design for ergonomics/human factors”human factors ergonomics reliability usability how do we...

“Design for Ergonomics/Human Factors”Brock Anderson MS, CPE, CIE, LSSBB, CSCS

CEO – Principal Consultant

“Me” In a Minute

“Neck – Up”Goal: Design work to fit the

mind.

1. Reduction in Errors2. Faster Decision Making3. Accurate Decision Making

“Neck – Down”Goal: Design work to fit the

body.

1. Reduction Injuries 2. Increase Productivity3. Improve Quality

Ergonomics

Human Factors

Anonymous Survey: Top Drivers in DesignAssembly ● Modularity ● Materials ● Aesthetics ● Dimension ● Functionality ● Reliability ● Sustainability ● Usability

Materials Assembly Sustainability Dimension Modularity Aesthetics Functionality Usability Reliability

①

②

③

1

3

4

2

5

5 Absolute Essential

4 Key Driver

3 Considered

2 Nice to Have

1 Not Considered

Auto / Aero / Tool (256)

Furniture Engineers (210)

Anonymous Survey: Top Drivers in DesignAssembly ● Modularity ● Materials ● Aesthetics ● Dimension ● Functionality ● Reliability ● Sustainability ● Usability

Materials Assembly Sustainability Dimension Modularity Aesthetics Functionality Usability Reliability

$ $ $

1

3

4

2

5

$

VOC

$ Cost Margin

Story

Associated Reason Why…$ ?①

Assembly Modularity Materials

• Ease • Convenience • Recycled• Strength

Aesthetics Dimension Sustainable

• Size• Shape • Weight

• Emotion Driven• Look• Feel

• Energy Use• Durability

Functionality

Water Proof Watch…….

WARNING: TO MAINTAIN WATER-

RESISTANCE, DO NOT PRESS ANY BUTTONS

UNDER WATER

• Purpose “Fit”

Usability Reliability

• Turns On• Enhances Human Performance

• Works• Meets Exact Outcome

Still Focused on the Product and not the Human…….

Reliability - % Predicted outcome is correct

42%

58%

Reliability - % Predicted outcome is correct

Reliability - % Predicted outcome is correct

Reliability - % Predicted outcome is correct

Reliability - % Predicted outcome is correct

Reliability - % Predicted outcome is correct

Usability – Enhance Human Performance?

Usability - Enhance Human Performance?

Usability - Enhance Human Performance?

Usability - Enhance Human Performance?

Usability - Enhance Human Performance?

Usability - Meet Human Capability?

Usable or Reliable?

“Neck – Up”Goal: Process Efficiency1. Reduction in Errors

2. Faster Decision Making3. Accurate Decision Making

“Neck – Down”Goal: Make work fit the body.

1. Reduction Injuries 2. Increase Productivity

3. Improve Quality

Ergonomics Human Factors

UsabilityReliability

How do we improve?

• Visibility & Feedback

• Natural mapping

• Affordances

• Constraints

Improve Reliability : % Correct Outcome

• Visibility and Feedback• Ability to observe and process information that is applicable.

Type of Visual Readings

• Quantitative: precise numeric value needed• Qualitative: changes in direction• Check: within parameters of good/bad

Improve Reliability : Visibility and Feedback

Improve Reliability : Visibility and Feedback

Principle #1: Make relevant parts visible.

Principle #2: Give each action an immediate and obvious effect (no lag time)

Improve Reliability : Compatibility & Natural Mappings

Conceptual Movement Spatial

Principle #3: Capitalize on the concept of natural mappings

Improve Reliability : Info Scale

Principle #4: Capitalize on the concept of natural mappings

Improve Reliability : Affordances• Affordance provide strong clues to the operation of things.

• Suggest how the object should be used - “Verb”-able

• Users know what to do just by looking at the object.

Examples: • Door plates

• Knobs

• Button

Principle #5: Use the affordances of objects to help

infer their use……

Improve Reliability : Constraints

Constraints limit how the design can be used

Types:Physical

Square object and round hole

CulturalLight switches

LogicalOrder (1,2,3 or a, b, c)

Principle #6: Restrict the kind of interaction

that can take place at a given moment

“Neck – Up”Goal: Process Efficiency1. Reduction in Errors

2. Faster Decision Making3. Accurate Decision Making

“Neck – Down”Goal: Make work fit the body.

1. Reduction Injuries 2. Increase Productivity

3. Improve Quality

Ergonomics Human Factors

UsabilityReliability

How do we improve?

