Integration of IE capabilities with Ergonomics in an advanced process design model enables preventive ergonomics and drives productivity improvement

1. Ergonomic Recovery Model
for Cyclical Industrial Work
Gabriele Caragnano
Technical Director Fondazione Ergo (Italy)

2. Ergonomic Recovery Model (ERM)
• It’s a model to determine the fair
quantity and distribution of
recovery periods within a workday
in industrial operations with
repetitive manual work cycles
• The goal of the model is to keep
the biomechanical load/local
muscle fatigue generated by the
planned cyclical work under
control (within the limits defined
in the ISO 11228.1/2/3 and ISO
11226) and support Productivity
improvement
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

3. Comprehensive Work Design
G. Caragnano - Fondazione Ergo (ITA), AEC 2018
Anthropometry
Physiology
Psychology
Targets
Equipment
Motion economy
Shift duration
Breaks
Teamwork/Mgmt
Technology
Product config.
Performance
Saturation
Risks of WMSDs

4. ERM Process
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

5. Work Measurement
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

6. Work Measurement: Stop-Watch
Main issues
• Subjectivity of the Performance Rating
• Granularity of the measure
Stop watched time Ts-w
Rated Performance P
Standard performance P
Basic time Tb = Tsw x P
P
Stop watched time Ts-w = 100
Rated Performance P = 90% (MTM scale)
Standard performance P = 100%
Basic time Tb = 100 x = 9090
100
Stop-watch procedure Example
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

7. Work Measurement:
Pre-determined Time Systems (PTS)
MTM is the most
adopted PTS, which
assigns a manual
task a normalized
time based on a
standard level of
performance (100%
level).
Example: MTM-UAS system
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

8. MTM Technical Platform
Mass
(MTM-1/MTM-2)
Task
Work org level
Operator’ s
specialization level
Task
Hedge to cope with method deviations
Batch
(UAS)
Method
level
Task
One-of-a-kind
(MEK)
UAS is the MTM technique
typically used in automotive
and white goods industries
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

9. UAS time study example
The container is located on the ground
The parts container rests on a
pedestal or lifting platform
Description Code TMU Description Code TMU
Part on table AA1 20 Part on table AA2 35
Container on floor KB 60
80 35
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

10. Worker Saturation
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

11. Preliminary Line Balancing (Tb)
Oper. 01
Oper. 02
Oper. 03
Oper. 04
Oper. 05
Oper. 06
Oper. 07
Oper. 08
Oper. 09
Takt Time (example: produce 100 units in 100 min  Tk = 1 min)
Work-st A Work-st B Work-st C
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

12. Worker Biomechanical Load
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

13. Ergonomic Assessment (EAWS)
Developed by and
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

14. Overall EAWS Evaluation
EAWS provides one score for each Macro-Section (whole body and
upper limbs), which is shown in a traffic light scheme (green, yellow,
red) according to the Machinery Directive 2006/42/EC (EN 614).
0-25
Points
Low risk Recommended; no action is needed
>25-50
Points
Possible risk
Not recommended; redesign if possible,
otherwise take other measures to control
the risk
>50
Points
High risk
to be avoided; action to lower the risk is
necessary
Green
Yellow
Red
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

15. Work Allowance Setting
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

16. ERM Model
EAWS score (OLI)
% Time Allowance
Main global users
G. Caragnano - Fondazione Ergo (ITA), AEC 2018 ISO_NP TR 23076 in progress

17. Balancing the Work Load
G. Caragnano - Fondazione Ergo (ITA), AEC 2018

18. ERM model is designed to balance the work
load and optimize Productivity
G. Caragnano - Fondazione Ergo (ITA), AEC 2018