Transcript No Slide Title

Design for Ergonomics
MPD575 DFX
Jonathan Weaver
Development History
• Originally developed by Cohort 1
students: Stephen Earl, Paul Geisler, &
Larry Rhein
• Revised by Cohort 2 students: Winnie
Jimenez, Sergio Munoz, Dave Paddock
& Lester Weitman.
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Design for Ergonomics
•
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Process
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
Supplemental Readings
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Design for Ergonomics
•
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Process
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
Supplemental Readings
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Introduction to DFE
Ergonomics is ….”The science of
matching things to people.”
– It pays to be precise about how things suit
people. It is the difference between taking a
guess and taking a measurement.
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Introduction to DFE
• Ergonomics was created in 1949 from
the Greek words:
– “ERGO” = Work
– “NOMOS” = Natural laws
Scientific study of humans interacting within
their environment
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Introduction to DFE
• Ergonomics considers the physical and
mental aspects of people in relation to a
product.
• By adding objective data about people into
the design process, a product or environment
can be designed so that all users are
considered, not just those that resemble the
designer.
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Introduction to DFE
• Ergonomics is all about quality
• The fact that something can be used is just
not sufficient – it should be easy to use.
• Just because most people find it easy is not
sufficient either – a large and known
percentage of people should be able to use it
easily.
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Introduction to DFE
The outcome of applying Ergonomics is
generally one or more of:
 User success
 User satisfaction
 Speed
 Safety
 Reliability
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Introduction to DFE
Some Do’s and Don’ts of using Ergonomics:
DON’T
1. Don’t think about ‘most people’ or ‘the average’
since that will lead to low standards.
2. Don’t speculate. Try to recognize when you don’t
know something about the people you are
designing for.
3. Don’t design the product for yourself. Use objective
data about people.
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Ergonomic Differences


1900
50th percentile U.S. male > 95th percentile U.S. female
U.S. female stature resembles Japanese male stature
95th
95th
Height (mm)
1800
50th
50th
1700
1600
1500
1400
1300
5th
U.S.,
German &
Swedish
Males
95th
50th
5th
British
Males
5th
Japanese
Males
95th
50th
5th
U.S.,
German &
Swedish
Females
95th
50th
5th
British
Females
95th
50th
5th
Japanese
Females
1200
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Introduction to DFE
Some Do’s and Don’ts of using Ergonomics:
DO’S
1. Decide who is going to use the design – age, sex,
reach, strength, etc.
2. Focus on how different the worst-case users are
from you.
3. Make explicit what the users’ goals will be as they
use the product, and what will measure success.
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Introduction to DFE
Some Do’s and Don’ts of using Ergonomics:
DO’S
4. Consider what happens to people outside the
formal design range
5. Work out what users will need to know before they
can complete the tasks. Build the learning into the
product, or design out the need for it.
6. Take account of stress and competing demands on
the users attention. Especially important when
designing labels.
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Introduction to DFE
• Human Factors engineering & Ergonomics
are commonly used interchangeably.
• Human Factors is a discipline that optimizes
the relationship between the technology and
the humans.
• Anywhere you find technology and people
interacting together, there will be a need for
some form of human factors and
ergonomics.
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Introduction to DFE
• Human Factors engineering & Ergonomics
considers the variation within a user
population and manner in which this will
affect individual and group performance for
a given task.
• These variations include gender, age, sex,
visual & mental capabilities, and strength.
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Introduction to DFE
• Both Human Factors & Ergonomics are
interdisciplinary sciences that deal with:
– Human characteristics
– Capabilities and limitations for the purpose of
designing products to achieve ease of use
– Comfort
– Convenience
– Health and safety
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Technical Fields that Interact with
Ergonomics
Ind. Design
Envir. Medicine
Anthropometry
Applied Physiology
Ergonomics
Engineering
Psychology
Oper. Research
Statistics
Dynamics
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Introduction to DFE
Psychology - Experimental psychologists who study people at work to
provide data on such things as: Human sensory capacities, Psychomotor
performance, Human decision making, Human error rates, Selection tests
and procedures, Learning and training.
Anthropometry - An applied branch of anthropology concerned with the
measurement of the physical features of people. Measures how tall we are,
how far we can reach, how wide our hips are, how our joints flex, and how
our bodies move.
Applied Physiology - Concerns the vital processes such as cardiac
function, respiration, oxygen consumption, and electromyography activity,
and the responses of these vital process to work, stress, and environmental
influences.
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Introduction to DFE
Environmental Medicine - Concerned with such environmental factors as
noise, illumination, temperature, humidity, g-forces, radiation, and noxious
gases and fumes, and their effects on health and human performance.
Engineering - Provides information on electrical, mechanical, and chemical
characteristics of elements and systems and principles of design,
construction, and operation of structures, equipment, and systems.
Statistics - For summarizing large amounts of data on human
measurements and human performance, and to design sampling schemes
and experiments for the conduct of human studies and performance
measurements.
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Introduction to DFE
Operations Research - Quantitative methods for the analysis of the
performance of manpower, machinery, equipment, and policies in
government, military, or commercial spheres.
Industrial Design - The design, color, arrangement, and packaging of
equipment to combine functionality and aesthetically satisfying appearance.
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Introduction to DFE
Guides to Designing for Ergonomics:
Standards and Codes
Standards - A set of rules, conditions, or requirements that define terms;
classify components, specify components; specify materials, performance,
or operations; delineate procedures; or define measurements of the
quantity or quality of materials, products, systems, services, or practices.
Standards can be classified as being safety or performance based.
