ergonomic factors in metal recycling sector: a challenge for ergonomic intervention theoni...

Ergonomic factors Ergonomic factors in metal recycling in metal recycling sector: A challenge sector: A challenge for ergonomic for ergonomic interventionintervention

Theoni KoukoulakiTheoni Koukoulaki(presentation: Antonis Targoutzidis)(presentation: Antonis Targoutzidis)

Recycling sector in Greece

Methods for assessment of ergonomic factors (QEC, RULA, KIM)

Painful work posts

Results of assessment in a sample of duties

General ergonomic principles

Proposed interventions

StructureStructure

Repetitive work

Painful body postures (extreme or static)

Use of force

Standing

Manual weight handling

Psychosocial factors

Ergonomic factors in recyclingErgonomic factors in recycling

18 systems for alternative handling, involving:Packaging (4)Vehicles (1)Electrical and electronic equipment (equipment, lamps)Lubricants (1)Used batteries (4)Used car tires (1)Construction and demolition waste (4)

Recycling sector in GreeceRecycling sector in Greece

27 units for packaging waste105 units for vehicles’ lifecycle end9 units for electrical and electronic equipment7 units for lubricant oil regeneration7 units for lead acid batteries6 units for mechanical processing, 1 for power exploitation, 1 for cutting

Recycling sector in GreeceRecycling sector in Greece

QEC (Quick Exposure Check),Geoffrey D., Woods V., Li. G., Buckle, P., The development of the Quick Exposure Check (QEC) for assessing exposure to risk factors for work-related musculoskeletal disorders, Appl Ergon., 2007

QEC assesses the exposure of upper limbs, QEC assesses the exposure of upper limbs, neck and back in static and dynamic duties. It neck and back in static and dynamic duties. It is one of the most recent methods for is one of the most recent methods for assessment of MSDsassessment of MSDs. .

Exposure levels are assessed for various work Exposure levels are assessed for various work postures, repetitive movements, use of force postures, repetitive movements, use of force and duration for various parts of body. It also and duration for various parts of body. It also takes interactions into accounttakes interactions into account..

Methods for assessment of Methods for assessment of ergonomic factorsergonomic factors

QEC (Quick Exposure CheckQEC (Quick Exposure Check))Duration of the taskDuration of the taskJ1 Less than 2 hoursJ2 2-4 hoursJ3 over 4 hours

Shoulder/ArmShoulder/ArmC Position of hands:C1 Waist heightC2 Chest heightC3 over shoulders

D D Shoulder arm movementShoulder arm movement D1 RareD2 Frequent D3 Very frequent

WeightWeightH1 light (5 kg or less)H2 moderate (6 -10 Kg)H3 heavy (11- 20 Kg)H4 very heavy (> 20 Kg)

Risk levelScore Low Medium High Very highS1: Back (static) 8-15 16-22 23-29 29-40S2: Back (dynamic) 10-20 21-30 31-40 41-56S3: Shoulder/arm 10-20 21-30 31-40 41-56S4: Wrist/hand 10-20 21-30 31-40 41-56S5: Neck 4-6 8-10 12-14 16-18

(Atamney et al, 1993),

It is a method for assessment of effects of It is a method for assessment of effects of repetitive movements on body, upper limbs repetitive movements on body, upper limbs and neckand neck. . Body postures are written down and scored Body postures are written down and scored through a check list.through a check list. Force required by muscles is estimated and Force required by muscles is estimated and scoredscored. . A global index risk combines all above scores A global index risk combines all above scores and action levels are definedand action levels are defined..

RULA (Rapid Upper Limb RULA (Rapid Upper Limb Assessment)Assessment)

RULARULA RULARULA

Action level Score Action1 1-2 Work postures

are accepted2 3-4 Further research

and potentially changes

3 5-6 Further research and changes soon

4 7+ Further research and changes immediately

RULARULARULARULA

Upper hand Lower hand Wrist

Neck

RULARULA RULARULA

Body

Legs

Steinberg, U.; Caffier, G.; Liebers, F.: Assessment of Manual Material Handling based on Key Indicators – German Guidelines. In: Handbook of Standards in Ergonomics and Human Factors. Ed. by W. Karwowski. Lawrenz Erlbaum Associates. Mahwah, New Jersey, London 2006. S. 319-338

AssessmentAssessmentLifting and carrying tasksLifting and carrying tasksPushing and pulling tasksPushing and pulling tasks

Parameters:Parameters:Frequency, durationFrequency, durationWeightWeightBody posturesBody posturesWorking conditionsWorking conditions

KIMKIM (Key Item) method, BauA(Key Item) method, BauA KIMKIM (Key Item) method, BauA(Key Item) method, BauA

KIMKIM (Key Item) method, BauA(Key Item) method, BauAMales Females Score

<10kg <5 1

10-20kg 5-10kg 2

20-30kg 10-15kg 4

30-40kg 15-25kg 7

>40kg >25kg 25

Working conditions Score

Good ergonomic conditions 0

Reduced workspace 1

Very short workspace and/or instable center of gravity of weight

2

Lifting Holding Carrying Score

No per day Duration per day

Distance per day

<10 <5min <300m 1

10-40 5-15min 300m-1km 2

40-200 15min-1h 1-4km 4

200-500 1-2h 4-8km 6

500-1000 2-4h 8-16km 8

>1000 >4h >16km 10

Body posture – weight position Score

Straight upper body, weight close to body 1

Light body bending or twisting, weight relatively close to body

2

Deep bending or light bending with twisting, weight far from body or over shoulders

