Acceptable weights and physiological costs of performing combined manual handling tasks in restricted postures

Eight healthy, male underground coal miners (mean age=36·9 yrs±4·5 SD) participated in a study examining psychophysical acceptable weights and physiological costs of performing combined lifting and lowering tasks in restricted headroom conditions. Independent variables included posture (stooping or kneeling on two knees), task symmetry (symmetric or asymmetric), and vertical lift distance (35 cm or 60cm). All tasks were 10min in duration and were performed under a 1·22 m ceiling to restrict the subject's posture. Subjects were required to raise and lower a lifting box every 10 s, and asked to adjust the box weight to the maximum amount they could handle without undue strain or fatigue. During the final 5 min of each test, data were collected to determine the energy expenditure requirements of the task. Results of this study demonstrated that psychophysical lifting capacity averaged 11·3% lower when kneeling as compared to stooping. Subjects selected 3·5% more weight in asymmetric tasks, and lifted 5·0% less weight to the 60 cm shelf compared to the 35 cm shelf. Heart rate was not significantly affected by posture, but was increased an average of 4 beats/min in asymmetric conditions, and by 3·5 beats/min while lifting/lowering to/from the high shelf. Oxygen uptake was increased by 9% when stooped, by 10% when lifting/lowering asymmetrically, and by 8·2% when performing the task to the high shelf. Results of this study indicate that, wherever possible, materials that must be lifted manually in low-seam coal mines be designed in accordance with the decreased lifting capacity exhibited in the kneeling posture.     

Acceptable weights and physiological costs of performing combined manual handling tasks in restricted postures

Eight healthy, male underground coal miners (mean age = 36.9 yrs +/- 4.5 SD) participated in a study examining psychophysically acceptable weights and physiological costs of performing combined lifting and lowering tasks in restricted head-room conditions. Independent variables included posture (stooping or kneeling on two knees), task symmetry (symmetric or asymmetric), and vertical lift distance (35 cm or 60 cm). All tasks were 10 min in duration and were performed under a 1.22 m ceiling to restrict the subject's posture. Subjects were required to raise and lower a lifting box every 10s, and asked to adjust the box weight to the maximum amount they could handle without undue strain or fatigue. During the final 5 min of each test, data were collected to determine the energy expenditure requirements of the task. Results of this study demonstrated that psychophysical lifting capacity averaged 11.3% lower when kneeling as compared to stooping. Subjects selected 3.5% more weight in asymmetric tasks, and lifted 5.0% less weight to the 60 cm shelf compared to the 35 cm shelf. Heart rate was not significantly affected by posture, but was increased an average of 4 beats/min in asymmetric conditions, and by 3.5 beats/min while lifting/lowering to/from the high shelf. Oxygen uptake was increased by 9% when stooped, by 10% when lifting/lowering asymmetrically, and by 8.2% when performing the task to the high shelf. Results of this study indicate that, wherever possible, materials that must be lifted manually in low-seam coal mines be designed in accordance with the decreased lifting capacity exhibited in the kneeling posture.     

Handles for manual materials handling

The humble handle is one device available to designers of products and packages to improve the coupling between a human operator and the load he/she has to lift, hold or carry. Studies of handle design show that handles can help and that some are better than others but agreement on how handles should be studied, parametric values of 'optimum' handles, and even criteria for handle choice is low. Design parameters are reviewed, two new experiments on handle diameter are presented and a guide for handle designers is provided.     

Seated work postures for manual,visual and combined tasks

An awkward and static work posture has been recognized as a risk factor for workrelated musculoskeletal problems. The objective of this study was to investigate some of the factors that can influence the posture adopted during work and in particular aspects of the task and how their influence is affected by work height. Three types of task were studied: a peg-hole assembly task, which was largely manual with very little visual component; a visual character identification task; and a combination of the two. Two levels of difficulty were included in each of the manual and visual elements. Postures of the head/neck, trunk and arm were recorded during performance of these tasks. The results showed that type and difficulty of task do influence the posture adopted, and that some of the postural responses (although complex) are predictable so that poor postures could be improved by adjusting task design in addition to workplace layout.     

Analysis of multiple activity manual materials handling tasks using A Guide to Manual Materials Handling

Manual handling of materials continues to be a hazardous activity, leading to a very significant number of severe overexertion injuries. Designing jobs that are within the physical capabilities of workers is one approach ergonomists have adopted to redress this problem. As a result, several job design procedures have been developed over the years. However, these procedures are limited to designing or evaluating only pure lifting jobs or only the lifting aspect of a materials handling job. This paper describes a general procedure that may be used to design or analyse materials handling jobs that involve several different kinds of activities (e.g. lifting, lowering, carrying, pushing, etc). The job design/analysis procedure utilizes an elemental approach (breaking the job into elements) and relies on databases provided in A Guide to Manual Materials Handling to compute associated risk factors. The use of the procedure is demonstrated with the help of two case studies.     