Examples of Standards:
Federal and Military Standards
Company Standards
Foreign Standards
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Introduction to DFE
Standards cont.-
The most commonly used Standards for use by human-factors
professionals:
OSHA Standards: Prepared by the Federal Occupational Safety and Health
Administration
MIL-STD-1472D: Military Standard dealing with human-factors
consideration in the design of equipment.
NASA-STD-3000: Slightly broader range of topics than the MIL-STD.
ANSI/HFS 100-1988 - Deals specifically with h.f. principals and practices in
the design of visual display and terminals, associated furniture, and the
office environment in which they are placed.
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Introduction to DFE
Standards cont.American National Standards Institute (ANSI) The most commonly used and most well recognized organization for
standards. The organization is a federation of trade associations, technical
societies, professional groups, consumer organizations, and industries that
serves as the United States clearinghouse for voluntary standards activity
at the national level.
Limitations of Standards:
Typically establish only minimum requirements.
They are often too general.
They usually have to be tailored.
The do not explain the Systems-Engineering Process.
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Introduction to DFE
Codes
Primarily concerned with safety matters, codes contain many regulations
and recommendations that directly or indirectly address human-factor
issues.
Examples of codes:
National Electrical Safety Code
Life Safety Code
BOCA National Building Code
BOCA National Mechanical Code
OSHA
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DFE Process
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Process
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
• Supplemental Readings
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DFE Process
Why Ergonomics?
• Olden Days:
Tools & machinery
made by individuals for
themselves or a select few.
• 20th Century:
Mass Production;
designed for the “average” user.
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DFE Process
“Our vehicles are manufactured for the
masses. They are, therefore, tailored
specifically to no one.”
Ford Motor Design Center
(Ford Motor Company quote).
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DFE Process
WHY NOW?:
•Global Markets reaching consumers with
wider range of physical attributes.
•More competition can provide customers
a choice of an easier to use product.
•Can be severe long term consequences unacceptable level of absenteeism, dissatisfaction,
complaints, accidents and under-use of product.
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DFE Process
Main areas of interface study in ergonomics
Physical aspects of man machine
interface
Size, shape, color, texture of displays &
controls
Cognitive aspects of machineuser interface
The finding & understanding of
instructions
Workplace design & workspace
layout
Layout of offices, factories, furniture,
and computers
Physical environment
Effects of noise, heat, light, vibration
Psychological environment
Organizational & group structures productivity
Job design, selection, timing
Shift, instructions, training, aids
(Six principle areas of Ergonomic study, along with several examples of each).
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DFE Process
We see that human characteristics are
extremely relevant to ergonomics, and
those that are most frequently measured
by ergonomists are…
• Physical characteristics
• Psychological characteristics
• Biological characteristics
(The 3 primary areas of study).
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Key Principles of DFE
•
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Process
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
Supplemental Readings
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Key Principles of DFE
Interface Reference Model (simple but eloquent)
User
Machine
Workspace
Environment
(Primary interfaces are adjacent, others are secondary).
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Key Principles of DFE
Input / Output Communication Model
Operator
Machine
(Shows that the outputs of one are the inputs of the other, and visa versa).
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Key Principles of DFE
System Design Model
Statement of objectives
Separation of functions
Allocation of functions
Human devel.
User/machine Interface
Hardware devel.
System Integration
(Ergonomics should be part of the complete process, but are most intense in red areas).
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Key Principles of DFE
Key principles of DFE – ‘VDC specific’
• Vehicle Design Center recommends three
distinct guideline segments:
– Controls Guidelines
– Display Guidelines
– Seat Guidelines
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Key Principles of DFE
The Controls Guidelines determine:
• Fundamental Criteria
– Visibility, Interpretability, Accessibility, Operability
• Mode Criteria
– Continuous, Discrete, Binary, Data entry
• Design Recommendations
– Natural, Convenient, Feedback, Stereotype, Blind reach
• Arrangement Criteria
– Emergency/Frequency, Grouped, Interference, Stereotype
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Key Principles of DFE
The Display Guidelines determine:
• Fundamental Criteria
– Visibility, Interpretability
• Mode Criteria
– Quantitative, Qualitative, Range, Binary status
• Design Recommendations
– Simplest, Least precise, Stereotype, Distance/angle
• Arrangement Criteria
– Emergency/Frequency, Compact, Standards, Grouped
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Key Principles of DFE
The Seat Guidelines determine:
• Comfort Criteria
– Contour, Suspension firmness, Posture, Support
• Accommodation Criteria
– Width, Length, Height, Depth, Angle
• Convenience Criteria
– Adjustments, Self-evident, Pivots, Placement
• Miscellaneous Criteria
– Entry/Egress, Progressive resistance, Irritants
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Key Principles of DFE
Key principles of DFE – ‘generic’
• Identify the client’s needs
• Identify the user’s needs
• Consider operator OP/machine IP
• Consider operator IP/machine OP
• Identify ergonomic issues affecting design
• Evaluate ergonomic design effectiveness
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Key Principles of DFE
Process & Principles Summary – effective
ergonomic design begins at the onset of
the task.
Identify the needs of the client & user
Incorporate into statement of objectives
Maintain proportionate ergonomic effort
Evaluate ergonomic effectiveness
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Key Principles of DFE
DFE requires teamwork!
Communication is a very important factor,
inside and outside of the team.
Success relies on the knowledge, resources,
and support of people outside your team
and outside your organization (final
customer/user)
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Ergonomics Team Members
Ergonomics
Committee
Management
Accounting
Purchasing
Materials
DFE Team
Engineering
Marketing
Quality
Medical
Health and
Safety
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Ergonomic Change Cost ($)
Reactive Versus Proactive
PD
Design
Job 1
Build
Proactive
Launch
Operate
Reactive
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Reactive Versus Proactive
•The diagram shows the relationship between cost and time
•Ergonomic solutions will be more complex and will need
more money as the design nears completion.
