BOS 3701, Industrial Ergonomics

Course Learning Outcomes for Unit IV

Upon completion of this unit, students should be able to:

• Perform ergonomics-related hazard assessments.

                6.1     Identify potential hazards and injuries from a worksite.

Reading Assignment

Chapter 8: Psychophysics

Chapter 9: Hand Tools

Unit Lesson

This unit will focus on the actual work involved in various job tasks and ergonomics or human factors from two perspectives. One key concern or perspective is known as the psychophysical perspective. This looks at the relationship between the psychological self and the physical demands of the job in question. The physical demands and physical environment of some jobs make them quite stressful to bear, and this needs to be considered from a human factors perspective when conducting ergonomic analyses. A second issue we will consider is the use of hand tools in the workplace. Although these two concepts might seem somewhat disparate, there is some overlap; having the proper tool in hand can certainly help to alleviate a great deal of stress in the workplace (Stack, Ostrom, & Wilhelmsen, 2016).

Psychophysical Perspectives

Right now, you may be reading this lesson and thinking about everything else you could be doing with your time. Your mind may be elsewhere, or you may not be in the mood to complete your coursework. The exertion needed to accomplish this task seems pretty significant. The psychological impact of learning the materials presented in this unit may then be very high for you. Conversely, you may enjoy learning all about ergonomics and not be able to think of anything else you would rather be doing!

Truthfully, we all experience similar perspectives as they relate to psychophysical issues. Think about something that is really exciting. For instance, a trip to Hawaii seems wonderful; does it not? Can you imagine yourself relaxing on the beach with warm tropical breezes gently brushing your skin and hair, cool drinks at your side, and the beautiful ocean at your disposal? Now, think about the logistics of getting to Hawaii and back. You have to buy the airline tickets, make the reservations, pack, get to the airport, go through security, board the plane, fly 6 hours in coach with a screaming infant in the seat behind you, get off the airplane in Honolulu, rent a car, drive to the hotel, check in, and finally get into your room. Do you think there might be some physical effort in doing this that might affect you psychologically? The entire day may leave you feeling drained, violated, and angry, but keep in mind that this is supposed to be a wonderful getaway with your spouse or significant other. Think about the effort-to-benefit ratio; how much benefit will you receive for the effort?

Similarly, we consider the effort-to-benefit ratio while conducting our various job tasks at work. Consider Adam, for example; Adam is a young man who is working at the same big-box department store as Amy, whom we discussed previously. He works in the automotive section performing oil changes, tire rotations, and tune-ups. His work area is noisy, dirty, and greasy, and he is under constant observation by the customers and a grouchy supervisor. Customers often make demands on Adam, which makes it more challenging for him to complete his job. For example, he once encountered a young, single mom who had very little money to fix her vehicle that needed quite a bit of work done. Her stress was clear, which added more pressure on Adam. To make matters more challenging, her young children were screaming and crying while Adam was

BOS 3701, Industrial Ergonomics           1 trying to assist her. This made it even harder for Adam to focus. Adam gets paid just a little more than minimum wage for his troubles. Is it worth it? The effort-to-benefit ratio is definitely not on his side.

His work is very physical: lifting tires, bending over the hoods of cars, reaching up from the oil-change pit to change out filters, and using a tire iron or impact wrench to loosen and tighten the lug nuts on the wheels. These are his duties for 8 to 10 hours a day. Additionally, he is inhaling the exhaust from the cars; hearing the noise of the tools he and others are using; and standing, kneeling, and sitting on concrete. This is his work environment. The physical effort he is expected to expend is considerable in addition to the psychological stress he experiences trying to do a good job. He is an excellent employee; therefore, it is important to make sure that workers like Adam are retained.

Certainly, there are many physical jobs that can also be psychologically stressful as well. Take some time to consider your worksite and the employees who make up your organization. What are their psychological and physical stressors? During a normal day, what kind of issues might they have to deal with? In evaluating workplaces, these issues need to be considered. Workers who must overexert themselves or workers who frequently face sources of psychological stress are less likely to perform as well as other employees and may consider leaving the organization. Turnover is costly, and the cost of injuries related to overexertion can be quite costly as well.

Let us take some time to consider the case study of the Marines involved in cannon operation. Please review this case study that starts on page 189 of your course textbook. The Marines felt significant stress and exertion when they did not get a break or when they believed they were undermanned; however, giving the Marines a break from the action and adding in a couple of other people made the effort-to-benefit ratio much more palatable. Once again, this exemplifies the need to pay special attention to the psychophysical demands placed on individuals due to their given job tasks and methods that might be employed to help make difficult jobs more bearable.

The main point here is that it is important for organizations to consider the combined impact of both the psychological and physical stress experienced by employees. The overall goal is to try to make jobs as bearable or as comfortable as possible. This is particularly true of jobs that can affect public safety such as that of over-the-road truckers or jet pilots. It is important to limit the stress faced by such individuals so they can focus on doing their jobs.

Hand Tools

Chapter 9 discusses the use of hand tools. Many employees use hand tools throughout the day. There was a time when workers would have used a simple screwdriver to insert the screws in items on an assembly line. A given employee would insert a screw and tighten it hundreds of times per hour, 8 hours per day, 5 days per week, and 50 weeks per year for an entire career of 25 or 30 years. Is it any wonder that many of these workers developed cumulative trauma disorders (CTDs) such as carpal tunnel syndrome and tendonitis? With the invention of power screwdrivers and robots, the issues with CTDs have decreased considerably. Indeed, many powered hand tools can now be seen hanging from the ceiling of the assembly line and are actually counterweighted to reduce the amount of force that needs to be applied. This has resulted in fewer ergonomics-related injuries and illnesses and has also resulted in increased productivity.