Seated work postures for manual, visual and combined tasks.

An awkward and static work posture has been recognized as a risk factor for work-related musculoskeletal problems. The objective of this study was to investigate some of the factors that can influence the posture adopted during work and in particular aspects of the task and how their influence is affected by work height. Three types of task were studied: a peg-hole assembly task, which was largely manual with very little visual component; a visual character identification task; and a combination of the two. Two levels of difficulty were included in each of the manual and visual elements. Postures of the head/neck, trunk and arm were recorded during performance of these tasks. The results showed that type and difficulty of task do influence the posture adopted, and that some of the postural responses (although complex) are predictable so that poor postures could be improved by adjusting task design in addition to workplace layout.     

A fuzzy neural network model for predicting clothing thermal comfort

This paper presents a Fuzzy Neural Network (FNN) based local to overall thermal sensation model for prediction of clothing thermal function in functional textile design system. Unlike previous experimental and regression analysis approaches, this model depends on direct factors of human thermal response — body core and skin temperatures. First the local sensation is predicted by a FNN network using local body part skin temperatures, their change rates, and core temperature as inputs; then the overall sensation is predicted. This is also performed by a FNN network. The FNN networks are developed on the basis of the Feed-Forward Back-Propagation (FFBP) network; the advantage of using fuzzy logic here is to reduce the requirement of training data. The simulation result shows a good correlation between predicted and the traditional experimental data.     

Manual materials handling capabilities in non-standard postures

Research efforts to establish manual materials handling (MMH) capabilities of individuals and populations have been conducted for many years. Most of the previous efforts have explored ‘standard postures’, utilizing two-handed, symmetric, sagittal plane MMH using unrestricted postures. Recognizing that many industrial MMH activities do not utilize ‘standard postures’, recent research projects have explored psychophysicaly determined MMH capacities in a variety of non-standard postures. Among the non-standard postures examined were: twisting while lifting or lowering, lifting and lowering from lying, sitting, kneeling, and squatting positions, and carrying loads under conditions of constricted ceiling heights. This paper presents the results of a series of previous research efforts at Texas Tech University. The results are presented in the form of population capabilities of both males and females for 99 MMH tasks using ‘non-standard postures’. The data tables contain means and standard deviations of the data, as well as percentile distributions for the subject populations. Sample sizes for the experimental populations ranged from 45 to 50 subjects of each sex in the first three experiments to 20 subjects of each sex in the fourth set of experiments.     

Optimum design of containers for manual material handling tasks

The container in manual material handling represents the point of interface between the worker and his task as well as with the surrounding environment. It is at this point that many of the well known handling hazards occur which manifest themselves in stresses and strains that are transmitted to the body via the musculo-skeletal system. If a substantial number of handling hazards is to be controlled or eliminated at the source, containers designed in accordance with principles of biomechanics and related recommendations provide a logical starting point. The container characteristics to be considered in the design process are weight (and its distribution), shape, stiffness, and availability of coupling devices. This paper presents several examples which outline and detail a number of problems associated with the design of containers involved in manual tasks. Application of basic mechanics, coupled with the use of optimization techniques, is presented as the approach for dealing with the hazards and problems of containers.     

A national cross-sectional study in the Danish wood and furniture industry on working postures and manual materials handling

Musculoskeletal disorders constitute a major problem in the wood and furniture industry and identification of risk factors is needed urgently. Therefore, exposures to different work tasks and variation in the job were recorded based on an observation survey in combination with an interview among 281 employees working in wood working and painting departments. A questionnaire survey confirmed high frequencies of symptoms from the musculoskeletal system: The one-year prevalence of symptoms from the low back was 42% and symptoms from the neck/shoulder was 40%. The exposure was evaluated based on: (1) classification of work tasks, (2) work cycle time, (3) manual materials handling, (4) working postures, and (5) variation in die job. Among the employees 47% performed feeding or clearing of machines, 35% performed wood working or painting materials, and 18% performed various other operations. Among the employees 20% had no variation in their job while 44% had little variation. Manual materials handling of 375 different burdens was observed, which most often occurred during feeding or clearing of machines. The weight of burdens lifted was 0·5-87·0 kg, where 2% had a weight of more than 50 kg. Among the lifting conditions 30% were evaluated as implying a risk of injury. An additional risk factor was the high total tonnage lifted per day, which was estimated to range from 132 kg to 58 800 kg. Working postures implied a risk of injury due to prolonged forward and lateral flexions of the neck, which was seen most frequently during wood working or painting materials. These data substantiate the finding that work tasks mainly during feeding or clearing of machines imply a risk of injury to the low back and a risk of injury to the neck and shoulder area mainly during wood working or painting materials. Optimal strategies for job redesign may be worked out by using these data in order to prevent occupational musculoskeletal disorders.     