•Normally, ergonomics analysis is applied to existing
products and then reaction plans are developed.
• Proactive gives the option to see and resolve problems
when the resources (people, money, etc.) are available
•The cost of ergonomic changes is inversely related to the
availability of funds.
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Ergonomic issues into a Product Development Milestone
Concept Phase
J1
Ergo Issues that
are Product related
Assigned to Product
Engineers for
Evaluation & Resolution
Ergo Issues that
are Process related
Assigned to Process
Engineers/Product
Specialists for
Evaluation & Resolution
Ergonomics
Team Assigned
to Complete
Reviews
Final Program
Status
Lessons Learned
are identified &
fed forward for
Continuous
Process
Improvement
Current
Production Jobs
in Plant with
Similar Product
Job Improvement
Cycle
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Key Principles of DFE
• The chart shows the DFE roll into Product
Development milestone considering similar
products or processes.
• Ergonomic issues can be fixed when the cost
of such fixes is relatively low.
• DFE gives the option to apply ergonomics
principles into the PD planning process.
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DFE Rules for LEAN
The change to Lean is a very good opportunity to
improve ergonomics.
The next twelve rules together with a team work,
are important to improve process ergonomics:
1. Avoid bending forward at the waist
2. Keep the work close to your body
3. Avoid twisting your trunk
4. Avoid lifting or working above shoulder height.
5. The work height depends on the task and the
operator.
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DFE Rules for LEAN (cont’d)
6. Keep the duration of muscle effort
short
7. Minimize walking distances.
8. Lift or lower only loads less than 40
pounds.
9. Bend the tool not the worker.
10. Maintain your tools and equipment.
11. Keep work in front of worker
12. Changes Postures and motions.
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EXAMPLES
•
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Process
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
Supplemental Readings
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GOOD EXAMPLES
Good ergonomic designs
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GOOD EXAMPLES
Computer Hardware Design Example:
The KEYBOARD
The keyboard on the left is the “standard” computer keyboard.
The keyboard on the right is called a “left handed keyboard”, which has the
numeric keypad on the left hand side.
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GOOD EXAMPLES
Split Keyboards:
Product on the left has an integrated mouse feature.
Product on the right has an integrated wrist rest.
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GOOD EXAMPLES
Adjustment for wrist splay in the horizontal plan: 0°-30°,
continuously variable. Adjustment for wrist pronation - vertical
tenting 0°-30°, continuously variable. Keyboard on left has
larger space bars, while keyboard on the right still incorporates
the wrist rests.
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GOOD EXAMPLES
Larger keys for individual with limited hand mobility or individuals with large
hands. Keys put in alphabetic order for children.
Keyboard on the right integrates the use of a trackball.
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GOOD EXAMPLES
Optimal split-your arms go out straight in front of you. Lateral
tilt so thumbs are effectively elevated. Built-in, padded palm
supports.
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GOOD EXAMPLES
Reduce wrist stresses associated with Carpal Tunnel
Syndrome. Move mouse clicks to your feet. Macros up to 13
keystrokes.
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GOOD EXAMPLES
Computer Hardware Design Example Continued:
The MOUSE
Various sizes for right and left hand users.
Thumb button for double clicking and scrolling without moving
the mouse.
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GOOD EXAMPLES
Designed as a pilot stick, it encourages a natural, vertical
hand position with the thumb pointing upwards.
A full 1.5 inches of length adjustment and low lateral profile
and a raised palm rest.
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GOOD EXAMPLES
Is the trackball for user preference or another attempt to
redesign a bad problem?
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GOOD EXAMPLES
Computer Hardware Design Example:
The KEYBOARD and MOUSE “FIXERS”
Wrist rests for the keyboard and mouse.
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GOOD EXAMPLES
Reduce wrist stresses associated with Carpal Tunnel
Syndrome. If the keyboard and mouse were designed
correctly in the first place, would you need to correct them?
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BAD EXAMPLES
Examples of where Ergonomics
was not applied
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BAD EXAMPLES
There are two problems
with these doors.
Handles are designed for
pulling rather pushing.
“Photograph courtesy of www.baddesigns.com”
The two sets of doors work
in opposite ways.
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BAD EXAMPLES
Commonly used
handle types for this
style of door.
The problem is you
don’t know which
end of the handle to
push.
“Photograph courtesy of www.baddesigns.com”
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
Manufacturers package both the shampoo and conditioner in nearly
identical bottles. Should be able to easy separate the two without too much
difficulty.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
Other than the letter difference in these labels, these two bottles of Insulin
types. This could be serious if one selects the wrong type.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
“Photograph courtesy of www.baddesigns.com”
The problem is that the handle to move the cabinet is very close to the top
drawer and is more obvious than the actual drawer handle.
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BAD EXAMPLES
Which light would choose ?
“Photograph courtesy of www.baddesigns.com”
There are so many traffic lights at this intersection, one would have to
wonder how many people get confused when they arrive at this
intersection.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
The outlet here is just below the mirror over a sink. You cannot plug it as
shown as it hits the mirror, and you cannot flip it up-side-down because the
prongs do not match up.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
These cupholders block access to the radio and cassette player. Not only
hard to use the radio, but increase the risk of spilling something into the
cassette player.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
Two very common mechanical pencils. The problem with the top one is
that you would constantly be taking off the cap and when you use the
eraser you would keep advancing the lead. The bottom one has a simple
button to advance the lead.
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BAD EXAMPLES
Frustrated with VCR cases ?