Ergonomics: Make Work Fit the Body

Normal Distributions

If your population distribution is symmetric and unimodal (i.e., with a hump in the middle), then all three measures coincide.

50% percentile male

95% percentile male5% percentile male

Dimension, In Body dimension Sex 5th 50th 95th 1. Stature (height) Male 63.7 68.3 72.6 Female 58.9 63.2 67.4 2. Eye height Male 59.5 63.9 68.0 Female 54.4 58.6 62.7 3. Shoulder height Male 52.1 56.2 60.0 Female 47.7 51.6 55.9 4. Elbow height Male 39.4 43.3 46.9 Female 36.9 39.8 42.8 5. Knuckle height Male 27.5 29.7 31.7

Female 25.3 27.6 29.9 13. Chest depth Male 8.4 9.5 10.9 Female 8.4 9.5 11.7

Anthropometric Data – Key Driver

Anthropometry

Creativity

Necessities

Intelligence

Determination

Visual Acuity

Strength

Age

Body Lengths

Body Circumference

Dexterity

Anthropos (human) + metrein (to measure)The study of how people vary in:

WDTFCTWSWT

ERCYIO

CPTSEW

CPTSEW

Primary Measures Secondary Measures

1. Functional Space

– Static (standing still)

Two dimensional

Three dimensional

– Functional

2. Strength

• Isometric• Dynamic – isotonic, iso- kinetic, iso-inertial etc.• MVC joint torques

3. Biomechanical / inertial properties • Segment mass• Segment center of gravity locations• Muscle attachment sites and lever arms• Failure stresses of ligaments, tendons, bones etc.

Additional Anthro Considerations

50% percentile male

95% percentile male5% percentile female

Average

50% percentile male

95% percentile male5% percentile female

ExtremeExtreme

50% percentile male

95% percentile male5% percentile female

Adjustability 95% = GOAL

Who to design for?

Who uses this? What’s its function?Design for Avg?

Who uses this? What’s its function?

Who to design for?

Who uses this? What’s its function?Customer Spec’s Cost?

Who to design for?

Who uses this? What’s its function?

Who to design for?

Lifting / Working Heights

24”

62”

Hand Working Lifting

Shelving Height(s)

Reaches

22”

Tools

Standing Workstation Height

Standing is preferred when:

- Work that requires reaches outside the comfortable envelope.

- Frequent walking is required

- Frequent low, high or extended reaches are required

- Large forces are to be exerted or heavy items are handled

- No leg room is available (knee)

Sitting Work Height

Sitting is preferred when:

- Longer work periods are required (+6 hours)

- Work tools and items are easily handled without excessive reaching

- User needs to use foot controls (or both feet at same time)

- High precision is needed

Better Usability

Better Usability

Better Usability

Better Usability

Better Usability

Better Usability

Better Usability

Better Usability

Better Usability

Business Case to Design for Ergo (not including W. C costs savings associated with injury reduction).

Quality Productivity Safety/Sustainability Design Lean

Specific examples on following pages.

• BDL

• Wasted product• Route to Market

• Time Savings

• ↓ MMH

• Wasted Motion

• Untapped Skill

• ↓ Carbon Footprint

• ↓ Fossil Fuel Use

• Risk Management

• OSHA Compliance

• Employee Engagement

• Culture & Behavior

• Packaging

• Facility

• Gizmos / Gadgets

• Quality: = $3,744 / Facility / Year

• avg. 9 pallets are broken/week @ $8.00 / pallet.

• Time: $541.66/ employee /year

• avg: 25 min/week or 21.6 hours / year

• Design: Pallet Stop – cost $3.50 to make

Cost Savings Example: Warehouse

• Safety: Risk Management - Employee Engagement

• Lean: avg. eliminates pulling 68 pallets / day

Time Savings:30 workers / Facility

= $21,640

Quality Savings: $460,000 Annually Time Savings: $65,700 Annually

Risk Reduction: High to Low

LEAN

WASTED MOTION

Productivity Savings: $46K Annually

225 Twisting Motions / Day

Lean Savings: ↓ 120 Twists / Day

1. Human Design Considers:- Usability, Reliability & Functionality

2. Consider WHO and WHAT the user will be doing

3. Build the Business Case to Justify Design (Redesign)

Key Take Away

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Contact Info:Brock Anderson CPE, LSSBB, CSCSFounder & Principal Consultant

404-804-6383info@ergo-ology.comwww.ergo-ology.com

Current clients observing increased profits and minimized loss (injury):