in ergonomics, the whole person matters · in ergonomics, the whole person matters aec orlando 2014...
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In Ergonomics,
The Whole Person Matters
AEC Orlando 2014
Colin G. Drury
Applied Ergonomics Group Inc.
Colin Drury, IIE/ACE Webinar
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Why Does the Whole Person
Matter?
Practitioners of Ergonomics / Human
Factors (E/HF) exist to make things better,
typically in the workplace.
When we go in to a new work situation, we
cannot be sure what the problems are.
They may not be what management thinks
an E/HF should do!
Can we build on our success to do more?
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Is the E/HF issue MSD, or cuts, or lighting, or incentives?
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Is the E/HF issue Steps/Falls, or restricted spaces, or quality?
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Is the E/HF issue
chemical weapons
safety..
or working in
DPE suits…
or isolation on
an atoll?
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The Point?
At first, we just don’t know for certain!
Typically the people who call us in
(or we!) have rather fixed ideas of what
E/HF practitioners should be doing:
Reducing musculo-skeletal disorders
Reducing complaints of office workers
Reducing human errors
Making the workforce happier
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All of the Above?
We come from a rather broad training in
E/HF: physical, cognitive, socio-technical
…but we don’t always get to use this
breadth in the race for rapid evaluations
and quick fixes (important as these are!)
Can we write ourselves a broader job
description?
Surprise and (hopefully) delight customers
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Back to Basics
The International Ergonomics Association
(IEA) defines the purpose of ergonomics
as “…to optimize human well-being and
overall system performance.”
Both are equally important measures:
Human Well-being
System Performance
Without both, we can’t optimize.
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Examining B-737 Hold for Cracks
Posture or Performance? Both!
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The Good News:
What we do for human well-being often
improves system performance (and vv.)
e.g. TQM and E/HF at L. L. Bean sewing
plant (Rooney, 1992/3). Replaced piece
work with annual bonus, added job
complexity with cross-training &
teamwork, plus E/HF job analysis
78% Drop in MS injuries over 4 years
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Remember Film?
Practical Manufacturing Example
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Practical Manufacturing Example
Two Assembly lines for Fun Saver
disposable cameras, multiple stations/line
For each Station, we measured:
Postural Stress, using non-neutral body
angles for back, neck, wrists, shoulders
Time Stress: Time needed for each task
despite fixed line speed
Quality: Errors /week at each station
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Kim, S.-W., Drury, C. G. and Lin, L. (2001). Ergonomics and Quality in paced assembly lines.
Human Factors and Ergonomics in Manufacturing, Vol. 11(4), 377-382.
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What Drives Camera Assembly Errors:
Line A:
Errors/week = 94.2 + 17.2 (Time Needed )
+ 3.63 (Posture Score), r2 = 0.863, p = 0.051
Line B:
Errors/week = -45.3 + 3.0 (Time Needed)
+ 3.9 (Posture Score), r2 = 0.584, p = 0.001
Quality is driven by E/HF factors:
Pacing & Posture!
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What do we Mean by Measures?
Human well-being: No injuries, No
illness AND job satisfaction
System Performance: Speed/
productivity AND Accuracy, Quality, No
Waste
It was never just about injury reduction!
In fact, all measures can be thought of as
errors we can reduce by E/HF design.
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Examples of Aha! Moments
When you are asked to look at factor A,
the workplace situation forces you to look
at B, or C or all of the above.
This is hardly new, but can still become a
restriction to factor A for many E/HF
practitioners.
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At a large airline, Safety Culture was Issue A…
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At a large airline, Safety Culture
was Issue A…
But artefacts revealed
much about the system
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At a food plant, product damage
was Issue A…
…but excess handling was a
root cause of damage & MSD.
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At a garment plant, MSD was Issue A…
… but managerial
issues were part
of the cause.
But 100% Direct Incentive!
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For Spacecraft Maintenance,
the brief was spot-on.
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The procedure
documents did not
meet E/HF good
practice.
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WARNING
THIS SEQUENCE INVOLVES HAZARDOUS
HYPERGOLIC OPERATIONS. PAD CLEAR, ORBITER
CONFIGURED FOR REMOTE OPERATION AND
PERSONNEL IF ON STATION, ATTIRED IN SCAPE
SHALL BE VERIFIED BEFORE PROCEEDING.
S0024 CONTROLS THE FOLLOWING REQUIREMENTS:
1. CLEAR PAD TO PERIMETER SPACE
2. VERIFY ESSENTIAL PERSONNEL ATTIRED IN
SCAPE
3. INITIATE RECORDING OF REQUIRED CAMERAS
AFTER PERSONNEL ARE ON STATION.
CAUTION
IF THE CROSSFEED AND ENGINE FEEDLINES ARE
SOFTFILLED AND THE PRESSURES ARE GREATER
THAN 70 PSIA, THIS SEQUENCE CAN NOT BE RUN
IN PARALLEL WITH THE FLOW INITIATION
SEQUENCER.
NOTE
OPERATIONS INVOLVING CRIT 1, 1R AND/OR 1S
ITEMS ARE CONTAINED IN THE FOLLOWING
SEQUENCE/STEPS.