“Photograph courtesy of www.baddesigns.com”
It is suppose to be easy when you return the VCR tape back to the
holder. Very common mistake people make when returning the tape to
the case is that there is only one way to put it back into the case.
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BAD EXAMPLES
“OUTCH ………watch out for
that bar”
How many times have you been in
this situation ? Most turn styles like
this one do not take in consideration
the various heights of individuals.
“Photograph courtesy of www.baddesigns.com”
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BAD EXAMPLES
IS IT 40 MPH OR 40 RPM ?
“Photograph courtesy of www.baddesigns.com”
This poorly designed instrument cluster has the speedometer and the
tachometer using the same scaling. The only item helping in choosing
between the two is the odometer.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
“Photograph courtesy of www.baddesigns.com”
The older stove top controls on the left are more difficult to determine
which one controls each of the four burners, while the newer style on the
right matches the pattern of the burners.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
People generally expect the controls to be close to the device. Here the
CD buttons are close to the tape player and the tape player controls are
close to the CD player.
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BAD EXAMPLES
TRUNK
FUEL
“Photograph courtesy of www.baddesigns.com”
Separating these controls would make inadvertent opening of the trunk less
likely. The greater the separation, the less likely it would be to accidentally
open the trunk lid when opening the fuel door.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
Which button should I push ? There are so many different labels and
displays on these pumps, it makes it very difficult to find the start button.
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BAD EXAMPLES
The first required action to use this Glue Stick product is the ‘removal’ of the
cap. The cap in this case is the small dark end, typically leading consumers
to try to remove the large white feed-end first. Solution: label, resize.
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BAD EXAMPLES
The two vertical controls are difficult to differentiate due to location, lighting,
and texture. Being the primary switch for the vehicle dome light, the left
control could be more accessible. Solution: relocate or change texture.
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BAD EXAMPLES
The left control makes excellent use of color to identify temperature-mix.
The right control makes no use of color, perpetuating waste by inadvertent
use of the vehicle AC compressor. Solution: add color indicators.
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BAD EXAMPLES
The solid arrow on the left indicates the direction to push to engage the
windshield washer pump, but so do the hollow double arrows on the right.
Solution: reposition hollows arrows.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
“Photograph courtesy of www.baddesigns.com”
Two different wiper controls made by the same manufacturer,
the only problem is that they are not consistent in their
operation.
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BAD EXAMPLES
Traditionally, rearview mirror levers give no indication of which position is
‘normal’ and which is for ‘filtered’ viewing. Have you ever experienced this
anomaly? Solution: add symbols, different mechanism.
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BAD EXAMPLES
As can be seen from these examples, gas cap location may differ from
vehicle to vehicle, sometimes even within the same manufacturer.
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BAD EXAMPLES
“Photograph courtesy of www.baddesigns.com”
This gas cap door is hard to determine which end you would select to
open the door. Good designs would have a lip on the door to grab onto.
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BAD EXAMPLES
Program Information
Customer:
Program Name/Description:
Work Task #:
Model Year:
Volume:
General Motors
GM Gen IV IAFEM Prototype Delivery
HGPVH
2005
1.2 - 1.5million
Program Mgr.:
Lead Design Sup.:
Lead Design Eng.:
GMSS Rep.:
Applications Mgr.:
Applications Sup.:
Applications Eng.:
Key Team Contacts
Paul Geisler (acting)
Brian Condron
Jim Kempf
John Glynn
Bob Hatch
Garlan Huberts
Paul Geisler
313-248-9431
313-390-9483
313-390-9322
248-458-2028
734-458-0814
734-458-0537
313-248-9431
Program Description
As a result of the RFP that was given to GM for a GEN IV IAFEM, Visteon is one of the 5 suppliers chosen to provide
functional evaluation hardware. GM will choose one supplier for Beta (engine) level hardware. The evaluation units are due 11/1/00.
Production sourcing by GM is expected 1/22/01.
Resouce Plan
Matrixed team of 5 full time - to support program. Program Mgr, Lead Eng., Support to Lead Eng., App's Eng., Fuel Sys. Eng.
Support personnel will be needed from many organizations.
Timing Status
Key Event
Manufacture SLS Prototypes
Complete SLS Testing
Complete Core Design
Tooling Completed
Complete Testing of Prototype
Delivery of Prototype Unit to GM
Test & Calibrate Demo Vehicle
Delivery of Demo Vehicle
Production Sourcing by GM
Required
Date
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Forcasted
Date
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Sourcing/Tier 2
Description of items
sourced
Design/Engineering
Plastics
Gaskets
NVH materials
Company
MPI
BASF
Wynn's
Dow
Program Issues
GM may force design of an Aluminium manifold.
GM truck may not want on engine air cleaner.
Visteon Issues
Critical Personnel are still needed on team.
Mark Miller is needed as Support role to Lead Design Eng. Request on site seating in VEMA bldg.
ETB design 1-designer, 0.5 systems
Program Manager - TBD
Identify Visteon's fuel injector strategy
Identify Visteon strategy if forced to go with Aluminium manifold
A real life example of bad visual effects which we have all seen and most of
us are guilty of. If it doesn’t convey the message, is it worth putting in?
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BAD EXAMPLES
Everyone is E237 has had initial difficulties in determining which switch
controls the projector screen, and just which lights the other switches
control. Solution: label or reposition.
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BAD EXAMPLES
This steering wheel exhibits good and bad ergonomic design. The cruise
controls are lighted, well textured, and easily defined. The horn button is
unlit, not easily defined, yet is more likely needed during an emergency.