Two-dimensional biomechanical model for estimating strength of youth and adolescents for manual material handling tasks

Youth and adolescents are routinely engaged in manual material handling (MMH) tasks that may exceed their strength capability to perform the task and may place them at excessive risk for musculoskeletal disorders. This paper reports on a two-dimensional biomechanical model that was developed to assess MMH tasks performed by youth 3-21 years of age. The model uses age, gender, posture of the youth performing the MMH activity, and weight of the load handled as input, and provides an estimate of the strength demands of the task and spinal disc compression and shear force resulting from the activity as output. The model can be used to assess whether a specific MMH task exceeds the strength demands for youth of certain ages or genders, which of the internal muscle strengths are most affected, and provides information about the estimated spinal disc compression and shear forces on the spine as a result of the specified MMH task. These results would be helpful in deciding whether a task is appropriate for a youth to perform or whether a certain task modification may be sufficient in reducing the physical demands to a level acceptable for a youth of certain age and gender.     

A knowledge-based system for the design of manual materials handling

The purpose of this paper is to develop and test an expert system for the design of new and existing repetitive manual materials handling (RMMH) tasks. For new jobs, the expert system provides recommendations on the maximum acceptable weight to be handled under a variety of worker and task variables. For existing jobs, the expert system provides possible solutions to the design of RMMH tasks if the weight handled on the job is greater than the recommended one. The expert system was implemented on an IBM PCXT personal computer. Two examples on how to utilise the expert system in designing new and existing jobs are given.     

Prospective validation of a low-back disorder risk model and assessment of ergonomic interventions associated with manual materials handling tasks

The evaluation of low-back disorder risk associated with materials handling tasks can be performed using a variety of assessment tools. Most of these tools vary greatly in their underlying logic, yet few have been assessed for their predictive ability. It is important to document how well an assessment tool realistically reflects the job's injury risk, since only valid and accurate tools can reliably determine whether a given ergonomic intervention will result in a future reduction in back injuries. The goal of this study was to evaluate how well a previously reported lowback disorder (LBD) risk assessment model (Marras et al. 1993) could predict changes in LBD injury rates as the physical conditions to which employees are exposed were changed. Thirty-six repetitive materials handling jobs from 16 different companies were included in this prospective cohort study. Of these 36 jobs, 32 underwent an ergonomic intervention during the observation period, and four jobs in which no intervention occurred served as a comparison group. The trunk motions and workplace features of 142 employees performing these jobs were observed both before and after workplace interventions were incorporated. In addition, the jobs' LBD rates were documented for these pre- and post-intervention periods. The results indicated that a statistically significant correlation existed between changes in the jobs' estimated LBD risk values and changes in their actual low-back incidence rates over the observation period.Linear and Poisson regression models also were developed to predict a change in a job's incidence rate and the number of LBD on a job respectively, as a function of the job's risk change using this assessment model. Finally, this prospective study showed which ergonomic interventions consistently reduced the jobs' mean low-back incidence rates. These results support use of the LBD risk model to assess accurately a job's potential to lead to low-back injuries among its employees.     

Prospective validation of a low-back disorder risk model and assessment of ergonomic interventions associated with manual materials handling tasks

The evaluation of low-back disorder risk associated with materials handling tasks can be performed using a variety of assessment tools. Most of these tools vary greatly in their underlying logic, yet few have been assessed for their predictive ability. It is important to document how well an assessment tool realistically reflects the job's injury risk, since only valid and accurate tools can reliably determine whether a given ergonomic intervention will result in a future reduction in back injuries. The goal of this study was to evaluate how well a previously reported low-back disorder (LBD) risk assessment model (Marras et al. 1993) could predict changes in LBD injury rates as the physical conditions to which employees are exposed were changed. Thirty-six repetitive materials handling jobs from 16 different companies were included in this prospective cohort study. Of these 36 jobs, 32 underwent an ergonomic intervention during the observation period, and four jobs in which no intervention occurred served as a comparison group. The trunk motions and workplace features of 142 employees performing these jobs were observed both before and after workplace interventions were incorporated. In addition, the jobs' LBD rates were documented for these pre- and post-intervention periods. The results indicated that a statistically significant correlation existed between changes in the jobs' estimated LBD risk values and changes in their actual low-back incidence rates over the observation period. Linear and Poisson regression models also were developed to predict a change in a job's incidence rate and the number of LBD on ajob respectively, as a function of the job's risk change using this assessment model. Finally, this prospective study showed which ergonomic interventions consistently reduced the jobs' mean low-back incidence rates. These results support use of the LBD risk model to assess accurately a job's potential to lead to low-back injuries among its employees.     

