers can do this, if they
are educated and trained to recognize matters of human well-being and system performance as
part of their work to make a workplace more efficient, productive and socially and economically
sustainable.

Quality control (standards and codes)

A standard is a set of specifications for parts, materials, or processes intended to achieve
uniformity, efficiency, and a specified quality. One of the important purposes of a standard is
to place a limit on the number of items in the specifications so as to provide a reasonable
inventory of tooling, sizes, shapes, and varieties.
A code is a set of specifications for the analysis, design, manufacture, and construction of
something. The purpose of a code is to achieve a specified degree of safety, efficiency, and
performance or quality. It is important to observe that safety codes do not imply absolute
safety.
The development of a Machine one the drawing board is part of the overall task of design. If the
designer's creation is to leave the drawing board and become a physical piece of hardware, it
must be manufacturable. In other words, the design of all the parts if a machine should be
such that they can be produced by some manufacturing methods and then assembled at
competitive cost. The designer should have a thorough knowledge of the capabilities and
limitations of the manufacturing methods. Only then can be properly design parts, select the
materials and manufacturing methods, specify tolerances, consider assembly procedures,
specify the reliability of the machine and incorporate human aspects in the design.

1. What is meant by "engineering standards”?

2. Why do we have standards and how did they come about?
3. Who enforces standards?

LEGAL FACTORS

Engineering design is not only applying scientific laws and principles to technical problems. It is
focused on improving the lot of society, and as such, it brings engineers into the mainstream of
business and industry. The following are examples of where a design engineer might be
concerned with legal and ethical issues:

 Preparing a contract to secure the services of a product data management fi rm.

 Reviewing a contract to determine whether a contractor who built an automated
production facility has satisfactorily fullfilled the terms of a contract.
 Deciding whether it is legal and ethical to reverse engineer a product.
 Managing a design project to avoid the possibility of a product liability suit.
 Protecting the intellectual property created as part of a new product development activity.
 Deciding whether to take a job with a direct competitor that is bidding on a contract in
the area where you are now working.

Assessment questions
1. A structural engineer designs structural steel roof for a client, using pirated structural design
software obtained from the Internet. The engineer later learns that the software gives accurate
stress analysis for tension, but does not properly predict buckling of beams in compression. The
computer program is repaired, and a revised analysis shows that the building is not as safe as
initially believed. An extreme snowfall could cause the beams in compression to buckle, and the
roof might collapse completely. Such a severe snowfall occurs about once every 5 years. What
should the engineer do?
a. Contact the client, disclose the problem, and try to negotiate a way to reinforce the
columns.
b. Hire a good lawyer for the Association's disciplinary hearing against the engineer for
negligence and unprofessional conduct.
c. Destroy all evidence of the revised analysis and hope for good weather.
d. Contact the client, disclose the problem and tell the client to sue the software developer.
2. The main purpose of the code of ethics is to
a. improve the image of the engineering profession.
b. conform to the tradition established by other professions.
c. conform to the tradition established by the technical societies.
d. protect the public.
3. James was asked to review a design that's not under his field of expertise, and he decided to
take that responsibility. Is it ethical?
a. Yes
b. No

4. Ergonomics has expanded as a discipline in its own right over the past 50 years and there is
often overlap between what ergonomists and work psychologists do. Simply put, ergonomics has
evolved to be concerned with:
a. adapting the person to the workplace.
b. design of work equipment.
c. design and development of equipment.
d. design of whole systems of work.

5. Ergonomics is the science of fitting the job to the worker.

a. True
b. False

6. From an ergonomic point of view, the choice of tool should depend?

a. On the task
b. On worker characteristics
c. On the price
d. On the task and the worker characteristics
 e. All the above

7. What are the BEST ergonomic considerations for hand tool design?
a. The tool is easy to use, the cheapest and the lightest
b. The tool is adjustable and has finger groves
c. The tool has overhead suspension, finger grooves and is easy to use
d. The tool allows for neutral postures, is easy to use, is selected to fit the workers hand
and is appropriate for the job
e. The tool is easy to use, is appropriate for the job and the cheapest

8. In an industrial setting, a pro-active ergonomic approach leads to...

a. A reduction in work-related injuries
b. Increased productivity
c. Reduced lost time and absenteeism
d. Reduce physical/mental stress
e. All of the above
a. Quality control helps to ____________ the risks of overdesign that ___________ the
overall cost.
a) Maximize, Increase
b) Minimize, Increase
c) Maximize, Decrease
d) Minimize, Decrease