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BAD EXAMPLES
While a display may be artistically balanced, this is not a guarantee of good
ergonomic design. Note the same degree of smudge on the green label as
on the yellow switch. Solution: combine, reposition, change colors.
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GOOD vs. BAD EXAMPLES
Good and bad ergonomic
designs
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GOOD vs. BAD EXAMPLES
This is a bad application of
ergonomics because lifting
put a strain on the back of the
user
This is a good application of
ergonomics because it puts
less strain on the back of the
user
GOOD vs. BAD EXAMPLES
This is a bad application of
ergonomics because in order to
operate this device the User
need to apply pressure
downward on the handle in
order to raise the vehicle
placing strain on the upper arm
and shoulder as well as the
back
This is a good application of
ergonomics because you rotate the
handle placing less strain on the
arm and back muscles.
GOOD vs. BAD EXAMPLES
This is a bad application of
ergonomics because in order to
make juice you must apply a
twisting pressure on the orange
that places a strain on the wrist
This is a good application of
ergonomics because you simply
utilize downward pressure that
doesn’t place a severe strain as
the other juicer
GOOD vs. BAD EXAMPLES
This is a bad application of
ergonomics because pulling on a
line through a pulley places strain
on the upper arms and back
This is a good application of
ergonomics because you are basically
winding the sail up by means of a
winch ratchet arrangement which
places less strain on the upper body
GOOD vs. BAD EXAMPLES
This weed puller shows a good application of ergonomics because it
doesn't place any undue strain on the user's body.
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GOOD vs. BAD EXAMPLES
This weed puller is an example of bad application of ergonomics, because
it places a strain on the upper legs and lower back of the user.
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Design for Ergonomics
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Process
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
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Design for Ergonomics
DFE Software
– ErgoManagerTM (human perf. & analysis)
– JACKTM (human modeling & simulation)
– SAFEWORK® (virtual human modeling)
– PeopleSize (anthropometry software)
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ErgoMaager
What is ErgoManager™?
ErgoManager™ is a suite of software solutions for
use within an office environment:
 ErgoSURE™ - assesses postural risk.
 ErgoSentry™ - a customizable work pacing
and reinforcement tool for individual workflow
management and employee training.
 Surveyor™ - collects data for reporting on user
and company-wide ergonomic tendencies.
ErgoMaager
Ergoomi
c
Maageme
t Tools
Keyboardig ad
Mousig Activity
Moitorig ad
Break Tool
Postural
Assessmet Tool
Electroic Data
Collectio
Stretchig,
Exercise ad
Traiig
Plug-is
Traiig
Tool
Symptom
Survey
History of
System Data
Traiig
Reiforcemet
Tool
Maagemet
Reportig ad
Aalysis Tool
(The 3 main modules and 6 sub-modules that make up the ErgoManager software product).
ErgoMaager
Why use ErgoManager™?
• Improve Office Productivity
• Improve Worker Efficiency
• Improve Worker Comfort, and …

ErgoSURE™

ErgoSentry™
ErgoAnalyzer, UserNotes,
Computer-based Training,
Guardian & More

Surveyor™

“How To Do” Manuals
ErgoMaager
Why use ErgoManager™ ? (cont.)
• Interactive
Educational
Training Tool
• Customizable
• Quick & easy
to use
• Simple Weblike interfaces
(ergonomic)
(An example of typical web-like hypertext is shown).
ErgoMaager
ErgoSURE
 Just Point and
Click!
(ErgoSURE allows easy quantification of employees’ work posture).
ErgoMaager
ErgoSURE
 Analyze injury
potential
 Consistent
 Quick & easy
to use
(ErgoSURE covers complete upper-body evaluation).
ErgoMaager
ErgoSURE
 Systematically
assess posture
 Record how an
employee is
working
(Allows easy logging of performance data…).
ErgoMaager
ErgoSURE
Reporting and
analysis from
ErgoSure
RULA
Rapid
Upper
Limb
Assessment
Scoring:
Best = Low Score
Worst = High Score
(And allows individual and group statistical tracking and display).
ErgoMaager
ErgoSentry
•
Computer-based Training
•
Workpacing Education
•
Ergonomic Monitoring
•
Simple Visual Indicator
(ErgoSentry green bar charts are used to display higher-stress timeframes).
ErgoMaager
ErgoSentry - ErgoMap
 Interactive
Training Tool
 Customizable
 Quick & easy
to use
(An example of a click-on Ergo Map used to educate workers on ergonomic ramifications).
ErgoMaager
Surveyor
 Gather
important
information
from
employees
 Electronic and
networked
 Fully
Customizable
 Quick & easy
to use
(One example of many surveys and quizzes used to develop performance and trend metrics from).
ErgoMaager
Surveyor
Ö Measure ANY influence on productivity
(Metric reporting capabilities on an individual, group, and division basis are possible).
ErgoMaager
Surveyor
Ö Measure ANY influence on productivity
(Data compilation and transmittal can be transmitted to the home base for final evaluation).
ErgoMaager
ErgoManagerTM Summary – EM will
improve office productivity, worker comfort,
reduce risks, and achieve compliance.
Cornell University Study – EM improves user’s
productivity 10% to 40%
Reduce risks of RSI’s and associated costs
Reduce employee turnover, provide increased
sense of well-being and improved morale
Compliant with existing and future state and
federal regulations
Design for Ergonomics
DFE Software
– Magnitude (human performance & analysis)
– JACK (human modeling & simulation)
– SAFEWORK® (virtual human modeling)
– PeopleSize (anthropometry software)
TM
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JACKTM
Human Modeling & Simulation
JACK is an ergonomics and human factors
product that helps enterprises improve the
ergonomics of their product designs and
workplace tasks by providing:
TM
– Biomechanically accurate Digital Humans
– Placement of DH in your virtual environment
– Task assignment to DH
– Performance analysis of DH
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JACKTM
Human Modeling & Simulation
(Shows blue range for left arm – spine back, red range for right arm – spine back & forward, and green range for
the summation or virtual interior).
