| With the age of the standard workforce getting | | | | Many industrial applications require the operator to |
| older, it is very important to use anti-fatigue mats | | | | do some sort of repetitive movement/lifting. |
| and matting to put operators in a good ergonomic | | | | Typically, this is the main cause for injury in an |
| position. Unfortunately, injuries related to repetitive | | | | industrial application. The amount a weight an |
| lifting are commonplace in most current | | | | operator has to lift combined with the heights |
| manufacturing facilities. This is mostly due to the | | | | they have to lift from should be taken into |
| fact that the operators work cell was not laid out | | | | consideration. There are several ways to analyze |
| correctly in the first place. Following is a guideline | | | | if your workcell could potentially have problems, |
| to reference when laying out a new work cell. | | | | but a simple way to calculate if you might have a |
| There are many things to consider when laying | | | | problem is to use the NIOSH (National Institute of |
| out a new work cell. The four main items are | | | | Organizational Safety and Health) Lifting Calculator. |
| part pick/placement height, walking distance to | | | | The common sense approach will also work, if the |
| complete a work cycle, time spent standing and | | | | application is going to require repetitive lifting of |
| tools needed to complete the job. | | | | components weighing over 25 lbs, it is probably |
| First, the time spent standing in a work cell can | | | | wise to put some sort of lifting device in place. A |
| take a toll on an operator's body. When an | | | | correctly designed lifting device will not only take |
| operator stands or walks on hard flooring for | | | | the lifting load off the operator, but can also |
| more than two hours a day, it greatly increases | | | | increase productivity. To work in conjunction with |
| the chances of foot, leg, or lower back pain. In a | | | | the lifting device, a lift table is commonly used. |
| situation where this occurs, it is recommended | | | | A lift table alone may be all you need to correct a |
| that anti-fatigue or ergonomic matting is placed in | | | | bad ergonomic situation. By consistently picking |
| the work cell. With the new materials on the | | | | and placing in a good ergonomic position (above |
| market today, there is little excuse why you | | | | the waist and below the shoulders), the operators |
| could not put a ergonomic mat in almost any | | | | save the time from not having to bend over. |
| environment. | | | | Many injuries occur from lifting below your waist |
| Currently, there is matting specific for the | | | | or above your shoulders. Hence, a lift table can be |
| following environments; autoclavable mats, food | | | | an inexpensive way to prevent operator injury |
| production mats, welding mats, chemical | | | | due to strain. |
| resistance mats, clean room mats, grease | | | | Lastly, in many assembly environments operators |
| resistant mats and many more. A comfortable | | | | are required to use hand tools in order to |
| employee can not only make the working | | | | complete their task. The most typical type of tool |
| environment more positive, but can also reduce | | | | is the small tool typically weighing under 5 lbs. |
| the number of breaks needed due to fatigue. | | | | Hand and wrist injury are typically seen in these |
| Next, when laying out a new work cell, the | | | | areas. |
| amount of steps needed for an operator to | | | | In situations like this, a small tool balancer to |
| complete a single cycle is very important. There | | | | support the weight of the tool will take the |
| are two main reasons for this: | | | | weight off the operator. Tools like this can put a |
| 1. Each step an operator takes results in increased | | | | large amount of torque on operators over time. |
| cycle time. More steps equals increase cycle time, | | | | In situations like this, a torque reaction arm could |
| which, in turn, means less production. In a | | | | be considered. A torque reaction arm is a rigid |
| manufacturing facility that runs three shifts, an | | | | arm that takes the torque of the gun off the |
| extra 2 seconds per cycle could mean a drastic | | | | operators. |
| increase in production. | | | | In conclusion, there are several ways to set up a |
| 2. Each step an operator takes means more | | | | work cell for ergonomic efficiency. If the |
| energy exerted by the operator. Not only can | | | | environment you work in was inherited, there are |
| you increase your productivity just by laying out | | | | still many ways to improve the area. By taking a |
| your work cell to reduce the steps needed to | | | | proactive approach to operator ergonomics, a |
| complete a job, but when an operator expends | | | | choice is being made to take care of your |
| less energy to do a job, he/she is more fresh | | | | operators. By taking care of your operators, they |
| near the end of the shift. | | | | will take care of you. |