The Occupational Ergonomics Handbook Second Edition Interventions, Controls, and Applications in Occupational Ergonomics The Occupational Ergonomics Handbook Second Edition fUNDAMENTALS AND ASSESSMENT TOOLS FOR OCCUPATIONAL ERGONOMICS INTERVENTIONS, CONTROLS, AND APPLICATIONS IN OCCUPATIONAL ERGONOMICS The Occupational Ergonomics Handbook Second Edition Interventions, Controls, and Applications in Occupational Ergonomics Edited by William S Marras The Ohio State University Columbus, Ohio, U.S.A Waldemar Karwowski University of Louisville Louisville, Kentucky, U.S.A Published in 2006 by CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2006 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group No claim to original U.S Government works Printed in the United States of America on acid-free paper 10 International Standard Book Number-10: 0-8493-1938-2 (Hardcover) International Standard Book Number-13: 978-0-8493-1938-9 (Hardcover) Library of Congress Card Number 2005052860 This book contains information obtained from authentic and highly regarded sources Reprinted material is quoted with permission, and sources are indicated A wide variety of references are listed Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use No part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc (CCC) 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400 CCC is a not-for-profit organization that provides licenses and registration for a variety of users For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe Library of Congress Cataloging-in-Publication Data Interventions, controls, and applications in occupational ergonomics / edited by William S Marras and Waldemar Karwowski p cm Includes bibliographical references and index ISBN 0-8493-1938-2 (alk paper) Human engineering Handbooks, manuals, etc Industrial hygiene Handbooks, manuals, etc I Marras, William S (William Steven), date II Karwowski, Waldemar, date TA166.I5685 2005 620.8'2 dc22 2005052860 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com Taylor & Francis Group is the Academic Division of T&F Informa plc and the CRC Press Web site at http://www.crcpress.com Preface Development of the 2nd edition of the Occupational Ergonomics Handbook was motivated by our desire to facilitate a wide application of ergonomics knowledge to work systems design, testing and evaluation in order to improve the quality of life for millions of workers around the world Ergonomics (or human factors) is defined by the International Ergonomics Association (www.iea.cc) as the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data, and methods to design in order to optimize human well-being and overall system performance Ergonomists contribute to the design and evaluation of tasks, jobs, products, environments, and systems in order to make them compatible with the needs, abilities, and limitations of people The ergonomics discipline promotes a holistic approach to the design of work systems with due consideration of the physical, cognitive, social, organizational, environmental, and other relevant factors The application of ergonomics knowledge should help to improve work system effectiveness and reliability, increase productivity, reduce employee health care costs, and improve the quality of production processes, services, products, and working life for all employees In this context, professional ergonomists, practitioners, and students should have a broad understanding of the full scope and breadth of knowledge of this demanding and challenging discipline Interventions, Controls, and Applications in Occupational Ergonomics contains a total of 52 chapters divided into eight parts Part I, Ergonomics Processes, describes the elements of the ergonomics processes, including success factors for implementation of industrial ergonomics programs, practical interventions in industry that utilize participatory approaches, surveillance, Occupational Safety and Health Administration (OSHA) recordkeeping requirements, and psychosocial work factors Part II, Surveillance, discusses the injury surveillance database systems and corporate health management for the design and evaluation of health in industrial organizations Part III, Industrial Process Applications, is devoted to ergonomics processes from the small and large industry perspectives The main focus of Part IV, Upstream Ergonomics, is on human digital modeling, as well as facilities planning and organizational design and macroergonomics Part V and Part VI deal with the engineering and administrative controls of work-related musculoskeletal disorders Part V, Engineering Controls, presents the methods and techniques for engineering control, including the knowledge of what works and what does not, general solutions for the control of upper extremity and low back disorders, application of lift assist rail systems and hand tools, as well such engineering controls as gloves, wrist supports, and lower extremity supports Part VI, Administrative Controls, discusses the theory and practice of ergonomics interventions in the workplace, worker selection for physically demanding jobs, physical ability testing, training, secondary assessment of worker functional capacities, interventions for low back pain, human resource management and selection, work v day length, shiftwork, and job rotation issues This part also provides an update on the use of back belts in industry, and discusses best practices for the prevention of musculoskeletal disorders at work Part VII, Medical Management, addresses the issues of medical management of work-related musculoskeletal disorders, systems approach to rehabilitation, wrist splints, and application of the clinical lumbar motion monitor Finally, Part VIII, Ergonomics Industrial Interventions, provides an overview of best practices for ergonomics interventions with respect to the design and use of chairs and office furniture, as well as design of computer keyboards and notebook computers This part also discusses ergonomics interventions in a variety of industries, including meat and poultry processing, agriculture, distribution centers (case picking), healthcare (patient handling), as well as service systems, that is, grocery stores/bakery, furniture manufacturing, and construction industry This section also addresses the problem of medical errors, discusses the challenges and rewards of applying ergonomics in developing areas, and looks into the future of human work The knowledge presented in this book should help the readers to improve their understanding of the complex interactions