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JACKTM
Human Modeling & Simulation
Why use Digital Humans? Because many
enterprises are presently facing a barrage of
similar problems:
– Shorten design times
– Reduce development costs
– Improve quality
– Increase productivity
– Enhance safety
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JACKTM
Human Modeling & Simulation
(DH shows realistic and complex joint and body interaction with a virtual product concept).
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JACKTM
Human Modeling & Simulation
Digital Humans in product design allows
you to gain insight about the customer.
–
–
–
–
–
–
–
Positioning and comfort
Visibility
Ingress & egress
Reaching and grasping
Foot pedal operation
Multi-person interaction
Strength assessment
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JACKTM
Human Modeling & Simulation
This added customer insight allows you to
realize these benefits during PD process:
– Faster time to market
– Higher product quality
– Reduced development costs
– Safer products
– Improved productivity
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JACKTM
Human Modeling & Simulation
The basic principles of JACK
TM
– Build a virtual environment
• Real-time, CAD/CAE models
– Create a digital human
• 68 joints, 33 spine & hands, 135 DOF, NASA anthropomorphic studies
– Define DH size and shape
• SAE, frame, height, body segment extremes
– Position DH in your virtual world
• Posture, behavior, environmental relationship
– Assign your DH tasks
• Field of view, movement, size and component swapping
– Analyze DH performance
• View cones, reach, test fit, force, torque
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JACKTM
Human Modeling & Simulation
(Shows 2 body size reach envelopes from 2 different seat positions, and relationship to virtual product concept).
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JACKTM
Human Modeling & Simulation
Task Analysis Toolkit
– Lower back force analysis
– Strength analysis
– Metabolic energy expenditure
– Fatigue/recovery time analysis
– Posture analysis
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JACKTM
Human Modeling & Simulation
(Can measure and analyze lower-back stress from X-repetitions of virtual product ingress/egress cycles).
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JACKTM
Human Modeling & Simulation
Occupant Packaging Toolkit
– SAE packaging guidelines
– Comfort assessment
– Advanced reach analysis
– Advanced anthropometry
– Specialized part libraries
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JACKTM
Human Modeling & Simulation
(Even sophisticated virtual product scenario’s can be coupled with complex DH interactions).
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JACKTM
Human Modeling & Simulation
JACKTM Summary – digital human modeling
software, supports and promotes:
 Virtual concept evaluation
 Earlier targeting of population segments
 DH descriptor combinations
 Interfaces with CAE & CAD work
 Reduced PD cycle
 Faster ‘ergonomic’ product to market
Design for Ergonomics
DFE Software
– Magnitude (human performance & analysis)
– JACK (human modeling & simulation)
– SAFEWORK® (virtual human modeling)
– PeopleSize (anthropometry software)
TM
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The Human Modeling Software
for Advanced Ergonomic Design
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GENICOM CONSULTANTS Inc.
Founded in 1984, Genicom Consultants Inc. is known
as a center of competence in Human Modeling
around the world as well as a development firm.
Genicom has basically two divisions:
• R&D division in which they develop products such as
SAFEWORK, the most complete human modeling
software available commercially
• Human factors consulting division in which they
analyze, correct and design workstations.
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SAFEWORK is a software tool which creates
virtual humans of various percentiles to study fit
and accessibility in a workstation. Features
include:
– Mannequins with 103 anthropometric variables
– Numerous forms of analysis (postural,reach, etc.)
– Simulate tasks by using animation
– Transparent interfacing to most CAD systems
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SOFTWARE BREAKDOWN
• Anthropometry
• Postural Analysis
• Libraries Concepts
• Vision
• Animation
• Collision Detection
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(Example of a simulation where the individuals are entering into a bus).
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(Highlighted area shows how driver is effected by the surroundings of driver’s area).
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(User is able to select a given variable and allowed to edit the various dimensions).
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(Profile editor allows the user to choose from the various types of body builds)
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(Side view of driver station showing the critical dimensions with the model used)
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Basic Scene
(Examples of human models used in the postural analysis module of the software)
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Single Range of Motion
(Postural analysis of the human thigh area)
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Coupled Range of Motion
(Postural analysis of the human thigh area and by adding movement to leg)
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Postural score and limitation database
(Statistical data on the area in which the user is examining)
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(Demonstration of the capabilities of the library functions of the software)
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(Demonstration of the capabilities of the library functions of the software)
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(Demonstration of the capabilities of the library functions of the software)
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(Ambinocular vision view of what the user would see if sitting at the control desk)
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(Vision attribute selection window allowing the user various display options)
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(Animation editor allow the user modify, delete, and add various animations
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(Collision detection editor allows used to see interferences with in a product)
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(Collision detection editor allows used to see interferences with in a product)
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Summary of Why People Use
SAFEWORK ?
 User Friendly Environment
 Full 3D Mannequin Representation
 Access to Standard Population Statistics
 Posture Analysis
 Virtual Viewing
 Animation Capabilities
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Design for Ergonomics
DFE Software
– Magnitude (human performance & analysis)
– JACK (human modeling & simulation)
– SAFEWORK® (virtual human modeling)
– PeopleSize (anthropometry software)
TM
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What is PeopleSize ?
• PeopleSize is ….. a software package which
gives data on human sizes through a virtual
interface.
• The main advantage of of the program is that
you visualize the item you are designing in
relation to the human body.