WARNING not in text box
CAUTION not in text box
NOTE not in text box
WARNING contains action
steps
Conditional steps not clear
No end point if condition TRUE
All text in CAPITALS
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CAUTION as IF, THEN, ELSE
Warning, Caution
and Note in boxes
Action steps as procedure
steps
Upper and Lower Case
Use STE words only
WARNING
This sequence involves hazardous hypergolic
operations. Follow this procedure from S0024 for
safety:
1. Clear pad to perimeter space
2. Make Sure essential personnel are attired in
scape
3. Start recording of required cameras after
personnel are on station.
CAUTION
IF the crossfeed and engine feedlines are
softfilled
AND the pressures are greater than 70 psia,
THEN do not run this sequence in parallel with the
flow initiation sequencer
ELSE ????????
NOTE
The following sequence/steps contain operations
involving Crit 1, 1R and/or 1S items.
Start with action verb
Use Active Voice
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So What do we Know in E/HF?
Physical E/HF: Body sizes, reach, clearance,
biomechanics, MSD causation, thermal
environment,…
Cognitive E/HF: Error causation,
Speed/accuracy Trade-off, Error-proofing of
controls & displays
Socio-Technical E/HF: (Macro Ergonomics)
Influence of work system on workers, work
design
Plus appropriate analysis tools for each
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Physical E/HF
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…includes Handles!
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Cognitive E/HF
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Cognitive
Includes
Inspection
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Cognitive includes arrays –
Good for inspection…
…terrible for controls!
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Fun Stuff from
The Cognitive Side
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Socio-Technical
Systems
Reorganization of whole shop floor
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Practical Advice
Presenting Symptoms are not the end of
your diagnosis.
Build on your reputation for success.
Work with other groups: Product Design
(e.g. shoe factory), Six-Sigma/Lean, (add
today’s latest movement here)
Many examples of E/HF + Quality, less
for E/HF and Lean.
Brush up on the Other Factors:
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Use Certification for Breadth
Example: Board of Certification in
Professional Ergonomics (BCPE) covers
the underlying science and application
If we all had this at our fingertips, we
could be more effective:
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Some BCPE Core Competencies
Anthropometry, Physiology,
Biomechanics
Psychology, information, software
Physical environment
Social environment
Organizational Environment, Macro Ergs
…includes tools for each.
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Don’t Forget the Fundamentals
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Don’t stop improving
Physical Work – it is the
basis of your reputation
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Use Broad Analysis Tools
Many physical work analysis tools (you
know them already)
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Action
level
RULA
score Interpretation
1 1-2 The person is working in the best posture with no risk of injury from
their work posture .
2 3-4
The person is working in a posture that could present some risk of
injury from their work posture, and this score most likely is the
result of one part of the body being in a deviated and awkward
position, so this should be investigated and corrected.
3 5-6
The person is working in a poor posture with a risk of injury from
their work posture, and the reasons for this need to be investigated
and changed in the near future to prevent an injury
4 7+
The person is working in the worst posture with an immediate risk
of injury from their work posture, and the reasons for this need to be
investigated and changed immediately to prevent an injury
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Use Broad Analysis Tools
Many physical work analysis tool (you
know them already)
Try Hierarchical Task Analysis for a
broader view.
Can find where mismatches occur
between job demands and human
capabilities
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HTA Format via TaskArchitect®
HTA for Mining
Haul Truck
Operation
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Use Broad Analysis Tools
Many physical work analysis tool (you
know them already)
Try Hierarchical Task Analysis for a
broader view
Analyze Accident Patterns
Colin Drury, IIE/ACE Webinar
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Ftl06c32
1.1.1.2:
Driving, Lost
Control,
Mechanical
Failure,
inadequate
performance
At 9:50 a.m. on Tuesday, May 23, 2006, a 23-year old miner with 10 months of
mining experience was fatally injured at XXX Coal LLC, YYY# 1 Mine. The accident
occurred when ZZZ, driving a Mack water truck, lost control while descending a steep
mine access road. The accident occurred because the service brakes were not
adequate, the engine brake was inoperative, and because the victim was not task
trained. The approved training plan was not followed and effective procedures were
lacking to ensure adequate braking systems. The truck overturned and slid over an
embankment.
Note: The actual accident had been analyzed in the Fatalgram
to ensure no repetition of that accident at that workplace.
Our task was to find repeating patterns.
Analyzed 40 Fatal Accidents to Develop Patterns:
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Use Broad Analysis Tools
Many physical work analysis tool (you
know them already)
Try Hierarchical Task Analysis for a
broader view
Analyze Accident Patterns
Try Socio-Technical Systems Analysis for
an even broader view. Good methodology
in “Performance by Design, Taylor (1993).
Colin Drury, IIE/ACE Webinar
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Discovery
Social Analysis Technical Analysis
Joint Optimization
Provisional Design
Implementation
System Scan
Socio-
Technical
Systems
Design
Colin Drury, IIE/ACE Webinar
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STS Design procedure
Starts with Discovery that something must
be done
System Scan defines inputs, outputs,
demands, purpose, boundaries
Technical Analysis focuses on product, not
on process or tasks. Where do Variances
arise? Where do they get controlled? Who
controls?
Produces technical variance matrix and
control table
Colin Drury, IIE/ACE Webinar
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Why Does the Whole Person
Matter?
Really the Whole Person +
the Whole System
Be aware of all aspects – You never know
beforehand where the issue might be.
Affect well-being AND performance.
Make a nuisance of yourself – expand
your boundaries
Colin Drury, IIE/ACE Webinar
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Applied Ergonomics Group Inc.
…and Enjoy
your Work