Changes in hand tool design have resulted in better, safer, and easier-to-use tools over the years as well. Take something as simple as a writing instrument. We all remember the number two pencil we used in school. Not a lot of consideration for ergonomics was placed into the manufacturing and use of that tool. Then, we were allowed to use, as we progressed in grades, ballpoint pens. Then, rollerball pens with rubber finger pads were developed. These pens made it easier to write because you did not have to push as hard. The fluidity of the ink made writing simpler and less difficult. Less friction and more fluidity of the ink improved our ergonomic situation with respect to the job task of writing. In today’s world of computers and word processing programs, we do not even write anymore. When was the last time you actually sent a handwritten letter to someone?

In order to help you appreciate the evolution of hand tools in recent years, examine the tools used at your worksite by various trades. Take a look at the tools you and your fellow employees are using. Depending on the worksite, you may find many tools used in the modern work environment are powered by air, electricity, or even gun powder. This is particularly true in the construction industry where the hammer and nail has been replaced with the nail gun, and the handsaw and plane have been replaced with power tools that do the job much more efficiently and with less physical exertion. The key point here is, of course, that many hazards have been eliminated over the years by re-engineering hand tools. In today’s world, we have a multitude of options for helping to eliminate unnecessary physical exertion, thereby making the workplace more ergonomically sound for the worker.

Some hand tools are not likely to be replaced by power-driven tools. Some hand tools combined with human skill continue to be the best combination for accomplishing some tasks. Sometimes, a hammer, hand saw, or non-powered cutting device is just what is needed for the job. Consider the use of knives in meat packing facilities, for instance. Certainly, there has been automation in this industry that has reduced the number of cuts that need to be made by workers wielding knives, but many operations still require human skill with a knife. In operations such as these, it is important to ensure that tools are well designed and well maintained (Lee & Rempel, 2012). Indeed, a great deal of effort is expended in the meat packing industry to provide workers with the tools and training they need to ensure that their knives are consistently as sharp as they can be. Sharp knives require less force, and less force results in fewer ergonomics-related injuries and illnesses.

Tools allow us to perform the work necessary to complete our jobs. Without tools, we would not be able to easily or safely perform the tasks that need to be performed. Without your computer, for instance, getting your assignment submitted for this unit would not be possible without some unusual accommodation being made by the university.

Likewise, think about Adam and the task of changing out your flat tire. Consider him trying to remove the lug nuts by hand without any tools. As you may imagine, this would be impossible. Fortunately, he has access to power tools that allow him to perform his tasks quickly and easily. He has a full toolbox that contains just about every imaginable tool there is for standard car maintenance. He is capable of removing the flat tire, taking the tire off the rim, finding the leak, fixing the leak, replacing the tire on the rim, and replacing the tire and rim back on the vehicle in less than 20 minutes. Quality, production, and safety are all accomplished with the use of those tools.

The right tool makes the job task easier to perform with little or no negative impact on the user. Using the wrong tool makes for a frustrated worker. The wrong tool can also lead to injury. Consider this final example. Those of you who have used socket wrench sets will relate to this scenario. You have to remove a bolt from an engine block. The use of a socket on the bolt head makes the work easy. Even with a stuck bolt, the work is easier. Now, use an adjustable wrench for the same task; it is not quite the same fit to the bolt head, and the chances of rounding off the bolt head are higher. If the wrench slips off the bolt head, your knuckles fly into the engine block, eliciting a string of expletives that make even the most seasoned sailor blush.

If you are unfamiliar with this example, consider watching the video below to gain a better understanding.

Repairs101. (2013, November 30). Sockets & socket wrenches – What you need to know [Video file]. Retrieved from https://www.youtube.com/watch?v=YA7lHjbELTo

The bottom line for this part of the unit is that the right tool makes life easier for the employee and decreases the employee’s chances of sustaining long-term CTDs. Indeed, proper tools can help to mitigate psychophysical issues, and the proper tool helps to make the work easier and helps to make the worker more efficient.

References

Lee, D., & Rempel, D. (2012). Ergonomics. In B. Plog & P. Quinlan (Eds.), Fundamentals of industrial hygiene (6th ed.). Cambridge, MA: NSC Press.

Stack, T., Ostrom, L. T., & Wilhelmsen, C. A. (2016). Occupational ergonomics: A practical approach. Hoboken, NJ: Wiley.

Suggested Reading

If you are unfamiliar with the type of work referenced in the Unit IV Lesson that Adam would complete, view the YouTube video below. This video explains the training Adam would likely have received and shows what his workstation would resemble. As you watch the video, consider the stressors that could arise.

Sears Auto Center. (2014, August 7). Sears Auto Center – Technician [Video file]. Retrieved from https://www.youtube.com/watch?v=YhZoUk2cM3Y

Learning Activities (Nongraded)

Nongraded Learning Activities are provided to aid students in their course of study. You do not have to submit them. If you have questions, contact your instructor for further guidance and information.

As part of this course, you are expected to become comfortable with the Occupational Safety and Health Administration website. For this unit, use the search box on the following website to search for “hand and power tools” to learn more about the hazards and responsibilities of using tools: https://www.osha.gov/

How might you use this information as a safety professional?