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How does the process work?
• Point and click three step process
• Select the measurements you want by pointing and
clicking on any triangle of the color illustrations of the
human body
• Visualize the item you are designing in relation to the
human body
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Step One
Select the nationality,
age group, and
percentile value.
Example:
UK male, 18-64, 1st
percentile
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Step Two
Click on the icon you desire
to see the larger illustration.
Choose from full body
views to individual body
parts to even full body
infant views.
Views available vary
depending on population
data.
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Step Three
Click on the various
triangles to select the
dimension you want.
Each triangle is a
measurement landmark.
Over 280+ dimensions to
choose from.
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Output Dialog
As you select each dimension,
the output dialog gives you
dimensions for the population
you specified in Step One.
Automatic adjustments are
added for clothing and sitting
slump.
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Examples:
Full body, front view
seated position
Each arrow
represents a critical
measurement
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Examples:
Full body, front view
Each arrow
represents a critical
measurement
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Examples:
Head: front view
Each arrow
represents a critical
measurement
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Examples:
Hand positions:
various
Each arrow
represents a critical
measurement
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Examples:
Hand: front view
Each arrow
represents a critical
measurement
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Examples:
Full body, side view
(infant)
Each arrow
represents a critical
measurement
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Client List – companies using PeopleSize
- American Airlines
- London Transport
- British Airways
- Ministry of Defense
- British Rail Research
- Motor Industry Research
- Ford Motor Company
- Nissan Motor Group
- Hewlett Packard
- Scandinavian Airlines
- Jaguar
- Transport Research Labs
- Land Rover
- Volvo BV
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Summary of PeopleSize
 Check current designs against different populations and
user groups
 Ensure new designs fit the desired percentages of the
population
 Look-up data to create or justify designing specifications
 Saves time by having all the data in one package
 See the effects of clothing on your users
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Design for Ergonomics
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Process
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
• Supplemental Readings
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DFE Hardware
– IETM (Interactive Electronic
Technical Manuals)
– Third Age Suit - Design Center
– Vehicle Bucks
– NVH Partial-Mannequin
– Anthropomorphic Mannequins
– Articulating Mannequins
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Design for Ergonomics
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Process
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
• Supplemental Readings
175 of 209
DFE Case Studies
DFE Case Studies
– IETM (Interactive Elect. Tech. Manuals)
– Third Age Suit - Design Center
– Jaguar X
– OSHA Refrigerator Assembly
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DFE Case Studies
DFE Case Studies
– IETM
– Third Age Suit - Design Center
– Jaguar X
– OSHA Refrigerator Assembly
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DFE Case Studies
Why IETM? (Interactive Electronic Technical Manual)
• Aircraft innovation rise
– Demanding civilian, military, and FAA requirements
• Aircraft maintenance plateau
– Increased demands on mechanics
– Unmanageable technical manual volumes
• Greater risk potential
• Need for Innovation in aircraft maintenance
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DFE Case Studies
Layered Problem
Aircraft
Manuals
Technicians
Larger
Increasing volume
Morale decreasing
System complexity
Increasing detail
Psychology effect
Systems increasing
More complex
Apathy developing
Electrical interfaces
More regulations
Productivity down
Quality demands
FAA pressure
Accuracy affected
(Aircraft maintenance is a layered problem…)
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DFE Case Studies
(… as well as a circular problem).
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DFE Case Studies
Proposed IETM Solution
Before
After
Traditional AME skills
Added AME skills
Technical manual repository
Personal portable high density
media storage/playback
30,000 pages of text reference
materials for F-18
Several high density DVD’s or
ROM cards for multi-media
storage
Static manual references
Dynamic user-manual interaction
via hypertext & hypermedia links
Multiple read & inspection
locations
Single on-site reading & inspection
location
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DFE Case Studies
Transitional Milestones
• Hardware
– Existing record & playback equipment
• Software
– User/media interaction - hypertext, hypermedia
• Ergonomics (Key)
– Technician OP / Device IP
– Device OP / Technician IP
Operator
Machine
• Customer
– Tech, Civilian, Military, FAA
(As of 1998, filled stars indicate solutions, empty stars indicate areas still needing resolution).
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DFE Case Studies
Ergonomics (Key)
– Technician OP / Device IP
• Speech recognition, joysticks, head-mounted gyro
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DFE Case Studies
Ergonomics (Key)
– Device OP / Technician IP, HDM’s
(Consumer PD finally delivered a translucent monocular which could meet OP/IP needs).
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DFE Case Studies
Milestone Achievements
• Hardware
– Record & personal playback
• Software
– User/media interaction, hypertext, hypermedia
• Ergonomics
– IP / OP & IP / OP
• Customer
– Technician, Civilian & Military aviation, FAA
(Since 1998, ergonomics has delivered a complete solution, now under Customer review).
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DFE Case Studies
IETM Summary – a quality ergonomic
solution will more likely to result in:
 Increased morale
 Maintained quality level
 Increased productivity
 Improved safety
 Improved competitive position
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DFE Case Studies
DFE Case Studies
– IETM
– Third Age Suit - Design Center
– Jaguar X
– OSHA Refrigerator Assembly
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DFE Case Studies
Why the Third Age Suit?
• To gain insight into the physical capabilities
of customers in the 3rd age demographic
• To let young engineers and designers
experience the effects of the aging process,
by actually wearing the suit
• To attempt to maintain our competitive
position
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DFE Case Studies
Third Age Suit - Design Center
(Show Video if Possible)
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DFE Case Studies
Third Age Suit Summary
 To proactively improve our overall design process by
taking advantage of promising new tools and
methodologies to stay competitive.