Manual materials handling capabilities in non-standard postures.

Research efforts to establish manual materials handling (MMH) capabilities of individuals and populations have been conducted for many years. Most of the previous efforts have explored 'standard postures', utilizing two-handed, symmetric, sagittal plane MMH using unrestricted postures. Recognizing that many industrial MMH activities do not utilize 'standard postures', recent research projects have explored psychophysically determined MMH capacities in a variety of non-standard postures. Among the non-standard postures examined were: twisting while lifting or lowering, lifting and lowering from lying, sitting, kneeling, and squatting positions, and carrying loads under conditions of constricted ceiling heights. This paper presents the results of a series of previous research efforts at Texas Tech University. The results are presented in the form of population capabilities of both males and females for 99 MMH tasks using 'non-standard postures'. The data tables contain means and standard deviations of the data, as well as percentile distributions for the subject populations. Sample sizes for the experimental populations ranged from 45 to 50 subjects of each sex in the first three experiments to 20 subjects of each sex in the fourth set of experiments.     

Usability of manual handling aids for transporting materials

Manual transport aids (trucks and trolleys) are in widespread use throughout most industries, but their use does not always result in the anticipated reduction of workload or musculoskeletal stress. A survey of users has shown that many of the aids currently used are poorly designed or inappropriate for the tasks performed. The information gained during the survey has been analysed to identify the most important design features and to provide guidance for their selection and evaluation, in order to ensure that aids are suitable for the tasks for which they are used and that they are effective and safe. It is clear that the first stage in establishing design criteria and guidelines should be developing an understanding of the task requirements and environmental conditions under which materials have to be transported in industry.     

Development of a microcomputer-based expert system for the analysis of manual materials handling tasks in industrial settings

This paper discusses the framework of a comprehensive knowledge-based expert system (M-LIFTAN) for analysis and design of manual materials handling tasks. The system, built using an expert system shell: ES / P ADVISOR written in Prolog 2, is implemented on a IBM AT® microcomputer. The knowledge base of M-LIFTAN allows the user to perform five different types of job analysis: (1) determination of maximum weights that can be handled manually by industrial workers for a variety of tasks, (2) determination of the NIOSH-based lifting recommendations, (3) prediction of maximum acceptable loads for lifting, (4) evaluation of the risk of overexertion injury while lifting loads under specified conditions, and (5) to seek advice for design/evaluation of complex manual handling tasks. An example of the consultation session illustrates the system's capabilities.     

A comprehensive data base for the design of manual materials handling

The main objective of the present paper is to provide a comprehensive data base of the material handling capabilities of the industrial work force. The data base encompasses the following: (1) five different types of manual materials handling activities, namely, lifting, lowering, carrying, pushing, and pulling, (2) worker variables (e.g., sex), and (3) task variables (e.g., frequency, and container size). The data base was developed for the IBM personal computer using the software package DBASE III PLUS.     

A novel optimization model for predicting trunk muscle forces during asymmetric lifting tasks

Low back pain (LBP) is a social and economic problem throughout industry. Repetitive asymmetric postures frequently occur in manual materials handling tasks and such asymmetric lifting has been epidemiologically linked to LBP. Therefore, biomechanical lifting models must be developed to predict muscle forces during asymmetric lifting tasks. This paper proposes an optimization model that was revised to take into account the activities of trunk muscles during asymmetric lifting tasks. Also, three optimization models (minimize maximum muscle intensity: MIN_I_MAX, minimize sum of magnitudes of the muscle forces raised to power 3: MIN_F³, and minimize sum of the muscle intensities raised to power 3: MIN_I³) are compared under various asymmetric lifting conditions. The revised model not only reflects the twisting effect of muscle force vectors for eight primary trunk muscles when trunk rotation is involved, but also accurately predicts the forces of left erector spinae, left latissimus dorsi and left external oblique muscles when compared with EMG signals obtained from experiments. Furthermore, MIN_I_MAX exhibits the best prediction capability among the three optimization models.Relevance to industryA novel optimization model proposed herein considers the twisting effect of muscle force vectors for eight trunk muscles when trunk rotation is involved. An accurate biomechanical model which reflects the asymmetric lifting conditions would significantly facilitate the evaluation of job and workplace design as well as provide a practical clinical evaluation technique.