between the people at work and other systems, which must be considered in the context of rapidly changing Occupational Ergonomics technology and evolving social needs We hope that this book will be useful to the professionals, students, and practitioners who aim to optimize the design of systems, products, and processes, manage the workers’ health and safety, and improve the overall quality and productivity of contemporary businesses William S Marras The Ohio State University Waldemar Karwowski University of Louisville vi About the Editors William S Marras, Ph.D., D.Sc (Hon), C.P.E., holds the Honda endowed chair in transportation in the department of industrial, welding, and systems engineering at The Ohio State University He is the director of the biodynamics laboratory and holds joint appointments in the departments of orthopedic surgery, physical medicine, and biomedical engineering He is also the co-director of The Ohio State University Institute for Ergonomics Dr Marras received his Ph.D in bioengineering and ergonomics from Wayne State University in Detroit, Michigan He is also a certified professional ergonomist (CPE) His research is centered around occupational biomechanics Specifically, his research includes workplace biomechanical epidemiologic studies, laboratory biomechanic studies, mathematical modeling, and clinical studies of the back and wrist His findings have been published in over 170 refereed journal articles, books, and over 25 book chapters He also holds several patents, including one for the Lumbar Motion Monitor (LMM) Professor Marras has been selected by the National Academy of Sciences to serve on several committees investigating causality and musculoskeletal disorders He also serves as the chair of the Human Factors Committee for the National Research Council within the National Academy of Sciences His work has attracted national and international recognition He has been twice winner (1993 and 2002) of the prestigious Swedish Volvo Award for low back pain research as well as Austria’s Vienna Award for Physical Medicine He recently won the Liberty Mutual Prize for injury prevention research Recently, he was awarded an honorary doctor of science degree from the University of Waterloo for his work on the biomechanics of low back disorders In his spare moments, Dr Marras trains in Shotkan karate (a black belt), enjoys playing and listening to music, sailing, and fishing vii Waldemar Karwowski, Sc.D., Ph.D., P.E., C.P.E., is professor of industrial engineering and director of the center for industrial ergonomics at the University of Louisville, Louisville, Kentucky He holds an M.S (1978) in production engineering and management from the Technical University of Wroclaw, Poland, and a Ph.D (1982) in industrial engineering from Texas Tech University He was awarded the Sc.D (dr hab.) degree in management science by the Institute for Organization and Management in Industry (ORGMASZ), Warsaw, Poland (June 2004) He is also a board certified professional ergonomist (BCPE) He also received doctor of science honoris causa from the South Ukrainian State K.D Ushynsky Pedagogical University of Odessa, Ukraine (May 2004) His research, teaching, and consulting activities focus on human system integration and safety aspects of advanced manufacturing enterprises, human –computer interaction, prevention of work-related musculoskeletal disorders, workplace and equipment design, and theoretical aspects of ergonomics science Dr Karwowski is the author or co-author of more than 300 scientific publications (including more than 100 peer-reviewed archival journal papers) in the areas of work systems design, organization, and management; macroergonomics; human– system integration and safety of advanced manufacturing; industrial ergonomics; neuro-fuzzy modeling in human factors; fuzzy systems; and forensics He has edited or co-edited 35 books, including the International Encyclopedia of Ergonomics and Human Factors, Taylor & Francis, London (2001) Dr Karwowski served as a secretary-general (1997–2000) and president (2000–2003) of the International Ergonomics Association (IEA) He was elected as an honorary academician of the International Academy of Human Problems in Aviation and Astronautics (Moscow, Russia, 2003), and was named the alumni scholar for research (2004 –2006) by the J B Speed School of Engineering of the University of Louisville He has received the Jack A Kraft Innovator Award from the Human Factors and Ergonomics Society, USA (2004), and serves as a corresponding member of the European Academy of Arts, Sciences and Humanities viii Contributors David C Alexander Gene Buer Marvin J Dainoff Auburn Engineers, Inc Auburn, Alabama Crane Equipment and Service, Inc Subsidiary of Columbus McKinnon Corp Eureka, Illinois Psychology Department Miami University Oxford, Ohio W Gary Allread Institute for Ergonomics The Ohio State University Columbus, Ohio Charles K Anderson Advanced Ergonomics, Inc Dallas, Texas David Caple David Caple & Associates Pty Ltd Melbourne, Victoria, Australia Pascale Carayon Joseph M Deeb ExxonMobil Biomedical Sciences, Inc Annandale, New Jersey Jack Dennerlein Ecole des Mines de Nancy, France Harvard School of Public Health Boston, Massachusetts Ernesto Carcamo C.G Drury WISHA Services Washington State Department of Labor and Industries Olympia, Washington Department of Industrial Engineering University of Buffalo Buffalo, New York Physical Therapy Department College of Health Professions Temple University Philadelphia, Pennsylvania Don B Chaffin Bradley Evanoff University of Michigan Ann Arbor, Michigan Washington University School of Medicine St Louis, Missouri Patricia Bertsche Industrial, Welding and Systems Engineering The Ohio State University Columbus, Ohio Susan Evans Larry J Chapman Fadi A Fathallah A Asmus Industrial, Welding and Systems Engineering The Ohio State University Columbus, Ohio Ann E Barr Ross Laboratories Chicago, Illinois R.R Bishu Department of Industrial and Management Systems Engineering University of Nebraska Lincoln, Nebraska Marilyn Sue Bogner Institute for the Study of Human Error, LLC Bethesda, Maryland A.-M Chany Sue Evans & Associates, Inc Fairfax, Virginia Department of Biological Systems Engineering University of Wisconsin Madison, Wisconsin Biological and Agricultural Engineering Department University of California Davis, California David J Cochran Sue A Ferguson Department of Industrial Engineering University of Nebraska Lincoln, Nebraska Industrial, Welding and Systems Engineering The Ohio State University Columbus, Ohio ix