 To more accurately consider the needs of the
population in the 3rd age range.
 Though not easy to properly fit to one’s individual
body, the insight gained from the accelerated aging
effect is extremely worthwhile.
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DFE Case Studies
DFE Case Studies
– IETM (Interactive Elect. Tech. Manuals)
– Third Age Suit - Design Center
– Jaguar X
– OSHA Refrigerator Assembly
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DFE Case Studies
Jaguar X-Type:
• Recognized ergonomics would provide
competitive advantage.
• Provided owners with extensive seat & steering
wheel adjustability.
• Carefully positioned all control switches.
• Even designed in switch feel & sound.
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DFE Case Studies
Jaguar X-Type:
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DFE Case Studies
DFE Case Studies
– IETM (Interactive Elect. Tech. Manuals)
– Third Age Suit - Design Center
– Jaguar X
– OSHA Refrigerator Assembly
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DFE Case Studies
OSHA Recommendations for Assembly:
• Use “slip resistant” gloves to avoid
increasing grip force required for lifting.
• Reach zones: > waist & < shoulder
• Trigger Grips: >2 fingers distributes force
• Use cushioned mats (anti-fatigue) to
reduce lower back injuries.
• Rotate people thru different operations, to
avoid stressing one muscle group.
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DFE Case Studies
OSHA Refrigerator Assembly:
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Design for Ergonomics
•
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Procedures
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
Supplemental Readings
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References
• Burgess, John H (1986). “Designing for
Humans: The Human Factor in Engineering”,
Petrocelli Books, Princeton, New Jersey.
• Woodson, Wesley E. and Conover, Donald W.
“Human Engineering Guide for Equipment
Designers”, Second edition, University of
California Press, Berkley,1964.
• Chapanis, Alphonse (1965). “Man–Machine
Engineering”, Wadsworth Publishing, London.
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References
• Chapanis, Alphonse (1996). Human Factors
in Systems Engineering, John Wiley and
Sons, Inc., New York, NY, USA
• Kantowitz, Barry and Sorkin, Robert (1983).
Human Factors, Understanding PeopleSystem; John Wiley and Sons, Inc., New
York, NY, USA
• McCormick, Ernest J (1970). Human Factors
Engineering, McGraw-Hill Co., New York, NY,
USA
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References
• O’Brien, Thomas G. and Charlton, Samuel G.
(1996). Handbook of Human Factors Testing
and Evaluation; Lawrence Erlbaum
Associates, Publishers, Mahwah, New
Jersey, USA
• Andreasen, Myrup/S. Kahler/T. Lund "Design
for Assembly", Second edition, IFS
Publications/Springer-Verlag, Berlin,
Heildelberg, New York, Tokio. 1988
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References
• Woodson, Wesley E. and Conover, Donald W.
“Human Engineering Guide for Equipment
Designers”, Second edition, University of
California Press, 1964
• O’Reilly & Associates, Inc.; 2000
www.patientcenters.com/wheels/news/adaptive.
html
• SAE 2000-01-0169; Ergonomic Consideration
in Steering Wheel Control
• SAE 2000-01-2167; A Generic Process for
Human Model Analysis
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References
• SAE 1999-01-1913; Measuring of Human
Anthropometry, Posture and Motion
• SAE 2000-01-2156; Digital Humans and
Electromagnetic Motion Capture
• SAE 2000-01-2165; Application of the 3-D
CAD Manikin RAMSIS to Heavy Duty Truck
Design at Freightliner Corporation
• Human Factors and Ergonomics, Wright
State University, www.web2.cs.wright.edu
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References
• NexGen Ergonomics, www.nexgenergo.com
• Cornell University Ergonomics,
www.ergo.human.cornell.edu
• Human Factors International,
www.humanfactors.com
• “Darnell, M. J. Bad Human Factor Designs”,
www.baddesigns.com
• Open Ergonomics, PeopleSize 2000,
www.openerg.com
• SAFEWORK, www.safework.com
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References
Ford Adv. Engrg Design Dept., 1997, A Human
Factors Design/Evaluation Manual
Galer, Ian A. (1987), Applied Ergonomics
Handbook
University of Pennsylvania, Center for Modeling
& Simulation,
http://www.upenn.edu/computing/printout/arc
hive/v12/4/jack.html
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References
• University of Pennsylvania, JACK Home
Page,
http://www.cis.upenn.edu/~hms/jack.html
• EAI, Engineering Animation Inc.,
http://www.transom.com/
• Magnitude, Computer Ergonomic Software,
http://www.magnitude.com/main/about.html
• Human Factor Issues in Aircraft,
http://members.aol.com/geo13/ietm.htm
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References
• The Ergonomics Society
http://www.ergonomics.org.uk
• Ergonomics
http://www.ergonomics.org
• Human Factors & Ergonomics Society
http://www.hfes.org
• OSHA (Success stories & case abstracts)
http://www.osha-slc.gov/SLTC/ergonomics/index.html
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Design for Ergonomics
•
•
•
•
•
•
•
•
•
Introduction to DFE
DFE Procedures
Key Principles of DFE
Examples
DFE Software
DFE Hardware
DFE Case Studies
References
Supplemental Readings
207 of 209
Supplemental Readings
1996 Human Factors & Ergonomics
Society’s 40th Annual Proceedings
“Presidential Address”:
Good Ergonomics is Good Economics
by Hal W. Hendrick:
Available @ www.hfes.org
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Supplemental Readings
The Ergonomics Society’s overview
of ergonomics, from their web
homepage Available @
www.ergonomics.org.uk
Additional articles identified by
Cohort 2 students will be made
available as further readings.
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