4

Bending and twisting, weight far from body, unstable body, or sitting on knees

8

++

++

XX

Risk spectrum

Risk score

Description

1 <10 Low strain – low disorder probability

2 10-25 Increased strain – possible disorders to less adaptable workers. Redesign is useful

3 25-50 High strain - possible disorders to adaptable workers. Redesign is suggested

4 >50 Very high strain – high disorder probability. Redesign is necessary

KIMKIM (Key Item) method, BauA(Key Item) method, BauA

1. Unloading: KIM method1. Unloading: KIM method

Lifting Pushing Pulling

Risk spectrum Risk score Description

1 <10 Low strain – low disorder probability

2 10-25 Increased strain – possible disorders to less adaptable workers. Redesign is useful

3 25-50 High strain - possible disorders to adaptable workers. Redesign is suggested

4 >50 Very high strain – high disorder probability. Redesign is necessary

3636 112112 2222

2.2. Electronics: QEC - RULAElectronics: QEC - RULA

QEC

Score Low Medium High Very high

S1: Back (static) 8-15 16-22 23-29 29-40

S2: Back (dynamic) 10-20 21-30 31-40 41-56

S3: Shoulder/arm 10-20 21-30 31-40 41-56

S4: Wrist/hand 10-20 21-30 31-40 41-56

S5: Neck 4-6 8-10 12-14 16-18

Prolonged standing Repetitive work Pulling pallet jacks

4242

Action level Score Action

1 1-2 Work postures are accepted

2 3-4 Further research and potentially changes

3 5-6 Further research and changes soon

4 7+ Further research and changes immediately77

3. Press (screens):3. Press (screens): KIM methodKIM method

Hands over shoulders

Pulling large bags

Risk spectrum Risk score

Description

1 <10 Low strain – low disorder probability2 10-25 Increased strain – possible disorders to less adaptable

workers. Redesign is useful3 25-50 High strain - possible disorders to adaptable workers.

Redesign is suggested4 >50 Very high strain – high disorder probability. Redesign is

necessary

505088

4. White devices: KIM method4. White devices: KIM method

Manual weight handling

Prolonged standing and repetitive work

Risk spectrum Risk score

Description

1 <10 Low strain – low disorder probability2 10-25 Increased strain – possible disorders to less adaptable

workers. Redesign is useful3 25-50 High strain - possible disorders to adaptable workers.

Redesign is suggested4 >50 Very high strain – high disorder probability. Redesign is

necessary

112112

55. . Manual copper sort: Manual copper sort: QEC-RULAQEC-RULA

Hands over shoulders

Twisting BendingWork on knees

QEC

Score Low Medium High Very high

S1: Back (static) 8-15 16-22 23-29 29-40

S2: Back (dynamic) 10-20 21-30 31-40 41-56

S3: Shoulder/arm 10-20 21-30 31-40 41-56

S4: Wrist/hand 10-20 21-30 31-40 41-56

S5: Neck 4-6 8-10 12-14 16-18

Action level Score Action

1 1-2 Work postures are accepted

2 3-4 Further research and potentially changes

3 5-6 Further research and changes soon

4 7+ Further research and changes immediately

5252

77

The worker must have access to The worker must have access to working surface without twisting or working surface without twisting or stretching without particular stretching without particular reasonreason. .

Avoid strainful work postures by Avoid strainful work postures by redesigning work posts or redesigning work posts or reduction in exposurereduction in exposure. .

Avoid working on floor. Use working Avoid working on floor. Use working tablestables..

Suspend equipment from ceiling to Suspend equipment from ceiling to reduce strainreduce strain. .

General ergonomic principlesGeneral ergonomic principles

Avoid prolonged standing where possibleAvoid prolonged standing where possible..

If a task does not require high force and If a task does not require high force and can be performed in confined space the can be performed in confined space the worker can be sittingworker can be sitting. .

Sit/stand for works requiring sitting and Sit/stand for works requiring sitting and standing.standing.

Resting and breaksResting and breaks

General ergonomic principlesGeneral ergonomic principles

Investigation for pre-cutting of materials (reduction in initial Investigation for pre-cutting of materials (reduction in initial volume and weight of scrap)volume and weight of scrap)

Handling less volume – better material storage before Handling less volume – better material storage before processingprocessing

Changes in productivity assessment (e.g. by table, collaboration)Changes in productivity assessment (e.g. by table, collaboration)

Assessment based on material’s handling difficulty (e.g. Assessment based on material’s handling difficulty (e.g. materials with cables) and not only based on weightmaterials with cables) and not only based on weight

Resting and breaksResting and breaks

Use of grapnels for “hair opening” in copperUse of grapnels for “hair opening” in copper

Changes in the shape of table and placement of bins to avoid Changes in the shape of table and placement of bins to avoid upper limb stretching and body twistingupper limb stretching and body twisting

Proposed interventionsProposed interventions

prep

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asse

ssm

ent

tech

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Use of mechanical lifts and conveyors for lifting white devices Use of mechanical lifts and conveyors for lifting white devices and other heavy weights to reduce manual handling.and other heavy weights to reduce manual handling.

AutomatisationAutomatisation

Training in correct manual lifting and breaksTraining in correct manual lifting and breaks

Better arrangement of materials around the press to reduce Better arrangement of materials around the press to reduce carrying large bagscarrying large bags

Conveyors must have he correct height and width to avoid Conveyors must have he correct height and width to avoid bending and stretchingbending and stretching

Improvement of tables in electronics and placement of waste Improvement of tables in electronics and placement of waste bins on conveyorsbins on conveyors

Proposed interventionsProposed interventions